D375A-5

D375A-5 / OPERATOR TRAINING.

DATE
LOCATION
M. APPLICATION
DISTRIBUTOR
INSTRUCTORS

: OCT17~20, 2010..
: SEBAIEA [LUXOR] / EGYPT.
: PHOSPHATE MINES.
: EIM.
: MR. AKITO SATA /JAPAN.
MR.SATOSHI TANIGUCHI /KME.

PROJECT MANAGER : MR. TETSUO TAKATORI

GM SERVICE, KME.
PARTICIPATING CUST,S
: --------------PARTICIPATING OPERATORS: ---------------

1) SAFETY.
A) SAFETY SIGN LOCATIONS.

1) PRECAUTION FOR
OPERTION, INSPECTION
& MAINTENANCE..

Please read
first.

2) PRECAUTION WHEN TRAVELLING IN

REVERSE.
A) Sound the horn to alert people nearby.
B) Make sure no one is nearby the
machine.
C) use spotter if view is obstructed.
Please follow even the machine is
equipped with back-up alarm.

3) PRECAUTION WHEN LEAVING

OPERATORS SEAT.
This sign indicates a hazard of
unexpected moving of a stopped
machine.

Please do as follows
before leaving the
operators seat.
A) Lower the work equipment to
the ground surface.
B) Move the lock levers to the
locked position.
C) Take the engine starting key
with you.

4 &5) RADIATOR CAP /

HYDRAULIC TANK CAP.
Never remove caps for check /
compensation when engine is at
operating high temperature.
STEAM OR HIGH TEMPERATURE
WATER / OIL BLOWING UP.

6) Precaution for check and adjustment of track

tension.
Safety label is attached to the back side of the
inspection cover.

7) PRECAUTION FOR HANDLING

ELECTRIC WIRES.

Read manual first for safe

and proper handling.

8) CAUTION FOR ENGINE

RUNNING.
Sign indicates a hazard of rotating parts.

Turn off the Engine before

inspection & Maintenance.

9) PRECAUTION FOR HANDLING ACCUMLATOR.

Sign indicates a hazard of explosion Causing injury.

Do not disassemble the accumulator, make hole in it,

weld, cut, roll, hit bring it near flame.

10) PRECAUTION FOR USE OF

SEAT BELT.

11) CAUTION FOR APPROACH WHEN

MACHINE IS MOVING.

For a comfortable and safe

operation, please follow the
instruction in the sign.

A) Sign indicates a hazard of being run

over by moving machine.
B) Keep a safe distance from moving
machine.

12) WARNING FOR ROPS.

ROPS Rollin Over Protection Structure.
A) Altering ROPS may weaken it.
Consult Komatsu DB.
B) ROPS may provide less protection if damaged or involved in roll over.
C) Always fasten seat belt when moving.

PORTABLE TAG.
keep a suitable and visible size tag in the
storage of the compartment.
Please hang it in position close to Engine
starting switch for the following conditions:
1) The machine under maintaining.
2) The machine under repair.
3) Emergency break down.

GENERAL PRECAUTIONS. 1/7

1)Safety rules.
* Only trained and authorized persons can operate & maintained the machine.
* Follow all safety rules, Precautions & instruction in the manual when operating &
Maintaining the machine.
* If you are not well or under influence of medicine, your ability for operation / repair the
machine may be impaired putting your self and everyone else on your job site in
danger.
* When working with another operator or persons on the work site traffic duty, discuss
the content of the operation beforehand and use the determined signals.

2) If abnormality.
If you feel abnormality in the machine during operation [Noise, vibration, smell, incorrect
gauges, smoke, oil leakage, ect., or and abnormal display on the warning device or
monitor], Report to the in charge person and have the necessary action taken.

3) Safety feature.
* Be sure that all guards, covers & mirrors are in their proper position. Have any item
repaired immediately if any damage.
* Understand the method of use of safety feature and use the properly.
* Never remove any safety feature. Always keep them in good operating condition.

4) Keep the machine clean.

* If water gets in to the electric system, It will cause malfunction or misoperatrion.
* If the inspection / maintenance is carried out
when the machine is still dirty, there is a hazard
that the dirt will get in to machine component.

5) Inside operators compartment.

* When you get in to the operators compartment,
Remove the mud/oil affixed to your shoes.
Your foot may slip from pedal causing a serious
accident.
* Do not leave tools / parts laying around the
operators compartment.
* do not use mobile phone while driving or
operating the machine.
* Do not bring flammable/ explosive items in the
operators compartment.
* Do not stick suction pads to the window glass.
Suction pads acts as lens and may cause fire.

