Saa6d170e-3 Engine PDF

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FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Before beginning operation or maintenance, operators and maintenance personnel must always observe the following points.
Read this manual thoroughly and understand its contents fully.
Read the safety messages and safety labels given in this manual carefully so that they should be understood fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below so that all personnel involved
in working on the machine can consult it periodically.
In case this manual should be lost or damaged, immediately contact Komatsu or your Komatsu distributor to obtain a new copy.
When you sell the machine, make sure that this manual should be provided to the new owner together with the machine.
In this manual, measurements are expressed in international standard units (SI). For the reference purpose, weight units used in
the past are also displayed in { }.
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FOREWORD FOREWORD
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FOREWORD FOREWORD
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1 -> (1))
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PRODUCT INFORMATION FOREWORD
PRODUCT INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
ENGINE SERIAL NO. PLATE POSITION

On the upper left side of engine cylinder block, when seen from the fan.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Engine serialNo.:
Distributor name:
Address:
Phone:
Service personnel for your engine:
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FOREWORD CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
PRODUCT INFORMATION 1- 6
ENGINE SERIAL NO. PLATE POSITION 1- 6
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 6
SAFETY 2- 1
GENERAL PRECAUTIONS 2- 3
PRECAUTIONS DURING OPERATION 2- 7
STARTING ENGINE 2- 7
OPERATION 2- 7
TRANSPORTATION 2- 7
BATTERY 2- 8
PRECAUTIONS FOR MAINTENANCE 2- 9
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF ENGINE 3- 2
EXTERIOR VIEW OF FUEL FILTER UNIT 3- 3
EXPLANATION OF COMPONENTS 3- 4
METER 3- 4
SWITCHES 3- 6
DUST INDICATOR 3- 6
OPERATION 3- 7
CHECK BEFORE STARTING ENGINE 3- 7
OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 13
STOPPING ENGINE 3- 14
EMERGENCY STOPPING 3- 14
CHECK AFTER STOPPING ENGINE 3- 14
MAINTENANCE OPERATION OF ENGINE FOR EMERGENCY GENERATORSPECIFICATION 3- 14
TRANSPORTATION 3- 15
METHOD OF LIFTING ENGINE 3- 15
COLD WEATHER OPERATION 3- 16
PRECAUTIONS FOR LOW TEMPERATURE 3- 16
AFTER COLD WEATHER 3- 17
LONG-TERM STORAGE 3- 18
BEFORE STORAGE 3- 18
DURING STORAGE 3- 18
AFTER STORAGE 3- 18
TROUBLESHOOTING 3- 19
AFTER RUNNING OUT OF FUEL 3- 19
IF BATTERY IS DISCHARGED 3- 19
OTHER TROUBLE 3- 20
MAINTENANCE 4- 1
GUIDE TO MAINTENANCE 4- 2
OUTLINE OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
OUTLINE OF ELECTRIC SYSTEM 4- 6
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CONTENTS FOREWORD
WEAR PARTS 4- 7
WEAR PARTS LIST 4- 7
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 8
FUEL, OIL, COOLANT 4- 8
HANDLING WHEN USING A GRADE HEAVY OIL AS FUEL 4- 12
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 14
TORQUE LIST 4- 14
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 15
SAFETY CRITICAL PARTS 4- 15
MAINTENANCE SCHEDULE CHART 4- 16
MAINTENANCE SCHEDULE CHART 4- 16
SERVICE PROCEDURE 4- 18
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 18
WHEN REQUIRED 4- 19
CHECK BEFORE STARTING 4- 29
EVERY 500 HOURS SERVICE 4- 30
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
INDEX 6- 1
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SAFETY INFORMATION SAFETY
SAFETY INFORMATION
GENERAL PRECAUTIONS 2- 3
SAFETY RULES 2- 3
IF ABNORMALITIES ARE FOUND 2- 3
CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 3
FIRE EXTINGISHER AND FIRST AID KIT 2- 3
SAFETY FEATURES 2- 3
KEEP MACHINE CLEAN 2- 4
PREVENTION OF BURNS 2- 4
FIRE PREVENTION 2- 5
UNAUTHORIZED MODIFICATION 2- 5
PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS 2- 6
PRECAUTIONS DURING OPERATION 2- 7

CHECK BEFORE STARTING ENGINE, ADJUST 2- 7
PRECAUTIONS WHEN STARTING 2- 7
PRECAUTIONS IN COLD AREAS 2- 7
OPERATION 2- 7
CHECK BEFORE STARTING OPERATION 2- 7
TRANSPORTATION 2- 7
SHIPPING 2- 7
BATTERY 2- 8
BATTERY HAZARD PREVENTION 2- 8
PRECAUTIONS FOR MAINTENANCE 2- 9

