Operation and Maintenance Manual: Compact Track Loader

CEAM017300
Operation and Maintenance

Manual
CK35-1
COMPACT TRACK LOADER
SERIAL NUMBERS CK35-1 A40001 and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
June 2006 Copyright 2006 Komatsu

Published in USA
Komatsu America Corp.
0INTRODUCTION
CK35-1 0-1
INTRODUCTION
FOREWORD
This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It
will help the operator and maintenance personnel achieve peak performance through effective, economical and
safe machine operation and maintenance.
Keep this manual handy and have all personnel read it periodically. If this manual is lost, damaged or becomes
dirty and cannot be read, request a replacement manual from your local distributor.
If you sell the machine, be sure to give this manual to the new owner.
The information, specifications, and illustrations in this publication are on the basis of information avail-
able at the time it was written. Continuing improvements in the design of this machine can lead to changes,
which may not be reflected in this manual. Consult your local distributor or for the latest available information on
your machine or for questions regarding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area. Consult your lo-
cal distributor or for those items that you may require.
Punctual periodic notes regarding the maintenance operations that have been carried out are important to have a
clear prospect of the situation and to know exactly what has been done and what has to be done after the next
maintenance interval. Therefore, it is advisable to consult either the hour meter and/or the maintenance schedule
frequently.
Over the years Komatsu distributors have gathered considerable experience in customer service. If more informa-
tion is needed, do not hesitate to contact your Komatsu distributor. He always knows how to get the best perfor-
mance from the machine, he can suggest the use of the equipment that is most suitable for specific needs and can
provide the technical assistance necessary for any change that may be required to conform the machine to the
safety standards and traffic rules. Furthermore, Komatsu distributors also ensure their assistance for the supply of
genuine Komatsu spare parts, which alone guarantee safety and interchangeability.
The table included in this manual must be filled in with the machine data, which are the data that must always be in-
dicated to the distributor when requesting assistance and ordering spare parts.
Improper operation and maintenance of this machine can be hazardous and could result in serious injury
or death.
Operators and maintenance personnel must read this manual thoroughly before operating or maintaining
this machine. This manual should be kept near or with the machine for reference and periodically reviewed
by all personnel who operate it.
Some actions involved in operation and maintenance can cause a serious accident, if they are not per-
formed in the manner described in this manual.
The procedures and precautions given in this manual apply only to the intended uses of this machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must be sure that
it is safe for you and others. In no event should you or others engage in prohibited uses or actions as
described in this manual.
KOMATSU delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety features and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable stan-
dards and regulations of your country, consult your local distributor or KOMATSU before operating the
machine.
The safety description is given in SAFETY INFORMATION and in the SAFETY section 1.
0-2 CK35-1
INTRODUCTION
SAFETY INFORMATION
Most accidents are caused by failure to follow fundamental safety rules for the operation and maintenance of the
machine. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the
machine before performing maintenance and machine operations.
To identify safety messages in this manual and on machine product graphics, the following signal words are used:
Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury. This signal word is to be limited to the most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or se-
rious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
erate injury. It may also be used to alert against unsafe practices.
Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is are useful to know.
Remark
This word is used for precautions that must be taken to avoid actions, which could shorten the life or damage
the machine.
The safety precautions are described in SAFETY section 1.
KOMATSU cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore the safety message in this manual and on the machine may not include all possible safety precautions. If
any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that
you and others can do such procedures and actions safely and without damaging the machine or causing injury. If
you are unsure about the safety of some procedures, contact your local distributor.
Before starting any maintenance operation, position the machine on a firm and level surface, lower the
equipment to the ground, engage the safety locks of the equipment and of the controls and stop the
engine.
To make the information clearer, some illustrations in this manual represent the machine without safety
guards. Do not use the machine without guards and do not start the engine when the engine hood is open,
unless this is expressly prescribed for some specific maintenance operations.
CK35-1 0-3
INTRODUCTION
It is strictly forbidden to modify the setting of the hydraulic system safety valves; Komatsu cannot be held
liable for any damage to people, property, or the machine, if this has been tampered with by modifying the
standard setting of the hydraulic system.
Before carrying out any electrical welding, disconnect the battery and the alternator (see See “ELECTRI-
CAL PRECAUTIONS” on page 1-32).
Install only authorized additional equipment (See “CHARACTERISTICS OF THE OPTIONAL EQUIPMENT
OF THE MACHINE VERSION WITH HIGH FLOW AND SUPER-FLOW HYDRAULIC SYSTEM” on page 5-5).
Travel on roads is allowed only if the machine is provided with appropriate lighting, signalling and safety
devices and properly authorized by the relevant permits.
Before travelling on roads, make sure that the equipment installed on the machine is approved and the
safety locks are correctly engaged.
It is absolutely forbidden to operate the machine while standing on the ground.

Every single maneuver must be carried out by the operator, correctly seated in the driving position.
0-4 CK35-1
INTRODUCTION
APPROVED AND NON APPROVED USES

APPROVED
The Komatsu MACHINES described in this manual have been designed and constructed to be used by duly
trained personnel mainly for EXCAVATION and EARTH-MOVING OPERATIONS.
If provided with suitable safety devices, they can be used with authorized optional equipment having the character-
istics illustrated at point, See “AUTHORIZED OPTIONAL EQUIPMENT” on page 5-2.
NON APPROVED
• The instructions regarding the authorized optional equipment are given in the relevant operation and
maintenance manuals; if the equipment is supplied by Komatsu, these publications are attached to this
manual.
• The instructions regarding the assembly of the authorized equipment, the controls requiring special
arrangements on the machine and the hydraulic couplings necessary for the operation of the equip-
ment are shown in the final section of this manual.
Komatsu MACHINES are constructed exclusively for the handling, excavation and treatment of inert materials;
therefore, the following uses are absolutely forbidden:
• USE OF THE MACHINE BY MINORS OR INEXPERIENCED PEOPLE.
• USE OF THE MACHINE FOR LIFTING PEOPLE OR OBJECTS.
• TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.
• USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.
• USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.
CK35-1 0-5
INTRODUCTION
PRODUCT INFORMATION
Listed are features and machine identification locations. Komatsu skid steer loader and main components are iden-
tified by serial numbers stamped on identification plates or decals attached to the machine or component.
MAIN FEATURES
★ Simple and easy operation.
★ Hydrostatic transmission obtained through a double variable displacement pump and axial piston motors
operating epicyclic reduction gears.
★ Two driving tracks always engaged through oil-immersed roller chains.
★ Main equipment and travel control through servo levers ensuring combination movements that can be modu-
lated proportionally and continually.
★ Foot control for the optional equipment (if installed).
★ Foot accelerator.
★ Lever accelerator.
★ Parking brake control.
★ Complete series of instruments visible from the operating position.
★ Easy maintenance with simplified intervals.
★ Road travel (on request).
BREAK IN PERIOD
Every new machine is properly adjusted and tested before delivery. A new machine must be operated carefully for
the first 100 hours to ensure proper run-in time for the various components. It the machine is subjected to exces-
sive or severe work loads at the beginning of it’s operation, it’s functions will be greatly reduced or damaged. Every
new machine must be used carefully, paying special attention to the following indications:
★ After start up, let the engine idle at a low RPM for 5 minutes, to warm up the machine gradually before begin-
ning actual operation.
★ Operate the machine with limited loads. Avoid abrupt starts, accelerations, sudden decelerations, abrupt rever-
sals or sudden stops.
★ After the first 50 hours, perform the following maintenance, in addition to normal maintenance performed at 50
hours:
A. Check the drive chain tension.
B. Check the rubber track tension.
★ After the first 250 hours, perform the following maintenance, in addition to normal maintenance performed at
250 hours perform:
C. Change the hydraulic system filter.
SYNTHETIC BIODEGRADABLE OIL TYPES

On machines in which synthetic biodegradable oil type HEES is used, the following operations are to be per-
formed, besides the standard maintenance operations:
★ After the first 50 hours of operation, change the hydraulic system filter.
★ After the first 500 hours of operation, change the hydraulic system oil and filter.
0-6 CK35-1
INTRODUCTION
PRODUCT IDENTIFICATION
The serial numbers and model numbers on the components are
the only numbers that your distributor will need when requiring
assistance or ordering replacement parts. It is a good idea to
record this information in this manual on page 0-9 (Serial Number
and distributor information). All views indicated below are viewed
from the operators position.
MACHINE SERIAL NUMBER

The machine serial number is stamped on the inner wall of the
right rear pillar.
MACHINE IDENTIFICATION PLATE AND PRODUCT

IDENTIFICATION NUMBER (PIN)
The PIN plate is located on the inner wall of the right rear pillar.
CK35-1 0-7
INTRODUCTION
ENGINE SERIAL NUMBER AND EMISSION PLATE

The plate (1) indicating the engine serial number and the exhaust
gas emission plate (2) are positioned on the top of the valve cov-
er.
TRAVEL REDUCTION GEAR SERIAL NUMBER

The serial number of the travel reduction gear is stamped on the
plate positioned on the hydraulic motor cover.
CAB SERIAL NUMBER

The cab serial number is stamped on the plate positioned on the
right side of the base cross member.
0-8 CK35-1
INTRODUCTION
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION

MODEL: CK35-1
Machine #
Product identifica-
tion # (PIN)
Engine #
Travel reduction
gear #
Cab #
Excavator #
(if installed)
Distributor:
Address:
Phone #
Contacts:
NOTES:
CK35-1 0-9
INTRODUCTION
CONTENTS
INTRODUCTION
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
APPROVED AND NON APPROVED USES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
NON APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
PRODUCT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
MAIN FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
SYNTHETIC BIODEGRADABLE OIL TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-6
PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-7
MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN) 0-7
ENGINE SERIAL NUMBER AND EMISSION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
TRAVEL REDUCTION GEAR SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
CAB SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-8
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
MODEL: CK35-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
SAFETY
SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

LOCATION OF THE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SAFETY PLATES FOR MACHINES WITH EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
DECALS DEFINED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
UNAUTHORIZED MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
LEAVING THE OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
CHECKING THE REAR-VIEW MIRRORS (IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
FIRE PREVENTION FOR FUEL AND OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
PREVENTING BURNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
DUST HAZARD PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
PREVENTING ACCIDENTS CAUSED BY IMPROPER OPERATION OF THE WORK
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
PRECAUTIONS CONCERNING THE CAB STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
PRECAUTIONS CONCERNING THE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
PRECAUTIONS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
SAFETY ON THE WORK SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
PRECAUTIONS TO BE TAKEN FOR THE OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . 1-17
0-10 CK35-1
INTRODUCTION
ROOM VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (IF INSTALLED) . . . . . . . . . . . . . . . . . 1-18
CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WIND-
SHIELD WIPER BLADES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
PRECAUTIONS TO BE TAKEN WHEN WORKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
RULES FOR TRAVELING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
MOVING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
WORKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
PREVENTING ELECTROCUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
VISIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
WORKING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
PREVENTING ACCIDENTS CAUSED BY THE IMPROPER OPERATION OF THE WORK
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
WORKING ON LOOSE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
LOADING AND UNLOADING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
THE ROUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
SAFETY PRECAUTIONS FOR WORK ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
PRECAUTIONS FOR EMERGENCY RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
PRECAUTIONS DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
PERSONNEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
EQUIPMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
ENGINE OPERATION DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
RULES FOR REFUELING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
COOLING SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
USING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
ELECTRICAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
PRECAUTIONS CONCERNING THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
PRECAUTIONS CONCERNING HIGH PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
PRECAUTIONS FOR WORKING ON HIGH PRESSURE SYSTEMS . . . . . . . . . . . . . . . . . . . 1-33
PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND
PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
ROTATING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST
THE RUBBER TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER
UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
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INTRODUCTION
HYDRAULIC ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
DISPOSAL OF WASTE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
HYDRAULIC ENVIRONMENTAL ESTER SYNTHETIC (HEES) OIL . . . . . . . . . . . . . . . . . . 1-35
OPERATION
SAFETY LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

LOADER ARM SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
EXCAVATOR LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
COLD PLANER LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
GENERAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
FRONT VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
REAR VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
INSIDE VIEW OF CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
HOUR METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
ENGINE COOLANT TEMPERATURE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
FUEL LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
ALTERNATOR WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
PREHEATING WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
ENGINE OIL PRESSURE WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
AIR CLEANER CLOGGING WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
HYDRAULIC OIL FILTER CLOGGING WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . 2-14
PARKING BRAKE WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
SPEED INCREASE INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
FLOAT SWITCH INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
DIRECTION INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
WORKING LIGHT INDICATOR LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
SAFETY DEVICE FUNCTIONALITY CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
SWITCHES AND PUSH BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
PARKING BRAKE PUSH BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
ROTATING BEACON LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
LEFT STABILIZER BUTTON (IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
RIGHT STABILIZER BUTTON (IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
WORKING LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
EMERGENCY (HAZARD) SWITCH (IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
PARKING LIGHT AND LOW BEAM SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
DIRECTION INDICATOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
FRONT EQUIPMENT HIGH FLOW HYDRAULIC SYSTEM MOMENTARY SWITCH
(3 LINES)(IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
FRONT EQUIPMENT SUPER FLOW HYDRAULIC SYSTEM CONTINUOUS SWITCH
(5 LINES)(IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
SPEED INCREASE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
FLOATING DEVICE SWITCH (IF INSTALLED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
SEAT OVERRIDE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
0-12 CK35-1
INTRODUCTION
AVAILABLE FOR OTHER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
ELECTRICAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
AUDIBLE ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
ELECTRIC OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
MASTER ELECTRICAL DISCONNECT SWITCH (IF INSTALLED) . . . . . . . . . . . . . . . . 2-25
MACHINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
SAFETY BARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
ISO PATTERN CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
LEFT PPC CONTROL JOYSTICK (TRAVEL AND STEERING) . . . . . . . . . . . . . . . . . . . . 2-29
RIGHT PPC CONTROL JOYSTICK (LOADER ARM AND BUCKET) . . . . . . . . . . . . . . . . . . 2-31
OPTIONAL PATTERN CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
LEFT PPC CONTROL JOYSTICK (LEFT TRACK TRAVEL, STEERING, AND LOADER
ARM CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
RIGHT PPC CONTROL JOYSTICK (RIGHT TRACK TRAVEL, STEERING, AND BUCKET
CONTROL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
AUXILIARY HYDRAULIC KIT CONTROL PEDAL (IF INSTALLED) . . . . . . . . . . . . . . . . . 2-37
FOOT ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
HAND ACCELERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
STANDARD FLOW HYDRAULIC SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
(2 OR 3 LINES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
SUPER FLOW HYDRAULIC SYSTEM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
SPEED INCREASE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
FLOATING POSITION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
PATTERN SHIFTING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
RIGHT STABILIZER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
LEFT STABILIZER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
OPTIONAL ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
MACHINE FUNCTION FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
STANDARD VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
VERSION WITH OPTIONAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
MAIN FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
GUARDS AND OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
REAR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
STANDARD SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
SUSPENSION SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
TECHNICAL DOCUMENTATION CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
OPERATING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
VISUAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
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INTRODUCTION
DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
STARTING A WARM ENGINE OR IN TEMPERATE CLIMATES . . . . . . . . . . . . . . . . . . 2-61
STARTING A COLD ENGINE OR IN COLD CLIMATES . . . . . . . . . . . . . . . . . . . . . . . . . 2-62
WARMING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
HEATING THE HYDRAULIC OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
MOVING THE MACHINE (ISO PATTERN CONTROL SYSTEM) . . . . . . . . . . . . . . . . . . . . . 2-64
STEERING (CHANGING DIRECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM) . . . . . . . . 2-68
HAND AND FOOT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
MACHINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
TRAVEL AND STEERING CONTROL JOYSTICKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET) . . . . . . . . 2-75
AUXILIARY HYDRAULIC CONTROL JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM) . . . . . . . . . . . 2-81
MOVING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
MAXIMUM IMMERSION DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
PARKING ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
PARKING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-88
STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
LOADING AND UNLOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
HOW TO LIFT THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
COLD WEATHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
PRECAUTIONS TO BE TAKEN AT THE END OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
WARM WEATHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95
OPERATING THE WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE . . . . . . . . . . . . . . . . . . . 2-96
ORGANIZING THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
LOADING HEAPED AND LEVEL MATERIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
LOADING OPERATIONS ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
DIGGING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
CHANGING THE BUCKET OR ATTACHMENT WITH STANDARD QUICK COUPLER 2-101
REMOVING THE BUCKET OR ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
INSTALLING THE BUCKET OR ATTACHMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
CHECKING THE POSITION OF THE LOCKING PINS . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104
ADJUSTING THE LOCKING PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105
USING THE RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
OPTIMAL USE OF THE RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
RUBBER TRACK WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
0-14 CK35-1
INTRODUCTION
PRECAUTIONS TO BE TAKEN WHEN USING THE RUBBER TRACKS . . . . . . . . . . 2-106
PRECAUTIONS FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107
LONG PERIODS OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
BEFORE THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109
DURING THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
AFTER THE PERIOD OF INACTIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
HOW TO MOVE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
IF THE FUEL HAS BEEN COMPLETELY DEPLETED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-111
BATTERY IS EXHAUSTED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
STARTING WITH BOOSTER CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
OTHER TROUBLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116
HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117
MAINTENANCE
GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

MAINTENANCE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
NOTES REGARDING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
NOTES REGARDING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
NOTES REGARDING THE ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
NOTES REGARDING LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING . . . . . . . . . . . . . . 3-5
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SELECTION ACCORDING TO THE AMBIENT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . 3-6
GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES . . . . . . . . . . . . . . . 3-10
LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
CRITICAL PARTS FOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
FUEL SUPPLY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
STANDARD FLOW HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
SUPER FLOW HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
OPERATOR’S SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
STANDARD TORQUE FOR BOLTS AND NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
SPECIFIC TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
MAINTENANCE PLAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
AFTER THE FIRST 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
EVERY 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
CK35-1 0-15
INTRODUCTION
MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . 3-22
EVERY 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
AFTER THE FIRST 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
EVERY 1000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
EVERY 2000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
AIR CLEANER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
DRAINING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
RELEASING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
CHECKING THE BATTERY CHARGE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
CHECKING THE RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
CHECKING AND ADJUSTING THE RUBBER TRACK TENSION . . . . . . . . . . . . . . . . . 3-30
CHANGING THE RUBBER TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
CHECKS BEFORE STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
VARIOUS CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
CHECKING THE FUEL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
HYDRAULIC SYSTEM OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
DRAINING WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
CHECKING THE WIRING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . 3-40
MAINTENANCE EVERY 50 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
CHECKING THE RUBBER TRACK TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
CHECKING THE COOLANT LEVEL IN THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . 3-41
CHECKING THE OIL LEVEL IN THE TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 3-41
FIRST 250 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
CLEANING THE OUTSIDE OF THE RADIATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
LUBRICATING THE JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
CHANGING THE ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
CHECKING THE TORQUE OF THE BOLTS AND NUTS THAT FASTEN THE
CARRIAGES TO THE MACHINE FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . 3-48
MAINTENANCE EVERY 500 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHANGING THE FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
CHANGING THE HYDRAULIC OIL DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
CHANGING THE OIL IN THE TRAVEL MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
CLEANING THE WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
DRAINING CONDENSATE FROM THE HYDRAULIC OIL TANK . . . . . . . . . . . . . . . . . 3-53
MAINTENANCE EVERY 1000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION
FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE . . . . . . . . . . . . . . 3-57
MAINTENANCE EVERY 2000 HOURS OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58
0-16 CK35-1
INTRODUCTION
CHANGING THE SUCTION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
CHECKING THE ALTERNATOR AND THE STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
SPECIFICATIONS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
STANDARD MACHINE OVERALL DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . 4-3
TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
OPTIONS, ATTACHMENTS
AUTHORIZED OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

BASIC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT . . . . . . . . . . . . . . . . 5-3
CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT . . . . . . . . 5-4
CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION
WITH HIGH FLOW AND SUPER-FLOW HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . 5-5
CHANGING THE AUTHORIZED EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
CONNECTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CONNECTING THE HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK . . 5-11
PREPARING THE MACHINE FOR USE WITH THE EXCAVATOR . . . . . . . . . . . . . . . . . . . 5-12
USING THE MACHINE WITH THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
PALLET FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
CK35-1 0-17
INTRODUCTION
0-18 CK35-1
1SAFETY
WARNING!
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
This safety section also contains precautions for optional equipment and attachments made by Komatsu.
CK35-1
SAFETY
SAFETY AND WARNING DECALS

LOCATION OF THE SAFETY DECALS
★ The safety decals must always be legible and in good condition. If they are dirty with dust, oil, or grease, clean
them with a solution of water and detergent. Do not use fuel, petroleum based products, or solvents.
★ If the decals are damaged they must be replaced before operating the machine.
★ When a component provided with a safety decal is replaced, make sure the decal is also applied to the
replacement component.
★ The machine may be provided with other decals, in addition to those shown below, which must be followed for
safe operation.
1-2 CK35-1
SAFETY
CK35-1 1-3
SAFETY
SAFETY PLATES FOR MACHINES WITH EXCAVATOR
1-4 CK35-1
SAFETY
CK35-1 1-5
SAFETY
DECALS DEFINED
The warning and danger decals applied to the machine are accompanied or represented by pictograms. The per-
sonnel charged with the operation and maintenance of the machine must know the symbols contained in the picto-
grams perfectly; the following descriptions illustrate what they look like and their respective meanings.
DANGER IN THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . .
(Only for machines with the excavator)
Do not approach or stand near the work equipment operating ra-

dius when the boom and the bucket of the excavator are raised.
MOVING PARTS IN ENGINE COMPARTMENT . . . . . . . . . . . . .
Keep clear of moving parts inside engine compartment.
CONSULT THE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carefully read the contents of the manual before using the ma-
chine or performing maintenance operations.
1-6 CK35-1
SAFETY
DO NOT LOOSEN THE BOLTS
Do not loosen or remove the fastening bolts of the rear damping

supports of the cab.
DANGER! TRACK TENSIONER ADJUST-

MENT
Carefully read the contents of this manual

before adjusting the track tensioner unit.
DANGER! LOADER ARM RAISED
Always engage the safety lock before carry-

ing out maintenance operations, checks, or
adjustments with loader arm raised.
Carefully read the instructions contained in
this manual.
OPENING AND CLOSING THE ENGINE

HOOD
Always engage the safety lock before carry-

ing out any maintenance operation with the
hood open.
Carefully read the instructions contained in
this manual.
OPENING THE REAR PANEL
For correct use of the rear panel safety lock,

follow the instructions contained in this man-
ual.
CK35-1 1-7
SAFETY
HYDRAULIC OIL FILL CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FILL THE SYSTEM WITH HEES TYPE OIL . . . . . . . . . . . . . . . .
HEES is a synthetic, biodegradeable type oil that is used only in

the hydraulic oil tank.
ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK FILLER TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE AIR FILTER CLOGGING WARNING . . . . . . . . . . . . . .
ENGINE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIFTING POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8 CK35-1
SAFETY
FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRIC OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ANCHOR POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CK35-1 1-9
SAFETY
SAFETY RULES AND PRECAUTIONS

GENERAL SAFETY RULES
Only trained and authorized personnel are allowed to operate
and service this machine.
Before operating this machine it is important to study the opera-

tor’s manual thoroughly and become familiar with all controls and
safety decals. Keep this manual with your machine at all times for
easy reference.
Safety must always be the operator’s most important concern.

Never operate a machine that is unsafe or in poor operating con-
dition. Always perform a pre-operational check on your machine
before operating it.
If the machine is equipped with a seat belt and rollover protective

structure, OSHA law requires the operator remain within the con-
fines of the rollover protective structure, with the seat belt fas-
tened snugly around their waist before operating the machine.
OSHA law states if your equipment is designed for operation by

one person, it is for one person only, never allow other personnel
to ride on your machine.
Never leave your machine running and unattended. Always park

the machine in a level area, lower any work equipment to the
ground, set the parking brake, lock the controls and turn the en-
gine off before exiting the operator’s compartment.
Be sure that all personnel are at least 12 m (13 yd) away from
any point on the machine before moving or operating the ma-
chine. Never allow anyone to stand near the machine while it’s
operating. Remember, the larger the machine the more restricted
your visibility will be.
If pedestrians are in the area proceed slowly and sound your

horn. Keep in mind, pedestrians have the right of way, and a
loaded or smaller machine has the right of way over an unloaded
machine.
Never use your machine for tasks it was not designed for, dam-
age to the machine or injury to the operator may result.
Follow all safety rules, precautions, and instructions when operat-

ing or performing maintenance on the machine.
It is the owner and/or operator’s responsibility to replace any

safety or warning decals if they are defaced or removed from the
machine.
Think before you act, study the job carefully. Careful operator and
service personnel are the best insurance against accidents.
The operator of this machine must be alert, physically fit, and free
from the influences of alcohol, drugs, or medications that might
affect his/her eyesight, hearing, or reactions.
1-10 CK35-1
SAFETY
When working with another person on a work site, or during traffic

control, be sure all personnel involved understand all hand sig-
nals that are to be used. When leaving a job site for long periods
of time always lower all work equipment to the ground, neutralize
work equipment controls and lock and secure your machine prop-
erly to avoid tampering by other personnel.
Never drive up to anyone standing in your path of travel. Always

be sure all personnel are standing to the side when you approach
them and acknowledge your approach. Follow all rules relating to
safety as outlined in this manual and by your company, never get
involved in horseplay.
SAFETY FEATURES
Be sure all guards and covers are in place, especially after ser-
vicing the machine. Have guards or covers repaired immediately
if they are damaged. See “PRECAUTIONS BEFORE STARTING
THE ENGINE” on page 1-17.
Use safety equipment such as safety locks and seat belt properly.
Never remove any safety features, always keep them in good op-
erating condition.
Always secure the machine in a safe position: See “PARKING

THE MACHINE” on page 1-23.
Seat belt: See “SEAT BELT” on page 2-57. Improper use of safe-
ty features could result in serious bodily injury or death. Be sure
the machine has the correct equipment required by local rules
and regulations.
PERSONAL PROTECTIVE EQUIPMENT

If your machine is equipped with safety equipment, OSHA law re-
quires this equipment to be used when operating your machine.
Avoid loose fitting clothing, jewelry and loose long hair. These
can catch on controls or in moving parts and cause serious injury.
Wear a hard hat, safety glasses, safety shoes, mask or gloves
when operating or maintaining the machine.
Always wear safety goggles, hard hat and heavy gloves, if your
job involves driving pins with a hammer or cleaning the air clean-
er element with compressed air.
Check to be sure no one is near your work area. Check to be

sure all personal protective equipment are in good condition be-
fore using.
When working for 8 hours with a noise level exceeding 85 dBA, it

is necessary to use headphones or ear plugs and to be particular-
ly careful, especially towards the end of the work shift. Always
check current local government noise regulations for compliance.
CK35-1 1-11
SAFETY
UNAUTHORIZED MODIFICATIONS
Any modification made without authorization can create a hazard. Before making any modifications, consult your
local distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modifica-
tions to the machine.
LEAVING THE OPERATOR’S SEAT
• When leaving the operator’s seat, even if temporarily, make
sure that the machine is in a safe position.
• Before leaving the operator’s seat, carry out the following

operations in the sequence indicated below:
1. Rest the equipment on the ground.
2. Apply the parking brake. See “PARKING BRAKE PUSH

BUTTON” on page 2-19
3. Engage the safety device of the optional equipment con-

trol pedal (if installed).
4. Lock the equipment and travel control by shifting the

safety bars to the lock position. See “SAFETY BARS” on
page 2-28
5. Stop the engine (See “STOPPING THE ENGINE” on

page 2-89)
6. If you have to go so far away that you will not be able to

see the machine, remove the ignition key.
1-12 CK35-1
SAFETY
MOUNTING AND DISMOUNTING

• Do not jump on or off the machine, either when it is at rest or
when it is moving.
• When getting on or off the machine, always use the appropri-

ate handles and footrests; get on and off the machine very
carefully.
• Never hold or rest on the control levers.
• Either when getting on or when getting off the machine,

always maintain three points of contact (holding or resting
points), to avoid losing your balance and falling down.
• Clean the handles and footboards if they are dirty with oil or
grease. Carefully clean the cab floor if it is dirty with oil,
grease, mud or rubble.
CHECKING THE REAR-VIEW MIRRORS (IF

INSTALLED)
• Make sure that the rear-view mirrors are clean and correctly
aimed; the operator must be able to check the area behind
the machine with no need to twist his trunk with respect to his
normal operating position.
• If the rear-view mirrors should move or break during opera-

tions, stop the machine immediately and fix or change them.
• Working without checking the area behind the machine

involves the risk of running over people who have carelessly
approached the machine or colliding with fixed obstacles or
maneuvering vehicles.
CK35-1 1-13
SAFETY
FIRE PREVENTION FOR FUEL AND OIL

Fuel, oil, and some types of antifreeze are flammable. Fuel is
particularly flammable and can be hazardous. Always observe
the following:
• Keep any open flames away from flammable fluids.
• Stop the engine and do not smoke when refueling.
• Refueling or adding oil should be done in well ventilated

areas and only after stopping the engine.
• Keep oil and fuel in its proper place.
• When refuelling, hold the fuel nozzle firmly and keep it

constantly in contact with the filler until you have finished,
to avoid sparks due to static electricity.
• Do not fill the tank completely, to leave room for the fuel to
expand.
• After refueling, tighten the fuel and oil filler caps securely.
• In case some fuel is spilled, wipe it up immediately.
PREVENTING BURNS
Wear gloves and safety goggles when checking any fluid levels:
engine oil, hydraulic oil, engine coolant, transmission fluid.
Before checking the engine coolant, engine oil, or hydraulic oil,

stop the engine and let the fluids cool down. If you don’t, the hot
fluids may spurt out and cause burns. If the coolant level, in the
radiator, needs to be checked due to overheating, slowly loosen
the radiator cap to release the internal pressure or the hot coolant
may spurt out and cause burns.
1-14 CK35-1
SAFETY
DUST HAZARD PRECAUTIONS