2/7

6) Hand rails & steps.

3/7

* Use the parts marked by arrow [A] in the diagram

when getting on /OR/ Off the machine.
* Never use the parts marked by arrow [B] in the
diagram when getting on / OR / Off the machine.
* Never jump on /OR/ Off the machine.
* Never get on /OR/ Off a moving machine.

This may cause a serious injury.

7) To ensure safety,
Always face the machine and make three
points contact [Both feet and one
hand Both hands and one foot] with hand rails
and track shoe to ensure that you support
yourself.
A) Check the hand rail before getting on the
machine.
B) Always keep hand rail clean. Remove any oil /
Mud if any.
C) Repair any damage.
D) Do not get on /OR/ Off the machine while
holding tools in your hand.

* The clearance around the work equipment

changes according to its movement.
If you get caught, this may lead to a serious
personal injury

8) Prevent burn.

4/7

A) HOT COOLANT.
To prevent burn from hot water or steam spurting out
when checking / drain coolant,
Wait to cool to a temperature where is possible to
touch the radiator cap by hand.
then loosen the cap slowly to release the steam
first.
B) HOT OIL..
To prevent from hot oil spurting out when
checking oil level / Drain oil.
Wait to cool to a temperature where is possible to
touch the radiator cap by hand.
then loosen the cap slowly to release the steam
first.

9) FIRE PREVENTATION.

Fuel, Oil, Antifreeze, Widow washing liquids are

particularly flammable.
TO PREVENT FIRE, ALWAYS OBSERVE THE
FOLLOWING:
1)
2)
3)
4)

Do not smoke or use any flame near fuel or oil.

Stop the Engine before fueling.
Tighten all fuel / Oil caps securely.
Do not spill fuel on overheated surfaces /OR/Electric
system.
5) Use well ventilated area for adding / Storing fuel & Oil.
6) Keep fuel & oil in determined place. Do not allow
unauthorized person to handle.
7) After fueling /OR/ adding oil, wipe any spilt material.
8) When carrying out grinding /OR/ welding, move any
flammable material to a safe place.
9) When washing parts with oil, use nonflammable liquid.
10) Put grease & flammable material in a safe container.
11) Do not cut / OR/ weld any tubes contain flammable
material.

5/7

10) CLOTHING AND OTHER PROTECTIVE ITEMS.

6/7

11) FIRE EXTINGUISHER AND FIRST AID KIT.

7/7

A) Be sure that fire extinguisher have been provided

B) Carry out the periodic inspection to ensure that the fire extinguisher and first aid kit can
always be used.

SAFETY AT WORKSITE

1/3

1) Working on loose ground.

Avoid operating / Travelling close to the edge
of cliffs, overhangs, embankment, deep
excavated ditches.
If the ground should collapse under machine weight
/OR/ vibration, There is a hazard the machine may fall
or tip over.

Precaution to be taken before operation :

Check the terrain, ground condition. Do not operate
if there is a hazard of landslides or rock fallen.
If you travelling / operate on shallow water, check
first the shape and condition of bedrock / depth &
speed of the water .
* If water lines, gas line, electric cables may be buried
under the worksite, contact each utility to identify
locations.

SAFETY AT WORKSITE
.

2) Working close to high voltage lines /

cables.
* Avoid operating / Travelling close to high voltage
lines /cables.

There is a hazard of electric shock. It may

cause of personal injury or death.
*Check with the power company for safe
operation.

2/3

SAFETY AT WORKSITE

3/3

TRAVELLING ON SLOPES
To prevent machine from tipping over or
slipping:
* Keep the blade approximately (20~30 cm)
above the ground surface.
If abnormal stability, lower the blade to the
ground surface.
* Always travel straight up /OR/ down slopes.
* Do not turn on the slopes /OR/ travel across
the slopes.
* When travelling down the slopes, never shift
the gear or place the T/M in the neutral
position.
* When turning on a downhill ground, lower the
speed.
* Travelling on grass, fallen leaves, wet soil/
plate even slight slope- the machine may
tip. Drive/Travel low speed.

Prohibited operation
1.
2.
3
4
5

Set the track at the right angle with the road edge. It is easer to escape if abnormality.
When operating the machine, take care it will not exceed its performance value [StabilityMax Load]. It prevents the machine from rolling under overload.
When machine is travelling, Do not reset your foot on the brake pedal.
Do not depress the brake pedal repeatedly if not necessary.
Use the Engine braking., When travelling downhill ,

Parking the machine:

3.
4.
5.
6.
7.

