Operation & Maintenance SEAMO1440005 DGOAEP-s BULLDOZER SERIAL NUMBERS D65A,E,P-45001 and up KOMATSUFOREWORD ‘This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment It will help the operator or anyone realize peak performance through effective, economical and safe machine ‘operation and maintenance. ‘= Please read this manual carefully BEFORE operating the machine. ‘© Please continue studying this manual until proper operauon is wuryletely reinforced into personal hebit. ‘e This manual describes the basic techniques. Skil 8 performed as the operator of anvone get the correct knowledge and performance of the machine ‘* Operation, inspection, and maintenance should be carefully carried out, ‘and the safety must be given the first priority. Sataty precautions are in Gieated with 4 marks and technical precautions with * marks in this manual. The safety information contained in this manual is intended unily to supplement safety codes, insurance requirements, local laws, rules ‘and regulations. ‘e Soma photographs and illustration pictures are different from your ma- ‘chine as technical improvement is continuously reflected on it. Revision to up-ta-date manual’s content is performed in ater editions. This operation & maintenance manual may contain attachments and op~ tional aquinment that are not available in your area, Pleese consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. FOREWORD[BREAKING IN YOUR NEW MACHINE BREAKING IN YOUR NEW MACHINE Each machine is carefully adjusted and tested before shipment. However, 2 new machine requires careful oneration during the first 100 hours to break in the various parts fa machine is subjected to unreasonably hard use at the initial operation, stage, the potential of performance will prematurely deteriorate and the service life will be reduced. A new machine must be operated with care. particularly with regard to the following items. ‘© After starting, let the engine idle © Ifthemachineisdelivered without When replacing oil filter elements for 5 minutes to allow proper any cooling water in the radiator, (cartridges). check their interiors engine warm-up prior to actual _—flush the cooling system with for dirt and dust. If heavily col- operation ample clean water to clean the lected. check for possible cause # Avoid operation with heavy loads system, then fill the radiator with before starting operation, for at high speeds naling water. + Hours of operation are indicated © Sudden starting or acceleration, by the service meter. unnecessarily abrupt braking and sharp turning should be avoided.OPERATION GENERAL LOCATIONS AND SPECIFICATIONS OPERATOR'S COMPARTMENT INSTRUMCNTS AND CONTROLS: CHECK BEFORE STARTING OPERATING YOUR MACHINE COLD WEATHER OPERATION BULLDOZER’S WORK BLADE OPERATION BLADE ADJUSTMENT |... REVERSING OF CUTTING EDGE AND REPLACEMENT OF END BIT ‘TIPS FOR LONGER UNDERCARRIAGE LIFE TRANSPORTATION . CONTENTS 5 18 24 36 a 43 40 4g 50 oI MAINTENANCE PERIODIC MAINTENANCE, MAINTENANCE TABLE EVENY ZOU MUUHS SERVICE EVERY 500 HOURS SERVICE EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE EVEHY 4000 HOURS SERVICE WHEN REQUIRED ADJUS IMENT ‘TROUBLE SHOOTING GUIDE STORAGE SERVICE METER MACHINE AND ENGINE SERIAL NUMBERS FUEL, COOLANT AND LUBRICANTS ENGINE EQUIPPED WITH TURBOCHARGER 53 54 87 68 69 75 76 7 87 a1 94 96 97 98 101GENERAL LOCATIONS 1, Blade utt cyinder °. 6 7 8 y GGENEHAL LOCA IONS AND SPECINGAIIUNS AND SPECIFICATIONS 065A fi DesE [ DesP OPERATING WEIGHT: 1DB9U Kg (107 70 kg) [18.200 Kg] PERFORMANCE Max. travel speed: Forward 10.6 km/h (10.9 km/h) [9.7 km/h] Reverse 13.6 km/h (13.7 km/h) [11.9 km/h ENGINE 1. Model Komatsu 6D125-1 diesel engine 2. Flywheel horsepower (at 1850 rpm) 155 HP (165 HP) (165 HP) NOTE: Specifications are subject change without notice.OPERATOR'S COMPARTMENT OPERATOR'S COMPARTMENT Fue! contro! lever Steering lever (LH) Steering lever (RH) Biade control lever Decelerator pedal Brake pedal (RH) Brake pedal (LH) Safety lever (for gear shift lever! Gear shift lever Brake lock lever Safety lever for blade control lever! Horn button13. Service meter 14. Engine water temperature gauge 15. Charge lamp 16. Engine oil pressure warning lamp 17. Heater signal 18. Starting switch 19. Lamp switch 20. Dust indicator 21. Torque converter oil temperature gauge OPERA TONS COMPARTMENTINSTRUMENTS AND CONTROLS startingswitcy 'NSTRUMENTS AND CONTROLS OFF Key insertion-withdrawal _posi- tion. None of electrical circuits activate, oN Charaing and lamp circuits acti vate. Keep key at ON after starting, START ‘At this key position. the starting motor will crank the engine. Release key immediately after starting HEAT Use this position when stertina in cold weather. Release the kev to allow it to return automatically to OFF and ‘then, without delay, tum it to START, + When starting, be sure to use the starting key.INSTAUIZENTS AND CONTROIS. ENGINE WATER ENGINE OIL PRESSURE CHARGE LAMP. TEMPERATURE GAUGE WARNING LAMP. @&) y © When indicator is in the green © This lamp indicates low engine This lamp indicates the charge range during operation, water _ oil pressure. level of alternator. ‘temperature is normal. ‘© Oil pressure is normal when lamp @ This lamp will come on when ‘© After engine start-up, warm up _is off during operation. If lamp is __ starting switch is turned ON. The the engine until indicator moves on, il pressure is lower. Stop charging is normal if lamp goes into green range. engine, determine the cause and off_--as_ engine _ revolutions © If indicator moves from green —_teke necessary curective steps. increase. into red range during operation, run the engine at iow idling speed until indicator retums green range. Occasionally check instruments for normal function during operation. amo aonINSTRUMENTS AND CONTROLS ‘TORQUE CONVERTER O!L HEATER SIGNAL LAMP SWITCH TEMPERATURE GAUGE aw ‘@ When indicator is in green range This signal is red-heated after With the lamp switch in position during operation. the oil tempera- the ‘starting switch is tumed to 1. the head lamp and illumination ‘ure is normal HEAT, thus indicating the electrical lamp for gauges will ight. (2 If indicator moves from green intake air heater is heated. With the lamp switch in position range into red range, reduce the 2, rear work lamp will also light. ‘work load until the oil tampera- ture goes down. -10—DUST INDICATOR Q This device indicates clogging of the air cleaner element. When the ‘ed piston appears in the transparent part of this indicator (1), the element Js clogged. immediately clean ele- ‘ment. After cleaning, push indicator button (2) 10 return red piston 10 original position. STEERING LEVER owe To turn the machine gently 10 ‘one direction, pull the steering lever con the same side halfway. When the steering lever is further pulled all the way out, the machine will make a sharp pivot turn. -Ne INS THUMEN |S AND CONTHOLS BRAKE PEDAL When both brake pedals are de- pressed simultaneously by stepping on the center area, both right and left brakes are actuated, Aide not place your foot on pedals unnecessary.INSTRUMENTS AND CONTROLS BRAKE LOCK LEVER This is the locking device of the brake pedal when parking. Operate the lever for locking or unlocking while depressing right brake pedal. Ai vinenever machine is parked, tock brake pedal without fail. FUEL CONTROL LEVER This lever is used to control the engine speed and output. @ Engine