Dust can be hazardous to your health, if it is inhaled. Komatsu
does not use asbestos in its products, but if you handle materials
containing asbestos fibers or other dust materials during demoli-
tion operations, always do as follows:
• Never use compressed air for cleaning. Only use an aspi-

rator and make sure the room in which you are working in
is well ventilated.
• Use water to keep down the dust when cleaning.
• If there is a danger there may be asbestos dust in the air,

operate the machine with the wind to your back whenever
possible. Use an approved respirator.
• Do not allow any other person into the area during opera-
tion.
• There may be a danger that non genuine Komatsu parts

may contain asbestos, use only genuine Komatsu parts.
• Always observe rules and regulations related to the job

site and working environment.
PREVENTING ACCIDENTS CAUSED BY

IMPROPER OPERATION OF THE WORK EQUIP-
MENT
Never stand under or place any part of your body between the
movable components such as the work equipment and cylinders
or between the machine and work equipment.
Keep in mind, when the work equipment is operated, the clear-

ance will change, this may lead to serious personal injury or
death. Never drive up to anyone standing in front of a solid object
or your path of travel, the brakes could fail or the machine could
slide on a slippery surface causing injury or even death.
FIRE EXTINGUISHER AND FIRST AID KIT

As a precaution, if a fire or an injury should occur, always keep a
fire extinguisher and first aid kit on your machine and do as fol-
lows:
• Make sure that fire extinguishers have been provided and
note their position.
• Be sure that the fire extinguisher is in good condition and
read the label on it to ensure you know how to use it.
• Keep a first aid kit in the storage area. Check the kit peri-
odically and replace any bandages, disinfectants, etc. as
necessary.
• Keep a list of emergency phone numbers in case of an ac-
cident.
CK35-1 1-15
SAFETY
PRECAUTIONS CONCERNING THE CAB STRUCTURE
• If the cab is inadvertently hit or the machine overturns during work, the cab may be damaged with consequent
reduction of its stiffness and of the safety that must be guaranteed to the operator. Consult your Komatsu dis-
tributor to have the cab structure and strength checked in case of impact or damage.
PRECAUTIONS CONCERNING THE EQUIPMENT

• When installing and using optional equipment, carefully read the relevant instruction manual and operate the
machine accordingly.
• Do not use optional or special equipment without the authorization of your Komatsu distributor. The installation
and use of unauthorized equipment may create safety problems and adversely affect the efficiency and life of
the machine.
• Komatsu cannot be held liable for any damage, accident, or product failure resulting from the installation and
use of unauthorized equipment.
1-16 CK35-1
SAFETY
PRECAUTIONS BEFORE STARTING THE ENGINE

Before starting your work operations, it is important to perform several procedures to be sure your equipment is in
a safe operating condition. It is also important to be aware of the hazards involved when operating your machine.
SAFETY ON THE WORK SITE

Before starting your machine and proceeding with any work oper-
ations it is important to be sure your machine is safe to operate.
• Before starting the engine, thoroughly check the area for any
unusual ground conditions that may cause the work to be dan-
gerous.
• Check the conditions of the work site and, before starting the
engine, define the work plan and the best and safest operating
procedure.
• Make the ground surface as level as possible before carrying
out any operation.
• In case of work on the road, protect pedestrians and cars by
designating a person for work site traffic duty and install fences
around the work site.
• If water lines, gas lines, and telephone or high-voltage electri-
cal lines are located under the work site, contact the relevant
utility company to find out their exact locations or to make them
inoperative until the end of the operations. Be careful not to
sever or damage any of these lines.
• Check the depth and flow of water before operating in water or
on river banks.
FIRE PREVENTION
• Completely remove all wood chips, rubbish, paper and other
flammable materials that may have accumulated inside the en-
gine compartment, since they can cause fires.
• Check the fuel and hydraulic system tubes/hoses for leaks

and, if necessary, repair them. Wipe up any excess oil, fuel or
other flammable fluids.
• Make sure that fire extinguishers are available in the work ar-
ea.
PRECAUTIONS TO BE TAKEN FOR THE OPERATOR’S CAB

• Do not keep objects or tools in the operator’s cab. They may hinder the operation of the controls and cause seri-
ous accidents.
• Keep the cab floor and the controls (pedals and levers) clean, by removing any trace of oil and grease and, as
far as the floor is concerned, remove any excess dirt (dirt, stones, etc.).
• Check the safety belt and change it if it is broken or damaged. Replace any component only with approved parts
supplied by your distributor.
CK35-1 1-17
SAFETY
ROOM VENTILATION
Exhaust gases are deadly. If starting the machine inside a build-
ing, connect a suction duct to the exhaust pipe to vent fumes out-
side.
PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (IF INSTALLED)

• Remove any trace of dirt from the lights, to ensure perfect visibility of the work area.
• Make sure that all the bulbs and the working lights are functioning properly. If necessary, replace any faulty bulbs
with new ones, making sure that their ratings are correct.
CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WIND-
SHIELD WIPER BLADES
• Remove any trace of dirt from the cab windows and clean the rear-view mirrors, to ensure unobstructed visibility
in the work area.
• Adjust the rear-view mirrors that may have moved, so that the operator seated in the driving position can clearly
see the area behind the machine. If any glass is damaged, replace it with new.
• Check the condition of the windshield wiper blades; the scraping edge must be smooth, with no indentations and
attached to the rubber back of the blade.
In case of doubts about the efficiency of the edge, change the blade.
1-18 CK35-1
SAFETY
PRECAUTIONS TO BE TAKEN WHEN WORKING

STARTING THE ENGINE
• Before operating the machine, walk around it and check for people or objects that might be in the way.
• Do not start the engine if warning tags have been attached to the steering wheel or control levers.
• Sound your horn to warn others in the area before starting the engine or moving the machine.
• Start the engine only when seated and with the seat belt fastened snugly around your waist.
• Do not allow anyone in the cab or on the machine during operations.
RULES FOR TRAVELING IN REVERSE

• When operating in areas that may be hazardous or where visi-
bility is poor, designate a person to direct the movements of the
machine and the traffic on the work site.
• Make sure that no unauthorized person is standing within the

machine operating radius or in its travel direction. If necessary,
put up appropriate fences.
• Before moving the machine, sound the horn to warn people

near the work area.
• There are blind spots behind the machine, which cannot be

seen by the operator and where someone may be standing.
Therefore, it is necessary to make sure that there is no one be-
hind the machine before traveling in reverse.
MOVING THE MACHINE
The use of the speed increase button is allowed only for the
high speed transfers of the machine.
• When moving the machine, lower the arm and roll the bucket
back completely; this position makes it possible to evaluate the
space required for movement more precisely and at the same
time ensures the stability of the machine.
• If the equipment control levers must be used during travel,
avoid moving them abruptly; sudden maneuvers change the
attitude of the machine and make driving difficult.
• When traveling on rough ground, keep the speed low and
avoid sudden movements of the bucket arm.
• If possible, avoid moving onto obstacles. If the machine has to
travel over an obstacle, keep the equipment as close to the
ground as possible and travel at low speed. Never move onto
obstacles that may drastically incline the machine (over 10°).
• If one of the rubber tracks goes over an obstacle or gets into a
hole in the ground, the machine may overturn. In these cases,
reduce the speed to a minimum and be very careful of the bal-
ance of the machine.
CK35-1 1-19
SAFETY
WORKING ON SLOPES
• Operations on slopes and on river or lake banks with damp
ground may result in the tipping over or sliding of the machine.
• Do not operate the bucket while the machine is on a slope.
• On hills, banks or slopes, keep the arm lowered and the bucket
rolled back, and in case of an emergency, quickly lower it to the
ground to help the machine stop.
• Do not change direction and, if possible, avoid traveling side-

ways when working on slopes. It is advisable to go down or up
to a flat surface before performing these maneuvers.
• Travel up or down slopes with the heaviest part of the loader

facing the top of the slope.
• Do not travel on wet grass or thick layers of leaves: if the ma-

chine moves sideways under these conditions, it may slide.
• Before carrying out any operation on a slope, always check the

functionality of the parking brake.
• Do not go down slopes at high speed; you may lose control of

the machine and cause serious damage and even death.
• Do not move on slopes with an inclination exceeding 15°, since

the machine may overturn.
• When the fuel level indicator reaches the red reserve area dur-
ing work on a slope, immediately provide for refueling; due to
the inclination of the machine, the engine may suck in air and
suddenly stop, which represents a grave risk for the safety of
the operator and of people in front of the machine.
• If the engine should stop suddenly, immediately lower the

bucket to the ground and apply the parking brake.
1-20 CK35-1
SAFETY
.
PREVENTING ELECTROCUTION
• Digging operations near overhead electric lines are extremely
dangerous and may also cause death due to electrocution; for
this reason, when working near overhead electrical lines, al-
ways respect the minimum safety distances prescribed by
competent authorities and by the accident-prevention rules in
force.
• As far as underground long-distance lines are concerned, the
minimum distance depends on the material of the pipes in
which the cables are laid.
• 1 - Wear shoes with thick rubber or leather soles.

• 2 - Request the aid of another person who can warn you if
the machine gets too close to the electric wires. Voltage Min. Safe Distance
• 3 - Operate at low speed. 6.6kV 3m 10 ft.
• 4 - Learn what is to be done first in case of electrocution. 66.0kV 5m 16 ft.
• 5 - Keep the phone number of the electricity company and 275kV 10 m 33 ft.
of the nearest first aid station at hand.
• If the work equipment accidentally gets entangled in the ca-
bles, the operator must remain still and must not leave the cab until the electricity company has shut off the pow-
er.
• When carrying out this kind of operation, warn everyone standing in the work area to keep at the minimum dis-
tance prescribed from the machine and the work equipment.
• Ask the electricity company in advance what are the voltage of the cables and the minimum safety distance are.
CK35-1 1-21
SAFETY
VISIBILITY
• Switch on the working lights as soon as visibility starts de-
creasing. If visibility decreases due to mist, smoke or heavy
rain, stop the machine in a safe position and wait for the weath-
er to improve until visibility becomes acceptable.
WORKING ON ICY OR SNOW-COVERED SUR-

FACES
• If the ground is icy or covered with snow, even a slight slope
may cause the machine to slip sideways, therefore it is advis-
able to move at low speed and to avoid abrupt starts, stops or
turns.
• When it has snowed heavily, the road shoulders and any ob-
stacles are buried in snow and are not visible, therefore pro-
ceed with care when clearing snow.
PREVENTING ACCIDENTS CAUSED BY THE

IMPROPER OPERATION OF THE WORK EQUIP-
MENT
• When working in tunnels, galleries, under electric cables or
other ducts (air, telephone lines) and wherever the height is
limited, proceed with the greatest care to prevent the bucket or
the arms from causing any damage.
WORKING ON LOOSE GROUND

• Avoid operating the machine too close to the edge of cliffs,
overhangs and deep ditches. These areas may collapse, mak-
ing the machine fall down or tip over and this could result in se-
rious injuries or even death. Remember that after heavy rain or
earthquakes these dangerous conditions usually get worse.
• The earth laid near ditches is loose and can easily collapse
due to the weight or vibrations of the machine. Be extremely
careful and remember to fasten your safety belt.
1-22 CK35-1
SAFETY
PARKING THE MACHINE

• Park the machine on firm and level ground. If this is not possi-
ble and it is necessary to park on a slope, position the machine
with the bucket facing downwards and carry out the following
operations:
• 1 - Rotate the bucket forward and rest it on the ground.
• 2 - Apply the parking brake.
• 3 - Stop the engine.
• 4 - Put wedges or safety blocks in front of the rubber tracks.
• Always rest the work equipment on the ground; if it is neces-

sary to park with the arms raised, make sure that the safety
locks are engaged (See “SAFETY LOCKS” on page 2-2).
• Always lock the equipment and travel control by shifting the

safety bars to the lock position (See “MACHINE CONTROLS”
on page 2-26).
• When leaving the machine, always apply the parking brake

and remove the ignition key.
• If it is necessary to park on public roads, provide for signalling

the presence of the machine according to the local regulations
in force (signalling fires, fences, road work ahead, alternate di-
rections and direction signs, etc.).
CK35-1 1-23
SAFETY
TRANSPORTING THE MACHINE

LOADING AND UNLOADING THE MACHINE
• Loading and unloading the machine on/from another vehicle
always involves potential hazards. Proceed with extreme care.
• Perform loading and unloading on firm, level ground. Maintain

a safe distance from the edges of ditches or road sides.
• If the vehicles used have not been appropriately equipped, put

support blocks under the ramps, to avoid any bending.
• Always lock the wheels of the transporting vehicle with chocks.
• Always use ramps that are sufficiently wide and can support
the weight of the machine. The longitudinal axes of the ramps
must be parallel to each other and perpendicular to the loading
board and their distance from each other must be sufficient to
accommodate the tread of the machine.
• Make sure the ramps are securely positioned and anchored to

the loading board and are the same length.
• Position the ramps with a maximum angle of 15°.
• Make sure that the ramp surface is clean and there is no trace
of grease, oil, soil or ice; remove any dirt from the tracks of the
machine before starting to load it on the vehicle. If the bucket is
empty or no optional accessories are fitted to the machine, this
end must face the rear.
• Do not reposition the machine while on the ramps. If neces-

sary, go down the ramps and start the operation again.
• After loading the machine, block the tracks with wedges and
secure it with tie-downs or chains that prevent any shifting (See
“TRANSPORTING THE MACHINE” on page 2-90).
THE ROUTE
• Define the route to be followed, taking into account the width,
height and weight of the transporting vehicle plus the machine.
Make sure that the overall dimensions of the vehicle and its
load are compatible with the roads and any tunnel, underpass,
bridge, power and telephone lines, etc. along the route.
• Adhere to the regulations in force regarding the permissible

width, height, weight and speed of heavy vehicles.
1-24 CK35-1
SAFETY
BATTERY
SAFETY PRECAUTIONS FOR WORK ON
BATTERIES
• Electrolytic batteries contain sulfuric acid which can cause
burns. It can also corrode clothing and make holes in it. If you
inadvertently splash battery acid on yourself or on someone
else, immediately wash the affected part with plenty of water.
• Battery acid may cause blindness if it comes into contact with

the eyes. If acid accidentally gets into your eyes, wash them
immediately with plenty of water and consult a doctor right
away.
• If you accidentally swallow battery acid, drink a large quantity

of water or milk, beaten egg white, or vegetable oil and in any
case antacid substances like magnesia, bicarbonate, etc.. Call
a doctor or a poison treatment center immediately.
• Always wear safety goggles when working on batteries.
• Batteries produce hydrogen gas, which is highly explosive and

can be easily ignited with small sparks or exposed flames.
• Before working with batteries, stop the engine and remove the
ignition key.
• Avoid short-circuiting the battery terminals through accidental

contact with metal objects or tools or through the reversing of
the cables.
• Tighten the battery cable clamps securely. Loose terminals

may generate sparks and even cause the explosion of the bat-
tery
STARTING WITH BOOSTER CABLES

• When starting the machine with booster cables, always wear
safety goggles.
• When starting the engine by means of another machine, avoid
any contact between the two machines.
• Be sure to connect the positive cable (+) first and then the neg-
ative or ground cable (-) when connecting the booster cables.
After the start, first disconnect the negative or ground (-) cable
and then the positive cable (+).
• Connect the batteries in parallel: positive to positive and nega-
tive to negative.
• When connecting the ground cable to the frame of the machine
to be started, select a point as far as possible from the battery.
(See “BATTERY IS EXHAUSTED” on page 2-112).
CK35-1 1-25
SAFETY
PRECAUTIONS FOR EMERGENCY RECOVERY

• The removal hooks are to be used exclusively for emergency
recovery and not for towing vehicles.
• Before moving the machine, make sure that all the controls are
in neutral.
• Release the parking brake of the travel hydraulic motors (See

“RELEASING THE PARKING BRAKE” on page 3-26).
• Incorrect maneuvers may result in serious injuries or even

death.
• To move the machine, use proper strength steel cables; do not

use worn cables or cables with broken strands (A), twisted ca-
bles (B), or deformed cables (C).
• During the recovery operation, no one is allowed to approach

the machines or the cables.
• Move the machine just far enough to permit the required re-
pairs.
• Do not move the machine in any way other than that indicated
in paragraph See “HOW TO MOVE THE MACHINE” on
page 2-111.
1-26 CK35-1
SAFETY
Never stand next to the tow lines when towing the machine.
The cable or chain could break causing injury. Always stay
clear of the towing equipment.
• The maximum pulling force for the emergency recovery is the

following: F = 3,870 kg. (8,333 lb.)
• Use cables of the same length and pull continuously, without

jerks.
• Arrange and connect the machine to be moved by positioning it

on the same axis as the towing vehicle; the force must be par-
allel to the axis of movement.
CK35-1 1-27
SAFETY
PRECAUTIONS DURING MAINTENANCE

All maintenance performed on this machine must only be per-
formed by trained and authorized personnel. When performing
maintenance it is important to follow the outlined maintenance
procedures and safety information outlined in this manual and in
the Shop Manual for this machine.
WARNING TAGS
Before performing any maintenance operations on this machine,
position the machine on a level and firm surface.
Lock the equipment controls, remove the ignition key and tag the
control levers.
Alert all personnel in your area that the machine is down for
maintenance. If necessary, tag the machine at specific points to
warn others that this machine is down for maintenance.
If the machine will be down for maintenance for a long period of

time, be sure to check and see if the warning tags are still in
place before you start your repair procedures the next day.
TOOLS
• Use only the tools provided with the machine and high-quality
tools suitable for the tasks to be performed.
• Do not use worn, damaged, low-quality tools or tools that are

not suitable for the tasks to be performed, to avoid any person-
al injury.
• After use, always put the tools in the appropriate compartment

(1) behind the driver’s seat.
1-28 CK35-1
SAFETY
PERSONNEL
Only authorized and duly trained personnel can service and re-
pair the machine; additional precautions must be taken when
grinding, welding and using a sledge hammer or heavy hammers.
When assembling the equipment or cylinder connection pins, use

wooden, plastic or in any case softer tools to check the centering
of the holes.
Do not use your fingers, since you run the risk of cutting them.
EQUIPMENT STORAGE
The normal or special equipment that must be installed on the
machine or that have been removed must be stored in safe plac-
es, preventing them from falling down. If they fall on someone,
they can cause serious bodily harm.
When assembling or removing any equipment, make sure that

the ropes and the lifting hook are in good condition and properly
sized for the load to be lifted.
WORKING UNDER THE MACHINE

Always use approved jack stands to support the machine when
performing maintenance under the chassis. Never rely on hy-
draulic jacks or the machines work equipment to support the ma-
chine when working under or on the machine.
Always lower the work equipment to the ground or in any case to

their lowest position before performing service or repairs under
the machine. Always lock the machine tracks securely. Do not
work under the machine if it is not sufficiently supported.
KEEPING THE MACHINE CLEAN

Never use flammable liquids to clean your machine. Use only ap-
proved non flammable cleaning solvents to clean parts of the ma-
chine itself.
Avoid using high pressure steam cleaners or caustic soaps to

wash the machine, if possible. Steam cleaning or using caustic
soaps may damage paint, wiring or sensitive electrical compo-
nents.
Never use high pressure water or flood the inside of the opera-
tor’s cab. Doing so may damage sensitive electrical components.
When pressure washing, keep the jet a minimum of 60 cm (24

in.) from any surface.
Always grease the machine after cleaning to push any water out
of the pivot point connections.
CK35-1 1-29
SAFETY
ENGINE OPERATION DURING MAINTENANCE

If during maintenance the engine must be running, be sure all
work equipment is locked.
Have someone remain in the operator’s seat while the engine is

running to stop the engine quickly, if required.
During maintenance operations with the engine running, never

disengage the safety locks of the controls from the LOCK posi-
tion.
Service personnel must not move any control lever.
CRITICAL PARTS
Periodically some parts must be replaced for safety purposes.
Even if these parts seem to be in good condition and operating
properly they may fail at some point causing possible injury to the
operator or a pedestrian. Listed are some of the systems contain-
ing these components that may fail under extended use:
• Fuel supply and delivery hoses.
• Hydraulic system: main delivery hoses and tubing.
• Hydraulic hoses: all the hoses that feed and return the hydrau-
lic fluid to and from the work equipment.
For additional information: See “CRITICAL PARTS FOR SAFE-

TY” on page 3-14.
STOP THE ENGINE BEFORE CARRYING OUT ANY

MAINTENANCE OPERATION OR INSPECTION
• Stop the machine only on firm and level ground and stop the
engine before carrying out any maintenance operation or in-
spection.
• If the engine must be running during a maintenance operation,

shift the safety bars to the LOCK position and carry out the
maintenance operation with the help of another person; one
operator must remain on the machine and the words and signs
to be used must be agreed upon in advance.
• The person who carries out the maintenance operations must

be very careful not to touch any moving part of the engine.
1-30 CK35-1
SAFETY
RULES FOR REFUELING THE MACHINE

Keep away from exposed flames while refueling or adding oil.
Spilled fuel or oil makes the ground slippery and may cause acci-
dents; clean any dirty area immediately and carefully.
Always tighten the fuel tank and the hydraulic circuit oil safety
caps securely.
Do not use fuel to clean any part of the machine that is dirty with
oil or dust.
Always top off the fuel and oil tanks in properly ventilated areas
and refrain from smoking.
When refueling, hold the fuel nozzle firmly and keep it constantly
in contact with the filler tube until you have finished, to avoid
sparks due to static electricity.
Do not fill the tank completely, to leave room for the fuel to ex-
pand.
COOLING SYSTEM PRECAUTIONS

Never add coolant to a hot or warm engine. Always allow the en-
gine time to cool down completely before opening the radiator
cap.
If it is necessary to remove the cap with the engine still hot, wear
suitable clothes and protection before loosening the cap. Loosen
the cap slowly to relieve pressure gradually.
Never dump used coolant on the ground, in a lake, stream or in a

sewer system. EPA law requires these fluids to be captured and
recycled properly. Failure to do so is in violation of the law.
USING LAMPS
When checking the fuel, oil, coolant or battery electrolyte levels,
always use approved explosion proof lights.
If such lighting equipment is not used, there is a danger of fire

and/or explosion.
CK35-1 1-31
SAFETY
ELECTRICAL PRECAUTIONS
When repairing the electrical system, disconnect the battery to
stop the flow of electricity.
When working on the electrical system, disconnect the negative

(-) battery cable b first, then the positive (+) battery cable c last.
Upon completion of work, reconnect the positive (+) cable c first,

then the negative (-) cable b last.
If electrical welding operations are to be performed on the ma-

chine, it is necessary to disconnect the battery and also the alter-
nator.
Be aware that the fuel injector harness contains high voltage and
high amperage.
PRECAUTIONS CONCERNING THE STARTER

Do not start the engine by tampering with the terminals of the
starter, since the machine may move.
Sudden or accidental movements of the machine may cause seri-

ous injuries or even death.
1-32 CK35-1
SAFETY
PRECAUTIONS CONCERNING HIGH PRESSURE

HOSES
Do not use bent, cut or cracked tubing or hoses which have been
previously rejected because of leaks or other defects. Faulty hos-
es can burst during operation causing injury or fire.
Repair or replace any loose or faulty fuel or hydraulic lines imme-
diately. Do not operate the machine with damaged or leaking
hoses or lines.
PRECAUTIONS FOR WORKING ON HIGH PRES-

SURE SYSTEMS
Remember that working hydraulic systems are always under
pressure. If you have to add or drain hydraulic fluid, service or in-
spect the hydraulic system, lower the equipment to the ground
and release system pressure and residual tank pressure before
starting any work.
Leaks from pressurized hydraulic lines are extremely dangerous
since the spray from them can penetrate your skin and enter the
bloodstream, or the eyes.
Always wear thick gloves and protective goggles when working
on the hydraulic system. Use a sheet of cardboard or plywood to
search for leaks.
If you are struck by a jet of hydraulic fluid under pressure, or if
you are injured even slightly, consult a doctor immediately for ap-
propriate treatment
PRECAUTIONS FOR MAINTENANCE WORK

INVOLVING HIGH TEMPERATURES AND PRES-
SURES
When you stop the machine at the end of a job, remember the
engine coolant, oil, all engine parts, exhaust stack and the hy-
draulic system are still hot and under pressure. If you attempt to
drain engine coolant, hydraulic fluid, or engine oil under these
conditions, you expose yourself to various dangers, including the
risk of serious burns.
Carry out maintenance procedures described in this manual only
when the machine has had time to cool down.
ROTATING PARTS
Take particular care near rotating parts. Keep your body at a safe
distance.
If hands, clothing, or tools become entangled in the fan blades or

fan belt, severe injury may result. Keep well away from all rotat-
ing parts.
CK35-1 1-33
SAFETY
PRECAUTIONS TO BE TAKEN WHEN USING

HIGH-PRESSURE GREASE TO ADJUST THE RUB-
BER TRACK TENSION
The grease contained in the rubber track tension adjustment de-
vice is pressurized. If the adjustment isn't carried out according to
the instructions given in the maintenance section, the grease
valve (1) may be ejected due to the high pressure and may be
dangerous for the operator.
When reducing the tension of the rubber tracks, do not loosen the
valve (1) more than five turns.
Keep face, hands and other body parts away from the valve (1).
DO NOT REMOVE THE SHOCK ABSORBING

SPRING FROM THE SHOCK ABSORBER UNIT
The shock absorber unit is provided with a shock absorbing
spring with high preload, which absorbs impacts on the front idler
roller.
Do not attempt to remove the spring, since this may lead to seri-
ous accidents and even death.
For any work to be carried out on the shock absorber unit, con-
tact your Komatsu distributor.
HYDRAULIC ACCUMULATOR
The hydraulic accumulator contains pressurized nitrogen.
When performing any work on the accumulator, proceed careful-
ly, since this may cause an explosion and consequent serious in-
jury and even death. For this reason, follow these instructions:
• Do not remove the accumulator;
• Do not bring the accumulator near sparks or open flames;
• Do not make holes in the accumulator, do not weld or use

oxyhydrogen flames;
• Do not hit or press the accumulator;
• When disposing of the accumulator, take care when releas-

ing the gas it contains.
Have this work done only by a Komatsu distributor.
1-34 CK35-1
SAFETY
DISPOSAL OF WASTE MATERIALS
Never dump waste fluids in a sewer system, on the ground, in riv-
ers, etc. Always drain fluids from your machine into the appropri-
ate containers. Never drain fluids directly onto the ground.
Obey appropriate laws and regulations when disposing of harm-

ful objects such as oil, fuel, filters, batteries, coolant, brake fluid
and hydraulic oil.
HYDRAULIC ENVIRONMENTAL ESTER SYN-

THETIC (HEES) OIL
HEES is a synthetic, biodegradeable oil intended for use in the
hydraulic system only.
• Never use HEES in the: engine, transmission, axle, braking

system or mix HEES with organic hydraulic oil. Doing so could
clog the hydraulic oil filter.
When switching to HEES for the hydraulic system:
1. Drain the organic oil from the tank completely. Disconnect the
hydraulic lines and drain the oil from the lines and the cylin-
ders.
2. Replace the hydraulic oil filter with a new one. Reconnect the
hydraulic oil lines.
3. Fill the hydraulic oil tank with HEES type oil.
4. Start the engine and let it idle until the hydraulic oil reaches
40°C(104°F). Operate all the work equipment to fill the hy-
draulic circuits.
5. Stop the engine and check the hydraulic oil level. Add oil as
needed.
CK35-1 1-35
SAFETY
1-36 CK35-1
2OPERATION
CK35-1 2-1
OPERATION
SAFETY LOCKS
If it is necessary to stop the machine with the loader arm

raised, always engage the mechanical loader arm support on
the loader arm and lock the equipment and travel control by
lifting the safety bars (See “SAFETY BARS” on page 2-28).
When traveling on roads with a machine approved for this
purpose and equipped with a backhoe, roll the bucket back
completely, apply the lock between boom and arm, the anti
rotation lock between boom and sliding plate and the center
lock of the sliding plate.
Raise the stabilizer supports completely, assemble the rele-
vant safety chains and finally lock the equipment controls by
shifting the safety device lever to the lock position. If the ma-
chine is also equipped with rear stabilizers, raise the sup-
ports and lock them with the relevant safety chains.
When traveling on roads with a machine approved for this
purpose and equipped with the cold planer, apply the lock on
the lifting jack to keep the equipment at a given distance
from the ground, lower the loader arm completely, and finally
lock the equipment controls by shifting the safety device le-
ver to the lock position.
Non-compliance with these rules may lead to serious acci-
dents.
LOADER ARM SUPPORT

The loader arm is provided with a loader arm support (1) to be used to
keep the arm raised when the machine is serviced or routine operations
are carried out.
The engagement of the loader arm support must be carried out by two
people, one seated in the driving position to check the movements of the
machine and the other standing on the ground to engage the support cor-
rectly.
It is important to remember that under operating conditions the loader
arm support (1) must be positioned against the arm and kept in this posi-
tion by means of the safety pin (2).
The loader arm support must always rest against the hydrau-
lic cylinder rod.
The loader arm support must be brought to its final position
by moving the contact surfaces slowly and continuously, in
such a way as not to damage the cylinder head surface.
2-2 CK35-1
OPERATION
After engaging the loader arm support (1), hold it in position

with the safety pin (2).
Do not perform any work under the raised loader arm if the
loader arm support (1) is not in the locked position.
The safety bars (3) located in front of the operator seated in the driving
position make it possible to lock the equipment and travel controls.
For the operation of the safety bars (See “SAFETY BARS” on page 2-
28).
The safety guard (4) locks the optional equipment control pedal in the
neutral position.
CK35-1 2-3
OPERATION
EXCAVATOR LOCKS
When traveling on roads, always position the backhoe fol-

lowing the longitudinal axis of the vehicle, apply the safety
locks and lock the equipment controls by shifting the safety
device lever to the lock position.
The backhoe safety locks must be used for traveling on roads and
applied by proceeding as follows:
• The safety locks of the excavator are necessary for movement on
roads and they must be applied by proceeding as follows:
2-4 CK35-1
OPERATION
Insert the spacers (1) to prevent the completely lowered loader
arm from touching the ground.
Fold the bucket completely and engage the retainer (2) between
boom and arm.
Lift the boom and apply the lock (3) for connection with the
revolving support.
Position the sliding plate to the center and engage the lock (4) to
secure it in this position on the frame of the excavator.
CK35-1 2-5
OPERATION
Raise the stabilizers completely and secure them in this position
with the safety chains (5).
If the machine is equipped with rear stabilizers, raise them com-

pletely and secure them in this position with the safety chains (6).
COLD PLANER LOCK
When traveling on roads, always position the cold planer fol-

lowing the longitudinal axis of the vehicle, apply the safety
locks and lock the equipment controls by shifting the safety
device lever to the locked position.
If the machine is equipped with a cold planer, it is also necessary

to install the spacers (1) to prevent the completely lowered loader
arm from touching the ground.
2-6 CK35-1
OPERATION
GENERAL VIEWS
FRONT VIEW OF MACHINE
1- Bucket 7 - Rear idler roller