Park the machine on level ground where there is no danger of rock fallen, Landslide, Or flood.
If it is necessary to park the machine on a slop, lower & dig the W/E to the ground- Set a block to the
track to prevent the machine from moving.
After stopping the Engine, Move the control levers of the W/E several time to release pressurized
oil .
Set the control levers to locked position.
Lock the operators compartment doors & widows.

PRECAUTIONS FOR MAINTENANCE .

1) Work place.
* Keep the working place clean.
* Clear any tools laying around the working place.
* Wipe up all grease, oil, or other material.

If work place is not clean, you may suffer a serious injury.

* Appoint a team work leader.
* Stop Engine before job is started.
* After Engine is stopped, operate
The control levers 2~3 times to
release the remain pressure.
* Set all control levers in the locked position.
* Check that the relay of battery is OFF
and main power is not connected.
* Put rubber blocks under the track to prevent movement.

1/3

2) Inspection when Engine running.

2/3

If it is necessary to carry out inspection while engine running, and to prevent personal injury,
note the following:
* One worker must always sit in the operator seat and be ready to stop the Engine at any
time.
* Set all control levers and parking brake in the locked position.
* Do not touch any control lever. If any lever to be operated, sound the horn first.
* When carrying out a work near the fan, belt, Keep seriously careful.
* Use only the tools suit the job.

3/3
3) Precaution when using a high pressure gun to adjust track
tension.
* Grease is pumped in to track tension adjusting system under high pressure.
If the specified procedure is not followed, grease drain valve (1) may fly.
* When loosen grease drain valve (1) to loosen the track tension, Never turn it more than one turn.
* Never put your face, hands, foot or any other part of your body directly in front of drain valve (1).
* Never attempt to disassemble the recoil spring. Contact Komatsu distributor.

INTRODUCTION.

1- Engine (SA6D170E-3)
14- Transfer Gear
2- Damper
15- Scavenging Pump
3- Universal Joint
(BAR 63 -277)
4- Power train pump (BAL 180+112)
5- PTO

7- Torque Converter
8- Transmission
9- Steering Clutch
10- Steering Brake
11- Final Drive

GENERAL VIEW OF CONTROL &

GAUGES.

FRONT PANEL. 1/2

MONITOR PANEL FUNCTION.

TO PERFORM SUITABLE OPERATION CORRECTLY AND SAFELY, IT IS A MOST
ESSENTIAL TO UNDERSTAND THE METHODS OF OPERATING THE EQUIPMENT , AND
THE MEANING OF MONITOR DISPLAY.

A) Check Monitor Group1) Park the machine on level

ground.
2) Turn the Ignition switch to
position the
ON.
Check the following:
** All Caution lamps light
up for 3
seconds.
** All Emergency caution
lamps light
up for 3 seconds
** Alarm buzzer sounds for
1 second.
3) Make sure that all lights
and alarm
have gone after the
designed time.
4) If any abnormality, the
lamp of the
defected function will not
light up.

B) Caution Lamps
Charge level lamp
Fuel level lamp
lamp

Radiator coolant level

Air filter restriction lamp

Air filter restriction pilot lamp

C) Emergence Caution 1/3

1) Engine oil pressure caution
lamp.
** Indicate low engine oil pressure.
** Alarm buzzer sounds & lamp lights up.

2) Engine coolant temperature

caution
lamp.
** When the lamp flashes,
run the engine at low idle speed until the
indicator
go back in the green range.

C) Emergence Caution 2/3

3) Power train oil
temperature caution
lamp.
** This lamp warns that T/C outlet oil
temperature
is higher than the normal.
** Stop the machine and run the engine at low
speed until the
temperature indicator goes back in the green
range.

4) Hydraulic oil temperature

caution
lamp.

** This lamp warns that the Hyd. oil temperature

is higher than the normal.
** Stop the machine and run the engine at low
speed until the
indicator goes in the green range.

C) Emergence Caution 3/3

5) Fuel temperature caution

lamp.
** This lamp warns that the fuel temperature is
higher than the
normal.
** Stop the machine and run the engine at low idle
until the indicator
goes back in the green range.

D) Meter Group & Indicating lamps

1) Engine coolant temperature gauge.
Gauge.
3) Fuel gauge,
pilot lamp.
5) Dual / single tilt dozer (If Equipped).
7) Service meter display.
display.
9) Torque convertor lock up pilot lamp.