stop position: Push the lever fully. ® Low idling position Pull the lever from engine stop position G) until you feel the operating force falls off ® High iding position Pull the lever fully from low idling position -12- Engine stop towing ( ‘%* When stopping engine, place lever in engine stop position by pushing lever beyond the low idling position after pulling the knob (A).INS THUMENTS ANU GONINOLS DECELERATOR PEDAL GEAR SHIFT LEVER SAFETY LEVER (For Ge This pedal is used to decelerate _-—-‘Three-speed forward and three- This is the locking device of the engine speed. speed reverse travel can easily be gear shiftlever. selected by simply shitting the gear Adwien arriving at the top of a shift lever to any desired speed AMWhen the machine is stopped slope, or when dumping earth position. for @ while, be sure to set the from a cliff, the machine will in-__* Place the gear shift lever in the gear shift lever in neutral and crease its speed with the neutral position before starting _set the safety lever toLOCK., sudden loss of load. Slow the _the engine. machine by depressing the -13-INSTRUMENTS AND CONTROLS FUSE BOX ze wD scm Loosen bolt (1) and remove cover (2) * Replace a fuse with another of the same capacity BDisotora replacing 9 fuse, be sure to turn off the starting switeh, arrangement and circuit rey 3 neice eo Es ener im | capacity 1 ‘Head lamp | @} F | 204 | tlumination lamp Torque converter oil | | toreaae Tapert pose Engine water tor perature 108 a perature gauge 1A | Torque converter oi! 7 teenperatore snge -14-HORN BUTTON To sound the hom, push the button located in front of the RH. armrest OPERATOR'S SEAT ‘Set operator's seat as follows for maximum comfort, 15 - le IMUMENTS AND CONTROLS FORWARD-BACKWARD ADJUSTMENT ‘Set the seat In the desired posi- tion by moving lever (1) to left; then release Ue fever The seat can be adjusted forward oF backward 160 mm.INSTRUMENTS AND CONTROLS SEAT BELT A soore fastening the s t belt. inspect the securing brackets and belt for abnormal conditions. Fasten the belt and remove it in the following manner. 1, Adjust the seat so that the brake Pedel can be depressed all the way with the operator's back against the backrest. 2. Sit in the seat. Hold buckle (1) and insert (2) into the buckle (1) Check that the belt has locked bv polling it 3.When removing the belt. raise the tip of the buckle lever to release it, + Fasten belt along your body with- ‘out kinking it. Adjust the lengths of the belt on both the buckle ‘and the insert sides so that the buckle is located at the mid-point of your body front. ‘Adjust the belt length in the fol- lowing manner. i) To shorten the belt, pull the free end of the belt on either the buckle body or insert side. -18- * * i) To lenathen, pull the belt while holding it at a right angle to buckle or insert. When operating @ machine equipped with ROPS, be sure to Use the seat belt. Inspect bolts and fittings on the chassis for tightness. Retighten any loose bolts to 2 to 3 kgm torque. If the seat belt is scratched or frayed or if any of the fittings are broken or deformed from long replace the seat helt immediately.INSTRUMENTS AND CONTKOLS LOCKING CAP A locking cap is available as an optional radiator cap, fuel tank cap or hydraulic tank cap. Open and ‘luge lacking vape 2 Fulivws. 1. To open the cap 2. Tolock the cap When the cap is locked against 1) fosert the key into the cap, 1) Tut the cap into place. vandalisml, it rotates frooly ‘% Insert the key as far as it 2) Turn the key clockwise and will go. If the key Is turned take the key vul before it is inserted all the way, it may break. 2) Turn the key counterclockwise and bring the rotor groove in line with the aligning mark on the cap. Turn the cap slowly until 2 “clicking” sound is made. This releases the lock and allows the cap to be opened. age‘CHECK BEFORE STARTING CHECK BEFORE STARTING Pre-operation checks forestall machine trouble. Never neglect them. ‘, Walk around the machine and — b. Check tightness of bolts and nuts, _¢. CHECK ELECTRIC WIRING chork far any trare nf nil nr watar and eatightan if required Particular Check for damaga of the fuse and leakage. Examine connections of checks are required for mounting of any sign of disconnection or short high pressure hoses, hydenulic air cleaner, muffler, track rnller sup- circuit in the electric wiring. Check cylinders, final drive, radiator and ports and shoe bolts. also for loose terminals and tighten floating seals with specin! atten- any Inase parts, tion, Check the following points carefully. any leakage is evident, check for © Rattary the cause and repair If difficulty is. © Starting motor encountered, coneult your © Alternator aie Bitte tse is domaged or there i See ea aT tloctric wing, name inuestgate ee eT + Please contact your Komatsu dis- tributor for investigation and eor- rection of the cause ~18-d. CHECK AND REFILL COOLANT Remove the radiator cap (1) and. check that the coolant level reaches ‘the vicinity of water filler, It level is low, add wate. If more water than ormat 1s requirea 10 TH up to tne specified level, coolant is considered to be leaking somewnere, Immedi- ately locate the leak and plug it. CHECK BEFORE STARTING e. CHECK FUEL LEVEL After removing cop, pull out fuel dipstick (G) and check fuel level. ‘After each operation, fill up the fuel tank through filler (F). Ado not remove cap (1) while cooling water is hot. Hot water may spout out. When removing cap (1), turn it slowly to relieve _ inner pressure, -19-(CHECK BEFORE STARTING. A clogged cap breather hole (1) may stop the fuel flow to the engine. Check it from time to time and clean Cap breather hole is bored in cap. Fuel capacity: 320% When adding fuel, never let the fuel overtiow. This may cause a fire {, CHECK OIL LEVEL IN ENGINE OIL PAN Use dipstick (G) to check the oil level. The oil level should be be- tween mark L and H. If necessary. add oil atoll filler) * The type of lubricant used depends on the ambient tempera- ture. Select according to the table "FUEL, COOLANT AND LUBRICANTS”. % When checking the oil level, park the machine on 2 level surface. stop the engine and wait for 15, minutes before checking. * Do not add oil above the H level markg. CHECK OIL LEVEL IN TRANSMISSION CASE (INCL. TORQUE CONVERTER CASE) Use aipstick (G) to check the ol! vel 5 minutes after stopping the engine. it necessary, aaa o1 at on filler () * The type ot tubneant used depends on the ambient ‘temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS” h. CHECK OIL LEVEL IN STEERING CLUTCH CASE (INCL. BEVEL GEAR CASE) Use dipstick (G) to check the ol! level. if necessary, add oil at oll filer w % The type of lubricant used Gepends on the ambient temperature, Select according to the table “FUEL, CUULAN! AND LUBRICANTS” % Stop the engine when checking the oil level aati (CHELR BEFORE STARTING. % In case the work Is carried out on sloped land of more than 25° declination, supply vil up ww HL level.