2- Bucket Cylinder 8 - Travel reduction gear
3- Front idler roller 9 - Lift cylinder
4- Rubber track 10- Frame
5- Track roller 11- Loader arm
6- Left carriage frame 12- Cab
CK35-1 2-7
OPERATION
REAR VIEW OF MACHINE
1 - Rear Panel 3 - Muffler

2 - Engine Hood 4 - Right carriage frame
2-8 CK35-1
OPERATION
INSIDE VIEW OF CAB
1 - Safety bars
2 - Left PPC control joystick
ISO PATTERN SYSTEM
- Travel and steering
OPTIONAL PATTERN SYSTEM
- Left track travel and loader arm control
3 - Right PPC control joystick
ISO PATTERN SYSTEM
- Loader arm and bucket control
OPTIONAL PATTERN SYSTEM
- Right track travel and bucket control
4 - Auxiliary hydraulic control pedal (if installed)
5 - Foot accelerator
6 - Hand accelerator
7 - Parking brake
8 - Dashboard
CK35-1 2-9
OPERATION
10 - Left console switches

11 - Right console switches
2-10 CK35-1
OPERATION
INSTRUMENTS AND CONTROLS
INSTRUMENTS
1 - Hour Meter
2 - Engine Coolant Temperature Indicator
3 - Fuel Level Indicator
HOUR METER
This instrument indicates the total number of operating hours on the
engine. The count is continuous and the number is increased by 1 when
the engine has run for one hour, independently of its speed. When the
engine is running, the LED (A) positioned under the instrument flashes
and counts for every second. The hour meter keeps functioning even if
the machine is not travelling or working. The reading of the hour meter
is to be considered valid for the calculation of the maintenance inter-
vals.
CK35-1 2-11
OPERATION
ENGINE COOLANT TEMPERATURE INDICATOR
This instrument indicates the temperature of the engine coolant, which,
under normal conditions, should be 80-85°C(176-185°F). After starting
the engine and before starting work, let it warm up until the
temperature indicator reaches the green range. If the indicator exceeds
the limit values while the engine is running and indicates overheating,
the red range, let the engine idle until the indicator returns to the
normal temperature, the green range.
When the indicator suggests overheating, the red range, the audible
alarm also sounds.
If this problem occurs repeatedly, find out the cause (See
“TROUBLESHOOTING” on page 2-111).
FUEL LEVEL INDICATOR

This instrument indicates the fuel level in the tank; this information is
available only with the ignition key in position <<I>> (See “IGNITION
SWITCH” on page 2-21).
The green range indicates the normal fuel level, while the red range
indicates a low fuel level (reserve).
If the indicator reaches the reserve, red range, while the machine is
working, stop and add fuel to the correct level.
2-12 CK35-1
OPERATION
INDICATOR LIGHTS
1- Alternator Warning Light 7- Speed Increase Indicator Light

2- Preheating Indicator Light 8- Floating Device Indicator Light
3- Engine Oil Pressure Warning Light 9- Direction Indicator Light
4- Air Cleaner Clogging Warning Light 10- Working Light Indicator Light
5- Hydraulic Oil Filter Clogging Warning Light 11- Safety Device Functionality Control Unit
6- Parking Brake Warning Light
ALTERNATOR WARNING LIGHT

This warning light lights when the starting circuit is energized and goes
out when the engine exceeds idle speed; if this warning light remains on
even when the engine is running at the normal operating speed, it means
that the alternator is not charging and the battery is not charged cor-
rectly.
If the warning light remains off when the ignition key is

turned to position "I", it means that the alternator is faulty or
broken.
CK35-1 2-13
OPERATION
PREHEATING WARNING LIGHT
This warning light lights when the ignition key is turned to position
<< >> to start the engine at low temperatures and goes out automati-
cally after approximately 13 seconds (See “STARTING THE ENGINE”
on page 2-61).
ENGINE OIL PRESSURE WARNING LIGHT

This warning light lights and activates the audible alarm with the engine
stopped when the starting circuit is energized and goes out as soon as
the engine lubrication circuit is pressurized. If this warning light
remains on or lights with the engine running, stop the machine immedi-
ately and try to locate the trouble.
AIR CLEANER CLOGGING WARNING LIGHT

This warning light lights when the engine air filter needs cleaning or
replacing.
HYDRAULIC OIL FILTER CLOGGING WARNING

LIGHT
This warning light lights when the hydraulic circuit filter needs replac-
ing.
2-14 CK35-1
OPERATION
PARKING BRAKE WARNING LIGHT
This warning light lights when the park brake circuit is not functioning
properly. If this light lights during normal operation, stop the machine
and try to locate the trouble.
SPEED INCREASE INDICATOR LIGHT

This light lights when the high speed button on the left joystick is
pressed (See “SPEED INCREASE BUTTON” on page 2-22).
FLOAT SWITCH INDICATOR LIGHT

This light lights when the float switch is selected (See “FLOATING
DEVICE SWITCH (IF INSTALLED)” on page 2-22).
DIRECTION INDICATOR LIGHT

This warning light lights intermittently when the lever on the left con-
sole is operated (See “DIRECTION INDICATOR SWITCH” on
page 2-21) or when the emergency switch is operated (See “EMER-
GENCY (HAZARD) SWITCH (IF INSTALLED)” on page 2-20).
CK35-1 2-15
OPERATION
WORKING LIGHT INDICATOR LIGHT
This light lights when the working lights are turned on with the switch
on the right console (See “WORKING LIGHT SWITCH” on page 2-
20)
SAFETY DEVICE FUNCTIONALITY CONTROL

UNIT
This control unit is positioned on the dashboard and checks the condi-
tion of the safety devices installed on the machine.
The signals are shown on the display by the lighting and extinguishing
of the warning lights.
The functions are as follows:
0A - RED WARNING LIGHT

LED off - This indicates that all the safety devices are on and
therefore all the machine functions are normal (the solenoid
valve ensures the lifting of the work equipment and the
machine travel).
LED on - This indicates that at least one safety function is
lacking; in this case the solenoid valve is closed and does not
permit the lifting and therefore the use of the work equipment
and the machine travel.
0B - GREEN INDICATOR LIGHT

LED on - This indicates that the operator is correctly seated in
the driving position and that the operator seat switch sensor is
on.
LED off - (With the red warning light coming on at the same
time) This indicates that the operator is standing or that he is
not inside the cab.
The operator presence signal (seat) starts the emergency

procedure after a delay of 1.5 seconds, all hydraulic func-
tions are locked out and the parking brake is applied. To re-
sume operation, the operator must sit in the driving position,
lower the safety bars and press the park brake push button
on the left console.
The delay allows the machine to be operated on uneven
ground without signalling repeated emergencies.
2-16 CK35-1
OPERATION
0C - GREEN INDICATOR LIGHT

LED on - This indicates that the safety bars are down and the
work equipment and the travel functions can be operated.
LED off - (With the red warning light coming on at the same
time) This indicates that the safety bars are not completely
down and therefore the work equipment and the travel func-
tions cannot be used.
The sounding of the audible alarm (buzzer) signals that the

PPC valve coil is not functioning properly.
This alarm sounds even with the engine stopped and the ig-
nition key removed from the ignition switch.
Take notice of the following conditions:
A) Engine stops and the audible alarm sounds.
Safety bars raised and temporary binding of the PPC sole-
noid valve.
Lower the work equipment to the ground (See "MACHINE
CONTROLS" on page 2-25), get off the machine and try to
locate the trouble.
B) Audible alarm sounds with the engine off.
PPC solenoid valve binding.
Lower the work equipment to the ground (See "MACHINE
CONTROLS" on page 2-25), get off the machine and try to
locate the trouble.
When troubleshooting for extended periods of time, discon-
nect the negative cable (-) at the battery, to avoid discharg-
ing it completely.
The green LED’s (seat and safety bar) light only if the opera-
tor has engaged all the safety locks and released the parking
brake (red LED on). The LED’s go out whenever the safety
bar is lifted (PPC controls off); to reactivate the PPC con-
trols, sit in the driving position, lower the safety bar and
press the parking brake push button (green and red LED’s
on).
CK35-1 2-17
OPERATION
SWITCHES AND PUSH BUTTONS
1 - Parking brake push button
2 - Rotating beacon light switch
3 - Left stabilizer button (if installed)
4 - Right stabilizer button (if installed)
5 - Working light switch
6 - Emergency (HAZARD) light switch
7 - Parking light and low beam switch
8 - Direction indicator switch
9 - Ignition switch
10 - Horn
11 - High Flow hydraulic system switch (3 lines) for front equip-
ment (if installed)
2-18 CK35-1
OPERATION
12 - Super Flow (momentary reverse) hydraulic push button for
optional attachments (if installed)
13 - Speed increase button
14 - Floating device button (if installed)
15 - Operates electro-hydraulic functions of optional attachments
(if installed)
16 - Seat Override switch
PARKING BRAKE PUSH BUTTON

If pressed, this switch engages the parking brake.
If pressed again, it disengages the brake, thus releasing the machine.
The parking brake is automatically engaged whenever the

engine stops; this is due to the lack of pressure in the hy-
draulic circuit.
The push button releases the brake only when the engine is
running and all the safety devices are engaged (warning
lights off).
ROTATING BEACON LIGHT SWITCH

This switch turns on the rotating beacon and must be operated when
necessary to travel on roads.
CK35-1 2-19
OPERATION
LEFT STABILIZER BUTTON (IF INSTALLED)
This is a button with three positions: forward, center and back.
Press the button forward or backward to lower or raise the stabilizer.
The center position turns the left stabilizer off.
For use, See “LEFT STABILIZER BUTTON (IF INSTALLED)” on
page 2-20.
RIGHT STABILIZER BUTTON (IF INSTALLED)

This is a button with three positions: forward, center and back.
Press the button forward or backward to lower or raise the stabilizer.
The center position turns the left stabilizer off.
For use,See “RIGHT STABILIZER BUTTON (IF INSTALLED)” on
page 2-20.
WORKING LIGHT SWITCH

Turns on the working lights.
EMERGENCY (HAZARD) SWITCH (IF INSTALLED)

Operates all the direction lights at the same time and must be used
whenever the machine is temporarily parked on the roadside or in an
abnormal position while traveling on roads.
2-20 CK35-1
OPERATION
PARKING LIGHT AND LOW BEAM SWITCH
This is a two-position switch:
The 1st click turns on the instrument lights and the parking lights.
The 2nd click turns on the low beam or working lights, according to the
position of the switch (2).
DIRECTION INDICATOR SWITCH

This is a lever switch with three positions. The neutral position is in the
center.
Shift the switch lever to the right or to the left to indicate the turn direc-
tion.
IGNITION SWITCH
This is a rotary key switch with four positions marked by the following
symbols « » - }(OFF) - I - « »(START).
For further details on the use of this switch, See “STARTING THE
ENGINE” on page 2-61.
HORN
This push button is located on the left joystick grip and serves to warn
people in the vicinity of the machine, at the beginning of work, and in
case of danger, after being pushed by the operator.
CK35-1 2-21
OPERATION
FRONT EQUIPMENT HIGH FLOW HYDRAULIC
SYSTEM MOMENTARY SWITCH (3 LINES)(IF
INSTALLED)
This is a momentary switch and allows increased oil delivery from the
hydraulic pump to flow in reverse only when it is pressed.
For use, See “STANDARD FLOW HYDRAULIC SYSTEM CON-
TROL” on page 2-40.
FRONT EQUIPMENT SUPER FLOW HYDRAULIC

SYSTEM CONTINUOUS SWITCH (5 LINES)(IF
INSTALLED)
This is a double-function switch and allows the oil delivery from the
hydraulic pump to constantly flow forward.
For use, See “SUPER FLOW HYDRAULIC SYSTEM CONTROL” on
page 2-41.
SPEED INCREASE BUTTON

This button is positioned on the underside of the left joystick grip and
serves to increase the machine speed when pressed.
For use, See “SPEED INCREASE CONTROL” on page 2-43.
FLOATING DEVICE SWITCH (IF INSTALLED)

This switch is positioned on the underside of the right joystick grip and,
when pressed, enables the electrohydraulic circuit of the floating device.
For use, See “FLOATING POSITION CONTROL” on page 2-43
2-22 CK35-1
OPERATION
SEAT OVERRIDE SWITCH
The operator must press this switch when using any attachment that
requires him/her to be out of the normal seated driving position when
operating that attachment.
AVAILABLE FOR OTHER FUNCTIONS

The operator has the opportunity to use 3 push-button controls for elec-
trohydraulic equipment with more than one function. For use, See
“OPTIONAL ELECTRICAL CONNECTIONS” on page 2-46.
CK35-1 2-23
OPERATION
ELECTRICAL ACCESSORIES
1 - Audible alarm
2 - Electric outlet
3 - Optional Master Electrical Disconnect Switch (if installed)
AUDIBLE ALARM
This audible alarm sounds when the circuits are energized with the igni-
tion key (rotation to position «I») and is automatically disengaged when
the engine is started.
The sounding of the alarm during operation signals:
• insufficient engine oil pressure;
• overheating of the engine cooling circuit;
• malfunction of the PPC control solenoid valve coil
2-24 CK35-1
OPERATION
ELECTRIC OUTLET
An electric outlet is positioned on the right rear of the cab inner wall for
the connection of a lighting device for routine and maintenance opera-
tions.
It is a two-pole outlet and is in compliance with the ISO 4165-1979
standard.
Power supply 12 V.
MASTER ELECTRICAL DISCONNECT SWITCH (IF

INSTALLED)
This is a removable lever-type switch positioned near the battery. To
reach it, it is necessary to open the engine hood (See “ENGINE HOOD”
on page 2-51).
The current transmitted by the battery to the electric system of the
machine can be stopped by rotating the switch clockwise (position B).
Always rotate the switch to “position B” if it is necessary to work on the
battery or the electrical system, or if electric welding must be carried
out on the machine.
The electrical connection can be restored by rotating the switch counter-
clockwise (position A).
CK35-1 2-25
OPERATION
MACHINE CONTROLS
1 - Safety bars
2 - Left PPC control joystick
Travel and steering - ISO PATTERN SYSTEM
Left wheel travel and loader arm control - OPTIONAL PATTERN
SYSTEM
3 - Right PPC control joystick
Loader arm and bucket control - ISO PATTERN SYSTEM
Right wheel travel and bucket control - OPTIONAL PATTERN
SYSTEM
Auxiliary hydraulic kit control pedal
5 - Foot accelerator
6 - Hand accelerator
7 - Parking brake
8 - Super Flow hydraulic system control (continuous forward) (if
installed)
9 - Super Flow hydraulic system control (momentary reverse) (if
installed)
10 - Speed increase control
2-26 CK35-1
OPERATION
11 - Float position control
12 - Pattern shifting control
13 - Right stabilizer control (if installed)
14 - Left stabilizer control (if installed)
15 - Optional Attachment Electrical Connection control
CK35-1 2-27
OPERATION
SAFETY BARS
Before leaving the operator seat, lower the equipment to the

ground and rotate the safety bars to the vertical (unlocked)
position.
The safety devices on this machine are composed of electri-
cal components. Before modifying or replacing any wiring or
electrical components, which may result in malfunctions of
the devices, contact your Komatsu distributor.
The locking of the PPC control safety device is performed by lifting the
safety bars (1) to a vertical position.
The safety device can be released by lowering the safety bars to the hor-
izontal position and pressing the parking brake push button (warning
light off).
Equipment movement and machine travel cannot be per-

formed with the safety bars (1) in the locked, or vertical posi-
tion.
2-28 CK35-1
OPERATION
ISO PATTERN CONTROL SYSTEM
LEFT PPC CONTROL JOYSTICK (TRAVEL AND
STEERING)
Before performing any maneuver with this joystick, the oper-

ator must be seated in the work position with the seat belt
fastened; before any maneuver the operator must take all the
precautions indicated in “3.6.5 HOW TO MOVE THE MA-
CHINE”.
Before moving, make sure that the safety bars are in the hor-
izontal (unlocked) position and the parking brake is disen-
gaged.
When traveling on roads, make sure that all the safety devic-
es have been engaged.
Failure to comply with these rules may lead to serious acci-
dents.
The left PPC control joystick (2) controls the forward/reverse move-
ments and the steering of the machine as indicated in the diagram
below.
N - Neutral
A - Forward gear
B - Counter rotation to the right
C - Reverse gear
D - Counter rotation to the left
CK35-1 2-29
OPERATION
If the joystick is operated in directions that are inclined with respect to
the machine axis, simultaneous steering movements proportional to the
angle of inclination are obtained, since the two hydraulic pumps corre-
sponding to each single function are engaged at the same time.
N - Neutral
A - Forward left steering
B - Forward right steering
C - Reverse left steering
D - Reverse right steering
Always travel at moderate speed to obtain maximum accura-

cy and efficiency while working.
While working, the movement of the joystick must be propor-
tional to the required effort to maintain constant engine
speed.
Maneuver the joystick smoothly, without abrupt movements,
and avoid counter rotations as much as possible, since
these maneuvers result in rapid track wear.
The joystick grip is provided with the horn, which must be
used to warn people in the vicinity of the machine at the be-
ginning of work and in case of danger.
All movement is cancelled by rotating the safety bars to the
locked (vertical) position (See “SAFETY BARS” on page 2-
28).
2-30 CK35-1
OPERATION
RIGHT PPC CONTROL JOYSTICK
(LOADER ARM AND BUCKET)

fastened and the safety bars in the unlocked (horizontal) po-
sition; before any maneuver perform the operations de-
scribed in “3.13 USING THE WORK EQUIPMENT”.
Before leaving the operating position, lower the equipment
to the ground and rotate the safety bars to the locked (verti-
cal) position, then stop the engine.
Failure to comply with these instructions may lead to serious
accidents.
The loader self-leveling system is operated automatically

only when the loader arm is lifted with a loaded bucket.
When the loader arm is in the lowering phase the system
cannot be operated.
At maximum height, the self-leveling system keeps the
bucket partially rolled back to prevent material from falling
out of the bucket.
The right PPC control joystick (3) controls the loader arm and bucket
functions of the machine as indicated in the diagram below.
The bucket should never be rolled back more than 45° with
the arm in the dump position.
The following diagrams show the basic maneuvers and the possible
combined maneuvers.
BASIC MANEUVERS
N - Neutral
A - Arm lowering
B - Bucket dumping
C - Arm lifting
D - Bucket roll back
CK35-1 2-31
OPERATION
If the joystick is operated in directions that are inclined with respect to
the machine axes, simultaneous movements proportional to the angle of
inclination are obtained, since the two hydraulic valves corresponding
to each single function are engaged at the same time.
N - Neutral
A - Arm Lower - Bucket Roll Back
B - Arm Lower - Bucket Dump
C - Arm Raise - Bucket Dump
D - Arm Raise - Bucket Roll Back
All movements are cancelled by shifting the safety bars to

the locked (vertical) position.
2-32 CK35-1
OPERATION
OPTIONAL PATTERN CONTROL SYSTEM
LEFT PPC CONTROL JOYSTICK (LEFT TRACK
TRAVEL, STEERING, AND LOADER ARM CON-
TROL)

fastened and the safety bars in the unlocked (horizontal) po-
sition; before any maneuver the operator must take all the
precautions indicated, See “MOVING THE MACHINE (ISO
PATTERN CONTROL SYSTEM)” on page 2-64 or See “HOW
TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL
SYSTEM)” on page 2-68.
Before moving, make sure the safety bars are in the horizon-
tal (unlocked) position and the parking brake is disengaged.
Before leaving the work position, lower the equipment to the
ground and rotate the safety bars to the locked (vertical) po-
sition, then stop the engine.
accidents.
The self-leveling system is operated automatically only when

the loader arm is lifted with a loaded bucket. When the loader
arm is in the lowering phase the system cannot be operated.
At maximum height the self-leveling system keeps the
bucket partially rolled back to prevent the material from spill-
ing out of the bucket.
The left PPC control joystick (2) serves to control the forward and
reverse movements, the steering of the machine to the right, and the
loader arm raising and lowering functions according to the movements
indicated in the diagram below.
To move the machine forward or backward, move the control

joysticks (2) and (3) at the same time and in the same direc-
tion.
CK35-1 2-33
OPERATION
N - Neutral
A - Forward right steering
B - Arm lowering
C - Reverse right steering
D - Arm lifting
Always travel at moderate speed to obtain maximum accura-

cy and efficiency while working.
While working, the movement of the joystick must be propor-
tional to the required effort to maintain constant engine
speed.
Move the joystick smoothly, without abrupt movements and
avoid counter rotations as much as possible, since these
maneuvers result in rapid track wear.
The joystick grip is provided with the horn, which must be
used to warn people in the vicinity of the machine at the be-
ginning of work and in case of danger.
All movements are cancelled by rotating the safety bars to
the locked (vertical) position (See “SAFETY BARS” on
page 2-28).
2-34 CK35-1
OPERATION
RIGHT PPC CONTROL JOYSTICK (RIGHT
TRACK TRAVEL, STEERING, AND BUCKET
CONTROL)

fastened; before every maneuver the operator must take all
the precautions indicated See “MOVING THE MACHINE (ISO
PATTERN CONTROL SYSTEM)” on page 2-64 or See “HOW
TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL
SYSTEM)” on page 2-68 and See “OPERATING THE WORK
EQUIPMENT” on page 2-96.
Before moving, make sure that the safety bars are in the hor-
izontal (unlocked) position and the parking brake is disen-
gaged.
ground and lock the safety bars (vertical position), then stop
the engine.
Failure to comply with these rules may lead to serious acci-
dents.
The right PPC control joystick (3) serves to control the forward and
reverse movements, the steering of the machine to the left, the bucket
roll back and dumping function, according to the movements indicated
in the diagram below..
To move the machine forward or backward, shift the control

joysticks (2) and (3) at the same time and in the same direc-
tion.
N - Neutral
A - Forward left steering
B - Bucket dumping
C - Reverse left steering
D - Bucket roll back
CK35-1 2-35
OPERATION
Always travel at moderate speed, to obtain maximum accura-

cy and maximum efficiency during work.
During work, the use of the joystick must be proportional to
the required effort to maintain constant engine speed.
Move the joystick smoothly, without abrupt movements, and
avoid counter rotations as much as possible, since these
maneuvers result in rapid track wear.
All movements are cancelled by rotating the safety bars to
the locked (vertical) position (See “SAFETY BARS” on
page 2-28).
2-36 CK35-1
OPERATION
AUXILIARY HYDRAULIC KIT CONTROL
PEDAL (IF INSTALLED)
Always engage the safety guard (2) when use of the control
is not required, during travel, and when parking the machine.
When connecting a hydraulic attachment, make sure the
control pedal (1) is always in the neutral or horizontal posi-
tion and covered with the safety guard.
Never set the control pedal to the maximum flow position
unless the machine is stopped, the safety bar is in the low-
ered position, and the operator is seated with the seat belt
fastened.
The pedal (1) controls the starting and stopping of the oil flow to the
attachment and has three fixed positions ( applied, neutral, and
applied).
To apply the pedal (1), lift the safety guard (2).
1 - Neutral or horizontal position (HYDRAULIC CIRCUIT

CLOSED).
No flow provided to the attachment.
CK35-1 2-37
OPERATION
2- applied position (HYDRAULIC CIRCUIT OPEN).
In the applied position, oil flow is supplied to the attachment
(excavator, demolition hammer, asphalt cutter, etc.) and is
obtained by pressing the pedal with the left part of the foot
pedal. To provide continuous oil flow, lock foot pedal in posi-
tion with lever (3).
To release pedal (1) to the neutral, or horizontal position, push
locking lever (3) forward to agree with illustration .
3 - Two direction variable flow position.

The pedal is also used to control the oil flow to attachments
with two hydraulic circuits (multipurpose buckets, drills,
asphalt cutters, etc.). Shift locking lever (3) to the unlocked
(forward) position and press pedal (1) to position or to
control the flow of oil to the attachment. The amount of flow in
each direction is proportional to the distance the pedal is
moved.
2-38 CK35-1
OPERATION
FOOT ACCELERATOR
The accelerator pedal (1) is positioned on the operator’s right and serves
to control the engine speed and power.
Use the accelerator pedal with care, especially when the machine is
under load or is working under difficult conditions.
Avoid useless acceleration, to reduce fuel consumption and extend the
life of both the engine and the machine.
HAND ACCELERATOR
The use of the hand accelerator is allowed only under the in-
dicated conditions; its use in other conditions may lead to
accidents.
The hand accelerator must be used during the warming up of the engine
and successively when operations with the optional equipment are to be
carried out; it can also be used for some maintenance operations.
• Idle position :
Lever pushed completely forward.
• Maximum speed position :

Lever pulled completely backward.
CK35-1 2-39
OPERATION
PARKING BRAKE
The parking brake must be applied whenever the operator

leaves the driving position, even if for a short time.
The machine must be positioned with the tracks resting firm-
ly on the ground. If one of the tracks is unstable or is resting
on a small obstacle, the machine may move.
Periodically check the functionality of the parking brake.
accidents or even death.
In case of failure of the hydraulic system, before moving the
machine, release the negative brake installed on the travel
hydraulic motors (See “RELEASING THE PARKING BRAKE”
on page 3-26).
The braking action is obtained by pressing the switch (1) (LED ON);
the release is obtained by pressing the switch again (LED OFF).
The parking brake is automatically engaged whenever the

engine stops; this is due to the lack of pressure in the hy-
draulic system.
Every time the engine is started or restarted, it is necessary
to release the parking brake before moving the machine.
STANDARD FLOW HYDRAULIC SYSTEM CONTROL

(2 OR 3 LINES)
Never connect an attachment to the hydraulic lines before

the attachment is mechanically installed and locked to the
machine front coupler.
Controls must be in neutral and deactivated prior to connect-
ing hydraulic lines to an attachment.
Connect hydraulic lines only with the engine off and the
parking brake engaged.
Do not risk serious injury. Always operate the attachment
from the operator’s seat. Do not allow other people close to
the machine or attachment.
Read and understand the attachment Operator’s Manual re-
garding attachment control functions and operation.
The oil flow, which is bidirectional, to the attachment is controlled by

the pedal (See “AUXILIARY HYDRAULIC KIT CONTROL
PEDAL (IF INSTALLED)” on page 2-37) and is proportional to the
distance the pedal is moved in either direction. The hydraulic lines are
located on the left arm.
2-40 CK35-1
OPERATION
SUPER FLOW HYDRAULIC SYSTEM CONTROL
(5 LINES)
Never connect an attachment to the hydraulic lines before

the attachment is mechanically installed and locked to the
machine front coupler.
Controls must be in neutral and deactivated prior to connect-
ing hydraulic lines to an attachment.
Connect hydraulic lines only with the engine off and the
parking brake engaged.
Do not risk serious injury. Always operate the attachment
from the operator’s seat. Do not allow other people close to
the machine or attachment.
Read and understand the attachment Operator’s Manual re-
garding attachment control functions and operation.
If the Super Flow button, (1) or (2), is pressed ON, be aware

that the hydraulic flow will operate the attachment if the but-
ton is pressed.
The Super Flow hydraulic controls can be used when the operator needs
increased oil delivery in the attachments hydraulic system. With the
“Super Flow” hydraulic system it is possible to use equipment that
requires a high-flow hydraulic line (left) and, at the same time, a stan-
dard-flow hydraulic line (right) with limited oil flow for secondary
functions (auxiliary hydraulic kit control pedal).
CK35-1 2-41
OPERATION
With the Super Flow hydraulic controls, the operator can utilize two
independent hydraulic circuits (located on the right and left arms). With
the Super Flow system, the standard flow lines are moved to the right
arm. The amount of oil flow in the right hydraulic lines and the flow
reversal are managed by means of the pedal (See “AUXILIARY
HYDRAULIC KIT CONTROL PEDAL (IF INSTALLED)” on page 2-
37).
Left side hydraulic lines are used only for the equipment requiring
Super Flow rates and controlled by push button (1) and push button (2)
on the left joystick.
To provide oil flow to the attachment, press and release push button (2)
(red LED above the button on); press the button again to completely
stop the oil flow (red LED off) thru the hydraulic lines.
To provide the oil flow and at the same time reverse it, press and hold
push button (1). Release push button (1) to restore normal operation.
2-42 CK35-1
OPERATION
SPEED INCREASE CONTROL
The button (1) that allows the machine travel speed to be increased is
positioned on the underside of the left joystick grip.
When the button is pressed, the speed increases; push the button again
to return to normal speed.
The speed increase function should be used only for the

high speed repositioning of the machine; in any other case,
it is advisable to use the normal speed.
Do not use the speed increase control when performing
steering or counter rotation maneuvers.
FLOATING POSITION CONTROL