2) Power train oil temp.

4) Engine pre-heating
6) Speed rang display.
8) Auto-shift mode

2) POWER TRAIN OIL TEMPERATURE

GAUGE.
** T/M oil temperature is normal until the scale
reaches the top of green range.
** If the scale enters the red rage, stop the
machine and run the engine at of full
throttle until the scale goes back in to the
green range.
** If the scale often enters the red range,
following immediate inspection is a must .
A) T/M oil level.
B) Ambient temperature.
C) Machine application.
D) Physical check for machine performance.
E) Operators skill [ Frequent stall].
F) Engine coolant temperature.
G) If abnormal engine coolant temperature,
check the engine cooling system and T/M oil
cooler.
H) T/M & T/C hyd. circuit pressure.
Note: When the scale enters the red range,

3) FUEL LEVEL GAUGE.

** Scale in the green range is recommended for
normal operation.
** It is not recommended to add fuel during
operation, it may cause
engine irregular performance.
** when the scale reaches the top of red range,
almost 150 liters of
fuel is left in the tank..
Note: When the scale enters the red range , caution
lamp
4) flashes.
ENGINE PRE-HEATING PILOT LAMP.
** Engine pre-heating is automatically starts
when engine starting
at cold weather time.
Note: A) Insert the key in to the starting switch
and turn the key
to starting position (B).
B)The engine controller detects the
coolant temperature
and automatically actuate pre-heating.
C) Pilot lamp light goes down when preheating is
completed.

OPERATING INFORMATION PANEL DISPLAYING.

DEFAULT/ NORMAL / OPERATOR MODE [1/2]
1) Speed range & engine speed
display.
** Zone (B) shows T/M speed & direction. [1st
forward].
** Zone (A) shows Engine speed.
** Zone (C) / red/ shows undesired engine speed
operation.
Note: Whenever the engine RPM scale enters the
red range , shift the gear to a lower speed.

2) Service meter.
** The meter displays the total operating hours
[00000,0 h] .
The meter is running while the engine is
runing even the
machine is stopping.
** Set the maintenance interval.
** as long as the engine is running, the sand
glass pilot lamp is
flashing.

** If any abnormality , abnormality code

and service meter alternately display

OPERATING INFORMATION PANEL DISPLAYING.

DEFAULT/ NORMAL / OPERATOR MODE [2/2].
AUTO SHIFT MODE DISPLAY LAMP.
1)Lamp (8) pointed by L.H arrow lights up when
[F1 - R2] mode is selected.
2)Lamp (9) pointed by R.H arrow lights up when
[F2 R2] mode is selected.
3) Lamp (8) & (9) are off at Manuel Shift..

9
8
TORQUE CONVERTER LOCK UP PILOT
LAMP.
1) T / M is set to direct drive mode.
Lamp (10) pointed by arrows lights up.
2) T / M is set to T / C drive mode. Lamp (10)
pointed by arrows lights off

10

Mode Selection Function. 1/6

1) Lock up mode selection
switch.
2) Economy mode selection
switch.
3) Reverse slow mode selection
switch.
4) Auto shift down mode
selection switch.
5) Auto shift mode selection
switch.

NOTE:
A)It is impossible to use
combination selection of lock
up mode and any other mode.
B)Economy mode and slow
reverse mode can be
combined selected.

Mode Selection Function. 2/6

1) LOCK UP MODE SWITCH.

1)Lock up is set to ON
Mode.
** Pilot lamp lights up.
** T/C lock up auto-selection
depends on
the load.
** T/M is automatically set to
direct drive
mode at light load.
** T/M is automatically set to T/C
drive
mode at heavy load.

Lock up is set to OFF

Mode.
2)

** Pilot lamp goes down.

** T/M is continuously set to T/C
drive
mode regardless the load.

T/C LOCK UP PIOLT LAMP CONDITIONS

1) Pilot lamp lights up when Lock Up is automatically set to T/M direct drive.
2) Pilot lamp lights goes off when torque convertor drive is being used

Application : Dozing loose material .

(suitable for long distance hauling operation).

Slot dozing operation.

Hillside dozing operation.

Mode Selection Function. 3/6

2) ECONOMY MODE SWITCH.

1) Economy mode 1 , Lamp (1) ON

about
2) Economy mode 2, Lamp (2)
about

ON

3) Normal mode 3 ,lamps (1), (2) OFF

to 100%

The engine is se

90% of full load

The engine is se

70% of full loa

The engine is se
of full load.