‘CHECK BEFORE STARTING i, CHECK DUST INDICATOR When air cleaner element is clogged, the red piston of dust in- icator (1) reaches service level and ets locked. In-that case, clean ele- ment referring to section “WHEN REQUIRED’ After cleaning element, push the button to return red piston. |, CHECK BRAKE PEDAL TRAVEL The standard travel is 95 to 150 mm at the top end of the pedal When this value exceeds 150 mm, or the brake fails to work, adiust the pedal referring to the ADJUST- MENT section, * With the engine stopped, mea- sure the travel ‘distance of the brake pedal by depressing each pedal with a force of 15 ka k. DRAIN WATER AND SEDI- MENT FROM FUEL TANK Loosen valve (1) on the bottom of the tank so that the precipitation and mixed water will be drained with fuel =22-1. CHECK FOR SEDIMENT AND WATER IN THE WATER SEPARATOR The water separator separates * Even if a water seporator ic ‘water mixed in the fuel If float (2) is installed, be sure to check the ot or abuve sed line (1), drain the fuel tanke to remove water and water. For the draining procedure, __sedimentin the fuel. sce section "WIICN REQUIRED" =23-(OPERATING YOUR MACHINE OPERATING YOUR MACHINE BEFORE STARTING THE ENGINE 1. Carry out an initial inspection. 3. Is the gear shift lever in NEUTRAL Before starting the engine, con- (For details of the inspection see position and locked with safety firm the positions of levers and CHECK BEFORE STARTING) lever (2)? pedals, 2.3 brake lock lever (1) in LOCK 4. Is blade lowered on the ground? position? And is safety lever (3) for blade control lever in LOCK position? a tei Lock avaitTO START THE ENGINE Confirm the safely of ine suround- 2, Turn starting key (2)t0 START and = Donotleave key in START for more ing area, then start the engine, start engine, than 20 seconds. 4% if engine will not start, repeat the starting procedure after about 2 % To start engine in cold weather, refer to "COLD WEATHER OPERA- TION". Special starting When starting after running out of fuel, fill with fuel, then fill the fuel 1. Set fuel control lever (1) to LOW 3. Release key (2), and key will return tilter cartridge with clean tuel and IDLING position. automatically to ON. bleed the air from the fuel system betore starting, Refer to FUEL FILTER in EVERY 500 HOURS SERVICE. Engine stop aaa Ue Low iating ~ 25OPERATING YOUR MACHINE CHECKS AFTER START-UP After starting the engine, carry out 2. Pull fuel control lever (2) and run 4, Check for normal coloration of the following checkspriarta machina the engine at madium speed for axhaust, any abnormal sound or operation. about § minutes with no toad. vibration, + Avni aheunt arcalaration until Low iting warm-up run is completed, + Da nat run tha engine at low idling or high idling for more than 20 minutes. If it is necessary to. run the engine at idling, apply 2 load : from time to time or raise the : engine speed to a medium speed. 1. Runtheangine atlow idling speed, 3 After warm-up rin is eamplated, and check that engine oil pressure check gauges, warning lamp and warning lamp (1) has gone out charge lamp for proper operation + Continue to run the engine at light load until engine water tempera ture gauge (3) falls within the green range 26 -‘TO MOVE THE MACHINE OFF ‘Before starting the machine, con- firm the safety around the machine, and make a signal DOPEHATING YOUR MACHINE 3. Put blade contol fever (9) in RAISE position to raise blade 400 to $00 mm off yround. 1 Pull fuel control fever (1) to ine crease engine speed. ‘Low ong oo os 4, Depress RH. brake pedal (4) and place brake lock lever (5) in FREE. 2. Unlock blade control lever (3) with safety lever (2), =27-OPERATING YOUR MACHINE 5. Unlock gear shift lever (7) with AM When starting the machine on safety lever (6). y (an v 1 Ay Lock 6. Shift gear shift lever (7) in a desired position and machine. A Fr mo re a i a steep uphill grade, run engine at full-throttle and shift gear shift lever into 1st with brake pedals depressed. When ma- chine has started stowly (or track shoes are slipping), propel the machine by slowly releasing brake pedals. -28- GEAR SHIFTING There is no need to stop machine to shift gears. Gears can be shifted into any po- sition by the gear shift lever (1) hl i me re mt Fa{G YOUR macrite FORWARD-REVERSE SHIFTING Forward-reverse shifting should 1. Lower the engine speed by de- 3. Increase engine speed by releas- be made after reduction of machine _ pressing decelerator pedal (1) ing decelerator pedal (1) speed for safety purpose and pre- venting stuck wy mactine, 2. Shutt gear shutt lever (2) 10 tne desired position. rons =29-(OPERATING YOUR MACHINE TURNING To make a turn while traveling, @ To make a gradual left turn ¢ To make a pivot left turn pull steering lever (1) on the side in Pull the LH. steering lever haif- Pull the LH. steering lever all the which you would like to turn, way (to the detent). The eteering way backward. The steering clutch will be disengaged, allow- _clutch will be disengaged and the ing the machine ta make 9 grad stooring brake will be anpliod val left turn To make a gradual right tum, * To make a pivot right turn, moni manipulate the RH. steering lever _—_pulate the RH. steering lever in jn the same manner ac described the same manner ao described above. above agilc YOUR MACHINE TURNING WHILE DESCENDING ASLOPE When descending such @ sharp» To make a gradual left turn 1 Tomake a pivot lett turn slope that the machine will go down Pull the ALH. steering lever half- Pull the LH. steering lever all the of its own weight or when going way to its stroke end. The ma- way backward. Then, the ma~ down a slope with a scraper or the chine will make a gradual left chine will make a pivot left turn like, you should exercise great care. _turn {compensation steering) (no compensation steering The machine will turn to the oppo- site side to that of the pulled lever. A. Av0id a8 much as possibie turn- ing the machine on a slope. The machine will tond to slip side- ways. Particular care should be taken on soft or clay land, + To make a gradual right turn, & To make a pivot right turn, mani- ‘manipulate the LH. steering lever _—pulate the RH. steering lever in in the same manner as described ‘the same manner as described above. above. -31-(OPERATING YOUR MACHINE TO STOP THE MACHINE 1. Lower engine speed by operating 3. Depress intersecting part of both fuel control lever (1). brake pedals (3) to stop the machine. Low idting High iding £ 2. Place gear shift lever (2) in NEU- 4. Lock brakes (3) with brake lock TRAL position, lever (4). =32-5. Lock gear shift lever (2) with 7. Lock blade control lever (6) with AM Always stop the machine on safety lever (5). safety lover (7) flat, stable ground. Avoid park- ing in a dangerous place. Lock Free 6. Put blade control lever (6) in LOWER position to lower blade to ground while keeping it horizontal Lower ait gg it‘OPERATING YOUR MACHINE TO STOP THE ENGINE 2. Place fuel control lever (2) in + If engine is stopped abruptly ENGINE STOP position with pull- before it cools down, engine life ing stopper knob (1). may be greatly shortend. Never stop engine abruptly except in case of emergency. % Especially when the engine is ‘overheated, allow the engine to idle without immediate stoppage so that the engine is gradually cooled down to be ready for proper stoppage. Engine stop Low iting 1. Cool the engine by running it at 3, Return starting switch key (3) to low idling speed for about 5 OFF and remove key. minutes.PRECAUTIONS FOR MACHINE OPERATION © Do not operate machine in such a depth tnat carrier rollers are sub- merged. Further, be careful so nar the cooting ran wai not come in contact with the water. @ If the steering clutch one side is used frequently or It many grad- val turns are made with steering Clutch hatf-engaged, une steering clutch will wear out in a short ne, Design the travel road weil and steer the machine properly © When going cownnil, shift gear shift lever into low speed to run engine at sow speed and travel down slope using the engine as a brake. If there is danger of over- running the engine, slow the ma- chine by braking - 35 - OPERATING YOUR MACIENE @ When the engine stops on a slope, Immediately depress brake pedals and stop the machine With the work eyulINENL how ‘ered. Then, lock the brake pedals by applying the brake lock lever ‘Thereafter, move the gear shift lever to neutral position and pro- ceed to the engine starting proce- ure again. ‘@ When torque converter oil tem- perature gauge indicator exceeds green range while operating, reduce load and watt for lowering of temperature.