The right joystick grip is provided with a switch (1) that, when pressed,
(INDICATING LIGHT ON) (See “FLOAT SWITCH INDICATOR
LIGHT” on page 2-15) frees the loader arm (floating position), that is,
allows it to automatically follow the undulations of the ground.
Press the switch again to restore the standard operating conditions
(INDICATING LIGHT OFF) (See “FLOAT SWITCH INDICATOR
LIGHT” on page 2-15).
CK35-1 2-43
OPERATION
PATTERN SHIFTING CONTROL
Before using the pattern shifting control, lower the equip-

ment to the ground, engage the safety devices and stop the
engine.
injuries or even death.
The pattern shifting control is located in the engine compartment on the

rear wall of the cab and can be reached after opening the engine hood
(See “ENGINE HOOD” on page 2-51).
The lever (1) of the pattern shifting control has two positions:
• ISO CONTROL SYSTEM
Lever in position A
• OPTIONAL CONTROL SYSTEM
Lever in position B
2-44 CK35-1
OPERATION
The control system selection lever (1) is held in the correct position by
means of a safety screw (2).
When it is necessary to modify the control system, loosen the safety
screw (2) until lever (1) can be moved. Use a 13 mm wrench or the fac-
tory supplied ring.
Select the desired control system and lock the lever in place by tighten-
ing the safety screw (2).
Before moving the machine, the operator must make sure

that the selected control system is the one that is required.
The control panels (3) located on the sides of the central

dashboard are lit from behind. The backlighting of the panels
is helpful to the operator in identifying the type of control
system selected (ISO PATTERN control or OPTION control).
CK35-1 2-45
OPERATION
RIGHT STABILIZER CONTROL
Before moving the machine in any way, make sure that the
stabilizer feet are completely raised.
Before traveling on roads, make sure that the safety locks of
the stabilizer feet have been applied.
The right stabilizer is operated by means of the button (1) installed on

the left console and according to the indicated positions.
1. Press the button forward to lower the stabilizer foot.
2. Press the button backward to raise the stabilizer foot.
LEFT STABILIZER CONTROL
Before moving the machine in any way, make sure that the
stabilizer feet are completely raised.
Before traveling on roads, make sure that the safety locks of
the stabilizer feet have been applied.
The left stabilizer is operated by means of the button (1) installed on the
left console and according to the indicated positions.
1 - Press the button forward to lower the stabilizer foot.
2 - Press the button backward to raise the stabilizer foot.
OPTIONAL ELECTRICAL CONNECTIONS
The right three-button joystick is used when the operator needs to con-
nect electro-hydraulic equipment with several functions.
Each push button corresponds to an electric line activated by a pulse
control: press the push button to activate the electric contact; release the
push button to deactivate the contact.
This feature is only available with the Super Flow Auxiliary Hydraulics.
2-46 CK35-1
OPERATION
FUSES AND RELAYS
When changing a fuse, make sure that the ignition switch is

in the OFF position. If the fuses are oxidized, corroded, or do
not fit perfectly in their seat, replace them only with new
fuses having the same capacity.
If the engine does not turn when the ignition switch is turned
to START, check the engine start fuse and if necessary
change it.
MACHINE FUNCTION FUSES

The fuses relevant to the machine functions are grouped on a single
base positioned on the dashboard behind the seat.
STANDARD VERSION
POSITION COLOR CAPACITY A CIRCUIT
1 Violet 3 Left parking lights
2 Violet 3 Control panel lights, right parking lights
3 Light Blue 15 Horn, low beam, or front working lights
4 Brown 7.5 Switch lights
5 Light blue 15 Rear working lights
6 Red 10 Power supply for joystick switches, floating device, pattern shifting
7 Red 10 12V electrical outlet, revolving beacon light
8 Red 10 Power supply for control panel, safety unit, solenoid valve stop, con-
trol bar sensor, seat sensor, brake switch
9 Brown 7.5 Back-up alarm
10 Brown 7.5 Fuel pump, safety relay (against repeated starting), alternator
11 Green 30 Solenoid pull relay, servo control safety pressure switch
CK35-1 2-47
OPERATION
VERSION WITH OPTIONAL CONNECTIONS
POSITION COLOR CAPACITY A CIRCUIT
1 Violet 3 Left parking light, number plate light
2 Violet 3 Control panel lights, right parking lights
3 Light blue 15 Horn, low beam, or front working lights
4 Red 10 Switch lights, direction indicator lights
5 Light blue 15 Rear working lights, stop lights
6 Red 10 Power supply for joystick switches, floating device, pattern shifting
7 Red 10 12V electrical outlet, revolving beacon light, emergency lights (HAZARD)
8 Red 10 Power supply for control panel, safety unit, solenoid valve stop, control bar
sensor, seat sensor, brake switch
9 Brown 7.5 Back-up alarm, power supply for Super-flow 3-way equipment hydraulic
system, stabilizers, safety valves
10 Brown 7.5 Fuel pump, safety relay (against repeated starting), alternator
11 Green 30 Solenoid pull relay, servo control safety pressure switch
MAIN FUSE
The main fuse (1) is positioned near the battery and can be reached by
tilting the cab (See “TILTING THE CAB” on page 2-54).
POSITION COLOR CAPACITY (A) CIRCUIT
1 RED 50 SYSTEM GENERAL CIRCUIT
2-48 CK35-1
OPERATION
RELAYS
The relays are positioned inside the engine compartment and can be
reached by tilting the cab (See “TILTING THE CAB” on page 2-54).
Some relays are grouped inside the box attached to the right side of the
machine frame and can be reached by removing the cover (A).
POSITION DESCRIPTION
1 Engine stop relay
2 Safety relay (against repeated cranking)
Other relays are contained inside the base installed on panel (B) behind
the seat and can be reached by removing panel (B).
CK35-1 2-49
OPERATION
3 Safety Unit
4 Relay board:
A - Stop lights
B - 1 way
C - 3 way
D - Momentary high-low
E - 2 way
F - Blinking
G - Detent high-flow
5 Stoplight relay
6 Floating device control relay
7 Parking brake relay
2-50 CK35-1
OPERATION
GUARDS AND OPERATOR’S SEAT
ENGINE HOOD
Do not open the engine hood when the engine is running. Do

not use the machine without the engine hood and do not
start the engine when the hood is open, unless this is
expressly prescribed for certain maintenance operations.
Failure to follow these rules may result in serious accidents.
OPENING THE HOOD

After releasing the lock, press the push button (1) and raise the engine
hood (2).
The maximum opening position is maintained by the lifting piston (3),
which is locked in position by the safety retainer (4).
CLOSING THE HOOD
Press the safety retainer (4) of the lifting piston (3) and at the same time
lower the hood.
Push it downwards until the lock engages.
Lock the hood.
Make sure that the safety retainer (4) is engaged every time
you open the hood.
CK35-1 2-51
OPERATION
REAR PANEL
Do not open the rear panel when the engine is running.

Do not use the machine without the rear panel and do not
start the engine with the panel open, if this is not expressly
prescribed for certain maintenance operations.
Failure to follow these rules may lead to serious accidents.
The rear panel can be opened only after opening the engine
hood.
When inspecting or carrying out a maintenance operation in-
side the rear panel, always engage the panel in the safety re-
tainer to keep it open.
To reach the release lever (2) for the rear panel (1), raise the engine
hood (See “ENGINE HOOD” on page 2-51).
To open the rear cover (1), lift the lever (2) positioned on the inner left
side of the machine, at the same time rotate the cover to the maximum
opening position and hold it open with retainer (3), by proceeding as
follows:
1. Lift retainer (3) and rotate it clockwise until it rests against the rear
cover (1).
2. Release retainer (3) and make sure that it has been engaged correctly.
To close the rear cover (1), release retainer (3) by rotating it counter
clockwise and resting it against the rear cover (1).
2-52 CK35-1
OPERATION
CAB
The cab is a combined ROPS-FOPS; if it is subjected to an

impact for any reason, or if the machine overturns, contact
your distributor, who will make sure the operator’s safety is
ensured.
For maintenance or routine operations, the cab must be
tilted; carry out this operation according to the procedure
described in section (See “TILTING THE CAB” on page 2-54)
and adhere to all safety precautions indicated therein.
The cab is of the semi-closed type.

The windows are positioned on the rear and upper part and the rear win-
dow can be removed.
In a special version of the machine, available on request, the cab can be
completely closed through the addition of side windows and front door.
CK35-1 2-53
OPERATION
TILTING THE CAB
Tilt the cab only with the machine parked on a firm and level
surface and with the loader arm lowered to the ground com-
plete with bucket or any other optional equipment.
Make sure that the surface on which the machine is parked is
not slippery.
Before tilting the cab, make sure that the engine hood is
open (see ENGINE HOOD on page 2-51.).
When lifting the cab, avoid removing the fastening screws
(A) of the rear dampening supports of the cab itself.
The cab must be raised or lowered by two people, one per
side and it is important to make sure that the handles and
hold points are not dirty with oil or grease.
After tilting the cab, always engage the safety split pin of the
cab overturning protection lock.
Do not carry out any operation on the machine if the hitch
pin clip of the cab overturning protection lock is not en-
gaged.
Always tighten the cab fastening screws to the torque indi-
cated in (See “SPECIFIC TORQUES” on page 3-20).
To carry out some maintenance or routine operations, it is necessary to

tilt the cab, an operation that must be carried out by two people accord-
ing to the following procedure:
1. Stop the machine on firm and level ground.
2. Lower the equipment to the ground.
3. Apply the parking brake and lock the controls by rotating the safety
bars to the lock (vertical) position.
4. Stop the engine as indicated in (See “STOPPING THE ENGINE”
on page 2-89).
5. Open the engine hood (See “ENGINE HOOD” on page 2-51) and
remove the rear screws (1) that fasten the cab to the frame.
Use a 19 mm hexagon wrench.
6. With the help of another person, raise the rear part of the cab using
the appropriate handles and pull it forward until it stops.
7. Engage the hitch pin clip (2) of the cab overturning protection lock
(3).
2-54 CK35-1
OPERATION
When lowering the cab, be careful of the hold points and car-
ry out the operation with the help of another person.
1. Remove the hitch pin clip (2) of the cab overturning protection lock
(3) and put it in the appropriate seat (4).
2. Lower the rear of the cab until it touches the support surface.
3. Reassemble the fastening screws (1) and tighten them to the torque
indicated in paragraph (See “SPECIFIC TORQUES” on page 3-20)
and close the engine hood (See “ENGINE HOOD” on page 2-51).
CK35-1 2-55
OPERATION
STANDARD SEAT
The seat can be adjusted longitudinally and the operator can choose the
driving position that is most suitable for his physique.
The longitudinal adjustment of the seat is obtained by operating the
lever (1) and making the seat slide on the guides; once the desired posi-
tion has been found, release the lever and move forward and backward
to make sure that the lock pin is engaged in its seat.
SUSPENSION SEAT
This seat is extremely comfortable, offering four adjustment options:
a - longitudinal adjustment;
b - back inclination adjustment;
c - adjustment of the suspension, aimed at dampening the inevitable
vibrations and jerks as much as possible;
d - seat cushion inclination adjustment.
The operator can choose the driving position that is most suitable for his
physique.
The longitudinal adjustment of the seat is obtained by operating the
lever (1) and making the seat slide on the guides; once the desired posi-
tion has been found, release the lever and move forward and backward,
to make sure that the lock pin is engaged in its seat.
The back adjustment is achieved by operating the lever (2); move the
lever and find the position that is most suitable for the operator’s physi-
cal structure. Three different degrees of inclination are possible.
The adjustment of the suspension is carried out with the lever (3),
according to the operator’s weight. The suspension can be stiffened or
lightened according to the operator’s needs; adjust the seat suspension
by positioning the lever (3) in one of the five positions available. Shift
the lever to the left to stiffen the suspension or to the right to soften it.
The inclination of the seat cushion is obtained by operating the lever (4)
and positioning the front part of the cushion at the same time; it is possi-
ble to select 2 different positions.
2-56 CK35-1
OPERATION
SEAT BELT
Before starting the engine, fasten the seat belt.

The seat belt must be changed when it is frayed, damaged or
worn and in any case every 4 years.
The seat belt (1) is of the type with two coupling points and adjustable
length (2); it must be well tightened and hold the operator’s hips, while
leaving the upper part of his body completely free.
EMERGENCY EXIT
The machine is provided with an emergency exit located in the rear win-
dow (1).
In case of emergency, pull the plate (2) positioned on the upper side of
the window and remove the weather strip completely.
Push the window toward the outside.
CK35-1 2-57
OPERATION
TECHNICAL DOCUMENTATION CASE
The Operation and Maintenance Manual and the Parts Book

are integral parts of the machine and must accompany it
even in case of resale.
The Operation and Maintenance Manual must be handled with care and
kept aboard the machine, so it can be easily consulted at any time. Put
the manual in the technical documentation case located inside the cab
on the left side, where the ownership documents and the logbook are
usually kept.
FIRE EXTINGUISHER
The machine’s owner must provide for installing and mount-

ing the fire extinguisher where prescribed.
Periodically make sure that the fire extinguisher is full.
The fire extinguisher (1) must be installed by the owner of the machine
and positioned inside the cab on the left side behind the left console.
FIRST AID KIT
Periodically make sure that the first aid kit contains the nec-
essary disinfectants, bandages, medicine, etc. and check
their condition and expiration dates. Replace as necessary.
The first aid kit must be installed by the owner of the machine and posi-
tioned inside the cab on the right side behind the right console.
2-58 CK35-1
OPERATION
OPERATING THE MACHINE
CHECKS BEFORE STARTING THE ENGINE

VISUAL CHECKS
Dirt, oil, and fuel in the engine compartment near its hot
parts may damage the machine and even cause fires.
Check frequently and eliminate any leakage; if leakages
occur repeatedly, contact your distributor.
Before starting the engine, check around and under the machine to ver-
ify:
1. If there are loose bolts or nuts.
2. If there are oil, fuel, or coolant leaks.
3. The wear of the work equipment.
4. The fastening of the electrical connections.
5. The fastening of the engine exhaust pipe and manifold.
6. The conditions and the wear of the rubber tracks.
7. If the safety and warning plates are sufficiently clean.
8. If the ladders and the handles for access to the operator’s seat are
clean.
Any leak or abnormality must immediately be repaired and any
trace of oil or grease must be removed.
Further visual checks concern:
9. The correct torque of the rear fastening bolts of the cab.
10. The condition of the seat belt.
11. The efficiency of the instruments and of the dashboard.
12. The condition of the cab windows and the efficiency of the lights,
working lights and direction indicators.
DAILY CHECKS
Do not smoke during fuel and oil topping off and do not use
open flames or non-approved lighting to check the fuel and
oil levels, to not cause fires. If fuel, oil, or lubricants are
spilled while filling the tanks, clean the dirty areas immedi-
ately.
Before starting any operation, check the engine coolant, engine oil, and
hydraulic circuit oil levels. At the end of work, refuel to avoid the for-
mation of condensation, always checking the fuel level on the indicator
provided on the dashboard.
CK35-1 2-59
OPERATION
Avoid filling the tank completely, to leave room for the fuel to
expand. After filling the tank, put back the filler cap, making
sure that the bleed hole is completely open. Check the
engine oil level with the machine level and the hydraulic cir-
cuit oil level with the front bucket resting on the ground.
OPERATIONAL CHECKS
All the checks must be carried out by the operator while

seated, with the seat belt fastened. When the machine is at
rest after use or maintenance, some safety locks may not be
engaged; when the operator gets into the cab, he must make
sure that all the mechanical safety locks are engaged and
that the equipment cannot move suddenly and create dan-
gerous situations.
The checks concern:

1. The locking of the safety bars.
2. The hand accelerator idle position.
3. The neutral position of the controls.
4. The application of the parking brake.
The following check is carried out by turning the ignition key to posi-
tion <<I>> to apply voltage to the control panel and check the function-
ality of the audible alarm, the fuel level indicator, and the engine oil
pressure, alternator, and preheating warning lights.
2-60 CK35-1
OPERATION
STARTING THE ENGINE
Before starting the engine, carefully read the instructions

and information regarding safety given in this manual and
make sure that you know the controls.
From the moment in which the engine is started, the operator
is directly responsible for any damage that may be caused
by wrong maneuvers and non compliance with the safety
regulations and the rules of the road.
Before starting the engine, make sure that there is no one
within the operating radius of the machine and sound the
horn.
STARTING A WARM ENGINE OR IN TEMPERATE

CLIMATES
1. Turn the ignition key directly to position « » (START).
2. As soon as the engine starts, release the ignition key, which will
automatically return to position «I».
If the engine does not start within 15 seconds, release the

key, which will automatically return to position I and wait for
30 seconds before trying again.
CK35-1 2-61
OPERATION
STARTING A COLD ENGINE OR IN COLD CLI-
MATES
Do not use any starting fluids or ether to assist in starting an

an engine in cold weather. These products may cause an
explosion, damaging the engine or causing injury.
1. Pull the accelerator lever until reaching half of its stroke and turn
the ignition key to the preheating position « » for a maximum of
13 seconds in the coldest weather.
Preheating is indicated by the warning light located on the dash-
board.
2. Turn the ignition key to position « » (START) until the engine
starts or for a maximum of 15 seconds.
3. As soon as the engine starts, release the ignition key, which will
automatically return to position «I» and reduce the engine speed to
idle.
If the engine does not start on the first attempt, repeat steps
1 and 2 after waiting for at least 1 minute, to not overload the
battery.
2-62 CK35-1
OPERATION
WARMING THE ENGINE
1. After starting the engine, let it warm up before starting work.
2. The ideal warming up of the engine is achieved with a constant
speed obtained with the hand accelerator
Do not use full throttle or accelerate abruptly until the cool-

ant temperature has reached at least 60°C (140°F).
3. To reduce the time necessary to warm up the engine, move the hand
accelerator lever now and then to the midpoint of its travel.
4. During the warming up of the engine, check the color of the
exhaust gases and verify if abnormal noises or vibrations can be
noticed; any problem must be verified and its cause must be elimi-
nated.
HEATING THE HYDRAULIC OIL

When warming up the engine, especially in cold weather, it is advisable
to also heat the hydraulic system oil. For this reason, when the coolant
temperature has reached approximately 60°C (140°F), proceed as fol-
lows:
1. Release the safety device of the controls by rotating the safety bars
down and releasing the park brake. (See “SAFETY BARS” on
page 2-28 and See “PARKING BRAKE” on page 2-40).
2. Slowly extend and retract the lift and bucket cylinders completely
several times.
3. Lower the bucket to the ground and lock the safety device again by
rotating the safety bars up(See “SAFETY BARS” on page 2-28).
CK35-1 2-63
OPERATION
MOVING THE MACHINE (ISO PATTERN
CONTROL SYSTEM)
Before moving the machine, make sure that you are com-
pletely familiar with all control functions and all relevant
safety regulations.
The operator must be seated in the driving position with seat
belt fastened.
Before moving the machine, check the position of the rear-
view mirrors and make sure that there is no one within the
operating radius of the machine and that there are no obsta-
cles in the surrounding area.
Be extremely careful when engaging reverse and make sure
there are no people, working means, or obstacles in the way.
Avoid maneuvers or changes of direction when travelling at
full speed, since the maneuvers carried out under these con-
ditions cause abrupt machine movements.
Do not use the speed increase function when changing di-
rection or carrying out a counter-rotation.
The use of the speed increase function is allowed only for
fast transfers of the machine.
Before moving the machine, check the instruments, warm up the engine
and the hydraulic system oil, make sure that the safety device for the
controls is released (safety bars down) and the bucket is rolled back; the
equipment control joystick must be in neutral position.
Release the parking brake.
2-64 CK35-1
OPERATION
1. Pull the hand accelerator lever to set the engine to the desired mac-
nine travel speed.
2. Operate the joystick (1), shifting it forward to make the machine

advance or backward to make it move in reverse.
CK35-1 2-65
OPERATION
STEERING (CHANGING DIRECTION)
If possible, avoid any abrupt change of direction. Counter ro-

tations should be carried out with the machine running at
moderate speed.
When traveling on roads, avoid carrying out counter rota-
tions, since they may create dangerous situations; carry out
counter rotations only during work cycles.
CHANGING DIRECTION WHEN THE MACHINE IS NOT MOVING
To turn to the LEFT, operate the travel joystick as indicated in the dia-
gram. To move FORWARD, push the joystick to the left with 45° incli-
nation. To move BACKWARD, pull the joystick to the right with 45°
inclination.
To turn to the RIGHT, operate the travel joystick as indicated in the dia-
gram. To move FORWARD, push the joystick to the right with 45°
inclination. To move BACKWARD, pull the joystick to the left with 45°
inclination.
2-66 CK35-1
OPERATION
CHANGING DIRECTION WHEN THE MACHINE IS MOVING
To turn to the LEFT, rotate the travel joystick counterclockwise by

approximately 45°.
To turn to the RIGHT, rotate the travel joystick clockwise by approxi-

mately 45°.
HOW TO CARRY OUT A COUNTER ROTATION

(with the machine not moving)
To turn to the LEFT, shift the travel joystick to the left with an angle of
90° with respect to the longitudinal axis.
To turn to the RIGHT, shift the travel joystick to the right with an angle
of 90° with respect to the longitudinal axis.
CK35-1 2-67
OPERATION
HOW TO MOVE THE MACHINE (OPTIONAL
PATTERN CONTROL SYSTEM)
Before moving the machine, make sure that you know the
control functions and all the relevant safety regulations per-
fectly.
The operator must be seated in the driving position with seat
belt fastened and the safety bars lowered.
view mirrors and make sure that there is no one within the
operating radius of the machine and that there are no obsta-
cles in the surrounding area.
Be extremely careful when engaging reverse and make sure
that there are no people, working means, or obstacles in the
way.
Avoid maneuvers or changes of direction when travelling at
full speed, since the maneuvers carried out under these con-
ditions cause abrupt machine movements.
The use of the speed increase function is allowed only for
fast transfers of the machine.
Before moving the machine, check the instruments, warm up the engine
and the hydraulic system oil, make sure that the safety device for the
controls is released (safety bars down) and the bucket is rolled back; the
equipment control joysticks must be in neutral position.
Release the parking brake.
1. Pull the hand accelerator lever and set the engine at the desired
travel speed.
2-68 CK35-1
OPERATION
2. Operate the joysticks (1) and (2) at the same time, shifting them
forward or backward to move the machine.
CK35-1 2-69
OPERATION
If possible, avoid any abrupt change of direction. Counter ro-

tations should be carried out with the machine running at
moderate speed.
When traveling on roads, avoid carrying out counter rota-
tions, since they may create dangerous situations; carry out
counter rotations only during work cycles.
CHANGING DIRECTION WHEN THE MACHINE IS NOT MOV-

ING
To turn to the LEFT, operate the right joystick by proceeding as follows:

to move FORWARD, push the joystick; to move BACKWARD, pull the
joystick.
To turn to the RIGHT, operate the left joystick by proceeding as fol-

lows: to move FORWARD, push the joystick; to move BACKWARD,
pull the joystick.
2-70 CK35-1
OPERATION
CHANGING DIRECTION WHEN THE MACHINE IS MOVING

(THE TWO JOYSTICKS ARE IN THE SAME POSITION)
To turn to the LEFT, shift the left joystick to the NEUTRAL position
(N): the machine will turn to the LEFT.
To turn to the RIGHT, shift the right joystick to the NEUTRAL position
(N): the machine will turn to the RIGHT.
HOW TO CARRY OUT A COUNTER ROTATION (WITH THE

MACHINE NOT MOVING)
To turn to the LEFT, pull the left joystick backward and push the right
joystick forward.
To turn to the RIGHT, pull the right joystick backward and push the
left joystick forward.
CK35-1 2-71
OPERATION
HAND AND FOOT CONTROL SYSTEM
MACHINE CONTROLS
The controls represented in the figures and not described in

this section remain unchanged and are the same present on
the standard version. For details on how to use them, See
“MACHINE CONTROLS” on page 2-26
1. Left PPC control joystick

HAND & FOOT CONTROL SYSTEM
(Left wheel travel)
2. Right PPC control joystick
(Right wheel travel and auxiliary hydraulic control)
3. Left foot operated hydraulic control
(Loader arm raising and lowering control)
4. Right foot operated hydraulic control
(Bucket dumping and roll back control)
2-72 CK35-1
OPERATION
TRAVEL AND STEERING CONTROL JOY-
STICKS
Before carrying out any machine movements with these joy-

sticks, the operator must be seated in the work position with
seat belt fastened and the safety bars in the unlocked (hori-
zontal) position; before any machine movement the operator
must take all the precautions indicated in "1.2 HOW TO
MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)".
Before moving, make sure the safety bars are in the horizon-
tal (unlocked) position and the parking brake is disengaged.
When traveling on roads, always make sure all safety devic-
ground and rotate the safety bars to the locked (vertical) po-
sition, then stop the engine.
The travel control joysticks (1) and (2) are positioned on the operator's
left and right side, respectively, and control the forward and reverse
travel of the machine according to the movements shown in the dia-
gram.
To move the machine forward or in reverse, shift the joy-

sticks (1) and (2) at the same time and in the same direction.
For further details on the use of the joysticks, see "pos. 1.2
HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL
SYSTEM)".
CK35-1 2-73
OPERATION
N - Neutral
A - Forward
B - Reverse
The right PPC control joystick (2) is used to control the right track and
also to control the auxiliary hydraulic circuit according to the move-
ments indicated in the following diagram:
N- Neutral
A- Right track forward travel
B- Right track reverse travel
C- Oil delivery from the male coupling of the auxiliary
hydraulic circuit
D - Oil delivery from the female coupling of the auxiliary
hydraulic circuit
For details on the use of the auxiliary hydraulic control, see "1.1.3
AUXILIARY HYDRAULIC CONTROL JOYSTICK"
Always travel with the engine running at moderate speed to

obtain maximum accuracy and productivity while working.
While working, use of the joysticks must be proportional to
the effort required to maintain a constant engine speed.
Operate the joysticks smoothly, without abrupt movements
and avoid counter-rotations as much as possible, since this
type of machine movement causes rapid track wear.
NOTE
The horn (3) is positioned on the grip of the left joystick (1) and
must be used to warn all the people in the vicinity before starting
work and in case of danger.
All movements can be stopped by rotating the safety bars to the
vertical (locked) position. (See "SAFETY BARS").
2-74 CK35-1
OPERATION
WORK EQUIPMENT CONTROL PEDALS (LOADER
ARM AND BUCKET)
Before carrying out any machine movement with these ped-

als, the operator must be seated in the work position with
zontal) position; before any machine movement the operator
must take all the precautions indicated in "1.2 HOW TO
MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)".
ground and rotate the safety bars to the lock (vertical) posi-
tion, then stop the engine.
The self-leveling system is automatically operated only when

the loader arm is lifted with a full bucket.
When the arm is being lowered, the self-leveling system
does not engage.
At maximum height, the self-leveling system keeps the buck-
et partially rolled back to prevent material from being spilled.
The control pedals (1) and (2) are positioned on the floorboard in front
of the operator seat and control the movements of the loader arm and
the bucket.
CK35-1 2-75
OPERATION
The pedal (1), positioned on the operator's left, controls the raising and
lowering of the loader arm, as indicated in the following diagram:
N - Neutral
A - Loader arm raise
B - Loader arm lower
On machines provided with a floating device, press the pedal

to position B (lower loader arm) and press the switch posi-
tioned under the right joystick (see "MACHINE CONTROLS").
2-76 CK35-1
OPERATION
The pedal (2), positioned on the operator's right, controls the roll back
and dumping of the bucket, as indicated in the following diagram:
N - Neutral
A - Bucket roll back
B - Bucket dumping
CK35-1 2-77
OPERATION
AUXILIARY HYDRAULIC CONTROL JOYSTICK
Before carrying out any machine movements with this joy-

stick, the operator must be seated in the work position with
zontal) position.
The control joystick (1) is positioned on the operator's right and controls
the movement of the right track and the auxiliary hydraulic circuit,
according to the movements indicated on the plate (2) and in the follow-
ing diagram:
N - Neutral
A - Right wheel forward travel
B - Right wheel reverse travel
C - Oil delivery from the male coupling (3) of the auxiliary
hydraulic circuit
D - Oil delivery from the female coupling (4) of the auxiliary
hydraulic circuit
2-78 CK35-1
OPERATION
The auxiliary hydraulic control starts and stops the oil flow to any
optional equipment and has four positions (neutral, left, right and detent
position).
1. Neutral position (N)

(CLOSED HYDRAULIC CIRCUIT)
No oil flow to the optional equipment.
2. Positions (C) and (D)

(OPEN HYDRAULIC CIRCUIT).
These positions are used to control optional equipment with bidi-
rectional oil flow (multi-purpose bucket, drill, asphalt cutter, etc.).
Move the joystick (1) to position (C) to deliver oil from the male
coupling (3) positioned on the left side of the loader arm, or to posi-
tion (D) to deliver oil from the female coupling (4).
CK35-1 2-79
OPERATION
3. Detent position (E)
(OPEN HYDRAULIC CIRCUIT).
This position is used to obtain a continuous unidirectional
oil flow for the operation of equipment such as excavator,
demolition hammer, sweeper, etc. To hold the joystick (1) in
the detent position (E), move the joystick further to the left.
The joystick (1) remains in detent position (E) only with a

pressurized hydraulic system.
When the joystick (1) is in position (E), pressurized oil is de-
livered from the male coupling (3), with return thru the fe-
male coupling (4).
2-80 CK35-1
OPERATION
HOW TO MOVE THE MACHINE (HAND & FOOT
CONTROL SYSTEM)
Before moving the machine, make sure that you are com-
pletely familiar with the control functions and all relevant
safety regulations.
The operator must be seated in the work position with seat
belt fastened and the safety bars in the unlocked (horizontal)
position.
view mirrors (if installed) and make sure there is no one with-
in the operating radius of the machine and that there are no
obstacles in the surrounding area.
Be extremely careful when shifting into reverse and make
sure that there are no people, other equipment, or obstacles
in the way.
Avoid any travel maneuver or change of direction with the
accelerator at maximum speed, since maneuvers carried out
under these conditions may cause dangerous machine
movements.
rection or carrying out a counter-rotation. The speed in-
crease function must be used only for traveling at high
speed.
Check the instruments and warm up the engine and the hydraulic sys-
tem oil before moving the machine. Make sure that the safety bars are
lowered to the horizontal (unlocked) position and that the bucket is
rolled back; the equipment control pedals must be in neutral position. At
this point, release the parking brake.
1. Set the manual accelerator lever to the desired travel speed.
CK35-1 2-81
OPERATION
2. Move the joysticks (1) and (2) forward or backward at the same
time to move the machine.
2-82 CK35-1
OPERATION
Avoid abrupt changes of direction as much as possible. Car-

ry out counter-rotations at moderate speed.
Avoid carrying out counter-rotations when traveling on
roads, since these maneuvers may cause dangerous situa-
tions; make counter-rotations only during work.
CHANGING DIRECTION WITH MACHINE AT REST
To turn to the LEFT, use the right joystick as follows: to move

FORWARD, push the joystick. To move BACKWARD, pull the
joystick.
To turn to the RIGHT, use the left joystick as follows: to move

FORWARD, push the joystick. To move BACKWARD, pull the
joystick.
CK35-1 2-83
OPERATION
CHANGING DIRECTION WITH MACHINE IN MOTION (THE