Economy mode application

Using the Economy mode makes it possible to
reduce wasteful shoe slippage and to reduce
the fuel consumption.

NOTE:- Speed range applicable for this

function (F1).
Application example:Fine leveling operation

Light Ripping and

Dozing operation

3) Reverse slow mode selection switch 4/6

When this mode is selected [ON] , pilot lamp lights up.
This mode is selected when small reductions in the travel speed
When travelling in R1 , R2or R3.
When the reverse slow mode is ON, the travel speed is set to
approx. 80% of the full travel speed.

REVERSE SLOW MODE

Travel speed is to approx. 75- 80% of full
travel speed.
Application operations :

Mode Selection Function. 5/6

4) Auto shift Selection: The selected speed range is
displayed in N position before starting,. When the Joystick
is in N position , If up switch or down switch is pressed
The shift mode selection can carried out.

Re

Remark :
If Up Or Down switches are operated , the previous set will be canceled
and T/ M goes to Manual operation.

Mode Selection Function. 6/6

5) Auto- shift down switch

(a) / OFF position: Automatic

operation canceled.
(b) / ON position: Automatically
shifts down to lower speed.
Note:

1)Travel speed is proportional to

the load, T/M controller detects
the travel speed and shift down
when the machine is travelling
at 2nd or 3rd speed.
2) Once the machine is shifted
down, shift up will not be
turned ON automatically.
3) This function is available for
forward & reverse.

Auto- shift down

SWITCHES. 1/3
1)
2)

Starting switch.
Buzzer cancel
switch.
3) Front lamp /
working
lamp switch.
4)
Rear lamp switch.
5)
Auto-shift down
switch.
6) Warning lamp.
7) Fuel control dial.
8) T/M & steering
control
lever.
9) Pin puller switch.
10) Blade control lever.
11) Ripper control lever.

SWITCHES. 2/3
UP &Down Gear shift switches.
1)UP shift
- Switch (C).
Each time the switch is pressed, the T/M
shifts up once.
2) Down shift -- Switch (D).
Each time the switch is pressed , the T/M
shifts down once.

Buzzer cancel switch.

** Rotate this switch to right or left
direction to stop alarm the buzzer,

Function Selection Switches.

** Service switch (3).

** Buzzer cancel switch
(4).
** Economy selection
switch (5).

FUSE BOX. 1/3

A) FUSE BOX I / CHASSIS.
1) Fuse box fs1 ---- 2) Fuse box
fs2.
3) Fuse box fs3. ---- 4) Circuit
breaker.
For more detail of Fuses capacity
and related devices, refer to
operation manual page (3 40).

FUSE BOX. 2/3

B) FUSE BOX II

/ CAB.

For more detail of fuses capacity

and related circuits, refer to
operation manual page (3 40 to
3 - 41).

FUSE BOX / CIRCUIT BREAKER. 3/3

CIRCUIT BREAKER .
Function:
1) If the starting switch does not work, open the
circuit breaker and
check.
2) To restore the electric circuit after it has been
cut-off, push in reset
button (1).
**If the circuit is normal, the reset button (1) will
stay pushed.
** If it comes out immediately after it is pushed,
the circuit must be
checked.
NOTE: The circuit breaker is a device installed to
the circuit where a
large current flows to protect electrical
circuit component &
wiring from damage.

WORK EQUIPMENT, POWER TRAIN LOCK LEVERS.

1)
2)
3)
4)
5)

Work equipment lock lever (1).

Power train lock lever (2).
Position (F)
Unlock.
Position (L)
Lock.
Engine will not start if any lever
is in unlock position.

PIN PULLER CONTROL SWITCH

(IF EQUIPPED) to change the
shank.
1)Position (a)
Pin pulled
OUT.
2)Position (b)
Pin Pushed
IN
Note: F : Front of The machine.

LOCATION OF IMPORTANT DEVICES.

** Steering controller
(1).
** T / M controller
(2).
NOTE:
T / Mcontroller
& steering
** Engine
controllers
are located in
(3).
In the rear side of the
operator's seat,

LOCATION OF THE
DUST INDICATOR.

MONITOR SYSTEM. 1/2

MONITOR SYSTEM. 2/2

OPERATION AND DISPLAY OF OPERATOR

MODE (OUTLINE)
Mode access.
1)Default mode -- Service mode:
Service switch (ON) + Buzzer
cancel switch (ON) 7 Sec.
2) The mode displayed differs
according to the selected Economy
mode switch (5).