(COLD WEATHER OPERATION COLD WEATHER OPERATION PREPARATION FOR LOW ‘TEMPERATURE Ifthe temperature becomes low, it becnmes difficult ta start the enaine. {and the coolant may freeze, so do as follows. FUEL AND LUBRICANTS Change to fuel and oil with low for all components. For details of the specified viscosity. see the TABLE OF FUEL, COOLANT AND LUBRICANTS. COOLANT ‘After cleaning inside of the cool- ina svstem. add antifreeze to the coolant to prevent the coolant fram freezing when the machine is not being used. % For details of the antifreeze mix- ture when changing the coolant, see WHEN REQUIRED. ~36 - Care in using Antifreeze Use a Permanent Antifreeze (eth viene alveol mixed with corrosion inhibitor, antifoam agent, etc.) meet- ing the standard requirements as shown below. With permanent anti- freeze, no change of coolant is re- quired for a year. Ifit is doubtful that an available antifreeze meets the standard requirements, ask the sup- plier of that antifreeze for informa tion. Standard requirements for permanent antifreeze © SAE © FEDERAL STANDARD 0-A-548D J1034Never use methanol, ethanol or propanol based antifreeze, Where no permanent antifreeze is available, an ethylene glycol an- tfrooze without corrosion ji tor may be used only for the cold season. In this case, clean the cooling system twice a year (in spring and autumn]. When refill ing the cooling system, add anti- freeze in autumn, but do not add any in spring, Absolutely avoid using any wate: leak preventing agent irrespective ‘of whether it is used indepen dently or mixed with an antifreeze. Do not mix one antifreeze with Uifferent brand. Antifreeze keep it away from any flame. BATTERY ‘As ambient temperature drops, bottory capacity will drop, ond elec- trolyte may sometimes freeze if bat- tory charge io low. Maintain bottory at a charge level of approx. 100% ‘and insulate It against cold tempera ture so that machine can be readily started the next morning, % Measure specific gravity of fluid and obtain rate of charge from the following conversion table: =] zoe | oc |-10'e] 20 128 | 129[ 130 | 131 vas | 127 | 18 | tas 124 | 1.26) 1.26 | 127 tas | r2e| rae | a0 -37- COLD WEATHER OPERATION + When cleetrolyte level is low, add distilled water in the morning bofore work instead of after the day's work. This is to prevent fluid from frees Aire ovoid bring fire or sparks m bettery Aiteane stectrotte gots on your tkin or clothes, immediately wea wih plewty of clon aeCOLD WEATHER OPERATION STARTING AT LOW ‘TEMPERATURE For the pre- and post-starting in- spection, refer to the section OPERATING YOUR MACHINE, 1. Pull fuel control lever (1) @ little toward you from LOW IDLING position. Engine stop 2, Place starting switch (2) in the HEAT position to red-hot heater signal The preheating times a shown below: ‘Ambient temoersture Avoveo°C orc to - 10% 10°C to 20°C we -aa- Preheat tine 20 seconds 20 seconds| as ‘3. When heater signal (3) becomes red, turn key (2) to the START position to start engine ore a G eS nn tT D e L %, 4. After the engine starts turn key (2) 40 the ON position Bereta org aie LM, vel‘cota WEATIIER OreMATION CAUTIONS AFTER COMPLETION OF WORK % Do not allow the starting motor to 1. Mud and water on the machine 2, Drain water collected in fuel sys- Wis Sains LSS Te Bae eal ie NM eta a io marth opal ies etic alae mecca tes A nicver vse stating si pectin nh pint Une underea ge from freweing the ground thereby preventing machine movement the next morning. Particular attention should be given to water drops collected on the surface of the hydraulic cylinder piston rods. ‘Such droplets must be fuloly wiped oft because if water is frozen tothe rod when the cylinder is utilized, the cylinder oll seals may be damaged, they may cause explo: rag‘COLD WEATHER OPERATION AFTER COLD WEATHER When weather becomes warm, perform the following without fal: % Replace lubricating oils for vari- us units with the ones specified for warm-weather use. + If for any reason permanont anti- freeze connot be used, and an ethyl glycol base antifreeze (winter, one season type) is used instead, or if no antifreeze is used, drain the cooling system ‘completely, then clesn out the inside of the cooling system thor- ‘oughly, and fill with fresh water. imag ibuuoozen's work. BULLDOZER’S WORK CUTTING INTO HARD OR FROZEN GROUND OR DITCHING Tor digging ond ditch exvevalivn uf tard ur frozen ground, tit the blade. Even hard ground can be dug ef- fectively by a tilted or angled blade. If the ground is harder, use a ripper attachment for better efficiency, SMOOTHING Uneven grouna surtaces remaining anter aigging ‘can be levelled off by fine operation of blade, The bbasic method is to operate the machine at iow speeds with the blade fully loaded with soil and sand. A flat Tinished surface is also possible by slowly backing the machine with the blade “floating” so it is dragged across the surface. However, avoid this on rocky or stony ground, as it may damage the blade. areBULLOOZER'S WORK. bozine ‘A bulldozer dias and transports dirt in @ forward di- When dozing toward one side only, operate with rection, Distance per trip should preferably be 70 angled blade (angledozer only). meters at maximum. f longer, use of a scraper is eco- nomical. Slope excavation can always be most effec- 4M Do not perform severe operations such as up- tively carried out by proceeding from the top rootina by analing or tilting the blade. downward. 42 -OPERATION OF ANGLEDOZER LEVER OPERATION Blade is stopped and held in this position, 3, LOWER 4, FLOAT Blade will move freely. BLADE OPERATION ag BLADE OPERATION SAFETY LEVER {for Blade Control Lever) iL ct - This is the locking device of blade control lever. Aivinen teaving the machine parked, be sure t0 lower sme blade and set the safety lever in LOCK positionBLADE OPERATION OPERATION OF TILTDOZER LEVER OPERATION Lever position Put blade control lever to A or B 1. RAISE fortiting 2, HOLD RIGHT TILT Blade is stopped and held in Therright end of the blade falls. position B. LEFT TILT 3. LOWER The left end of the blade falls. 4. FLOAT Biado will move freely. - 44 — paisSAFETY LEVER (for Blade Con ol Lever) Laver lock This device is used to lock the blade control lever. Aiwiven parking machine, be eles cae ce saree caver LOCK position. Lever position Lever lock: The blade control lever is locked, Tilt lock ‘The blade control lever should be locked at direction of right and left. It can be moved at direction of front and rear. Free: The blade control lever is moved freely. Sane BLADE OFEMALIONBLADE ADJUSTMENT BLADE ADJUSTMENT ANGLING OF BLADE langledozer) Angle of 25° is provided on both i) Pull out pins (1) on both sides ii) To angle the blade, fit arm (2) to sides of the blade. and remove arm (2) from frame. ‘the desired bracket (three brack- Raise the blade 400 to 500 mm ets for each side of the machine) above ground level and apply block and lock with pin (1). to the frame, and operate as follows. Ai Toke care that blade can move freely after removing arm (2).TILTING OF BLADE For angledozer Itis possible to tilt the blade up to 400 min un either side by the fol lowing procedure: First raise the Lode epprur. 