TWO JOYSTICKS ARE SHIFTED TO THE SAME POSITION)
To turn to the LEFT, shift the left joystick to the NEUTRAL position
(N) and the machine will turn to the LEFT.
To turn to the RIGHT, shift the right joystick to the NEUTRAL

position (N) and the machine will turn to the RIGHT
.
HOW TO PERFORM A COUNTER-ROTATION
(with machine at rest)
To perform a counter-rotation to the LEFT, pull the left joystick

backward and push the right joystick forward.
To perform a counter-rotation to the RIGHT, pull the right joystick

backward and push the left joystick forward.
2-84 CK35-1
OPERATION
MOVING ON SLOPES
Before working on slopes, always check the functionality of

the parking brake.
Always go up or down slopes at moderate speed and with
the heavier end of the loader always directed towards the top
of the slope.
When going up or down slopes, keep the equipment low-
ered; movements with the arm raised may cause the ma-
chine to overturn.
Do not use the speed increase function when the machine
travels on slopes.
When working on slopes the following precautions should be taken to

avoid risks for the operator and anyone in the vicinity; the checks and
operations to be carried out are the following:
1. Always check the work area for snow, landslides, gravel, loose
ground and anything that may suddenly modify the work condi-
tions and the stability of the machine.
2. When it is necessary to travel downhill, the front bucket must
always be directed downward, in transport position.
3. When loading or traveling uphill, the front bucket must always be
directed upward.
4. When moving the machine during work cycles, always lower the
bucket.
5. Carry out any lateral movement on a flat surface at the beginning or
at the end of the slope; if this is not possible, move at an angle,
keeping the machine axis as parallel to the slope direction as possi-
ble. Do not move at too great an angle or, even worse, with the
machine axis rotated by 90° with respect to the slope direction.
CK35-1 2-85
OPERATION
MAXIMUM IMMERSION DEPTH
If it is necessary to work with the machine immersed in water

on river banks or sea shores, always check the water depth
and the current flow. Make sure that the surface on which
you are working is sufficiently firm.
If it is necessary to work with the machine immersed in water, make

sure that the maximum depth does not exceed 24 cm and in any case
that the engine cooling fan does not touch the water, since it may get
damaged or even break.
When working in water or on muddy ground, lubricate the

articulated joints more frequently than usual. After work,
remove any dirt or mud and lubricate the articulated joints.
2-86 CK35-1
OPERATION
PARKING THE MACHINE
PARKING ON LEVEL GROUND
Park the machine on firm and flat ground, in a sufficiently

wide space, so that the checks, daily lubrication, and refuel-
ing can be carried out without problems. Lower the work
equipment to the ground. Engage all safety locks and apply
parking brake. Keep to all the safety rules, to avoid any
movement of the machine when the operator is absent.
When leaving the machine, remove the ignition key.
1. Park the machine on firm and flat ground, in a sufficiently wide

space.
2. Lower the bucket to the ground.
3. Lock the equipment and travel hydraulic control by shifting the
safety bars to the lock position (vertical) (See “SAFETY BARS”
on page 2-28).
4. Engage the safety guard to lock the optional equipment control
pedal.
5. Apply the parking brake.
6. Stop the engine following the procedure indicated in paragraph
(See “STOPPING THE ENGINE” on page 2-89).
7. Remove the ignition key.
8. Leave the cab using the handles and the footboards.
9. Refuel taking the necessary precautions.
CK35-1 2-87
OPERATION
PARKING ON SLOPES
The movement of the machine when the operator is not on

board may cause serious accidents or even death; to pre-
vent this, carry out the operations described below. Park on
slopes only when it is absolutely necessary. Park only with
the front bucket directed downwards.
1. Park the machine with the bucket directed downwards and resting
against an obstacle. If this is not possible due to the absence of nat-
ural obstacles, rotate the bucket to the dump position and thrust the
teeth into the ground.
2. Lock the equipment and travel hydraulic controls by rotating the
safety bars to the lock (vertical) position (See “SAFETY BARS”
on page 2-28).
3. Engage the safety guard to lock the optional equipment control
pedal.
5. Stop the engine following the procedure indicated, (See “STOP-
PING THE ENGINE” on page 2-89).
6. Remove the ignition key.
7. Leave the cab using the handles and footboards.
8. Put wedges under the tracks.
9. Refuel taking the necessary precautions.
2-88 CK35-1
OPERATION
STOPPING THE ENGINE
The sudden stop of the engine while it is running shortens

its life. Do not stop it suddenly, except in case of emergency.
It is likewise recommended not to stop the engine suddenly
if it has been running for a long period and is still hot; in this
case, let the engine idle at a min. speed of 1200 rpm for
about 5 minutes, to allow it to cool down gradually before
stopping.
Before stopping the engine, proceed as follows:

1. Rest the work equipment on the ground.
2. Shift the joysticks to the neutral position and engage the safety
devices.
3. Move the hand accelerator lever to the idle position.
Stop the engine by turning the ignition key to position «O» (OFF).
CK35-1 2-89
OPERATION
TRANSPORTING THE MACHINE
LOADING AND UNLOADING
The loading and unloading of the machine on-off the means

of transport must be carried out on a flat surface and at a
safe distance from the edges of ditches or from the road
side. Block the means of transport by positioning wedges in
front of and behind each track. Make sure that the ramps are
sufficiently strong; if necessary, reinforce them with blocks
to prevent any dangerous bending. Make sure the ramps are
the same length, firmly anchored to the motor vehicle, paral-
lel to each other and perpendicular to the loading board; the
distance between the ramps must be suitable for the
machine gauge. Position the ramps with a maximum inclina-
tion of 15°. Remove any trace of oil, grease or ice from the
ramps and the loading board. Do not change direction when
the machine is already on the ramps; if necessary, go down
and find the correct direction.
1. The machine, with empty bucket or without optional accessories,

must move on the ramps with the bucket (1) at the back and raised
above the ground.
2. Once the machine has been loaded, lower the work equipment to
the bed and rotate the safety bars to the lock (vertical) position.
4. Stop the engine and remove the ignition key.
5. Keep the machine in position also by putting wedges (2) in front of
and behind each track.
6. Attach the machine with tie downs or chains (3) in the tie down
hooks(5) and (6).
7. Cover the end of the exhaust pipe (4).
2-90 CK35-1
OPERATION
TRANSPORT
1. Check the overall dimensions; the height, width and weight of the
means of transport - machine included. It must be compatible with
the road and any tunnel, subway, bridge, electric or telephone line
that may be found on the way.
2. Observe all regulations regarding signals, speed limits, road traffic,
permits, etc.
CK35-1 2-91
OPERATION
HOW TO LIFT THE MACHINE
To lift the machine use cables of adequate strength; do not

use worn cables or cables with broken strands.
Do not lift the machine with the operator on board and make
sure that no one is approaching the machine before lifting it.
Before lifting the machine, make sure the eye bolts are cor-
rectly attached to the cab roof.
The owner of the machine is responsible for installing the

eyebolts correctly on the cab roof.
Torque to 80 Nm (59 lbf-ft)
Use only eyebolts approved by Komatsu for this specific
type of machine.
Approved eyebolts must be requested from your Komatsu
Distributor, specifying the machine model and serial number.
To lift the machine, proceed as follows:

1. Lower the loader arm to the ground and roll the bucket completely
back.
2. Rotate the safety bars to the lock (vertical) position and stop the
engine.
3. Insert chains or nylon ropes in the two front eye bolts on the cab
roof and attach with the appropriate retainers or safety pins.
4. Assemble the chains or nylon ropes in the two couplings on the
rear shoulders of the frame, near the arm fulcrum.
5. Connect the ropes or chains to the spreader bar as indicated in the
figure.
Always use the four attaching points provided for the lifting
of the machine.
6. Lift slowly until the ropes or chains are tensioned and make sure
that the machine is hooked correctly before lifting it off the ground.
During the lift, avoid jerks and abrupt changes of direction.
When lifting the machine, make sure that it is correctly bal-

anced and that it can be lifted level.
Do not lift the machine with optional equipment installed on
it.
2-92 CK35-1
OPERATION
COLD WEATHER PRECAUTIONS
During cold weather or in areas where the temperature is particularly
low, especially during the night, it is necessary to take some counter-
measures meant to limit the damage resulting from low temperatures.
FUEL AND LUBRICANTS

1. Change the fuel and use winter fuel ASTM D975N.1 when the
ambient temperature is below -10°C.
2. Change the engine oil for an oil of suitable viscosity. For the rele-
vant specifications, See “FUEL, COOLANT AND LUBRI-
CANTS” on page 3-6.
COOLANT
The coolant containing antifreeze is flammable; do not

smoke and do not use open flames when checking and pre-
paring the mixture. Do not use methanol-, ethanol- or pro-
panol-based antifreezes.
1. Use only permanent, ethylene glycol-based antifreeze, with corro-

sion inhibitors and antifoam products.
2. The antifreeze to water ratio must be 1:1 (50% antifreeze and 50%
water).
3. Do not use plugging additives, either alone or added to the anti-
freeze, to eliminate leakage.
4. Do not mix antifreezes of different brands.
5. The use of permanent antifreeze requires only the checking of the
level and the periodic changing of the fluid. It is not necessary to
wash the coolant system.
6. The required standards for the permanent antifreeze are SAE-J1034
and FEDERAL STANDARD O-A-548D. In case of doubt regard-
ing the compliance of the antifreeze used with the standards, con-
tact the manufacturer and ask for precise information.
CK35-1 2-93
OPERATION
BATTERY
To avoid explosions due to the presence of gas, do not pro-

voke sparks and do not use open flames near the battery.
The battery electrolyte is dangerous. If it comes in contact
with the eyes or skin, immediately rinse with plenty of water
and consult a doctor without delay.
1. When the ambient temperature decreases, the battery capacity

decreases accordingly and, if the battery charge is low, the electro-
lyte may freeze. Keep the battery completely charged and insulate
it to protect it from low temperatures, so the machine can be started
without problems the following day.
2. Measure the specific gravity of the fluid and check the battery
charge percentage in comparison to the following table:
CHARGE% FLUID TEMPERATURE
20°C (68°F) 0°C(32°F) -10°C(14°F) -20°C(-4°F)
100% 1.28 1.29 1.30 1.31
90% 1.26 1.27 1.28 1.29
80% 1.24 1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26
3. To prevent the fluid from freezing, add distilled water in the morn-
ing, before starting work.
OTHER PRECAUTIONS
1. Before using the machine in normal operating conditions, carry out
some slow movements either forward or in reverse, and operate all
the work equipment cylinders slowly more than once. These opera-
tions serve to warm up and decrease the viscosity of the oil in the
hydraulic circuit and the transmission.
PRECAUTIONS TO BE TAKEN AT THE END

OF WORK
1. Completely remove mud and water from the machine body. Park
the machine on firm ground; if the machine must be parked near
banks or ditches, park it on wooden boards to distribute the weight
of the machine over a larger area.
2. Be careful of water drops forming on the hydraulic cylinder rods:
these drops must be completely removed, since if they freeze the
cylinder seals may be damaged. After removing the water drops,
protect the rods with oil.
3. Drain any condensate that may have formed in the fuel tank, to pre-
vent the water from freezing overnight.
4. Since the battery capacity may decrease considerably at low tem-
peratures, after work cover the battery or remove it and store it at a
suitable temperature.
2-94 CK35-1
OPERATION
WARM WEATHER PRECAUTIONS
1. At the end of the cold weather, change the lubricants, the coolant,
and the fuel.
The engine coolant must be changed only if it is not perma-

nent, See “FUEL, COOLANT AND LUBRICANTS” on page 3-
6.
2. Make sure the cooling fan belt is in good condition.

3. Make sure that the fins of the radiator and of the heat exchanger are
clean.
4. Check the radiator cap gasket and spring; in case of doubt regard-
ing tightness and setting, change the cap.
CK35-1 2-95
OPERATION
OPERATING THE WORK EQUIPMENT
Always fasten the seat belt. Before moving the equipment,

make sure that there is no one standing in the work area.
Carry out all the possible movements and make sure that the
control joysticks operate correctly. If visibility is insufficient
or there are ducts of any kind, proceed at low speed and ask
the assistance of another person. Always warn the people
present in the work site, even if they are authorized, by
means of the horn. The basic illustrations shown are those
necessary for the proper use and utilization of the machine;
the operator must get to know the controls, the prescribed
operating method, and learn how to organize work in an
open area, while seated in the driving position.
LOWERING THE EQUIPMENT IN CASE OF

MACHINE FAILURE
Carry out the operations while seated in the work position

with the seat belt fastened.
After lowering the equipment to the ground, move the con-
trol joysticks more than once to release any residual pres-
sure.
If the machine should suddenly stop with the work equipment raised
due to a mechanical or hydraulic failure, the operator must lower the
equipment to the ground before leaving the machine to locate the trou-
ble. Make sure that the safety bars are lowered (open hydraulic circuit),
turn the ignition key to position «I» and lower the bucket to the ground
by shifting the equipment control joystick; only limited movements are
possible.
2-96 CK35-1
OPERATION
ORGANIZING THE WORK AREA
If, after a first inspection, the area appears to be uneven, encumbered
with big obstacles or characterized by considerable height differences, it
is advisable to level the ground as much as possible, before starting
work, for the benefit of the loader and the vehicles to be loaded.
This preliminary operation will make work quicker, ensure better
results, and at the same time reduce the operator’s stress and the strain-
ing of the machine components; furthermore, this will considerably
reduce the time necessary to load the trucks destined for the transport of
the material.
To obtain the best performance from the machine it is necessary to syn-
chronize the movements of the equipment with the traveling move-
ments, by operating the joysticks smoothly and without jerks. The
changes of direction must be carried out correctly with ample steering
radii. Short steering radii or counter rotations involve useless efforts of
the machine and rapid track wear.
CK35-1 2-97
OPERATION
LOADING HEAPED AND LEVEL MATERIAL
The efficiency of the bucket depends on how the operator starts loading;
proceed as follows:
1. Start moving with the arm completely lowered and direct the
bucket towards the base of the pile.
2. While the upper material falls down filling the bucket, raise the
arms gradually and at the same time roll the bucket to the end of its
stroke.
3. Reverse the motion of the machine and dump the bucket into the
truck.
Start loading the truck from the cab side and, if the material
is sufficiently mixed, dump from the maximum height to
increase the compaction of the material and its distribution
on the loading platform.
4. After removing the pile completely, incline the bucket forward,

lower the arm until the rubber tracks are slightly raised and, mov-
ing in reverse, level the ground distributing the material uniformly.
Repeat the operation reducing the inclination of the bucket for the
finishing work.
2-98 CK35-1
OPERATION
LOADING OPERATIONS ON SLOPES
Travel uphill with the bucket directed forward; the same rule
must be followed when loading. Travel downhill in reverse
with the loader directed forward and bucket lowered. Move,
changing direction very slowly, with the bucket as low as
possible. Avoid any transverse position with respect to the
slope direction. Sudden movements of the bucket and dan-
gerous positions may cause the machine to overturn and
lead to serious accidents or even death
CK35-1 2-99
OPERATION
DIGGING METHOD
1. At the beginning of work, keep the bucket at the correct penetration

angle.
2. Once the desired digging depth has been reached, position the
bucket with its back parallel to bottom of the excavation and then
start filling.
3. During the collection phase, move the bucket and arm simulta-
neously. Combined movements facilitate the filling of the bucket
and therefore increase productivity.
4. The removal depth must be correct and suitable for the type of
ground; an excessive digging depth may cause the locking of the
movements due to the overloading of the engine and pump, and
therefore slow down the digging operations.
5. To dump material from piles, unload the bucket as soon as it gets
near the dumping area; the inertia resulting from the movement will
ensure the compaction of the material with no need to use the
bucket for this purpose, which avoids impacts and vibrations that
facilitate the wear of pins and bushings.
6. The correct method is illustrated in pictures ①, ✍, and ③.
CORRECT
The bucket starts digging with a slight penetration angle.
INCORRECT
If the penetration angle is too wide, the bucket is thrust

downwards, slowing the digging work.
2-100 CK35-1
OPERATION
CHANGING THE BUCKET OR ATTACH-
MENT WITH STANDARD QUICK COUPLER
• Stop the machine on a firm and level surface and lower the
bucket or attachment to the ground.
• Before leaving the machine, stop the engine, release the
residual hydraulic pressures by operating the equipment
control joystick more than once in all directions and raise
the safety bars to the locked position.
• Clean the upper and lower mounting areas of the bucket or
attachment of all dirt and debris before mounting or releas-
ing it to or from the quick coupler.
• Before starting work, make sure the quick coupler locking
pins are completely engaged in, and protruding from, the
retaining tabs (slots) provided on the bucket or attachment
and that the coupler levers are pushed down to a horizon-
tal (locking) position.
• After locking the equipment and before starting work,
make sure that the locking pins are correctly engaged and
the length of the protruding portion of the pins is in com-
pliance with the prescribed safety values (See “CHECKING
THE POSITION OF THE LOCKING PINS” on page 2-104).
Keep the levers lubricated and free of dirt and debris. Lubri-
cate the coupling pins and keep the area around the pins
free of dirt and debris.
Do not use your fingers to align the holes, since your fingers
may be injured or cut in the event of the loader bucket or
attachment suddenly moving.
The loader is designed in such a way as to permit the installation of var-

ious types of buckets or attachments.
To ensure their quick and comfortable change, a special, universal cou-
pler is provided with the machine, which permits the release or installa-
tion of the bucket or attachment via a spring loaded over-center lever
and pin latching system that secures the machine coupler to an attach-
ment or bucket.
LOCKING THE BUCKET OR ATTACHMENT
Rotate the levers (1) down to a horizontal position facing the center of
the bucket or attachment (2).
UNLOCKING THE BUCKET OR ATTACHMENT
Rotate the levers (1) completely upward to a vertical position.
For Non-Komatsu attachments, read the manufacturer’s

instruction manual before installing any attachment.
Refer to the Komatsu Skid Steer Attachment Directory for a single

source of work site application choices of attachments.
CK35-1 2-101
OPERATION
REMOVING THE BUCKET OR ATTACHMENT
AVOID INJURY.
Perform all operations with the bucket or attachment at
ground level.
1. Lower the arm completely and rest the bucket on the ground in a
horizontal position.
2. Stop the engine, release any residual hydraulic pressures, raise the
safety bars to the locked position and leave the operator’s seat.
3. Pull both lock levers (1) completely upward to a vertical position to
disengage coupling pins (2).
4. Return to the operator’s seat, fasten the seat belt, lower the safety
bar, start the engine and release the brake.
5. Rotate the coupler (3) forward allowing the bucket or attachment
retaining lip (4) to slide off the top edge of the coupler.
2-102 CK35-1
OPERATION
INSTALLING THE BUCKET OR ATTACHMENT
Do not use your fingers to align the holes, since they may
become stuck or even cut in case of sudden or uncontrolled
movements.
1. Make sure that levers (1) are in a vertical position and that coupling
pins (2) are completely retracted.
2. Incline the top of coupler (3) forward and slowly approach the
bucket (4) or attachment until the top edge of the coupler is com-
pletely under the top flange of the bucket (4) or attachment. Make
sure you center the coupler with the bucket or attachment.
3. Tilt the coupler backward until the cutting edge of the bucket or
attachment is slightly off the ground.
4. Roll back the bucket or attachment completely.

5. Stop the engine, release the residual hydraulic pressures, raise the
safety bars to the locked position and leave the operator’s seat.
6. Lock the bucket or attachment to the coupler by rotating levers (1)
toward the center of the bucket or attachment to a horizontal posi-
tion.
7. Before moving the machine, make sure that the locking pins (2) are
completely engaged in the tabs provided on the bucket or attach-
ment.
8. To confirm engagement, tilt the bucket or attachment down and
apply downward pressure. Back up the machine to make sure there
is no movement between the bucket or attachment and the coupler.
CK35-1 2-103
OPERATION
CHECKING THE POSITION OF THE LOCKING PINS
The position of the coupler locking pins (1) must be checked with the
levers in the locked or horizontal position. The length of the protruding
part of the pins must be in compliance with the specified values, as indi-
cated in the figure.
To check the locking pin protrusion:
1. Slowly raise the arm.
2. Roll the bucket or attachment forward until the pin protrusion can
be seen from the operator’s seat.
3. If the length (1) does not appear within the specified range, adjust it
by proceeding as indicated in See “ADJUSTING THE LOCKING
PINS” on page 2-105.
Coupler locking pins must extend through the holes in the

bucket or attachment. Levers must be fully down and locked.
Failure to secure the locking pins can allow the bucket or
attachment to come off and may cause serious injury or
death.
2-104 CK35-1
OPERATION
ADJUSTING THE LOCKING PINS
The pin adjustment must be carried out with the bucket flat on the
ground and the levers (1) of the quick coupler in a horizontal or locked
position and proceeding as indicated below:
1. Check the protrusion of the locking pins per See “CHECKING
THE POSITION OF THE LOCKING PINS” on page 2-104.
2. Loosen lock nut (3).
3. Adjust nut (2) until the specified dimension is reached.
4. Tighten lock nut (3) against adjusting nut (2) to maintain the speci-
fied dimension.
CK35-1 2-105
OPERATION
USING THE RUBBER TRACKS

OPTIMAL USE OF THE RUBBER TRACKS
The materials used for the construction of the rubber tracks offer many
advantages that improve the performance of the machine, but at the
same time have some problems regarding resistance. For this reason, it
is important to know the characteristics of the rubber tracks, to take the
precautions suggested, and to avoid performing operations that are not
allowed. In this way, the rubber tracks will last longer and it will be pos-
sible to take full advantage of their pluses. Before using the rubber
tracks, read paragraph "3.13.7.4 PRECAUTIONS FOR USE".
RUBBER TRACK WARRANTY

It is important to carry out checks and routine maintenance to ensure
that the tension of the rubber tracks is always correct. These must not be
used on work sites where they may be cut due to the presence of steel
plates, U-shaped grooves, pointed stones or rocks, steel rods or iron
scraps. Komatsu takes no responsibility for any damage to the rubber
tracks due to incorrect use by operators who carry out unauthorized
operations or fail to take the precautions indicated.
This type of damage is not covered by the warranty.
PRECAUTIONS TO BE TAKEN WHEN USING THE

RUBBER TRACKS
UNAUTHORIZED USES
For correct use of the rubber tracks, bear in mind the following:
1. Rotations or other operations on hard rocky surfaces, rocky sur-
faces with protrusions, steel bars or scraps, or near the edges of
steel plates may damage the rubber tracks.
2. In places where there are many small and large stones, like river
beds, the stones may get stuck in the rubber tracks, which may
come off or be damaged. Using the machine to carry out leveling
operations when the tracks slide on the ground may damage the
tracks and reduce their service life.
3. Do not dirty the rubber tracks with oil, fuel or chemical solvents. If
one of these substances gets on the tracks, clean them immediately.
Do not use the machine on roads where there are traces of oil.
4. When the machine is going to remain unused for a long period (3
months or more), keep it indoors, away from direct sunlight and
protected from the rain.
5. Avoid using the machine in areas where the temperature is particu-
larly high, for example near burning wood, hot steel plates or roads
being asphalted.
2-106 CK35-1
OPERATION
PRECAUTIONS FOR USE
During work, always adhere to the following rules and take the precau-
tions indicated:
1. Avoid abrupt steering or counter rotations on concrete surfaces.
2. Do not carry out abrupt changes of direction that may damage or
cause the untimely wear of the rubber tracks.
3. Do not move or steer on surfaces distinguished by considerable dif-
ferences in height. When there is a difference in height, move per-
pendicularly. This will prevent the track from coming off.
4. If the machine has been raised from the ground by means of the
work equipment, lower it slowly.
5. Avoid using the machine to handle materials or substances that
once crushed produce oil (like soy, maize or other vegetables from
which oil is derived), or wash the machine soon after use.
6. Avoid using the machine in the presence of materials that may
affect the adhesion of the steel core, like salt, ammonium sulfate,
potassium chloride, potassium sulfate or calcium super phosphate,
or wash the machine after use.
7. Since salt affects the adhesion of the steel core, avoid using the
machine in coastal areas.
8. When handling salt, sugar, flour or soy seeds, the presence of deep
cuts in the tracks may cause the infiltration of these products into
the tracks or the dispersion of rubber pieces into the products.
Therefore, it is advisable to repair the tracks before use.
9. Avoid using the machine when the rubber tracks may rub against
concrete walls.
10. Rubber tracks slip very easily on snow or ice. Be careful not to slip
when travelling or working on slopes.
11. If the machine works in very low temperatures, the properties of the
rubber tracks may change and their service life may be reduced.
12. Considering the particular properties of rubber, it is advisable to use
tracks made with the same material at temperatures between -25°C
and +55°C.
13. Make sure that the track tension is always correct, to prevent the
tracks from coming off. If the tracks are slack, they may come off in
the situations indicated on the following page. When carrying out
the maneuvers on the following page, proceed with the utmost care
even if the track tension is correct.
CK35-1 2-107
OPERATION
1. Do not change direction when travelling on curbs, rocks or surfaces
with great differences in height. If this cannot be avoided, always
proceed perpendicularly to the obstacles.
2. When travelling up slopes in reverse, avoid steering at the begin-

ning of the slope. If it is necessary to steer on the slope, carry out
this maneuver gradually.
3. Do not proceed along the edge of a slope or on uneven ground

keeping one track in horizontal position and the other inclined or
partially raised. To avoid damaging the rubber tracks, always pro-
ceed with both tracks resting on the same horizontal plane.
4. In the situations described in points from 1 to 3, avoid changing

direction when the rubber track does not conform exactly to the
ground, as shown in the figure.
2-108 CK35-1
OPERATION
LONG PERIODS OF INACTIVITY
BEFORE THE PERIOD OF INACTIVITY
When draining the fuel, do not smoke or bring exposed

flames near the machine. Place a container under the
machine to gather the fuel and prevent it from spreading
around. If some fuel is spilled, clean the dirty surface imme-
diately. To protect the cylinder rods when the machine is not
used, position the work equipment as shown. This serves to
prevent the cylinder rods from rusting.
If the machine must be stored for a long period of inactivity, it is advis-

able to put it in a sheltered place and to take the following precautions,
to keep all its components sound and efficient:
1. Clean the machine thoroughly, repainting it where necessary to pre-
vent oxidation.
2. Drain and replace all the hydraulic circuit fluids and the lubricants,
axles, reduction gears, converter and engine, keeping to the rules
indicated in the section regarding maintenance.
3. Change all the filtering elements, air cleaner, engine oil filter,
hydraulic circuit filters, diesel oil filter.
4. Change the coolant to permanent type coolant.
5. Drain the normal fuel and fill the tank with at least 5 l of special
cleaning and preservation fuel.
6. Let the engine run for about 10 minutes, to eliminate the remaining
regular fuel from the filters, the injection pump and the entire fuel
supply system. This operation avoids the freezing of the injection
pump and the injectors. Stop the engine and refuel with normal die-
sel oil.
7. Remove the battery, check the electrolyte level and make sure that
the battery charge is sufficient. Store the battery in a room with
suitable temperature and periodically recharge it.
8. Grease the hydraulic cylinder rods and the equipment joints.
9. Seal the end of the exhaust pipe.
10. Move the machine controls to the neutral position and engage all
the safety locks.
11. Hang a warning notice on the controls to indicate the condition of
the machine.
12. Lock the engine hood.
CK35-1 2-109
OPERATION
DURING THE PERIOD OF INACTIVITY
If it is necessary to carry out a rust prevention treatment

while the machine is kept indoors, open doors and windows
to increase ventilation and avoid poisoning by gas.
Start the engine and move the machine for a short distance once a
month, so a new oil film covers all the moving parts and the surfaces of
the components. Provide also for charging the battery.
AFTER THE PERIOD OF INACTIVITY
If the machine is stored without carrying out the monthly

rust-prevention treatment, have maintenance performed by
your distributor.
When using the machine after a long period of inactivity, proceed as fol-
lows:
1. Remove the seals from the exhaust pipe and the fuel tank.
2. Check all the fluid levels: engine oil, coolant, fuel, hydraulic circuit
oil.
3. Make sure that the battery charge is sufficient and install the bat-
tery.
4. Disconnect the engine stop solenoid.
5. Turn the ignition key directly to the start position and crank the
engine until the engine oil pressure warning light goes out. This
operation serves to start the circulation of the lubricating oil and to
carry out a first lubrication cycle.
6. Reconnect the stop solenoid valve and start the engine.
7. Run the engine at idle for about 20 minutes.
8. While the engine is warming up, remove the protection grease from
the hydraulic cylinder rods.
9. Before moving the machine, make sure that the instruments, the
warning lights, and working lights work properly.
10. Warm up the hydraulic cylinders, by slowly moving all the work
equipment as soon as possible.
2-110 CK35-1
OPERATION
TROUBLESHOOTING
HOW TO MOVE THE MACHINE
When moving the machine, use a wire rope suitable for the
weight of the machine to be removed.
If the machine gets stuck in mud and cannot get out using only its
motive power, or in case of breakdown, use a wire rope as shown in the
figure at right.
In case of failure of the hydraulic circuit, before moving the

machine release the negative brake installed on the rear axle
(See “RELEASING THE PARKING BRAKE” on page 3-26).
IF THE FUEL HAS BEEN COMPLETELY

DEPLETED
Before starting the engine, when the fuel has run out and therefore air
has entered the fuel supply circuit, it is necessary to bleed the fuel sup-
ply circuit. For the necessary operations, See “EVERY 500 HOURS OF
OPERATION” on page 3-22.
CK35-1 2-111
OPERATION
BATTERY IS EXHAUSTED
When checking or carrying out any operation on the battery,

stop the engine and make sure that the ignition switch is in
OFF position. The battery produces hydrogen, which may
explode. Do not use open flames and do not smoke near the
battery, and avoid creating sparks. The battery electrolyte is
made of diluted sulfuric acid that may corrode clothes and
even skin; in case of contact with this fluid, immediately
rinse the involved area with plenty of water. If the acid gets
into the eyes, immediately rinse with plenty of water and
consult a doctor without delay. When working on the battery,
always wear goggles and gloves.
When removing the battery, first disconnect the ground
cable (-); when installing the battery, first connect the posi-
tive cable (+). If a tool comes into contact with the positive
terminal and the machine structure at the same time, this
may generate sparks with consequent risk of explosion.
Carefully tighten the connection terminals, since false con-
tacts may generate sparks with consequent risk of explo-
sion. When starting the engine with the aid of another
machine, connect the batteries in parallel. When connecting
the cables, avoid any contact between the positive cable (+)
and the negative cable (-).
When starting the engine with booster cables, always wear
safety goggles. Take care to avoid any contact between the
machine to be started and the machine used as starting aid,
to avoid sparks and therefore the explosion of the hydrogen
produced by the batteries. The explosion of a battery may
cause serious damage and injuries. Take care not to reverse
the cables and connect the ground cable (-) last, as far from
the battery as possible. Remove the cables with great care;
prevent the cables disconnected from the battery from
touching other parts of the machine, to avoid the explosion
of the hydrogen. The cables and pliers must be suitable for
the current load that must be transferred. The battery to be
used for the starting must have greater capacity or at least
the same capacity as the battery of the machine to be
started. Make sure that the cables and pliers are neither cor-
roded, nor damaged. Make sure that the pliers hold the ter-
minals firmly.
2-112 CK35-1
OPERATION
STARTING WITH BOOSTER CABLES
CONNECTING THE CABLES AND STARTING THE ENGINE
1. Make sure that the ignition key is in OFF position.