1) NORMAL DISPLAY / OPERATOR MODE /

DEFAULT MODE.
When normal condition, the monitor
panel displays the following
information:
A) Speed range display:
** L. H.S
Direction (P, N, F, R).
** R.H.S
Speed range (!, 2, 3).
** Bottom
Shift mode.
** Graphics
Engine speed.
B) Service meter display:
** Service meter (00000.0 h).
C) User code display.

USER MODE DISPLAY.

A) If an abnormality occurs during the operation
and it is necessary to inform the operator,
the user code and service meter are
displayed in turn on service meter display
(2).
B) If the user code indicate a serious problem,
the warning lamp flashes and buzzer alarm
sounds at same time.
C) The user code is displayed only when a
serious problem.
D) There are cases , an abnormality occurs, but
the user code is not displayed.
If you feel there is in a problem, always
check for a service code display.
Note: E01 ,E02,Call03 and Call , you have to
consulate
Komatsu DB.

Monitoring Mode.
Content of display as below
table:
1
Steering system

38 Items

T/M system.

27 Items

Work equipment system.

13 Items

Engine system.

9 Items

Monitor panel system.

15 Items

1) The monitoring codes are in the internally

set order.
2) If the following switches are operated, the codes
are scrolled
forward or in reverse in the internally set order, so
scroll to the 3) code to be selected.
Slow reverse mode switch (6): Scroll forward
Buzzer cancel switch (4): Scroll in reverse
4) When the system is switched to the monitoring
mode, the 1st code is displayed

Service Display Code Mode.

1 - Service switch (ON) +
Hold Buzzer cancel switch (ON) for at least 7 Sec.
2 - Use Economy mode switch to select Service code display.
3 If Multiple code are recoded :
*- Use Slow reverse mode switch No.(6 ) to Scroll forward.
*- Service code Can not Scroll down.
4 Letter at head of service code :

E : Code for problem detected at present.

P : Code For problem not detected at present.
5 - Delete Service Code.
Buzzer Cancel Switch (4) : ON .
Note : only code headed by ( P) Can be Deleted.

Note : The service meter when failure

occurrence is subsequently displays
with the error code .

HPI Engine Control System

HPI ( High Pressure Injection )

Lubrication System Diagram.

1. Oil Pan
2. Oil level sensor
3. Oil pump
4. Regulator valve
5. Oil cooler
6. Thermo valve
7. Oil filter
8. Safety valve
9. Main gallery
10. Crankshaft
11. Camshaft
12. Rocker arm
13. Piston cooling nozzle
14. Timing gear ( rear side)
15. Auxiliary equipment drive gear ( front gear)
16. Oil pressure gauge
17. Turbocharger
W. Cooling water

Cooling System Diagram

1. Water pump
2. Oil cooler
3. Corrosion resistor
4. Cylinder liner
5. Cylinder block
6. Water manifold ( inside cylinder head )
7. Thermostat
8. Radiator
9. Fan
10. Air compressor
A. From oil pump ( oil)
B. To all parts of engine ( oil)

Daily Service

Check Before Starting ( No1)

1- Check Machine Monitor
* Turn Starting switch (1) to On Position.
* Check that The Monitor and Gauges light up for 3 sec
* check the alarm buzzer sounds for 1 sec..
Remarks : If the lamps dont light up, their might be
a failure of disconnection in the monitor or wiring.

Check Before Starting (No.2)

* Check Engine Coolant level.
1- Open the engine side cover on the left side of
the chassis and check the coolant is between FULL
and LOW marks on sub-tank (1) .if the coolant level is low
add coolant to the FULL level through coolant filler port of
sub-tank..
2-.After adding coolant ,tighten the cap securely.
3- If sub-tank is empty , first check of any water leak
then remove the radiator cab (2) and check the coolant
Water is above the bottom surface of the strainer

Check Before Starting ( No3)

3- Check fuel Level

* Turn the starting switch to On position and check

the fuel level with the fuel gauge (G ) on the monitor

panel.

Remarks : * Drain water / sediment from fuel tank by open valve (2).
* Drain water / sediment from the water separator.
* Check the breathing hole no (1) on the cab if the hole
is clogged, the pressure in the tank will drop and fuel
will not flow.
* Avoid to add fuel while operation just before operation ,
If necessary, please shut down the engine,
add fuel, dont start the engine before
15 mints after completing the fueling .
* Clean fuel tank strainer.
1- Clean the strainer if any dirty collected in it
2- Clean with diesel fuel.