400 Ww 500 un uff the ground and apply block to the fraine. Loosen set boit (1) and insert a bar handle into the hole (2) in the brace. Turn the brace on one side of uirection shorten or lengthen the brace and lun the brace on the opposite side of the machine in the reverse direc ton. After tilting the blade to any desired height, securely tighten set bolt (1) on each brace. Tuite blade up within a range of 400 mm. BLAUE ABUS IMENT For straight-tiltdocer By shifting the blade control lever ty RH. or CH, tiking 470 mm at right side or 445 mm at left side of Ulaus is pussibte Lengthen the brace (1) by turning bar (2) at one side of the biade until 780 mm of maximum tilting can be obtained, % Tilt the blade up within a range of 780 mm, -47-BLADE ADJUSTMENT ADJUSTING THE DIGGING ANGLE Blade cutting angle (6) is adjust- able to obtain the optimum angle for each kind of soll Talend the longi (8) of uh brace when the bar (1) handles to in- crease the angle (0), and vice versa. Standard digging angle (6) is 55 degrees. 48 -REVERSING OF CUTTING EDGE ANU HEFLALEMEN| OF END HIT REVERSING OF CUTTING EDGE AND REPLACEMENT OF END BIT Reverse the cutting edge before it is worn out to the blade end. If, due to neglect to reverse or replace, it has been worn out up to the fitting surface, repair the fitting surface and then reverse or replace. METHOD OF REVERSING AND REPLACEMENT 1. Raise the blade to a proper 2. Remove the cutting edge and the 4. When the end bit worn out, re- height and apply 2 block to the end bit and clean the mounting —_—_ place with new one. frame s0 as to prevent fall of the _surface. + Nut tightening torque: blade. 3. Reverse the cutting edge when 45 5S kgm worn out. % After several hours of running, * If the cutting edges on both sides _—retighten tne nuts. are worn out, replace with new one. eonay -49-TIPS FOR LONGER UNDERCARRIAGE LIFE TIPS FOR LONGER UNDERCARRIAGE LIFE Undercarriage life areatly varies dependina on operation method, inspection and maintenance, For most efficient operation, keep the following point in mind. OPERATION METHOD @ Select the track shoe that best @ Avoid sudden starts, acceleration @ On a slope, operate the machine suits the type of soil to be en- or stops, unnecessarily high parallel to the inclination of the ‘countered in service. speeds and sharp turns. slope. Do not operate across the © Do not allow shoe slipping to @ Always operate machine in a slope. Also when on a slope, the ‘eccur during operation. If shoe straight line whenever possible. machine should face toward the slipping occurs, reduce load until When making tums, be careful top of the slope. slipping stops. ‘not to allow the machine to stay © Prior to operation, clear boulders to one side, so operation in both and obstacles to prevent machine turning directions can be done from riding over them while H properly. Make turns with the lar- operating, / / ‘gest possible radius. ~50- BoosTRANSPORTATION TRANSPORTATION When transporting the machine, observe the various road rules, road transportation vehicle lawe and vehielo limit ordinances, ete. Itis good idea to obtain a special platform for loading and unloading the machine. When it is unavoidably necessary to use ramps, however, at the leaet obeerve the following for safety. 1. Properly apply the brakes on the trailer and insert blocks benoath the tires to ensure that it does not move. Then fix the ramps in line with the centers of the trailer and the machine. + Make sure the ramps have suffi- cient width, length and thickness to enable the machine to be safely loaded and unloaded. If the ramps sag appreciably, reit force it with blocks, etc, 2. Determine the direction of the =, ten slowly load or Unload the machine. A rover change travel direction itenioe bask un ot ee round A remove the mud from the un dercarriage to prevent the ma- chine from slipping to the side ‘on clopes. Load machine at @ suitable place ‘on trailer. To prevent machine from moving during transporta- tion, hold it securely in place by applying blocks to front and rear of track shoe and by fastening machine with chain or wire rope. ‘Secure machine with special care to provent shifting sideways. -51- 4. Lower the blade, keep various control levers. in the following places: Fuel control lever in Engine stop position ¢ Gear shift lever Neutral @ Blade control lever Hold Brake lock lever Tek Take off the starting key. + Determine the route for trans- porting the machine by taking into account the width, height ‘and weight of the machine. Awhen toading the machine, park the on a flat firm roadbed. Keep 8 fairly long dis- taneo between the road shoul- der and the machine.PERIUDIL MAINTENANCE PERIODIC MAINTENANCE Proper lubrication and maintenance assure trouble-free operation and long machine life. Time and money spent for scheduled periodic mainte- nance will be amply compensated by prolonged machine operation and re- duced operating cost. All hourly figures given in the following descriptions are based on service meter readings. in practice, however, itis recommended to rearrange all of them into units of days, weeks and months to make the maintenance schedule more convenient. Under rough job site or operating conditions, itis necessary to somewhat shorten the maintenance intervals stated in this manual kone 53 -MAINTENANCE TABLE For the maintenance of engine equipped with turbocharger, refer to the last section of this manu MAINTENANCE TABLE =] vem ee a saa | CHECK BEFORE STARTING | “a nanBVERY 250 HOURS SERVICE 2 | Oi and water ak Check 18 hours only for new machines} Tb | Nuts and botts | Check and retighton | 18 + | Foci titer Replace cartridge | 67 I mi (eeemese zag Sy Chang arad |g © | etre wig eh and [vie a pon na ner rare eee ail Coes Check and supply | 19 + [Tee iene convener ene! | deena ul © | Fost Choc a wooiy [vo + | SS Caro Gy 7 eee JT ttc eta arf Saree ao oneee ae Sees, TEE can [Seneeseeny [a | Pte ell | Seerng CMTE case ‘Check and supply | 21 @ | Lobrieeting 87 i ose acane Hanae ovate eaicar bai ieee eal el i Boa Cheek ve 2 oe | oe era | rut tank ‘rain wate 2 Uieiicam Bein | ay TT [ water separator Tnspect float 23 | Cylinder support yoke Lubricate 4 points | 58 ae Cylinder support shaft | Lubricate 2points | 58 - ison rod berieg "| cate 2 pein | 8 -54-For the tenance of engine equipped with MAINTENANCE turbocharger, refer to the last section of this manual. ‘Check oil evel | 38 T EVERY 500 HOUKS SERVICE i ae Se a ere Sea asic Hydraulic tank Creckandsuppy | 59 & | Engieoilpanangtier | Shaner Tang | gr 24 canine Cama ir sere Ata | AT en A Ce ATA LS ea cerca aga ii a co | ea aii i sea 1 [eer ower cece @ EVERY 1000 HOURS SERVICE | Feet titer Dainwatrend—)Gy tatwcatng 7 | il peracneee eaeeameeil lal ee eps al i | Fan bete Check tension 6 Diagonal brace Lubricate 2 points “Teo 1 [Resmertn —— Peneandcean [eb | Teeter