2. Connect the positive poles (+) of the two batteries with each other
A.
3. Connect the cable of the negative terminal (-) of the charged battery
to the engine block of the machine to be started B.
4. Start the engine of the machine that supplies current and increase
its speed.
5. Start the engine of the machine that does not work, See “START-
ING THE ENGINE” on page 2-61.
REMOVING THE CABLES
When the engine has started, remove the cables in reverse order of the
connection process.
1. Disconnect the negative cable (-) from the engine block of the
engine that has been started and then from the battery B.
2. Disconnect the positive cable (+) first from the battery used for the
starting and then from the depleted battery A.
CK35-1 2-113
OPERATION
OTHER TROUBLES
✩ Always contact your distributor when you have to carry out this operation.
★ If the problem or its cause are not included in the failures indicated below, contact your distributor for the necessary
repair.
ELECTRICAL CIRCUIT
TROUBLE CAUSE REMEDY

Lights do not work satisfactorily even • Faulty cables ★ Check and repair any loose termi-
with engine running at high speed nal and connection
Lights come on intermittently with en- • Faulty fan belt tension ✩ Adjust fan tension, see EVERY
gine running
250 HOURS.
Alternator charge warning light does • Faulty alternator ★ Change

not go out with engine running and in- • Faulty cables ★ Check and repair
creasing speed
Alternator emits an abnormal noise • Faulty alternator ★ Change

Starter does not turn with key in • Faulty cables ★ Check and repair
START position • Battery charge insufficient ✩ Charge battery
• Faulty main fuse ✩ Change
Starter pinion engages and then dis- • Battery charge insufficient ✩ Charge battery
engages
Starter makes engine crank slowly • Battery charge insufficient ✩ Charge battery
• Faulty starter ★ Change
Starter disengages before engine has • Faulty cables ★ Check and repair
started • Battery charge insufficient ✩ Charge battery
Engine oil pressure warning light does • Faulty bulb ★ Change

not come on when engine is stopped, • Faulty pressure sensor ★ Change
ignition key in <<I>> position
Alternator charge warning light does • Faulty bulb ★ Change

not come on when engine is stopped, • Faulty cables ★ Check and repair
ignition key in <<I>> position
2-114 CK35-1
OPERATION
HYDRAULIC SYSTEM

Pump emits an abnormal noise • No oil in the tank ✩ Top off
• Faulty pump ★ Repair or change
• Hydraulic oil unsuitable for the ✩ Change oil
temperature
Equipment moves only at low speed • Faulty pump ★ Repair or change

• Max. pressure valve setting incor- ★ Calibrate or change
rect or not closed due to impurities
• Dirty drain filter ✩ Change
CK35-1 2-115
OPERATION
ENGINE

Oil pressure warning light remains on • Oil level in oil pan too low. ✩ Top off.
even with engine at high speed • Oil filter clogged. ✩ Change filter.
• Oil unsuitable for the season. ✩ Change.
Steam comes out of radiator breather • Fluid level low, fluid leakage. ✩ Top off, repair.
pipe • Fan belt slackened. ✩ Check and adjust belt tension.
• Mud or limestone accumulated in ✩ Change fluid and clean cooling
cooling system. system.
Engine coolant temperature indicator • Radiator fins damaged or closed. ✩ Repair or clean.
reaches overheating (red) range:
• Faulty thermostat. ★ Change.
• Radiator cap loose or broken. ✩ Tighten or change cap.
(Working at considerable altitude)
Temperature indicator always on the • Faulty temperature indicator. ★ Change.

right end of the scale
Temperature indicator pointer always • Faulty thermostat. ★ Change.

on the left end of the scale • Faulty indicator. ★ Change.
Engine does not start with starter • No fuel. ✩ Refuel.
cranking • Air in fuel system. ✩ Bleed system.
• Compression defect, valves with ★ Adjust valve clearance.
wrong clearance.
Exhaust gases white or light blue • Too much oil in oil pan. ✩ Correct oil level.
• Unsuitable fuel. ✩ Change with suitable fuel.
Exhaust gases occasionally tend to be • Air cleaner clogged. ✩ Clean or change.

black • Faulty injectors. ★ Change.
• Faulty compression. ★ Adjust valve clearance.
Combustion noise occasionally makes • Faulty injectors. ★ Change.
a breathing sound
Abnormal noises, during combustion • Fuel with low cetane rating. ✩ Change to fuel compliant with
or in mechanical parts standards.
• Overheating. ✩ See defects of temperature indica-
tor.
• Muffler insides damaged. ★ Change.
• Excessive valve clearance. ★ Adjust valve clearance.
2-116 CK35-1
OPERATION
HYDROSTATIC TRANSMISSION

Machine moves neither for- • Oil level insufficient. ✩ Top off.
ward, nor backward: • Suction filter clogged. ✩ Change.
• Faulty flexible coupling. ★ Change coupling.
• Max. pressure valves faulty or dirty. ★ Clean or change valves.
• Positioning hydraulic connection interrupted. ★ Restore connection.
• Travel motor faulty. ★ Repair or change.
Machine moves with delay Ab- • Oil level too low. ✩ Top off.
normal noise • Presence of foam. ✩ Use the recommended oil.
• Suction pipe tightness. ★ Check and eliminate leakage.
• Suction filter clogged. ✩ Change.
• Fuel supply max. pressure valve faulty. ★ Disassemble, clean, or change.
• Travel motor faulty. ★ Repair or change.
Traction force in the two travel • Engine does not reach max. speed. ★ Change diesel oil filter and
directions is insufficient check injection pump.
• Auxiliary fuel pump (gear pump) faulty. ★ Repair or change.
• Max. pressure valve setting incorrect. ★ Set.
• Connection to servo control faulty lever angle ★ Restore connection shift lever
incorrect. to correct position.
• Pressure relief valve setting incorrect. ★ Set.
• Excessive oil temperature. ✩ Check oil level and clean ex-
changer.
• Travel motor faulty.
★ Repair or change.
Traction force is insufficient in • Engine strongly overloaded. ✩ Reduce loads due to lifting.
one direction only • Incorrect setting of the max. pressure valve rele- ★ Set valve.
vant to that direction.
Oil overheating • Oil level too low ✩ Top off.

• Exchanger clogged or dirty. ★ Check and change if neces-
sary.
• Unsuitable oil. ★ Use the recommended oil.
• Suction pipe tightness. ★ Check and eliminate leakage.
• Setting and operation of the max. pressure valves. ★ Check setting - repair or
change.
• Travel pump faulty.
• Pressure relief valve with high setting.
★ Set valve.
• Travel motor faulty.
CK35-1 2-117
OPERATION

Machine does not reach max. speed • Suction filter clogged. ✩ Change
selected • Engine does not reach max. speed ★ Change diesel oil filter and check
• Auxiliary pump (gear pump) faulty. injection pump.
• Pilot pressure insufficient. ★ Check delivery, repair or change.
• Pressure relief valve setting incor- ★ Set.
rect. ★ Set to rated value.
Machine decelerates intermittently • Mechanical connection with servo ★ Check if rotation is smooth.
control lever too hard.
Machine accelerates slowly. • Engine power drop. ★ Check clogging of diesel oil filter,
injection pump and valves.
• Pressure relief valve setting incor- ★ Set to rated value.
rect.
Oil leakage from engine propeller • Sealing rings faulty. ★ Change.

shaft and/or pump. • Counterpressure in pump casing. ★ Drain pipes clogged or damaged.
• By-pass valve setting too high. ★ Check and restore.
2-118 CK35-1
3MAINTENANCE
CK35-1 3-1
MAINTENANCE
GUIDE TO MAINTENANCE
★ Before opening the engine hood, engage safety locks and stop the engine. If it is necessary to check the hydraulic oil level
in the reservoir, lower the arm and rest the bucket on the ground, See “SAFETY LOCKS” on page 2-2.
★ Carry out any operation on firm and level ground, after applying the parking brake.
★ Raise the cab taking all the precautions indicated in See “TILTING THE CAB” on page 2-54.
★ Use genuine Komatsu oils and greases; choose oils suitable for the ambient temperature. Use clean oils and greases. Keep
the oil and grease containers clean. Keep any foreign matter away from oils and greases.
★ Always keep the machine clean. This makes it easier to locate any parts causing problems. Keep the grease fittings, the
breathers, and the areas near the openings for the fluid level checks clean and prevent any impurities from getting into/on
them.
★ Draining hot oil or coolant immediately after stopping the engine is hazardous. Wait for the engine to cool down to at least
40 to 50°C (104-122°F) before draining hot liquids. After changing the oil or the filters, check if metal particles are
present. If you find large quantities of metal particles, contact your distributor. Check and change the oil in clean locations
and prevent any impurities from getting into the tank/container.
★ Before carrying out any maintenance operation, hang the warning plates on the ignition switch and control levers to pre-
vent anyone from starting the engine by mistake. When performing maintenance operations, always take the precautions
indicated on safety decals applied to the machine.
★ Instructions for arc welding.
1. Turn ignition key to the OFF position.
2. Disconnect the battery (first, negative - pole and then positive + pole). Disconnect the alternator.
3. Do not apply more than 200V continuously.
4. Connect the ground cable within 1 mm of the point on which welding will take place.
5. Avoid placing gaskets and bearings between the welding area and ground cable.
★ Do not use flammable fluids to clean machine parts. Keep exposed flames and lit cigarettes away from these fluids. When
o-rings and gaskets are removed, thoroughly clean sealing surfaces and replace all o-rings and gaskets with new ones. Fit
the o-rings and gaskets correctly when reassembling.
★ Avoid keeping loose objects or tools in your pockets: they may fall out and drop into the machine, especially when you
open covers and work on the machine while bending over it. When washing the machine, do not direct high pressure
water jet onto the radiator and heat exchanger. When washing the machine, protect electric system connectors and avoid
getting the ignition switch wet.
★ Before starting work in mud, in rain, on seashores, or river banks perform general lubrication. Wash the machine immedi-
ately after work to protect components from rust. Lubricate equipment joints more frequently than usual.
★ When working at dusty work sites, proceed as follows:
1. Check the air cleaner for any clogging and clean it more frequently than usual.
2. Clean the radiator and the heat exchanger frequently, to avoid any clogging of the fins.
3. Change the diesel oil filter more frequently than usual.
4. Clean the electrical components, especially the starter and alternator, to avoid any accumulation of dust.
★ Never mix oils of different brands. Do not top off with any oil different from oil used in the machine. If necessary, drain
all the oil and fill tank with new, different brand oil.
Oils, filters, coolant, and the batteries are considered special waste and must be collected and disposed of
according to the regulations in force. Combustible material of some components may become extremely
dangerous if it burns. For this reason, avoid any contact of burnt material with your skin or eyes and do
not inhale fumes.
3-2 CK35-1
MAINTENANCE
MAINTENANCE NOTES
★ Use only genuine Komatsu replacement parts. Do not mix different types of oil. Unless specified otherwise, oils and cool-
ant used by Komatsu before delivery of the machine are as follows:
ITEM SPECIFICATIONS
• Engine oil SAE 10W-30 API classification CD
• Hydraulic system oil SAE 10W API classification CD
• Biodegradable hydraulic system oil. Only for machines

in which the synthetic biodegradable oil type HEES (not SHELL NATURELLE HFX-32
of plant origin) is used.
• Chain case oil SAE 10W-30 API classification CD
Ambient temperature above -10° C(14°F):

ASTM D975 no. 2 diesel oil
• Fuel
Ambient temperature below -10° C(14°F):
ASTM D975 no. 1 diesel oil
Permanent, ethylene glycol-based antifreeze, with corro-

• Radiator coolant
sion inhibitor for protection up to -36°C (-33°F).
NOTES REGARDING THE ENGINE

ENGINE OIL
★ Engine oil must be selected very carefully, since it lubricates the engine, which is the machine’s heart; the main mainte-
nance operations required for engine oil are as follows:
1. Daily check of the oil level.
2. Check condition of the oil with periodic analysis.
3. Periodic oil changes.
CK35-1 3-3
MAINTENANCE
COOLANT
★ Engine coolant serves to keep the engine at the correct temperature and therefore to ensure optimal operating conditions;
check coolant level in the expansion tank daily and top off if necessary. The quantity of antifreeze to be added to the cool-
ant depends on the minimum temperature in the place where the machine is working.
★ Use only permanent ethylene glycol-based antifreeze with the addition of anticorrosion and anti foam products. The anti-
freeze-water ratio must be 50% (50% antifreeze and 50% water).
★ The use of permanent antifreeze requires only the routine change. It is not necessary to wash the cooling circuit.
★ Use drinkable water and in any case soft water.
★ Do not use corrosion inhibitors containing soluble oil, since they damage the rubber hoses.
★ The required standards for permanent antifreeze are the following: SAE-J1034 and FEDERAL STANDARD O-A-548D.
In case of doubt regarding the compliance of the antifreeze used with the standards, contact your Komatsu Utility distrib-
utor and ask for precise information.
FUEL
★ Always use fuel suitable for the engine. Other fuels with different specifications may damage the engine or reduce its
power.
★ Always refuel at the end of the work day.
★ When refueling, make sure that there is no water on the fuel drum cover and take care not to draw condensation from the
drum bottom.
★ If fuel runs out, or if the fuel filter has been replaced, it is necessary to bleed the circuit.
NOTES REGARDING THE HYDRAULIC SYSTEM

★ Be extremely careful when performing maintenance on the hydraulic system, since the oil is very hot. The system is pres-
surized not only during work, but also at the end of work.
★ The maintenance operations required for the hydraulic system are the following:
1. Daily check the oil level in the tank.
2. Periodically change the oil filter.
3. Periodically change the oil and clean the suction filter.
★ Always bleed the system after changing the oil filter and the oil. When a component is removed from the circuit, check the
gaskets and o-rings and change them if they are damaged. When a cylinder or a component of the hydraulic system is
removed, after reassembly bleed the system by proceeding as follows:
1. Start the engine and let it idle.
2. Make all the cylinders perform 4 to 5 movements, stopping them at about 100 mm from the end of their
stroke.
3. Slowly make all the cylinders reach the end of their stroke for 3 to 4 times.
NOTES REGARDING THE ELECTRICAL SYSTEM

★ If the cables are wet or their insulating material is damaged, the electrical system may short, and may result in machine
malfunctions. The maintenance operations required for the electrical system are the following:
1. Check the alternator belt tension.
2. Check the alternator belt for damage or breakage.
3. Check the battery electrolyte level.
★ Do not remove or eliminate any electrical component installed on the machine and do not install any electrical component
with characteristics different from those specified and approved by Komatsu.
★ Be careful to keep the electric system dry. When working on seashores or river or lake banks, protect the jack plugs from
corrosion. Do not connect any optional device to the fuses, ignition switch, battery, relays, etc. For the installation of any
optional equipment, contact your distributor. If any electric welding needs to be done, disconnect the battery and the alter-
nator.
3-4 CK35-1
MAINTENANCE
NOTES REGARDING LUBRICATION

★ Lubrication makes the operations carried out with the machine and work equipment smoother, while preventing wear and
the noise that may be produced if the joints are dry.
★ Lubrication is to be carried out with grease or oil. The maintenance operations required for the components that need
lubricating are the following:
1. Check the fluid and lubricant levels.
2. Change oil at recommended intervals.
3. Inject grease through the grease fittings.
★ Use only the specified lubricants, according to the ambient temperature. Always clean the grease fittings before injecting
grease and remove any excess grease after lubrication; this cleaning operation must be performed with extreme care on
the revolving parts. Keep the lubricants at the correct levels; excessive or insufficient quantities are to be avoided.
PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING
★ The parts subject to wear such as filters, bucket teeth, etc. must be replaced according to the periodic maintenance inter-
vals prescribed or when they reach their wear limit. The timely change of these parts ensures economical use of the
machine. Use only genuine Komatsu parts, which alone can guarantee excellent quality and interchangeability.
ITEM DESCRIPTION QTY CHANGE INTERVAL
Hydraulic oil filter Cartridge (drain) 1 500 hours
Engine oil filter Cartridge 1 250 hours
Fuel filter Cartridge 1 500 hours
Air cleaner Main cartridge 1 When required

Safety cartridge 1 When required
Front bucket Tooth 6 –

Screw 12 –
Nut 12 –
CK35-1 3-5
MAINTENANCE
FUEL, COOLANT AND LUBRICANTS
SELECTION ACCORDING TO THE AMBIENT TEMPERATURE
Ambient Temperature Capacity

Kind of
Reservoir
fluid -30 -20 -10 0 10 20 30 40 50°C1
Specified Refill
-22 -4 14 32 50 68 86 104 22°F
SAE 5W-30
SAE 10W
Engine oil 10 l 10 l
SAE 30
pan (2.64 gal) (2.64 ga)
API CD
SAE 40
Oil
SAE 10W-30
Hydraulic SAE 5W-30

system and 50 l 32 l
hydrostatic SAE 10W (13.2 gal) (8.4 gal)
transmission
Hydraulic
See
system with 50 l 32 l
page 3-
biodegrad- (13.2 gal) (8.4 gal)
12
able oil
Travel
Oil 1.17 l 1.17 l
reduction SAE 10W-30
API CD (.31 gal) (.31 gal)
gears (ea.)
ASTM D975
Diesel No. 1 72l
Fuel tank -
fuel (19.0 gal)
ASTM D975 No. 2
Perma-
Engine cool- nent 15 l
-
ing system anti- (3.9 gal)
freeze★
★ Special red permanent antifreeze compatible with aluminum radiators. If pure, dilute with (50%) water.
GREASE
LUBRICATION POINTS CONSISTENCY TYPE
Joints, grease fittings NLGI 2 (See note 1)
Track tensioner unit NLGI 2 LITHIO EP +MoS2
Note 1:
The recommended lubricating grease is No.2 multi purpose lithium grease with 3% molybdenum disulfide (Lithio EP +
MoS2).
3-6 CK35-1
MAINTENANCE
Remark
When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance
hours described in this manual. Change oil according to the following table if fuel sulphur content is above
0.5%.
Fuel sulphur content Change interval of oil in engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
★ When starting the engine in an atmospheric temperature of lower than 0°C, be sure to use engine oil of SAE10W,
SAE5W-30 or SAE10W-30, even though atmospheric temperature goes up 10°C more during the day time.
★ Use engine oil with CD classifications; if oil with CC classification is used, reduce the engine oil change interval by one
half.
★ Use genuine Komatsu oil which has been specifically formulated and approved for use in the engine, hydraulic work
equipment, in the reduction gears, and in the transmission.
First filling quantity: total quantity of oil, including the oil for the components and pipes.
Oil change quantity: quantity of oil necessary to fill the system or unit during the normal inspection and maintenance opera-
tions.
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
API: American Petroleum Institute
NLGI: National Lubricant Grease Institute
CK35-1 3-7
MAINTENANCE
Antifreeze Coolant
Transmission Oil
Engine Oil [Ethylene Glycol
No. Supplier GM Dexron® II C4 Grease LI, EP, MoS2
API CD, CE or CF-4 Base]
Allison C4
Permanent Type
1 KOMATSU Premium multi grade Komatsu PM704 Komatsu Super Grease
Engine Oils PM701 (1902) Dexron® III NLGI 2
–
SAE 10W/30 PM706
SAE 15W/40 ASTM D128
2 AMOCO Amoco 300 Dexron II ATF Molylith grease 2 Ready Antifreeze
SAE 15W/40
3 ARCO Arcofleet S3 plus ATF Dexron II Litholine HEP 2 Sincol-Blu (-40°C)
SAE 15W/40 Arco EP moly D
Hy-Vis HD extra S3
plus SAE 15W/40
4 BP Vanellus C3 Autran MBX Grease LTX2-M Sigil Fluid (-40°C)
SAE 15W/40
Vanellus C3 Extra
SAE 15W/40
5 CALTEX RPM Delo 500 ATF-HD Molytex EP2 AF engine coolant
RPM Delo 600 CX engine coolant
RPM Delo SPH
6 CASTROL Turbomax RX super TQ - Dexron II Spheerol LMM Antifreeze (pure)
7 CHEVRON Delo 400 Supreme Automatic Moly grease Flurant
Delo 500 Transmission Fluid
8 CITGO – D-21571 – –
9 CONOCO *Fleet motor oil D21718 Fleet Heavy Duty
–
SAE 15W/40 D21570
10 EXXON Essolube TD ATF Dexron II D MP Grease All-season coolant
(ESSO) SAE 15W/40 D-21849 (East Canada) Moly
Heavy Truck Diesel D-21848 (West Canada)
Motor Oil SAE 15W/
40
11 GULF Super duty Gulfcrown EP2 Antifeeze and coolant
SAE 15W/40 Gulfcrown EP special
–
Super duty plus
SAE 15W/40
12 MOBIL Delvac 1300 Super ATF 220 Mobilgrease sp.I ó
SAE 15W/40
Delvac 1200 Super –
SAE 15W/40
Delvac 1300 Super
SAE 10W/30
13 PENNZOIL Supreme duty fleet Pennzoil ATF Multi-purpose white grease Antifreeze and sum-
SAE 14W/40 705 mer coolant
707L White-bearing grease
14 SHELL Rimula Super Donag TG (Dexron II) Alvania EP grease Shellzone all season
SAE 15W/40 MP MOS (Can.) antifreeze
Myrina X Retinax AM (Corea)
SAE 15W/40
Rotella T
SAE 10W/30
15 SUN - - Sunoco ultra prestige 2EP Sunoco antifreeze and
Sun prestige 742 summer coolant
3-8 CK35-1
MAINTENANCE
Antifreeze Coolant
Transmission Oil
Engine Oil [Ethylene Glycol
No. Supplier GM Dexron® II C4 Grease LI, EP, MoS2
API CD, CE or CF-4 Base]
Allison C4
Permanent Type
16 TEXACO Ursa Super TD Havoline ATF Molytex EP2 ó
SAE 15W/40 Dexron II
Texamatic 7045 –
Ursa Super LA
SAE 15W/40 (9226)
17 UNION Guardol D21460 Unoba EP –
CK35-1 3-9
MAINTENANCE
APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE
HEES
Our machines can be filled with synthetic biodegradable hydraulic oil type HEES not of plant origin, therefore use of oils indi-
cated in the following table is authorized and recommended:
SUPPLIER HEES SYNTHETIC BIODEGRADABLE OIL
KOMATSU BO 46 G4 (KES 07.872)
AGIP –
ARAL –
AVIA –
BP –
CONDAT CONDAT D 46 K
ELF –
ESSO –
FINA BIOHYDRAN SE 46
FUCHS –
KENDALL –
KUWAIT PETROLEUM K8 –
MOBIL EAL SYNDRAULIC
MOBIL (USA) –
PAKELO –
PANOLIN HLP SYNTH 46
SHELL NATURELLE HFE-46
TAMOIL –
TEXACO –
TOTAL HYDROBIO 46
VAVOLINE –
3-10 CK35-1
MAINTENANCE
It Is not possible to mix the synthetic biodegradable oil type HEES with ordinary hydraulic oils, since when
the temperature increases insoluble compounds are generated, which are deposited on the filters and clog
them (the maximum concentration of ordinary oil cannot exceed 1% of the total quantity of oil). The syn-
thetic biodegradable oil can be used only in the hydraulic system; it cannot be used in the engine, the
transmission, the braking system, etc. Before introducing the synthetic biodegradable oil in the hydraulic
system, empty the system completely, disconnecting the cylinders and all the parts that may contain ordi-
nary oil, and replace the drain filter with a new one. Start the engine and let it idle without using the work
equipment, wait until the oil reaches a temperature of at least 40°C(104°F), then start moving the equip-
ment, so all the parts of the system are filled with oil. Stop the engine and check the oil level, (See “ENGINE
OIL LEVEL” on page 3-37).
For the lubrication procedures for the single points, See “MAINTENANCE PLAN” on page 3-21.
The type of lubricant to be used is indicated in the lubricant table (See “FUEL, COOLANT AND LUBRICANTS” on page 3-
6).
CK35-1 3-11
MAINTENANCE
LUBRICATION DIAGRAMS
GENERAL
3-12 CK35-1
MAINTENANCE
PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY
To ensure safety at all times while driving and using the machine, the operator must carry out all periodic maintenance opera-
tions prescribed. Furthermore, the operator must periodically replace the components indicated in the table on the following
pages, which are especially related to safety and fire prevention rules. These components are subject to wear and since it is
particularly difficult to evaluate their conditions through simple periodic maintenance, after a certain period it is advisable to
change them regardless of their condition, to keep them efficient over time. Repair or replace these components immediately
in case of failures or abnormalities, even if the time interval prescribed for their change has not yet elapsed. If the hose clamps
show signs of deterioration, like deformations or cracks, replace them at the same time as the hoses.
In addition to periodic replacement of the components listed on the following pages, the inspections described below are to be
performed on the hydraulic hoses. In case of abnormalities, perform the necessary adjustments and replacements, or institute
any other required measure.
TYPE OF CHECK CHECK ITEM
Check before starting Leakage from joints, grease fittings, hydraulic hoses, or fuel
lines.
Periodic check (monthly check) Leakage from joints, fittings, hydraulic hoses, or fuel lines.
Damaged hydraulic or fuel lines, cracks, wear and tear.
Periodic check (annual check) Leakage from joints, fittings, hydraulic hoses fuel lines.
Deteriorated, twisted, damaged hydraulic hoses fuel lines,
cracks, wear and tear, or in contact with other parts of the
machine.
CK35-1 3-13
MAINTENANCE
CRITICAL PARTS FOR SAFETY
FUEL SUPPLY SYSTEM
NO COMPONENTS RELATED TO SAFETY THAT REQUIRE REPLACING QTY REPLACEMENT INTERVAL
1 Fuel line (Fuel tank - precleaner) 1
2 Fuel line (Precleaner - fuel pump) 1
3 Fuel line (Fuel pump - fuel filter) 1

Every 2 years or 4000 hours,
4 Fuel line (Fuel filter - injection pump) 1
whichever occurs first
5 Fuel line (Fuel filter - fuel tank) 1
6 Fuel recovery line (Injection pump - fuel filter) 1
7 Fuel recovery line (Between the injectors - injection pump) 3
★ For serial numbers and quantity of components that periodically need replacing, consult the replacement parts manual sec-
tion regarding the components connected with safety and components that must be periodically replaced.
★ When replacing hoses, always change o-rings, gaskets, and associated components.
3-14 CK35-1
MAINTENANCE
STANDARD FLOW HYDRAULIC SYSTEM
1 Hydraulic hose (Travel pump supply) 4 Every 2 years or 4000 hours,

2 Hydraulic hose (Machine function pump supply) 1 whichever occurs first
CK35-1 3-15
MAINTENANCE
3 Hydraulic hoses (Lift cylinders) 6

4 Hydraulic hoses (Bucket cylinders) 6
5 Hydraulic hoses (Auxiliary hydraulic kit - 2 line) 2
3-16 CK35-1
MAINTENANCE
SUPER FLOW HYDRAULIC SYSTEM
1 Hydraulic hose (Travel pump supply) 4

2 Hydraulic hose (Machine function pump supply) 1
3 Hydraulic hose (Flow rate increase pump supply) 1
CK35-1 3-17
MAINTENANCE
4 Hydraulic hoses (Lift cylinder) 6

5 Hydraulic hose (Bucket cylinder) 6
6 Hydraulic hose (Auxiliary hydraulic kit - 3 line) 2
3-18 CK35-1
MAINTENANCE
OPERATOR’S SAFETY
No Components needing replacement Qty Interval
1 Safety belt 1 Every 4 years
CK35-1 3-19
MAINTENANCE
TIGHTENING TORQUE
STANDARD TORQUE FOR BOLTS AND NUTS
Property class designation

Thread Wrench
Pitch
diameter size 8.8 10.9
(mm)
(mm) (mm)
N•m N•m
6 1 10 9.5 ± 1 13.5 ± 1.5

8 1.25 13 23 ± 2 32.2 ± 3.5
10 1.5 17 45 ± 4.9 63 ± 6.5
12 1.75 19 77 ± 8 108 ± 11
14 2 22 122 ± 13 172 ± 18
16 2 24 191 ± 21 268 ± 29
18 2.5 27 262 ± 28 366 ± 36
20 2.5 30 372 ± 40 524 ± 57
22 2.5 32 511 ± 57 719 ± 80
24 3 36 644 ± 70 905 ± 98
27 3 41 945 ± 100 1329 ± 140

30 3.5 46 1287 ± 140 1810 ± 190
SPECIFIC TORQUES
This torque table is not valid for bolts or nuts that contain nylon parts or spring washers.
Item Description N•m
Cab Rear fastening bolts 98 ± 7.3
Wheels Front 186± 9.8

Rear 186± 9.8
Engine Front support bolt 186 ± 9.8

Rear support bolt 186 ± 9.8
3-20 CK35-1
MAINTENANCE
MAINTENANCE PLAN
WHEN REQUIRED
ITEM DESCRIPTION OPERATION PAGE
a. Engine air cleaner Check, clean or change 24
b. Parking brake Release 26
c. Fuel tank Drain condensate 25
d. Rubber tracks Checking for wear 28
e. Battery Check charge level 27
f. Rubber track tension Check and adjust 30
g. Rubber track Changing 33
CHECKS BEFORE STARTING
a. Various checks Check 35
b. Fuel tank Check and top off 36
c. Coolant Check and top off 41
d. Engine oil Check and top off 41
e. Hydraulic oil tank Check and top off 38
f. Water separator Drain water 39
g. Electrical system Check 39
AFTER THE FIRST 50 HOURS OF OPERATION
a. Front and rear carriage fasteners Check torque 47
Hydraulic oil drain filter

b. (only for machines filled with biodegradable Change cartridge 50
oil)
EVERY 50 HOURS OF OPERATION
a. Rubber tracks Check tension 40
b. Radiator Check level 41
c. Reduction gears Checking oil level 41
CK35-1 3-21
MAINTENANCE
MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
★ Perform these operations together with those to be initiated every 250 HOURS
.
a. Hydraulic oil drain filter Change 50
a. Fan belt Check condition and tension 42
b. Radiator Clean outside 43
c. Pivot points Lubricate 44
d. Engine oil Change 45
e. Engine oil filter Change 46
f. Front and rear carriage fasteners Check torque 47
AFTER THE FIRST 500 HOURS OF OPERATION