Check Before Starting (No.4)

* Check oil level in engine oil pan.

1234-

Open the engine side cover on the left side of the chassis.
Remove dipstick (G) and wipe the oil with a cloth.
Fully insert dipstick (G) into filler pipe (F) then remove it.
The oil level should between the H and L marks on the
ENGINE STOPPED side of the dipstick ( G)
5- if the oil below the L mark , add oil through oil filler (F).
6- If the oil is above the H mark ,remove the drain plug (1)
to drain the excess oil and then check the oil level again.
7- When checking the oil level after engine has been operated
wait for at least 15 minutes after stopping the engine .
8- It is possible to check oil level with engine idling but
Recommend to check the following points:
Check oil with engine coolant temperature within green range.
Read the dipstick on its reverse side marked ENGINE ILDLING
Note : Before oil level check , place the Machine on
horizontal position .

*Check oil level in engine oil

pan.
1- Safe Engine Oil Level.
Oil level is between (H) & (L)
marks.
2- Unsafe Engine Oil Level.
Oil level reach ( L) mark.
Oil level higher than ( H )mark.

Check Before Starting (No.5)

* Check oil level in T/M , T/C and Bevel gear case

1- Remove dipstick (G) and wipe the oil with a cloth.
3- Fully insert dipstick (G) into filler pipe (F) then remove it.
4- Check oil level with cold side of dipstick (G)
5- Oil level Should be between the (H )and (L )marks on dipstick. (G).
Remarks :A : Cold stop oil temperature gauge
B : Hot idle oil temperature gauge .
Note : Before oil level check , place the Machine on
horizontal position

Check Before Starting (No.6)

* Check Dust Indicator.

1- Check for the yellow piston overlapping the

red zone on the dust inductor (1).
2- If the yellow piston overlapping the red zone
clean or replace the outer element.
3- After check, clearing or replacing the element
Press the knob of the dust indictor to return
the yellow piston to the original position.
4- Never remove the inner element .
5- Compressed air , Max.99 PSI ( 0.69 MPa ) for cleaning..
6- When replacing the outer element replace the
inner element at same time.
7- Condition for element change:
Immediately check the dust indicator after the element
cleaned , If the yellow piston comes close to the red zone
Replace both inner and outer elements .
Note : Never remove the outer element for cleaning unless
the yellow piston comes close to the red zone
or the caution lamp lights up on the monitor.

Check Before Starting (No.7)

* Check oil level in hydraulic tank.

1- Lower Blade and Ripper to the ground level , stop engine and
wait for 5 minutes before check the oil level.
2- Oil level should be between the ( H ) and ( L) mark in the sight gauge
(G).
3- If the oil level is below the ( L ) mark , add oil through oil filler (F).
4- If the oil level is above the ( H ) mark , remove drain plug (P) ,
loosen drain valve (1)and drain excess oil.

Warning : When removing the oil cap , oil may spurt out,
So stop the engine and wait for the oil temp.
Note : Before oil level check , place the Machine on
horizontal position

Check Before Starting (No.8)

Other Checks

1-Check Electrical Wiring for any damage.

2- Check for damage fuse.
3- Check for loose of battery cables.
4- Check battery electrolyte level .
5- Check water , fuel and oil leakage.
6- Check loosening bolts and nuts.
7- Check fan and alternator belts tension.
8- Check for leaky idler , track rollers and carrier rollers .
9- Check for leaky final drive .

Check after engine starting.

1- Check monitor panel caution

indicators.
* Engine oil pressure lamp.
* Battery charge lamp.

2- Check Brake performance .

3- Check work equipment operation.
4- Check for abnormality ( sound
,vibration , heat,
smell and exhaust color).

Scheduled oil check

A- Every 250 hours.

1/4

1- Check oil level in Damper case.

1- Check oil level with machine at horizontal position
2- Check oil level with engine stopped.
3- Remove dipstick (G) and wipe the oil with a cloth.
4- Fully insert the dipstick in the filler pipe (F ) and then
remove it.
5- Oil level should be between H and L mark on the dipstick (G).
6- If oil level is below L mark , add oil through the dipstick holder.
7- If oil level is above H mark, drain excess oil from the drain plug
and then check the oil level again.