ene) | coast at esa oe I ee ee + | Underearinge components hes ising a areMAINTENANCE TABLE For the maintenance of engine equipped with turbocharger. refer to the last section of this manual. ve Te eeavice ws ee weaves ae i s 3 | Decelerator pedat shatt Lubricate 4 points | 84 | Fnoot rsa « |eemewindnwe ——|Gmkedat [7 “6 | Batwohcinersten | tarawna penn | 4 1 [i Oro EVERY 4000 HOURS SERVICE | water pume (Cheek 76 WHEN REQUIRED Track ‘Check tension 7 b | Aircteaner | ‘Ghek, sean ore piece when required | 78 dl ie fit © | coating ye a Tsang Satoh BS Ba manne pa [ze Lurie a poine | 8 2 | Brake tock iver sate Lobia t point | 84 —56—EVERY 250 HOURS SERVICE Carry out the following mainte a, LUBRICATING nance only after the first 250 hours. Apply grease tothe grease fittings 2. Brace © FUEL FILTER, REPLACE shown by arrows. DesP (6 points) CARTRIDGE ENGINE Ol PAN AND riLTER, CHANGE OIL AND REPLACE CARTRIDGE ‘* TRANSMISSION CASE (INCL. ‘TONQUE CONVERTER CASE), CHANGE OIL AND CLEAN STRAINER © STEERING CLUTCH CASE (INCL. tise DEVEL GEAR CASE), CHANGE OIL AND CLEAN STRAINER 1, Equalizer bar pin (1 point) © HYDRAULIC TANK AND FILTER, CHANGE OIL AND REPLACE ELEMENT © FINAL DRIVE CASE, CHANGE ou For details of the method of re- placing oF maintaining, see the sec- tion on EVERY 500 HOURS AND 1000 HOURS SERVICE,EVERY 250 HOURS SERVICE 4. Cylinder support shaft '. Piston rod bearing D65AE (points) D6 5P (points) DB5P. (2 points) 3. Cylinder support yoke (4 points) = 58- erb. CHECK AND CORRECT OIL LEVEL 1. Final drive case Remove plug (F) and check Whether final drive case is filled oll to lower odye uf ply hole. If oil level is below this point, refill with engine olf through plug hole. * Check while parking the machine ‘on level ground. * The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS". 2. Hydraulic tank Lower blade to yround in horizon tal position, stop engine and wait for obuwt 5 inuies befwe checking cil level. foil level is not between top and bottom of red= Circle in sight gauge (G), refill tonk with engine oil Umvuyh vil fillor() —59- Aiwinen oit temperature is high do not remove cap. Hot slowly pressure. A The type of lubricant used depends on the ambient temperature. Select according to the table “FUEL, COOLANT AND LUBRICANTS".EVERY 250 HOURS SERVICE ¢. STEERING CLUTCH CASE OIL FILTER 1, Remove floor plate. 2, Remove bolts (1) and cover (2), ‘and take element (3) out from cas 3. Clean inside of case and removed parts, and install a new element. Fill case with oil and fix cover (2) with bolts (1). 4. After replacement of element, loosen air vent plug (4) and start engine. Overflow oil until no air bubble comes out from plug (4) and tighten plug (4) “> Use genuine Komatsu el ent. ~60-4d. TRANSMISSION CASE OIL FILTER 1. Remove floor plate 2. Loosen bolts (1), remove cover (2) and take element (3) out from case. 9. Cleon inside uf vase and reniuved parts and install a new element. Fill case with oil and fix cover (2) with bolts (1), eveny 260 0Uns oemvice, 4, After replacement of element, ousen ait vent plug (4) ond stert ‘engine. Overflow oil until no air Lubbic wuines wut from plug (4) and tighten plug (4).. A Use a genuine element. Komatsu -61-EVERY 250 HOURS SERVICE e. FUEL TANK BOTTOM f. BATTERY ELECTROLYTE ‘STRAINER Add distilled water if battery fluid Tighten valve (1) and take strain- level is below prescribed level (10 to er out from case removing cap (2). 12 mm above plates). If electrolyte Clean strainer and strainer case. has been reduced bv soil. have a * As strainer is soldered to cap (2), battery service shop fill battery with 4 To avoid gas explosions, do not take strainer out from case dilute sulfuric acid of same strenath. bring fire or sparks near the together with cap (2) Clean air vent of battery cap battery. when checking fluid level % Do not use metalic funnel tor AM the adding Fu jetrolyte gets on your skin or clathas, immediately wash with plenty of cl water,9. DRAIN WATER AND SEDIMENT FROM FUEL FILTER 1. Remove the drain plug (1) on the bottom of the filter to drain water and sediment accumulated on the ButUM, Afr draining, gle en the plug (1). 2. Loosen the air vent plug (2). 3. Loosen feed pump knob (3) and move the pump up and down to draw off fuel until air ceases to come out of plug (2). 4, Tighten the air vent plug (2) push the feed pump knob (3) into place, and tighten it. -63- every 250 nouns exnvict h. TRACK SHOE BOLT ‘The shoe bolt (1) attaching the track shoe to the link will be broken if it is used as loosened. So, you are required to retighten every time you Taide veered wi. Tightening torque Mester link bolt: 60 + 6 kgm Shoe bolt: 70 + 8 kgm & Master pin is marked on both sides with center holes.EVERY 250 HOURS SERVICE (Order for tightening Tighten the bolts in the order shown in the diagram. After tighten: ing, check that the nut and shoe are in close contact with the link mating surface. FAN BELT Push the belt at the middle be- tween the fan pulley and the alterna- tor pulley (Approx. 6 kg). If the belt slack is about 10 mm, the belt is considered to have the correct ten- To adjust, loosen the bolt (1) and ‘nut (2) to shift the alternator (3), * When adjusting the V-belt, do not attempt to push the alternator (3) directly with a bar or the like, but use @ wood pad to prevent dam- age to the core. Check each pully for damane, and V-grooves and V-belt for wear. Particularly, check whether V-belt is in contact with bottom of V: groove through wear. Replace belt if it has stretched, leaving no allowance for adjust- ment, or ifthere is a cut of erack on belt. Where two belts are used. replace both belts, at same time. —64—For the maintenance of engi turbocharger, refer to the last secti ye equipped with EVERY 250/10URS SenViCE n of this manual. i, RADIATOR FINS Loosen the six bolts (1) te open the radiator grille (2), Mud, Just, ut leaves blocking the fin shall be blown off by com- proseeu ot ‘Seam or water may also be em- ployed instead of compressed air % Check the rubber hose on this oc- casion and replace hose that is cracked or fragile. Further, also inspect loosened hose clamps. awa eesEVERY 500 HOURS SERVICE EVERY 500 HOURS SERVICE ‘a. FUEL FILTER, 1. Using the tool provided, remove cartridge (1) by turning it counter- clockwise, 2, Fillthe new cartridge with fuel and refitit after applying a dab of oil to the gasket face. % To refit the cartridge, place the gasket face in contact with the seal face of the filter stand, then screw up the cartridge 1/2 to 3/4 of aturn, 3 4 ++ Maintenance for every 250 hours should be carried out at the same time. After replacing the cartridge, loosen air vent plug (2) Loosen feed pump knob (3) and move the pump up and down to draw off fuel until air ceases to come out of vent plug (2). Tighten air vent plug (2), push feed pump knob (3) into place, and tighten it * Alter replacing the cartridge, start up the engine and check the filter seal face for possible oil leakage. % Be sure to use a genuine Komatsu cartridge,b, ENGINE OIL PAN AND FILTER 1. Remove cover (1] mounted under machine body. 2, Remove drein plug (21 and loosen drain valve (3). Tighten drain valve (0) end plug (2) after drain oil, 19 @ filter wrench, remove cartridge (4) of the engine oil filter by turning it counterclockwise. Apply a dab of oil to the gasket of the new vartshdye, and efter the gasket contacts the seal face, tighten it