★ Only for machines in which synthetic biodegradable oil, type HEES is used. Perform these operations together with those
to be initiated every 500 HOURS.
Hydraulic oil and suction filter

a. (only for machines filled with biodegradable Change oil and clean filter 55
oil)
a. Fuel filter Change cartridge 49
b. Hydraulic oil drain filter Change cartridge 50
c. Water separator Clean 52
Hydraulic oil tank 53

d. (only for machines filled with biodegradable Drain condensate
oil)
e. Reduction gears Change oil 51
3-22 CK35-1
MAINTENANCE
a. Hydraulic oil and suction filter Change oil and filter 55
b. Engine valves Check clearance, adjust 57
a. Coolant Change 58
b. Suction filter Change 60
c. Alternator and starter Check 61
CK35-1 3-23
MAINTENANCE
WHEN REQUIRED
AIR CLEANER CARTRIDGE
Remove the air cleaner only after stopping engine, and do

not start engine after the air cleaner is removed. Always wear
safety goggles during cleaning operations.
★ The air filter system consists of a primary filter element with

considerable capacity and of a secondary cartridge that en-
sures additional safety protection. The primary element can
be cleaned with compressed air, while the cartridge must be
replaced. The filter must be cleaned when the clogging warn-
ing light A positioned on the instrument panel comes on or
flashes.
The air cleaner can be reached after raising the engine hood and open-
ing the rear panel. To clean the primary element, proceed as follows:
1. Release safety locks b, moving them toward the outside and
remove the filter cover c.
2. Remove the main filtering element d.
3. Lightly tap the filter element d on the palm of your hand, in a man-
ner to remove the dust, and blow compressed air on the inner sur-
face, keeping the air jet at a distance of approximately 15 cm (5.9
in.) and taking care to prevent pressure from exceeding 4 to 5 kg/
cm² (58-73 psi).
4. Carefully clean the inside of the filter case e, taking care to prevent
foreign debris from getting into the suction duct and reassemble the
unit making sure that the ejector is positioned vertically and at the
bottom.
If the clogging warning light comes on after starting the en-

gine, it is necessary to replace the primary filter element and
safety cartridge.
Replace the primary filter element after 5 cleaning operations
or after one year. Every time the primary filter element is re-
placed, the safety cartridge must also be replaced.
3-24 CK35-1
MAINTENANCE
To change the safety cartridge, after removing the primary element, then
proceed as follows:
5. Remove the safety cartridge f and replace it with a new one.
6. Once the safety cartridge f has been installed inside the filter case
e, make sure that it is perfectly seated in its housing.
7. Reassemble the unit as described above, making sure that all filter
components are perfectly locked.
8. Push the safety locks b toward the housing.
DRAINING THE FUEL TANK
When draining the fuel tank, avoid spilling fuel, since this
may cause fires.
If some fuel is accidentally spilled, clean the dirty area imme-
diately, to prevent it from getting slippery and to avoid fires.
This operation serves to let all the impurities and the condensate flow
out of the tank.
Proceed as follows:
1. Raise the engine hood (See “ENGINE HOOD” on page 2-51).
2. Open the valve (1), using the lever (2) supplied with the machine.
3. Turn the extension (2) counterclockwise, until clean fuel flows out.
4. Turn the extension (2) clockwise to stop the fuel flow.
5. Close the engine hood (See “ENGINE HOOD” on page 2-51) and
put the extension (2) in the technical documentation case (See
“TECHNICAL DOCUMENTATION CASE” on page 2-58).
The tank must be drained before starting the engine, with

temperatures exceeding 0ºC (32°F); when the temperature is
below 0ºC (32°F), the tank must be drained at the end of work
or in any case with the machine at operating temperature, to
prevent the condensate from freezing.
The condensate and the impurities that may have accumulat-
ed inside the tank must be eliminated before refueling.
CK35-1 3-25
MAINTENANCE
RELEASING THE PARKING BRAKE
In case of failure of the hydraulic system and before moving

the machine, release the negative brake installed on the trav-
el motors.
The release of the parking brake is obtained by acting on the negative

brake installed on the travel motors, according to the following proce-
dure.
1. Raise the cab (See “TILTING THE CAB” on page 2-54).
2. Disconnect the pipe (1) that supplies pressure to the travel motors.
3. Connect a grease nipple (3) to the union (2).
4. Using a grease pump, inject grease until reaching the minimum
pressure required to release the brake.
5. After releasing the brake, carry out the necessary maintenance
operations.
6. To restore the braking circuit to the standard configuration, remove
the grease nipple (3) from the coupling (2) and put back the pipe
(1).
7. Lower the cab (See “TILTING THE CAB” on page 2-54).
After restoring the circuit to the standard configuration, it is

not necessary to make any adjustments.
3-26 CK35-1
MAINTENANCE
CHECKING THE BATTERY CHARGE LEVEL
Check the battery charge level only with the engine stopped.
To prevent gas explosions, do not use open flames, do not
smoke, and avoid producing sparks due to short circuits.
The battery electrolyte is dangerous: in case of contact with
the eyes or the skin, wash with plenty of running water and
consult a doctor. The battery is maintenance-free.
Make sure that the connection terminals are not oxidized; if

necessary, clean them and cover them with anti-oxidation
grease.
The battery (1) can be reached after opening the engine hood (See
“ENGINE HOOD” on page 2-51).
The change of color of the indicator shows the battery charge level,
according to the table positioned beside the indicator itself:
- Green: the charge is correct
- Grey: the battery needs recharging
- White: the battery must be changed
If a dry battery is installed, check the electrolyte level, which

must be approximately 6 mm above the edge of the plate ; if
necessary, top off using distilled water only.
If, on the contrary, the level is low because some electrolyte
has been spilt, add sulphuric acid, dilute as much as neces-
sary to reach the concentration suitable for the ambient tem-
perature (See “FUEL, COOLANT AND LUBRICANTS” on
page 3-6).
It is advisable to add distilled water before starting work, to
prevent it from freezing.
Before putting back the cell plugs, make sure that the
breather holes are not clogged.
CK35-1 3-27
MAINTENANCE
CHECKING THE RUBBER TRACKS
Change the rubber tracks upon reaching the indicated wear limits.
1. When the height "A" of the rubber claw is less than 5 mm (3/16”)
the track may slip and its traction force reduced.
1 - Roller
2 - Rubber track
2. When the steel core (3) is visible in two or more points of the track.
3. When more than half of the steel core cords at the center of the
track are cut.
4. When one or more steel cores (4) have come off the track or are
pushed out due to excessive tension.
3-28 CK35-1
MAINTENANCE
5. If the rubber track cannot be tensioned correctly through the injec-

tion of grease, check the track tensioner seals and if necessary
change them or the track.
(See "4.8.1.f CHECKING AND ADJUSTING THE RUBBER
TRACK TENSION").
Do not exceed the tension indicated in the figure.
6. If the broken area between the rubber track support claws reaches a
length (1) of approximately 60 mm (2-3/8 in), the track must be
repaired.
It must also be immediately repaired when the steel cores are visi-
ble, even if the broken area is very small.
If the length of the broken area (2) is less then 30 mm or its

depth is less than 10 mm (.39 in), it is not necessary to repair
the track.
For any repair or replacement, contact your Komatsu Distrib-
utor.
CK35-1 3-29
MAINTENANCE
*
CHECKING AND ADJUSTING THE RUBBER TRACK TENSION
This operation must be carried out by two people. One oper-

ator must be seated in the cab and maneuver the machine
following the signals of the other operator who performs the
check and adjustment.
The track tension must be checked with the frame raised
from the ground; be careful not to shift any control lever
while the operator is carrying out the check.
The wear of the rubber tracks may vary according to the operating con-
ditions and to the type of ground on which the machine works, therefore
it is necessary to check the wear and tension of the tracks frequently. To
carry out the check and the corresponding maintenance operation, stop
the machine on firm and level ground.
In particular, on new machines or after the installation of new tracks, it
is advisable to carry out a first check after 30 hours of operation. Adjust-
ing the track tension frequently until the initial slackening doesn't occur
repeatedly will prevent the track from coming off due to insufficient
tension.
If the machine works with slackened rubber tracks, they may come off
and cause the untimely wear of the steel cores.
CHECK PROCEDURE
1. Stop the machine on a firm and level surface and lower the bucket
to the ground.
2. Raise the front part of the machine, pushing the bucket blade
against the ground until the front idler roller reaches a height of
approximately 75 mm (2.95 in) from the ground.
3. Move the machine slowly forward to create any slack.
4. Stop the engine.
5. Measure the slack between the contact surfaces of the central track
rollers and the track rolling guide. The standard slack must be
between 15 and 20 mm (9/16 and 13/16 in).
If the slack is not within the standard values, adjust it accordingly.
NOTE
Check both tracks.
Adjust the support "A" at a minimum distance of 5 mm (.2 in)

from the track surface, with the machine resting on the
ground.
When using the machine on SANDY GROUND, mainly on lev-
el surfaces, it is advisable to reduce the tension to a maxi-
mum of 40 mm (1.57 in), to prolong the life of the
components.
If the machine works on slopes exceeding 10°, it is advisable
to adjust the tension to the usual values of 15-20 mm (9/16-
13/16 in).
3-30 CK35-1
MAINTENANCE
*
ADJUSTMENT
The grease contained in the hydraulic cylinder is pressur-

ized.
For this reason, do not give the grease valve (1) more than 5
turns when loosening it; in fact, if the valve is loosened ex-
cessively it may be pushed out due to the grease pressure
and this is very dangerous for the operator. Do not loosen
any component apart from the valve (1). If the rubber track
tension doesn't decrease after this operation, contact your
Komatsu distributor.
If the resistance met when injecting the grease is excessive,

move the track slowly covering a short distance.
To adjust the rubber tracks, position the machine by proceeding as

described below:
to the ground.
approximately 75 mm (2.95 in) from the ground. Position two
stands or safety blocks under the frame.
3. With the aid of a crane or a lift truck, raise the rear part of the
machine until the rear idler roller reaches a height of approximately
75 mm (2.95 in) from the ground. Position two stands or safety
blocks under the frame.
4. Slowly lower the machine onto the stands or safety blocks, making
sure that it is in a stable and safe position.
To increase the tension
1. Loosen the screws and remove the cover over the adjusting device
(2). Use a 5 mm Allen wrench.
2. Carefully clean the grease valve (1) and inject grease through the
grease nipple until the tension reaches the correct value. If the
injection of grease doesn't proceed smoothly, move the track slowly
over a short distance.
CK35-1 3-31
MAINTENANCE
To decrease the tension
It is extremely dangerous to let the grease out without fol-

lowing the one indicated below.
If the rubber track tension doesn't decrease after this opera-
tion, contact your Komatsu Distributor.
1. After removing the cover over the adjusting device (2), gradually
loosen the grease valve (1) to let the grease out; do not give the
valve more than five turns.
Use a 5 mm Allen wrench and a 22 mm hexagon wrench.
2. If the grease doesn't come out smoothly, move the track slowly over
a short distance.
3. Tighten the valve (1) and remove any trace of grease.
4. Move the track forward and backward and, after stopping it, check
that the tension is correct.
5. If the rubber track cannot be tensioned enough by injecting grease,
it is necessary to change the track or the track tensioner seals.
For any repair or replacement, contact your Komatsu Distributor.
The wear of the rubber tracks may vary according to the op-
erating conditions and the type of ground on which the ma-
chine works (see "3.13.7 USING THE RUBBER TRACKS").
Therefore it is necessary to check the track tension frequent-
ly and to adjust it when necessary.
After the installation of new tracks, it is advisable to carry
out a first check after 50 hours of operation.
3-32 CK35-1
MAINTENANCE
CHANGING THE RUBBER TRACKS

following the signals of the other operator who carries out
the change and the adjustment.
The track tension must be checked with the frame raised
from the ground; be careful not to shift any control lever
while the operator is carrying out the check.
During the change do not remove any component other than
the track.
If the rubber track tension doesn't decrease after this opera-
tion, contact your Komatsu distributor for the necessary re-
pairs.
REMOVING THE TRACK
The grease contained in the hydraulic cylinder is pressur-

ized.
For this reason, do not give the grease valve (1) more than 5
turns when loosening it; in fact, if the valve is loosened ex-
cessively it may be pushed out due to the grease pressure
and this is very dangerous for the operator.
Do not loosen any component other than the valve (1). If the
rubber track tension doesn't decrease after this operation,
contact your Komatsu distributor.
When installing or removing the tracks, make sure that the
grease contained in the cylinder has been removed before
turning the sprocket.
Secure the machine in the correct position by placing sup-
port blocks under the front and rear part of the frame.
Stop the machine on a firm and level surface and lower the equipment to
the ground.
Raise the machine approximately 75 mm (2.95 in) from the ground and
secure it in this position by placing safety blocks under the frame.
Follow the same procedure indicated for the adjustment of the track ten-
sion.
1. Loosen the screws and remove the cover over the adjusting device
(2).
Use a 5 mm Allen wrench.
2. Gradually loosen the grease valve (1) to let the grease out; do not
give the valve more than five turns. Use a 22 mm hexagon wrench.
Remove any trace of grease.
3. If the grease doesn't come out smoothly, move the track slowly over
a short distance.
4. Introduce steel tubes (3) in the track, turn the sprocket in reverse
(4), so that the steel tubes move with the track and become engaged
with the front idler roller; slide the track sideways (5), and remove
it.
CK35-1 3-33
MAINTENANCE
INSTALLING THE TRACK
1. Before installing the track, make sure the grease contained in the
track tensioner cylinder has been removed.
2. Install the rubber track on the sprocket, fitting the drive blocks,
insert the guides in the seat of the rear idler roller and guide the
track until it is in the correct position on the front idler roller.
3. Slowly turn the sprocket in reverse (1) while pushing the track
towards the machine frame.
4. Using a steel tube (2), position the track guides correctly in the seat
of the front idler roller and turn the sprocket again in reverse (1).
5. Make sure that the track is correctly positioned on the sprocket,
track rollers and idler rollers.
6. Adjust the track tension following the procedure and keeping to the
values indicated in "4.8.1.f CHECKING AND ADJUSTING THE
RUBBER TRACK TENSION".
7. Lower the machine until the tracks rest on the ground.
3-34 CK35-1
MAINTENANCE
CHECKS BEFORE STARTING
VARIOUS CHECKS
Dirt, oil, and fuel spread in the engine compartment near hot
areas may cause fires and damage the machine. Check to
see if there are frequent leaks, and perform any necessary
repairs immediately. If this occurs repeatedly, contact your
distributor.
Before starting the engine, check the following:

1. Check for loose screws or nuts.
2. Check for oil, fuel or coolant leakage.
3. Check for worn equipment.
4. Check condition of wheel rims, and condition and wear of
the tires.
5. Check condition and efficiency of instruments and warn-
ing lights on the dashboard, working lights and direction
indicators.
The other general checks concern safety, and functionality:
1. Soundness of the safety belt.
2. Clearness and legibility of the warning decals.
3. Cleanliness of the ladders and hand rails used to reach
the drivers seat, cleanliness inside the operator’s com-
partment.
CHECKING THE COOLANT LEVEL
Carry out this check with the machine parked on a level sur-
face and the equipment resting on the ground.
Do not remove the radiator cap; the coolant level must be
checked in the coolant reservoir with the engine cold.
The coolant reservoir (1) can be reached by raising the engine hood
(See “ENGINE HOOD” on page 2-51) and opening the rear panel (See
“REAR PANEL” on page 2-52). The coolant level must fall between
the MIN. and MAX. marks.
If necessary, add coolant and, if a constant and considerable decrease in
the fluid level is noticed, check the tightness of the radiator-engine unit
and of the radiator.
CK35-1 3-35
MAINTENANCE
CHECKING THE FUEL LEVEL
When refueling, avoid spilling fuel to prevent any risk of fire.

If some fuel should inadvertently be spilled, clean the dirty
area immediately.
Fuel is flammable; neither use open flames, nor smoke while
refueling.
Place the fuel nozzle into the filler neck when refueling.
To check the fuel level, use the indicator (1) positioned on the dash-
board, after turning the ignition key to position «I».
To refuel, if necessary, open the engine hood (See “ENGINE HOOD”
on page 2-51).
Do not fill the tank completely, in order to leave room for the fuel to
expand.
It is advisable to refuel after work, in order to avoid the for-

mation of water condensate.
After refueling, tighten the filler cap (2) thoroughly, lower the
engine hood, and lock it.
3-36 CK35-1
MAINTENANCE
ENGINE OIL LEVEL
After the machine is stopped, the engine is very hot. Let the
engine cool down before performing any check. Hot engines
may cause burns. If it is necessary to check the oil level dur-
ing or soon after work, stop the engine and wait for 15 min-
utes before checking.
The dipstick b can be reached after opening the engine hood. The check
must be performed with a cold engine and the machine located on level
ground.
The oil level can be checked on the graduated dipstick b and must be
between MIN. and MAX. marks. If the level is near the MIN. mark, top
off with oil, through filler tube c, of the same brand, suitable for the
ambient temperature, as prescribed in the lubricant chart (See “FUEL,
COOLANT AND LUBRICANTS” on page 3-6).
CK35-1 3-37
MAINTENANCE
HYDRAULIC SYSTEM OIL LEVEL
The oil level in the hydraulic system must be checked with

cold oil and the machine positioned on a level surface and
the bucket resting on the ground. If it is necessary to top off,
stop the engine and then eliminate the residual pressures
present in the work equipment by moving the controls more
than once and in the tank by slowly loosening the filler cap.
When adding oil, do not exceed the MAX level. This would
damage the hydraulic system and cause oil to overflow. If a
constant or abnormal decrease of the oil level is observed,
thoroughly check the hydraulic system, the pistons, and the
pump for leaks. After topping off, tighten the hydraulic tank
cap completely.
To check the oil level in the hydraulic circuit, open the rear panel (See
“REAR PANEL” on page 2-52). The oil level must be visible through
the gauge (1) positioned on the tank and must be between the MIN. and
MAX. marks. If the level is near the MIN. mark, top off through the
filler opening (2) with suitable hydraulic oil (See “FUEL, COOLANT
AND LUBRICANTS” on page 3-6), after removing the cap. Reinstall
and tighten the cap after topping off.
3-38 CK35-1
MAINTENANCE
DRAINING WATER SEPARATOR
Fuel is flammable; do not use open flames and do not smoke

while draining the water separator. If some fuel is spilled,
wipe it up immediately.
The water separator can be reached after opening the engine hood (See
“ENGINE HOOD” on page 2-51). The check must be carried out by
means of the red ring (1) installed in the filter.When the red ring floats
on the surface of the water contained in the water separator, it is neces-
sary to drain it. Provide a suitable container to catch the drained liquid.
Proceed as follows:
1. Turn the valve (2) to close the fuel flow.
2. Loosen the wing nut (3) and drain the condensate until clear diesel
fuel flows out. Close the wing nut (3).
3. Open the valve (2).
4. Drain the fuel tank as described in paragraph See “DRAINING
THE FUEL TANK” on page 3-25.
5. Bleed the fuel supply circuit as described in paragraph See
“CHANGING THE FUEL FILTER” on page 3-49.
6. Properly dispose of the drained liquid.
If the filtering element is considerably clogged or damaged,

change it.
CHECKING THE WIRING SYSTEM
If the fuses are corroded, oxidized or they are not perfectly

held in their seat, replace them only with fuses having the
same capacity; before changing a fuse, make sure that the
ignition key is in position «O».
If there are signs of short circuits on the cables, find the
cause and repair them; always contact your Komatsu distrib-
utor for troubleshooting.
Before checking the wiring, take all the necessary precau-
tions to ensure safety.
Make sure that there are no disconnected cables or signs of short cir-
cuits in the electrical system. Make sure that all the cables are well
tightened in the corresponding terminals; tighten any loose cables.
CK35-1 3-39
MAINTENANCE
MAINTENANCE AFTER THE FIRST 50
HOURS OF OPERATION
These maintenance operations must be carried out after the first 50
hours of operation, together with those to be carried out “EVERY 50
HOURS”.
★ CHECK THE TIGHTNESS OF THE CARRIAGE TO FRAME
BOLT TIGHTNESS
★ CHANGE THE HYDRAULIC OIL DRAIN FILTER (only for
machines filled with biodegradable (HEES) oil)
For details on the various maintenance operations, see sections See
“EVERY 250 HOURS OF OPERATION” on page 3-22 and See
“EVERY 500 HOURS OF OPERATION” on page 3-22.
MAINTENANCE EVERY 50 HOURS OF

OPERATION
CHECKING THE RUBBER TRACK TENSION

following the signals of the other operator who carries out
the check and adjustment.
The track tension must be checked with the frame raised off
the ground; be careful not to shift any control lever while the
operator is carrying out the check.
The wear of the rubber tracks may vary according to the operating con-
ditions and the type of ground on which the machine works, therefore it
is necessary to check the tension of the tracks regularly.
To carry out the check, stop the machine on firm and level ground.
In particular, on new machines or after the installation of new tracks, it
is advisable to carry out a first check after 30 hours of operation. Regu-
lar checks will prevent the tracks from coming off and the steel cores
from wearing out due to insufficient tension.
CHECK
to the ground.
approximately 75 mm (2.95 in) from the ground.
3. Move the machine slowly forward to create any slack.
4. Stop the engine.
5. Measure the slack between the contact surfaces of the central track
rollers and the track rolling guide. The standard slack must be
between 15 and 20 mm (9/16 and 13/16 in).
If the slack is not within the standard values, adjust it accordingly.
(See "4.8.1.f CHECKING AND ADJUSTING THE RUBBER
TRACK TENSION").
3-40 CK35-1
MAINTENANCE
CHECKING THE COOLANT LEVEL IN THE RADIA-
TOR
Carry out this check with the machine parked on a level sur-
face and the equipment resting on the ground. Do not re-
move the radiator cap when the fluid is hot, since it may be
sprayed out violently and cause burns. Loosen the cap slow-
ly in order to release the pressure before removing it.
The radiator cap can be reached after raising the engine hood (See
“ENGINE HOOD” on page 2-51). Remove the cap (1) and make sure
that the fluid level reaches the filling hole.
If the fluid level in the radiator is low and the expansion tank
is full of coolant, check the tightness of the radiator cap and
make sure that there is no air leakage from the radiator to ex-
pansion tank hose. If this cap looseness occurs repeatedly,
contact your distributor.
CHECKING THE OIL LEVEL IN THE TRAVEL

MOTOR
Carry out the check with the machine parked on a firm and
level surface and the bucket resting on the ground.
Right after the machine is stopped the oil is very hot; allow it
to cool down to 40-45°C (104-113°F) before performing the
check.
This check must be carried out on each travel motor positioned with the
plug (1) at a distance of 20 mm (.79 in) from the horizontal axis, as
shown in the figure. If necessary, move the machine slightly until reach-
ing the specified position, which is necessary for an accurate check.
Remove plug (1), check for the oil level to be at the bottom of the hole;
if necessary, remove the plug (2) and top off using the prescribed oil
(see "4.3 FUEL, COOLANT AND LUBRICANTS").
Put back plugs (1) and (2).
Use an 8 mm Allen wrench.
CK35-1 3-41
MAINTENANCE
FIRST 250 HOURS OF OPERATION
Perform the following maintenance after the first 250 hours, together
with those to be initiated EVERY 250 HOURS.
★ HYDRAULIC OIL DRAIN FILTER
For details on the various maintenance operations,
★ See “EVERY 500 HOURS OF OPERATION” on page 3-22.
These operations must be carried out together with those to be carried

out See “EVERY 50 HOURS OF OPERATION” on page 3-21.
FAN BELT TENSION

The fan belt can be reached after opening the engine hood, See
“ENGINE HOOD” on page 2-51
The test is manual: press the belt b with your thumb on the indicated
point with a force equal to about 10 kg (22 lb.) N; the resulting deflec-
tion must be about 10 to 15 mm (0.4-0.6 in). If the deflection exceeds
this value, loosen the bolt c that fastens the alternator d and, with a
lever inserted between the engine block and casing, move the alternator.
Lock the bolt and check again. Use a 12 mm wrench.
A Fan pulley
B Driving shaft puller
C Alternator pulley
If the belt is worn, replace it and check the tension again af-
ter a few hours of operation.
3-42 CK35-1
MAINTENANCE
CLEANING THE OUTSIDE OF THE RADIATORS
If compressed air, steam or water are directed against a per-

son, they may cause injuries. Always wear an eye shield and
safety shoes.
The radiator/hydraulic oil cooler can be cleaned after opening the rear
panel (See “REAR PANEL” on page 2-52), using a compressed air jet
and, if necessary, carrying out a washing cycle with low pressure water
or steam; the specific detergents available on the market can be used,
provided that the instructions given on the package are followed and
that at the end of the operations the washed parts are rinsed and dried.
Do not use products containing petroleum products, even if

in slight quantities, since these promote the sticking of dust,
which reduces the heat exchange process. Clean the outside
of the radiators whenever the radiator and the hydraulic oil
cooler are dirty, even if accidentally, with oil, diesel oil,
greasy or oily substances. If the machine is used in dusty
places, clean the radiator/hydraulic oil cooler more frequent-
ly, to avoid the clogging of the fins.
CK35-1 3-43
MAINTENANCE
LUBRICATING THE JOINTS
Clean the grease nipples before applying the grease pump. After lubrication, remove any excess grease.
If the machine is used in difficult conditions, perform these maintenance operations more frequently.
These maintenance operations must be carried out with the arm completely lowered and the bucket resting on the ground. For
the lubrication, use a grease pump and the recommended grease. (See “FUEL, COOLANT AND LUBRICANTS” on page 3-
6).
As a general rule, consider that each cylinder is provided with two grease nipples positioned on the cou-
plings and that each pin serving as fulcrum for a movement is provided with at least one grease nipple.
EQUIPMENT LUBRICATION POINTS
1 - Bucket coupling pin (2 points)
2 - Tool-holder plate fulcrum pin (2 points)
3 - Bucket cylinder head pin (2 points)
4 - Bucket cylinder base pin (2 points)
5 - Lifting cylinder head pin (2 points)
6 - Arm fulcrum pin (2 points)
7 - Lifting cylinder base pin (2 points)
3-44 CK35-1
MAINTENANCE
CHANGING THE ENGINE OIL
Immediately after the engine has been shut off the engine oil
is very hot and may cause burns; let the engine cool down
until it reaches a temperature of 40-45°C (104-113°F) before
draining the oil.
The oil that may be spilled during the change makes the
ground slippery, therefore, use anti-slip shoes and immedi-
ately remove any trace of oil from the floor.
Oils, filters, coolants and batteries are considered special
waste and must be collected and disposed of according to
the anti-pollution regulations in force.
Drain the oil after positioning the drain hose outside the en-
gine compartment.
Change the engine oil at the same time as the engine oil filter (See
“CHANGING THE ENGINE OIL FILTER” on page 3-46). This opera-
tion must be carried out with the machine parked on firm and level
ground and performing the following steps:
1. Detach the lower cover (1) after removing the fastening screws (2).
Use a 17 mm wrench.
2. Extract the oil drain flexible hose (3) from the lower opening.
4. Remove the drain plug (4) from the drain hose (3), gathering the
used oil that flows out into a container with suitable capacity. Use a
27 mm wrench. While the oil flows out, remove the filler cap (5),
so that the oil can flow freely.
5. After the oil has completely drained from the pan, screw the drain
plug (4) back into the drain hose, tuck the drain hose away. Pour the
specified quantity of new oil into the pan, using the dipstick (6) to
make sure that the oil reaches the MAX. level.
6. Replace the filler cap (5), start the engine, let it run for 5 minutes
and then stop it. Check the level again and top off, if necessary.
7. Assemble the lower cover (1).
8. Close the engine hood.
Use oil suitable for the ambient temperature (See “FUEL, COOLANT
AND LUBRICANTS” on page 3-6).
After the oil change and after removing any trace of oil, put
the drain hose back inside the engine compartment.
CK35-1 3-45
MAINTENANCE
Some versions of the machine come with special safety drain plugs. To
change the oil proceed as follows:
Remove the plug (7), apply the special union provided and turn manu-
ally until the oil drains. Carry out the change procedures described for
the standard version. At the end of the operation, remove the special
union and put it in the appropriate tool container.
Reassemble the plug (7).
CHANGING THE ENGINE OIL FILTER
Immediately after the engine has stopped, the engine oil is

very hot and may cause burns; let the engine cool down until
it reaches a temperature of 40-45°C (104-113°F) before drain-
ing the oil. The oil that may spill during the change makes
the ground slippery, therefore, use anti-slip shoes and imme-
diately remove any trace of oil from the floor. Oils, filters,
coolants and batteries are considered special waste and
must be collected and disposed of according to the anti-pol-
lution regulations in force.
This operation must be carried out during every oil change.