B- Every 500 hours

* Check oil level in final drive case.
1- Before oil level check , place the Machine on
horizontal position .
2- Remove oil level plug (G) , check whether
the final drive case is filled with oil to lower
edge of the plug hole.
3- If the oil level is low , add oil through
the oil filler plug hole (F) until the oil
overflows.
Note: Before removing oil plug (F) , remove
all dirty and mud from the around of the oil
filler plug

2/4

C- Every 1000 hours

* Check oil level in recoil spring

1- Remove bolts (1) and then remove cover (2)

Be careful that dirt or sand not let to get in.
2- Insert a scale and check that oil level is
96 to 116 mm from the bottom edge
of the inspection port.
3- If the oil level is low, add Class CD SAE 10
engine oil regardless of the ambient temperature.

D- Every 2000 hours.

2- Check Pivot Bearing Oil Level.
1- Remove plug (1), be careful not to let dirt or dust get it.

2- Check that the oil is at the level shown in the diagram

Should be 25 mm as shown..

3- If the oil level is low , add engine oil through the

hole of plug (1)
Note : Use class CD SAE 30 engine oil regardless
of the ambient temperature.

4/4

Check when required

* Testing and Adjusting Track Shoe Tension (1)

A- Testing .
1- Drive the machine forward and stop on
a horizontal surface.
* Stop the machine without using the brake.
2- Put straight steel rod (1 ) on the top of the track
between the idler and the front carrier roller and
measure clearance ( a ) from the bottom of the
steel rod to the track shoe grouser.
Standard clearance (a ) 20 - 30 mm.

1/4

Check when required

Testing and Adjusting Track Shoe Tension (2)
B- Adjusting
* If the track shoe tension is not correct ,
Adjust as follows.
1- Remove cover (2) .
2- If tension is too high , loosen plug (3) and
Release some grease
* Never loosen the Plug more than 1 turn
(internal high pressure)
3- If tension is too low, Pump in grease through
Fitting (4)

2/4

Check when required

* Check , clean and replace air cleaner element .
1- Check if small holes or thinner parts are found
on the element .

2- Check that the inner element ( 5 ) is not loose.

3- Check the clearance between the air cleaner body

and cover ( 3) is not too large ( if it is too large , install the cover gain)
4- Check dust seal for any cracks or damage.

3/4

Check when required

* Clean and check the radiator fins .

4/4

LUBRICANTS

1/3

* Always use Komatsu genuine parts for replacement parts

,grease and oil
* Machine is shipped from factory with oil and coolant listed in
the table.

item

Type

.Engine oil pan

Engine oil EO15W40 DH (komatsu genuine parts)

Damper case

Power train oil TO30 (komatsu genuine parts)

Power train oil pan

Power train oil TO30 (komatsu genuine parts)

Final drive case

Power train oil TO30 (komatsu genuine parts)

Hydraulic oil
system

Power train TO10 (komatsu genuine parts)

Radiator

Super coolant AF-NAC (density 30% or above )

(komatsu genuine parts)

LUBRICANTS
Recommended coolant and lubricant.

2/3

LUBRICANTS
Machine Refill Capacity

3/3

Greasing

1/7

*** Every 50 hours greasing .

* Pre- caution before job starting
Lower the work equipment to the ground
then stop the engine and remove key switch.
* Using a grease pump , pump in grease thought
the grease fittings shown arrows.
* Clean any collected dust from the fitting before greasing ,
then Wipe off any old grease that was pushed out.

Note : Make Sure that the grease have flown trough

the fitting by observing old grease pushed out.
from both bushing sides.
( 1 ) Blade lift cylinder support yoke ( 4 places )

( 2 ) Blade lift cylinder support shaft ( 2 places )

Greasing

( 3 ) Blade arm ball joint ( 3 places )

( 4 ) Brace screw ( 2 places )

2/7

Greasing

( 5) Ripper tilt cylinder bottom pin ( 2 places)

( 6) Ripper lift cylinder bottom pin ( 2 places)
( 7) Ripper tilt cylinder rod end pin ( 2 places)
( 8) Ripper lift cylinder rod end pin ( 2 places )
( 9) Ripper arm pin (front , 2 places )
(10) Ripper arm pin ( rear , 2 places )

3/7

Greasing
(11) Equalizer bar side shaft ( 2 places )

(12) Equalizer bar center shaft ( 1 place )

( 13 ) Fan pulley ( 1 place )

4/7

Greasing

Decelerator linkage ( 1 place )

Brake Pedal ( 1 place )

Brake rod lever ( 1 place )

5/7

Greasing.

Steering ,directional and gearshift

lever rotating link ( 4 places )

6/7

Greasing

Universal Joint ( 2 places )

7/7

Thank
you