up 3/4 to 1 of a turn, After replacing the cartridge, fil engine oil through oifiller(F). Then idle the engine for a while, and recheck oil level. I Tiler wartidye (4) G0 immediately after stopy engine, oil will spill, Wait at feast 10 minutes after stopping the engine before replacing dre filter cartridge. -67-EVERY 600 HOURS SERVICE ¢. BREATHERS, + Refill capacity: 262 Remove the breather and wash out % Thetype oflubricant used depends dust remaining inside with diesel fuel fon the ambient temperature. Se- oil lect according to the table “FUEL, COOLANT AND LUBRICANTS", + Use a genuine Komatsu cartridge. ‘* Change the engine oil every 6 months regardless of service hours, % Use API category CD class oll. if CC class oil must be used, change the oil and replace the oil fiter at half the usual interval. ‘Transmission case breather 1g clutch case breather Final drive case breather 68 -Every 1000 HOURS SERVICE EVERY 1000 HOURS SERVICE * Maintenance for every 250 and 600 hours should be carried out at the eamo timo. 2. LUBRICATING b, TRANSMISSION CASE (INCL. Apply grease to grease fittings TORQUE CONVERTER CASE) shown by arrows. 1, Remove cover on the underside 3. As for strainer in transmission 1. Universat joint (2 points) ‘oT macnine pogy and remove case, remove pipe (9) anu volts drain plugs (1) and (2) inside to (6), g SRB «ran used ov. Atter araming, ‘Than take strainer together with g . retighten drain plugs.. cover (7) from case, aa 2. Remove bolts (3) and take strain- ‘i er together with cover (4) from Be torque converter case. Ee ay 48 2. Diagonal brace (2 points)EVERY 1000 HOURS SERVICE 4 Clean inside af race Parts and strainer and install ‘them. If strainer is damaged, ea place it with a new one, 5 After raplarament nf ail filter ala ment in transmission case (refer to Fvery 250 HOURS SERVICE, supply the specified amount of engine oil through ail filler (F) * Refill capacity: 47 & + The tyne of lubricant used depends on the ambient temperature. Select according ta the table “FUEL, COOLANT AND LUBRICANTS”EVERY 1000 HOURS SERVICE c. STEERING CLUTCH CASE INCL. BEVEL GEAR CASE) +. Remove drain plug (P) under ma- 2. Remove tloor plate inside leit 9. Loosen bolt (1), and remove ine body to drain used oil step plate. cover (2) to take out spring (3) After draining retighten drain and strainer (4) plug. 4, After clesning the inside of the case, strainer and other parts re- ‘moved, re-install them in position. If the strainer has been broken, replace it with a new one. eaeVEY 1000 HOURS SERVICE 5. After replacement ot steering clutch oil filter element (refer to EVERY 250 HOURS SERVICE) supply the specified amount of engine oil through oi! filer (F, ® Refill capacity: 652 The type of lubricant used depends on the ambient tempera- ture. Select accoraing to the table "FUEL, COOLANT AND LUBRICANTS”. d. FINAL DRIVE CASE Hist, remove oil filing plug (F) from both sides of machine. Then, remove drain plug (P) to drain oil After draining, tighten plug (P| and fil prescribed quantity of engine oi through respective oil filing plugs (H). (feter to EVERY 250 HOURS SERVICE) * The type ot lubricant used depends on the ambient tempera- ture, Select according to the table "FUEL, COOLANT AND LUBHIGAN + Refill capacity for each side: DBDSAE: 318 DeSP: 368 e. HYDRAULIC TANK AND FILTER 1, Place the blade on the ground hotwontally, With the engine stopped, move the blade control lever forward and backward or right and left and slowly turn the ccapof the oi iter (F) to purge al. ‘Then, remove the cop. 2.70 drain oll Inside the tank, remove the drein plug (P) under the tank, Alter draining the ol, tighten the plug (P. re3. Remove bolts (1) and the cover (2) in this order to take out the element. Clean the inside of the filter case as well as the parts re- moved. Then, install a new ‘element. Supply specitied amount of oil through the oil filler (F). (refer to EVERY 250 HOURS SERVICE) Oil capacity: 108% The type of lubricant used depends on the ambient tempera- ture. Select according to the table “FUEL, COOLANT AND LUBRICANTS”. Use a genuine Komatsu element. aula EVERY 1000 HOURS SERVICE {. UNDERCARRIAGE COMPONENTS Stop machine on level ground and check consumption of il in track roller, carrier roller and idle '# Slowly loosen seal bolt and see it cil oozes out of screw. If oil oozes out, oil is stil sufficient Tighten bott immediately. © If oil does not flow even after seal bolt has been removed, oil amount is insufficient. Request Komatsu distributor to perform necessary repairs.EVERY 1000 HOURS SERVICE For the maiintenanee of engine equipped with turbocharger, refer to the last section of this manual 4g. CORROSION RESISTOR 1. After screwing in valves (1) (2% It is recommended genuine points) on corrosion resistor (2) Komatsu cartridge are used. remove the cartridge by turning it % Be careful not to screw In more counterclockwise and replace it than required. with new one # When installing & new caruiye, 2, Turn the cartridge in until its seal- coat the sealing surface with lubri wourfave comesintocontactwith cating oll. the head. Then, retighten the car- Uidge about 2/3 uf a turn, 3. After replacement, open valves (1). mgFor the maintenance of engine equipped with turbocharger, refer to the last section of this manual. EVERY 2000 HOURS SERVICE a. ENGINE BREATHER Take breather (1) out of place and ‘wash the inner element in clean light oil to remove dust from it + Before taking the breather out of place, wipe the dust off the sur- rounding area, When restoring the element to its original position, be sure to coat the new O-ring with engine oil be car b, ALTERNATOR AND STARTING MoToR The brush may be worn, or the bearing may have run out of grease, 0 pleese contact your Komatsu dis tributor for inspection or repair. % If the engine is started frequentiy, carry out inspection every 1000 hours. mgt EVERY 2000 HOURS SERVICE + Maintenance for every 250, 500 and 1000 hours should ied out at the same time. ¢. ENGINE VALVE CLEARANCE As special tool is required for removing and adjusting the parts, you shall request Komatsu distributor for 4. ENGINE VIBRATION DAMPER Check the vibration damper for cracks or separation on rubber sur- face. If there are cracks or separation, contact your Komatsu distributor for replacement.EVERY 4000 HOURS SERVICE ® Maintenance for every 250, 500, 1900 and zou hours should be carried out at the same time. a. WATER PUMP. Cheok that there is no play, oll leakage, water leakage, or clogging of the diain hole. if any abnormality js found, please contact your Komatsu Uisuibutur for disassembly and re- pair or replacement. = 76WHEN REQUIRED #. TRACK TENSION Inspection Without applying brakes, stop the machine on a flat land, and put a straight rod on the carrier roller and. the idler as shown on the Photo. When the distance between the rod and the shoe grouser is 20 to 30, mm at the center, the tension 1s the standard one ‘Agustment For tightening the tension, pressurize grease through lubricator (1). On the other hand, for loosening the tension, extract grease by versely rotating lubricator {1) for rotation”, Grease may be pressurized ti! S will be O mm. In case the tension is yet luose after applying pressurized injection of grease till the above- ‘mentioned limit, i indicates that the pin bush is reduced by too much abrasion, So its necessary elther to turn or replace the pin and bushings. Consult your Komatsu distributor for repair. ‘Ako not loosen tubricator (1) over one complete rotation. Also, be careful not to loose any part other than lubricator «. If lubricator (1) oF any other part should be loosened exces- sively, it will be liable to fly out uncer the high pressure of Jammed grease. If grease does not aoze smoothly, try moving the machine back and forth for a short distance. ity gis WHEN REQUIREDb. AIR CLEANER Checking Whenever the red piston in the dust indicator (1) appears, clean the air cleaner element. Stop the engine when cleaning the element Cleaning or replacing outer element 1, Remove bolt (2), cover (3) and tne outer element 2. Clean the air cleaner body interior and the removed cover. 