Proceed as follows:
2. Drain the engine oil (See “CHANGING THE ENGINE OIL” on
page 3-45) into a suitable container.
3. Position a container below the filter to catch any oil. Unscrew the
used filter (1) with the special wrench provided and dispose of it
properly.
4. Clean the contact surface between the seal and the filter base (2).
5. Lubricate the seal of the new filter and screw on until the filter con-
tacts the base.
6. Give the filter a further half turn by hand.
7. Fill the engine with new oil and complete the operations as
described in, See “CHANGING THE ENGINE OIL” on page 3-45.
Start the engine, make sure that there is no leakage and that the oil pres-
sure warning light goes out.
Close the engine hood.
Do not use the wrench to tighten the filter, since this may
cause damage and result in oil leaks.
3-46 CK35-1
MAINTENANCE
CHECKING THE TORQUE OF THE BOLTS AND
NUTS THAT FASTEN THE CARRIAGES TO THE
MACHINE FRAME
On new machines, check the torque after the first 50 hours of

operation and successively every 250 hours of operation.
This operation must be carried out on both sides, with the machine
parked on firm and level ground.
Before carrying out the check, raise the loader arm and secure it with the
safety lock (see "3.1.1 LOADER LOCKS").
The check must be carried out using a torque wrench calibrated accord-
ing to the value indicated in paragraph "4.4.2 SPECIFIC DRIVING
TORQUES FOR SCREWS AND NUTS" and serves to restore the driv-
ing torque of the nuts (1) and screws (2) that fasten the carriage to the
machine frame. Use 22 and 24 mm wrenches.
NOTE
Do not lubricate the threads when the torque must be checked.
The check must be carried out on both the front and rear carriages
on each side.
If the entire carriage has been removed, before reassembling

it contact your Komatsu distributor and ask for precise in-
structions regarding the correct procedure for fastening
bolts and nuts.
CK35-1 3-47
MAINTENANCE
MAINTENANCE AFTER THE FIRST 500

HOURS OF OPERATION
★ (Only for machines filled with synthetic biodegradable oil type
HEES)
★ The following maintenance operation must be carried out after the
first 500 hours of operation, together with those to be carried out
EVERY 500 HOURSî.
• HYDRAULIC OIL CHANGE AND CLEANING OF THE
SUCTION FILTER
For details on the various maintenance operations, See “EVERY 1000

HOURS OF OPERATION” on page 3-23î.
3-48 CK35-1
MAINTENANCE

OPERATION
These operations must be carried out together with those to be carried

out EVERY 50 and 250 HOURS.
CHANGING THE FUEL FILTER
Change the filter element after work and after the engine has
cooled down to 40-45°C (104-113°F). When this operation is
performed, fuel may spill; clean the spill immediately, to pre-
vent any risk of slipping or fire. Oils, filters, coolants and bat-
teries are considered special waste and must be collected
and disposed of according to the anti-pollution regulations
in force.
The fuel filter and the fuel pump can be reached by opening the engine
hood (See “ENGINE HOOD” on page 2-51).
FUEL FILTER
1. Clean the outside of the filter and then unscrew the used filter (1)
with the special wrench provided and dispose of the filter properly.
2. Clean the inside of the head (2).
3. Lubricate the new filter seal and screw on until the seal contacts the
base.
5. Bleed the fuel supply circuit.
BLEEDING THE CIRCUIT
After filling the tank, turn the ignition key to position «I» and wait for
approximately 15-20 seconds, to bleed the fuel supply circuit.
After bleeding the circuit, turn the ignition key to position

« » for a few seconds and wait at least 2 minutes before
starting the engine. If the engine starts without problems and
then stops or runs irregularly, check if there is air in the cir-
cuit; if so, check the tightness of the fuel filter and of the fuel
pump prefilter.
If the machine has run out fuel, bleed the circuit by proceed-
ing as described above and repeat the operation at least 2-3
times after filling the tank.
CK35-1 3-49
MAINTENANCE
CHANGING THE HYDRAULIC OIL DRAIN FILTER
Immediately after the engine has stopped the hydraulic oil is

very hot; let it cool down until it reaches a temperature of 40-
45°C (104-113°F) before changing the filter. The hydraulic
system is pressurized; loosen the filling cap slowly to re-
lease the residual pressure. Oils, filters, coolants and batter-
ies are considered special waste and must be collected and
disposed of according to the anti-pollution regulations in
force.
On new machines, change the hydraulic oil filter cartridge af-

ter the first 250 hours of operation and successively every
500 hours. On machines filled with synthetic biodegradable
oil type HEES, the first change must be carried out after the
first 50 hours of operation and the successive changes every
500 hours.
The filter is positioned on the hydraulic system drain outlet and blocks
the metal particles that come off the various components due to their
wear. The filter can be reached after opening the rear panel (See “REAR
PANEL” on page 2-52).
To change it, proceed as follows:
1. Slowly loosen the filler cap (1) to release the residual pressure from
the tank and then remove the cap.
2. Unscrew the used filter (2) and discard it.
3. Clean the contact surface between the seal and the filter base (3),
lubricate the seal of the new filter and screw on until the seal con-
tacts the base.
5. Close the rear panel.
6. Check for oil leaks after running the engine.
Do not use the wrench to tighten the filter, since this may
cause damage and result in oil leakage. If the machine con-
tains synthetic biodegradable oil type HEES, the filter must
be changed after the first 50 hours of operation.
3-50 CK35-1
MAINTENANCE
CHANGING THE OIL IN THE TRAVEL MOTORS
Soon after the machine has been stopped the oil is very hot;
allow it to cool down to 40-45°C (104-113°F) before carrying
out the check. Oils, filters, the coolant and the battery are
considered special waste and must be collected and dis-
posed of according to the regulations in force.
This operation must be carried out on each travel motor with the
machine parked on level ground and at a temperature of 40- 45°C (104-
113°F), so that the oil becomes fluid and can be easily drained, which
facilitates the elimination of any suspended solid particles.
1. Move the machine until the drain and level plug (1) is in its lowest
position and vertically aligned with the filling plug (2).
2. Remove the drain plug (1) and let the used oil flow out completely,
gathering it into a container with suitable capacity. While the oil
flows out, remove the filling plug (2).
Use a 8 mm Allen wrench.
3. Once the oil has been drained, move the machine gradually until the
drain and level hole (1) is positioned at a distance of 20 mm (.79 in)
from the horizontal axis.
4. Fill through the filling hole (2), using oil of the prescribed type,
until reaching the lower edge of the hole (1).
5. Put back the plugs (1) and (2).
Move the machine forward and backward a few times, stop the machine
and check the levels again. Always use oil of the prescribed type, (see
"4.3 FUEL, COOLANT AND LUBRICANTS").
CK35-1 3-51
MAINTENANCE
CLEANING THE WATER SEPARATOR
Change the precleaner at the end of work and after the en-
gine has cooled down to 40-45°C (104-113°F). When these
operations are performed, fuel may spill; clean the dirty ar-
eas immediately, to prevent any risk of slipping or fire.
The water separator can be reached after opening the engine hood (See
“ENGINE HOOD” on page 2-51).
CLEANING THE WATER SEPARATOR.
1. Close the valve (1).
2. Loosen the metal ring (2) and remove the cup (3) and the filtering
element, collect the fluid in a container of suitable capacity.
3. Clean the inside of the cup and the filter with diesel oil or oil.
4. Replace the filter and the cup (3), tighten the metal ring (2) and
open the valve (1).
When disassembling the water separator, be careful not to

lose the red ring contained in the cup. If the filtering element
is clogged or damaged, change it.
BLEEDING THE CIRCUIT
After filling the tank, turn the ignition key to position «I» and wait for
approximately 15-20 seconds, to bleed the fuel supply circuit.
After bleeding the circuit, turn the ignition key to position

« » for a few seconds and wait at least 2 minutes before
starting the engine. If the engine starts without problems and
then stops or runs irregularly, check if there is air in the cir-
cuit; if so, check the tightness of the fuel filter and of the fuel
pump prefilter.
If the machine has run out fuel, bleed the circuit by proceed-
ing as described above and repeat the operation at least 2-3
times after filling the tank.
3-52 CK35-1
MAINTENANCE
DRAINING CONDENSATE FROM THE HYDRAULIC
OIL TANK
(Only for machines filled with synthetic biodegrad-
able oil type HEES)
Lower the loader arm completely, rest the bucket on the

ground and, after stopping the engine, eliminate the residual
pressures that may be present in the equipment (by operat-
ing the controls more than once) and lock the safety bars
(See “SAFETY BARS” on page 2-28). Let the oil cool down
until it reaches 40-45°C (104-113°F) before performing any
maintenance operation. Immediately clean any area dirty
with oil.
Stop the machine on a firm and level surface, lower the equipment to
the ground, stop the engine and release the residual pressures that may
be present in the equipment by operating the controls more than once.
Raise the engine hood (See “ENGINE HOOD” on page 2-51) and open
the rear panel (See “REAR PANEL” on page 2-52).
the tank and remove the cap.
2. Position a container of suitable capacity under the drain plug.
CK35-1 3-53
MAINTENANCE
3. Loosen the lower plug (2) until the condensate has completely
drained. Use a 12 mm hexagon wrench.
4. Retighten the lower plug (2), check the oil level and top off if nec-
essary. Install the filler cap (1) and close the rear panel and the
engine hood.
Be careful to only loosen the lower plug enough to allow the

condensate to drain and not lose too much hydraulic oil.
The draining of the tank must be carried out at temperatures

exceeding 0°C (32°F), before starting the engine; when the
temperature is below 0°C (32°F), the hydraulic oil tank must
be drained at the end of work, or in any case when the tem-
perature of the machine is high enough to prevent the con-
densate from freezing and to allow it to flow out of the tank
without problems.
3-54 CK35-1
MAINTENANCE
MAINTENANCE EVERY 1000 HOURS OF OPERATION
These operations must be carried out together with those to be carried out EVERY 50, 250, 500 HOURS.
CHANGING THE HYDRAULIC SYSTEM OIL AND

CLEANING THE SUCTION FILTER
On machines filled with synthetic biodegradable hydraulic

oil type HEES the oil must be changed after the first 500
hours of operation and successively every 1000 hours, and
in any case at least once a year.
Lower the loader arm completely, lower the bucket to the

ground, stop the engine, release the residual pressures from
the work equipment circuits (by operating the controls more
than once) and lock the safety bars (See “SAFETY BARS” on
page 2-28). Let the oil cool down until it reaches 40-45°C
(104-113°F) before carrying out any maintenance operation.
Immediately clean any area dirty with oil. Oils, filters, cool-
ants and batteries are considered special waste and must be
collected and disposed of according to the anti-pollution
regulations in force.
the ground, stop the engine and release the residual pressures from the
work equipment circuits by operating the controls more than once.
the tank and then remove the cap.
CK35-1 3-55
MAINTENANCE
2. Remove the lower plug (2) and let the used oil flow out completely,
gathering it in a container with suitable capacity. Use a 12 mm
hexagon spanner.
3. Once the oil has been drained, disconnect the suction pipe (3) and
remove the flange (4) after removing the screws (5). Use a 17 mm
hexagon spanner.
4. Clean the filtering element (6).
5. Put back the flange (4), the filter (6), the gasket (7) and the lower
plug (2).
3-56 CK35-1
MAINTENANCE
6. Fill the tank with the specified oil until reaching the correct level
(8). Use only the prescribed type of oil (See “FUEL, COOLANT
7. Raise the cab (See “TILTING THE CAB” on page 2-54) and make
sure that the oil in the hydraulic pump reaches the maximum level.
To do this, remove the upper plug (9) and make sure that the hole is
completely filled with oil. Use a 1/2” square drive wrench.
8. If the oil does not reach the maximum level, top off with the speci-
fied oil (See “FUEL, COOLANT AND LUBRICANTS” on
page 3-6).
9. After the check, lower the cab, install the filler cap (1), close the
rear panel and the engine hood and deaerate the system.
10. Make sure that all the control levers are in neutral position and let
the engine idle for 2-3 minutes before operating the work equip-
ment. Move each piston more than once to deaerate the system;
check level again and top off if necessary.
Never start the engine with an empty tank, since this would
certainly damage the pump.
CHECKING AND ADJUSTING THE ENGINE VALVE

CLEARANCE
Since the check and adjustment of the engine valve clearance require
the use of special tools, have these operations carried out by your dis-
tributor.
CK35-1 3-57
MAINTENANCE

OPERATION
Carry out these operations together with those to be performed EVERY
50, 250, 500 and 1000 HOURS.
CHANGING THE COOLANT
The coolant must be replaced every 2000 hours of operation

or every 2 years, whichever occurs first.
Immediately after the engine has stopped the coolant is very

hot and under pressure and it may cause serious burns; let
the engine cool down until it reaches approximately 40-45°C
(104-113°F) before changing the coolant.
Slowly loosen the radiator cap, to release the residual pres-
sure.
Changing permanent type coolant does not require descal-
ing the system.
1. Raise the engine hood (See “ENGINE HOOD” on page 2-51) and
open the rear panel (See “REAR PANEL” on page 2-52).
2. Loosen and remove the filler cap (1) of the radiator.
3. Open the drain cock (2) of the radiator, remove the drain plug (3)
positioned on the engine block and let the fluid flow into a suitable
size container. Use a 17 mm hexagon wrench. While the fluid flows
out, drain the coolant tank (4).
4. Close the drain cock (2) and install the plug (3) on the engine
block. Fill the radiator with new coolant (See “FUEL, COOLANT
3-58 CK35-1
MAINTENANCE
5. Start the engine and let it idle for a few minutes; check the level
again and if necessary top off before putting back the radiator cap
(1).
6. Fill the tank (4) until the coolant reaches the maximum level.
7. Close the rear panel and the engine hood.
CK35-1 3-59
MAINTENANCE
CHANGING THE SUCTION FILTER
Lower the loader arm completely, rest the bucket on to the

ground, stop the engine, eliminate the residual pressures
that may be present in the equipment (by operating the con-
trols more than once) and lock the safety bars (See “SAFETY
BARS” on page 2-28).
Before carrying out any maintenance operation, let the oil
cool down until it reaches 40-45°C (104-113°F).
Immediately clean any area dirty with oil.
the ground, stop the engine and release the residual pressures from the
equipment by operating the controls more than once.
The suction filter must be changed every two hydraulic oil changes.
1. Slowly loosen the filler cap (1) in order to release the residual pres-
sure from the tank and then remove it.
3-60 CK35-1
MAINTENANCE
2. Drain the hydraulic oil (See “CHANGING THE HYDRAULIC
SYSTEM OIL AND CLEANING THE SUCTION FILTER” on
page 3-55).
3. Once the oil has been drained, disconnect the suction pipe (3) and
remove the flange (4) after removing the screws (5). Use a 17 mm
hexagon spanner.
4. Change the filtering element (6).
5. Put back the flange (4), the filter (6), the gasket (7) and the lower
plug (2).
6. Complete the tank filling operations by proceeding as described in
See “CHANGING THE HYDRAULIC SYSTEM OIL AND
CLEANING THE SUCTION FILTER” on page 3-55
Never start the engine with an empty tank, since this would
certainly damage the pump.
CHECKING THE ALTERNATOR AND THE

STARTER
For any inspection and/or repair, contact your distributor.
If the engine is started frequently, the alternator and the starter should be
inspected every 1000 hours of operation.
CK35-1 3-61
MAINTENANCE
3-62 CK35-1
4SPECIFICATIONS
CK35-1 4-1
SPECIFICATIONS
SPECIFICATIONS
STANDARD MACHINE OVERALL DIMENSIONS
The weight of the machine increases by 120 kg (264 lb.) when it is equipped with additional rear counter-
weights.
If the bucket is provided with teeth, the machine length increases by 100 mm (3.9 in).
With the extended bucket the machine length increases by 130mm.
OVERALL DIMENSIONS WITH STANDARD BUCKET L 2030 mm (6’8”) AND 450 mm (1’6”) RUBBER
TRACKS
Unit: mm
OVERALL DIMENSIONS WITH STANDARD BUCKET L 1880 MM (6’2”) AND 320 MM (1’1”) RUBBER TRACK
Unit: mm
4-2 CK35-1
SPECIFICATIONS
MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT
The weight of the machine increases by 120 kg (264 lb.) when it is equipped with additional rear counter-
weights.
OVERALL DIMENSIONS WITH EXCAVATOR (E35-2)
Unit: mm
OVERALL DIMENSIONS WITH ASPHALT CUTTER
Unit: mm
CK35-1 4-3
SPECIFICATIONS
TECHNICAL SPECIFICATIONS
TOTAL WEIGHT
Max. with L 2030 standard bucket and 450 mm(1’6”) track 4320 kg (9504 lb)
Max. with L 1880 standard bucket and 320 mm(1’1”) track 4300 kg (9460 lb)
Max. total mass with E35-2 excavator and 450 mm(1’6”) track 5160 kg (11,352 lb)
Max. total mass with asphalt cutter and 450 mm(1’6”) track 5150 kg (11,330 lb)
BUCKET CAPACITY
Standard bucket L 20300 (SAE) 0.448 cu.m. (0.586 cu.yd.)
Narrow bucket L 1880 (SAE) 0.415 cu.m. (0.543 cu.yd.)
ENGINE
Komatsu diesel engine model S4D98E-2NFE
Rated power (2500 rpm EEC 80/1269) 64 kW (85.8 HP)
Maximum torque (1600 rpm EEC 80/1269) 286 Nm (211 lb.ft)
ELECTRICAL SYSTEM
Alternator 12 V
Electrical output 40 A
Ground Negative
Battery 100 Ah-12 V
Starter 3.0 kW (4.02 HP)
SPEED
FORWARD REVERSE
GEARS 1 2 1 2
km/h 5.88 9.89 5.88 9.89
MPH 3.65 6.145 3.65 6.145
RUBBER TRACKS
SIZE MAKE
STANDARD TRACK WIDTH 450 MM (1’6”)
OPTIONAL TRACK WIDTH 320 MM (1’1”)
4-4 CK35-1
OPTIONS, ATTACHMENTS 5
Komatsu does not assume any responsibility for the performance of any attachments used on the machine that
have not been designed, tested, or manufactured by Komatsu. The attachment manufacturer is solely responsile
for any defects or failures, personal injury, or property damage caused by the equipment or its use.
CK35-1 5-1
AUTHORIZED OPTIONAL EQUIPMENT
Komatsu machines can be supplied with optional equipment in addition
to the standard equipment. If optional equipment is installed and used
on your machine, read and study all operations and safety information
instructions relating to the optional equipment you will be using. Failure
to do so may result in damage to the equipment or injury to the operator.
Komatsu cannot be held liable for damage, accident or reduction of
machinery performance due to the application and use of unauthorized
equipment. Always use authorized equipment on your machine.
BASIC PRECAUTIONS
The installation of optional accessories or equipment other than those
authorized by Komatsu shortens the life of the machine and may also
cause problems concerning safety. It is advisable to contact a Komatsu
distributor before installing any accessory not indicated in this opera-
tion and maintenance manual. In case of failure to comply with this rec-
ommendation, Komatsu declines any responsibility for accidents or
damage.
Install or remove optional equipment on a firm level surface.

Be sure the equipment you are installing is in good operating
condition.
When operations are performed using two or more person-
nel, agree to a set communication signals in advance and
stick to them.
Always use an overhead crane when lifting equipment
weighing more than 25 kg (55 lb.).
Always support any heavy part before removing it. When
heavy parts are lifted, be always careful to the position of the
center of gravity of the object being handled.
It is very dangerous to carry out any operation with a sus-
pended load; therefore, always position the load on a sup-
port and make sure that it is in a safe position.
When installing or removing any equipment, make sure that
it is stable and cannot fall down.
Never stand under loads being lifted by a crane. Take care to
choose a safe position, where you do not run any risk in
case the load should fall down.
Cranes must be operated by specialized personnel. Do not

allow non-specialized personnel to use cranes.
For further details regarding installation and removal operations, con-

tact your distributor.
5-2 CK35-1
PRECAUTIONS REGARDING THE INSTAL-

LATION OF EQUIPMENT
The use of lengthened work equipment reduces the stability

of the machine.
If it is necessary to go up or down a slope, be particularly
careful, since the machine may lose its balance and over-
turn.
When installing work equipment with dimensions exceeding
those of the standard equipment, be aware of the space nec-
essary for the movements of the equipment and of the ma-
chine.
CK35-1 5-3
CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT
★ Specific weight of the handled material = 1.8 tons/m³
MAX. MAX. DIMENSIONS MAX. SAE MAX. OPERAT- MAX. FLOW

EQUIPMENT WEIGHT CAPACITY ING PRESSURE RATE
Width Height
(kg) (mm) (mm) (cu m) (bar) (l/min.)
Front bucket 215 2030 520 0.415 — —
Multi-purpose front bucket — 2030 550 — 206 80
Excavator 1100 ● S Excavator

206 80
– 3200 —
Excavator bucket 73 800 — — — —
Hydraulic hammer 150 — — — 206 80
Drill 190 ¹ 600 — — 206 80
Pallet fork 160 1500 710 1000 206 —
Manure fork 120 1800 — — 206 —
Grapple fork 190 1800 — — 206 80

● Max. outreach
S Max. digging depth
¹ The value is the drill diameter
Max. tooth length
5-4 CK35-1
CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH
HIGH FLOW AND SUPER-FLOW HYDRAULIC SYSTEM
★ Specific weight of the handled material = 1.8 tons/m³
MAX. MAX. DIMENSIONS MAX. SAE MAX. OPERAT- MAX. FLOW

EQUIPMENT WEIGHT CAPACITY ING PRESSURE RATE
Width Height
(kg) (mm) (mm) (cu m) (bar) (l/min.)
Front bucket 215 2030 520 0.415 — —
Multi-purpose front bucket — 2030 550 — 206 80
Asphalt cutter 900 1000 — 206 130
Excavator 1100
● S Excavator
206 80
— 3200 —
Excavator bucket 73 800 — — — —
Hydraulic hammer 150 — — — 206 80
Drill 190 ¹ 600 — — 206 80
Pallet fork 160 1500 710 1000 206 —
Manure fork 120 1800 — — 206 —
Grapple fork 190 1800 — — 206 80

● Max. outreach
S Max. digging depth
¹ The value is the drill diameter
Max. tooth length
Cutting depth
CK35-1 5-5
5-6 CK35-1
CHANGING THE AUTHORIZED EQUIPMENT
to
Stop the machine on a firm and level surface and lower the
equipment to the ground.
Before getting off the machine, stop the engine, release the
residual pressures by moving the equipment control levers
more than once in all directions and lock the safety bars
(“SAFETY BARS” on page 2-28).
Before starting work, make sure the quick coupler locking
pins are completely engaged in, and protruding from, the re-
taining tabs (slots) provided on the bucket or attachment and
that the coupler levers are pushed down to a horizontal
(locking) position.
Do not use your fingers to center the pins, since they may be
injured or even cut due to sudden or uncontrolled move-
ments.
The machine is provided with a special tool-holder, called a universal

quick coupler, which is used for the installation of buckets or optional
equipment. Change the optional equipment using the same procedure
adopted to change the bucket. “CHANGING THE BUCKET OR
ATTACHMENT WITH STANDARD QUICK COUPLER” on page 2-
101.
Besides the assembly on the tool-holder, the hydraulic excavator also
requires fastening to the machine by means of two connecting tie-rods
and the hydraulic connection for the independent control of the equip-
ment. When changing equipment with independent hydraulic circuits,
stop the oil flow to the equipment with the auxiliary kit pedal and dis-
connect the quick disconnects before releasing the equipment from the
tool-holder. “CONNECTING THE HYDRAULIC CIRCUIT” on
page 5-9.
CK35-1 5-7
CONNECTING THE EXCAVATOR
Couple the excavator to the PAN-TACH with the same procedure adopt-
ed for the standard equipment and apply the connection tie-rods.
1. Asemble the tie-rods (1) to the excavator and secure them with the
safety pins (2).
2. Engage the tie-rods with the couplings (3) and connect the hydrau-
lic circuit. See “CONNECTING THE HYDRAULIC CIRCUIT”
on page 5-9.
To disconnect the excavator from the PAN-TACH device, proceed as

follows:
1. Remove the safety pins (2), release the tie rods (1) from the plates
(3), and disconnect the hydraulic circuit of the excavator.
2. Raise the tie rods (1) and secure them with the safety locks (4).
5-8 CK35-1
CONNECTING THE HYDRAULIC CIRCUIT
Before performing any operation on the hydraulic circuit, stop the

engine and eliminate the residual pressures from the equipment cir-
cuits by operating the controls more than once, then lock the safety
bars (see “SAFETY BARS” on page 2-28).
Before and after any operation on the hydraulic circuit, clean up
any oil.
After the mechanical connection of equipment with the independent hy-

draulic circuit, make sure that the auxiliary kit control pedal is in posi-
tion A - flow interrupted - and assemble the flexible hoses of the
equipment to quick disconnects (1) and (2). See B,C and D.
The quick disconnect couplings must be in compliance with the ISO
8434-3 standard.
Remark
In case there are questions regarding the connection of the
hydraulic circuit to the equipment, contact your Komatsu dis-
tributor.
CK35-1 5-9
5-10 CK35-1
CONNECTING THE RETURN CIRCUIT WITH
DIRECT DRAINAGE INTO THE TANK
Before performing any operation on the hydraulic circuit, stop the

engine and eliminate the residual pressures from the equipment cir-
cuits by operating the controls more than once, then lock the safety
bars (see "3.3.5 pos. 1 - SAFETY BARS").
Before and after any operation on the hydraulic circuit, clean up
any oil.
The machine may be fitted for the application of equipment with sepa-
rate return circuits directed into the tank.
The return system is positioned on the left side of the loader arm and the
equipment drain pipe must be connected to quick disconnect (1).
Remark
In case there are questions regarding the connection of the
hydraulic circuit to the equipment, contact your Komatsu dis-
tributor.
CK35-1 5-11
PREPARING THE MACHINE FOR USE WITH THE
EXCAVATOR
After the installation of the excavator, make sure that the mechanical
and hydraulic connections have been carried out correctly and proceed
as follows:
1. Press the auxiliary kit control pedal to the left with your toe and
pull the lever to the rear to lock the pedal in position (B); this posi-
tion ensures the flow of oil to the equipment.
2. For the use of the excavator, see the specific instruction manual.
3. Before leaving the seat, press the SEAT OVERRIDE SYSTEM

button on the left console.
4. If the machine is equipped with rear stabilizers, lower them until

the rubber tracks are partially raised; this maneuver stabilizes the
machine and avoids any overload on the tracks (see "3.3.5 pos. 13 -
RIGHT STABILIZER CONTROL (IF INSTALLED)" e pos. 14 -
LEFT STABILIZER CONTROL (IF INSTALLED)").
USING THE MACHINE WITH THE EXCAVATOR
Before using the excavator, read the relevant operation and mainte-
nance manual carefully and follow the instructions contained
therein.
If the machine is equipped with rear stabilizers, always lower them
before using the excavator.
After the digging operation and before moving the machine, bring
the stabilizers back to their original position.
If it is necessary to travel on roads, engage all the safety locks pro-
vided. See "3.1 SAFETY LOCKS".
5-12 CK35-1
PALLET FORKS
Before using the forks for any operation, the operator must
get acquainted with the increased dimensions of the ma-
chine and must also practice the use of the swinging move-
ments.
After grasping the material with the forks and before lifting
the load, swing the equipment in such a way as to lift the tips
of the forks and prevent the load from slipping.
Use the lifting, swing and travel controls slowly and smooth-
ly, to avoid jerks that may cause the load to move.
Use the maximum fork width possible.
The forks must always be resting on the plate and be se-
cured in their position with the safety pins.
The pallet forks make it possible to use the machine like a normal lift
truck and the controls for lifting and swinging the loads are the same
used to control the standard bucket. “MACHINE CONTROLS” on
page 2-26.
The pallet forks may require being set to different widths (distance from
each other) according to the load to be handled: adjustment is made by
sliding them on the upper coupling bar; once the desired position has
been found, carry out slight movements to make sure that the upper lock
pin is engaged in its seat.
CK35-1 5-13
5-14 CK35-1
Komatsu America Corp.
DataKom Publications & Training PROPOSAL FOR MANUAL OR CSS REVISION
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Operation and Maintenance Manual: Compact Track Loader

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Operation and Maintenance Manual: Compact Track Loader

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CEAM017300

Operation and Maintenance

SERIAL NUMBERS CK35-1 A40001 and UP

June 2006 Copyright 2006 Komatsu

Other signal words

The safety precautions are described in SAFETY section 1.

It is absolutely forbidden to operate the machine while standing on the ground.

APPROVED AND NON APPROVED USES

• USE OF THE MACHINE BY MINORS OR INEXPERIENCED PEOPLE.

• USE OF THE MACHINE FOR LIFTING PEOPLE OR OBJECTS.

• TRANSPORT OF CONTAINERS WITH FLAMMABLE OR DANGEROUS FLUIDS.

• USE OF THE BUCKET FOR DRIVING OR EXTRACTING PILES.

• USE OF THE MACHINE FOR TOWING DAMAGED VEHICLES.

★ Two driving tracks always engaged through oil-immersed roller chains.

★ Foot control for the optional equipment (if installed).

★ Parking brake control.

★ Complete series of instruments visible from the operating position.

★ Easy maintenance with simplified intervals.

★ Road travel (on request).

A. Check the drive chain tension.

B. Check the rubber track tension.

C. Change the hydraulic system filter.

SYNTHETIC BIODEGRADABLE OIL TYPES

MACHINE SERIAL NUMBER

MACHINE IDENTIFICATION PLATE AND PRODUCT

ENGINE SERIAL NUMBER AND EMISSION PLATE

TRAVEL REDUCTION GEAR SERIAL NUMBER

CAB SERIAL NUMBER

SERIAL NUMBERS AND DISTRIBUTOR INFORMATION

SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

GUIDE TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

AUTHORIZED OPTIONAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

SAFETY AND WARNING DECALS

SAFETY PLATES FOR MACHINES WITH EXCAVATOR

DANGER IN THE WORK AREA . . . . . . . . . . . . . . . . . . . . . . . . .

(Only for machines with the excavator)

Do not approach or stand near the work equipment operating ra-

MOVING PARTS IN ENGINE COMPARTMENT . . . . . . . . . . . . .

Keep clear of moving parts inside engine compartment.

CONSULT THE MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DO NOT LOOSEN THE BOLTS

Do not loosen or remove the fastening bolts of the rear damping

DANGER! TRACK TENSIONER ADJUST-

Carefully read the contents of this manual

DANGER! LOADER ARM RAISED

Always engage the safety lock before carry-

OPENING AND CLOSING THE ENGINE

Always engage the safety lock before carry-

OPENING THE REAR PANEL

For correct use of the rear panel safety lock,

HYDRAULIC OIL FILL CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FILL THE SYSTEM WITH HEES TYPE OIL . . . . . . . . . . . . . . . .

HEES is a synthetic, biodegradeable type oil that is used only in

ENGINE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK FILLER TUBE. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE AIR FILTER CLOGGING WARNING . . . . . . . . . . . . . .

ENGINE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLANT PRESSURE . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYDRAULIC OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY RULES AND PRECAUTIONS

Before operating this machine it is important to study the opera-