3. Clean and Inspect the element. (See the item “Cleaning outer element’ for cleaning procedure.) Install the cleaned element. 4, Pusit button of dust indicator 10 return red piston. + Replace the outer element which has been cleaned 6 times repeat- edly or used throughout a year. Replace the inner element at the same time, ‘% Replace seal washer (>) or wing nt (4) if they are broken. % when inspecting or cleaning the air cleaner, remove evacuator valve (6) and clean with com- pressed air.% Replace both inner and outer ele- ments when the dust indicator red piston appears soon after install- ing the cleaned outer element even though it has not been cleaned 6 times. %* Check inner element mounting ruts for looseness and, if neces: sary. retiahten. % Remove one seal from the outer element. The number of times the ‘outer element has been cleaned can be seen by the number of removed seals, WHEN REQUIRED Replacing inner element 1. First remove the cover and the NOTE: Do not attempt to reinstall a outer element, and then remove cleaned inner element. the inner element. 2. Cover the air inlet port. AX2e not clean or replace the air 3. Clean the air cleaner body interior. cleaner element with the engine Removethecoverfromtheairinlet_ running. port. 4, Fit a new inner element to the ‘connector and tighten it with nuts. 6. Install the outer element and the cover. Push the dustindicator reset button, nM giWHEN nEQUIRED Cleaning outer element With compressed air Direct dry compressed air (less than 7 kg/cm!) to element from ide slong its folds, then direct it from outside along its folds and again from inside, and check element. Aiwiren using compressed air, ‘wear safety glasses and oth things required to maintain safety. The following methods require spare parts. With water Dash city water ess than 3 kg/cm’) on element from inside along folds, then from outside and again from inside. Dry and check it. With cleaning agent For removing olls and fats as well as carbon etc. attached on the ele- ment, the element may be cleaned in lukewarm solution of mild deter- gent, then rinsed in clean water and left to drip dry. % Drying can be speeded up by blowing dried compressed air Mless than J kg/em*) trom the inside to the outside of the element. Never attempt to heat the element + Using warm water (about 40°C) instead ot soapy water may also be effective. = 80- Hf small holes or thinner parts are found on element when it is checked with an electric bull after cleaning and drying, replace the element. If element is usable, wrap it and store itin dry place. Do not use element whose folds bor yasket or seal ere damaged When cleaning element, do not hititor beat against somethingWHEN REQUIRED ¢. CLEAN INSIDE OF COOLING SYSTEM Clean the inside of the cooling Be sure to replace the corrosion Add antifreeze in the cooling wa- system, change the coolant, and resistor cartridge ter replace the corrosion resistor, accord: * Use city water for the cooling When deciding the ratio of anti ing to the table. water. freeze to water, check the lowest + Stop the machine on level ground _Ifriver water, well water or other temperature in the past, and de- when cleaning or changing the such water supply must be used, cide from the mixing rate table coolant. contact your Komatsu distributor. _given below. + Usea permanenttype of antifreeze. itis actually better to estimate @ If, for some reason, it is impos- A Antifreeze is flammable, so keep temperature about 10°C lower sible to use permanent type anti- it eway from any flame. when deciding the mixing rate. freeze, use an antifreeze contain: Mixing rate of water and antifreeze ing ethylene glycol. Win Kind of cootet coating system and Replacing corrosion -20]-25) -30 Every year (autuma or | very 2000 aur whichever as] 19 [225] 26] 29 [sis Non permanent ype Every @ monthe op very 1000 hours and when Amount of ‘ntireere conaining aur) Cleaning the inside ofthe water | 495) 44 [40s] 37| 34 [915 ‘iyene lyeo! {Drain sneeze in pcing, | cooling system ana hen TWhrtor one seewon por | sad anttrecre im autumn’ | changing covlont, apes We recommend use of an anti- Whon net ing artivease | ven 1000 howe whishover freeze density gauge to control the somes fest mixing proportions. gga1, Stop the engine, and close corra- 3. Loosen drain valve (3) at the 5. When the water reaches the sion resistor valvoe (1). bottom of radiator and drain plug vicinity of the water filler, put the 2, Turn radiator cap (2) siowly until (4) at the side of oil cooler and engine at low idling, open the it comes off. drain off the cooling water. drain valve (9) and plug (41, then 4, Close up drain valve (3) and plug pass water through the cooling At me water temperature ie (4) and pour in clean water (ex. system until clean water comes high, do not remove the cap. city water) up to the vicinity of out from the drain valve and plug Thie ie booausc of the possibil the water filler. for 10 minutes. ty of scalding water spurting * When flushing, adjust the flow out, 30 thet water is added at the When removing cap, turn cap same rate as the water is drained slowly to allow pressure to bo to keep the radiator always full. Corrosion resistor Drain valve (bottom of radiator)6. After washing the cooling system, stop the engine. Drain water and close drain valve (3) and plug (4) 7. After draining off the cooling water, wash out the cooling system using commercially available detergent. Follow the in- structions on the detergent container. Drain plug (oil cooter) 8. After washing the cooling system, din off al the water then close up drain valve and plug, and pour in clean water (ex. city water) slowly up to the vicinity ofthe water file. 8. When’ the water reaches the Vicinity of the water filer, put the engine at low idling, open the drain valve and plug, then pass water through the cooling Eystem until clean water comes cut from the drain valve and plug * When flushing, adjust the flow so that water is added at the same rate as the water is drained to keep the radiator always full 10. When the water becomes com- pletely clean, stop the engine and close the drain valve and plug, iitegint 12, 14, WHEN REQUIRED Replace the corrosion resistor cartridge and open valve (1). For details of replacoment of the corrosion resistor, see EVERY 1000 HOURS SERVICE. Supply water until it overflows from water filler. Run the engine 6 minutes at low idling and then for anoth 5 minutes at high idling to efi nate air trapped in the cooling system Uleave radiator cap off during this operation) Stop the engine and wait for about 3 minutes. Supply cooling water up to the specified level tighten the cap.