WARNING TAG 2- 9
KEEP WORK PLACE CLEAN AND TIDY 2- 9
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 9
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 9
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 9
MIND YOUR STEP WHEN CARRYING OUT MAINTENANCE 2- 9
PROPER TOOLS 2- 10
LIFT ENGINE CAREFULLY 2- 10
PERSONNEL 2- 10
NOISE 2- 10
PRECAUTIONS WHEN USING HAMMER 2- 10
REPAIR WELDING 2- 10
REMOVING BATTERY TERMINAL 2- 10
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 11
PRECAUTIONS FOR HIGH-PRESSURE FUEL 2- 11
HANDLING HIGH-PRESSURE HOSES, PIPING 2- 11
PRECAUTIONS FOR HIGH VOLTAGE 2- 11
WASTE MATERIALS 2- 12
COMPRESSED AIR 2- 12
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS 2- 12
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SAFETY GENERAL PRECAUTIONS
GENERAL PRECAUTIONS
SAFETY RULES
Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may
be severly impaired putting yourself and everyone else on your jobsite in danger.
When working with another operator or with a person on worksite traffic duty, be sure that all personnel
understand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUND

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

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

Always follow the precautions below to prepare for action if any injury or fire should occur.
Be sure that fire extinguishers have been provided and read the
labels to ensure that you know how to use them in emergencies.
Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
Provide a first aid kit at the storage point. Carry out periodic
checks and add to the contents if necessary.
SAFETY FEATURES
Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if
they are damaged.
Understand the method of use of safety features and use them properly.
Never remove any safety features. Always keep them in good operating condition.
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GENERAL PRECAUTIONS SAFETY
KEEP MACHINE CLEAN

If water gets into the electrical system, there is a hazard that it
will cause malfunctions or misoperation. Do not use water or
steam to wash the electrical system (sensors, connectors).
If inspection and maintenance is carried out when the machine
is still dirty with mud or oil, there is a hazard that you will slip and
fall, or that dirt or mud will get into your eyes. Always keep the
machine clean.
PREVENTION OF BURNS
Hot coolant
To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap by
hand before starting the operation. Even when the coolant has
cooled down, loosen the cap slowly to relieve the pressure
inside the radiator before removing the cap.
Hot oil
To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to at temperature where
it is possible to touch the cap or plug by hand before starting the
operation. Even when the oil has cooled down, loosen the
cap or plug slowly to relieve the internal pressure before
removing the cap or plug.
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SAFETY GENERAL PRECAUTIONS
FIRE PREVENTION
Fire caused by fuel or oil
Fuel, oil, and antifreeze are particularly flammable and can be
hazardous. To prevent fire, always observe the following:
Do not smoke or use any flame near fuel or oil.
Stop the engine before refueling.
Do not leave the machine while adding fuel or oil.
Tighten all fuel and oil caps securely.
Do not spill fuel on overheated surfaces or on parts of the
electrical system.
Use well-ventilated areas for adding or storing oil and fuel.
Keep oil and fuel in the determined place and do not allow
unauthorized persons to enter.
After adding fuel or oil, wipe up any spilled fuel or oil.
When carrying out grinding or welding work on the chassis,
move any flammable materials to a safe place before
starting.
When washing parts with oil, use a non-flammable oil. Diesel
oil and gasoline may catch fire, so do not use them.
Put greasy rags and other flammable materials into a safe
container to maintain safety at the work place.
Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
Fire caused by accumulation of flammable material

Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, or battery.
Fire coming from electric wiring

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

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

When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications.
If such lighting equipment is not used, there is danger of explosion that may cause serious injury.
When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.
UNAUTHORIZED MODIFICATION
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.
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GENERAL PRECAUTIONS SAFETY
PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS

Engine exhaust gas includes substances that may harm your
health or even kill. Always select a place with good ventilation
when starting the engine or operating the machine.
If it is necessary to start the engine or run the machine inside a
building or underground, where the ventilation is poor, take steps
to remove the exhaust gas and bring in ample fresh air.
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SAFETY PRECAUTIONS DURING OPERATION
PRECAUTIONS DURING OPERATION

STARTING ENGINE
If there is a warning tag hanging from the controls, do not start the
engine.
CHECK BEFORE STARTING ENGINE, ADJUST

Carry out the following checks before starting the engine at the beginning of the day's work.
Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check
for damage to the electric wiring.
Check that the gauges work properly.
PRECAUTIONS WHEN STARTING

Do not short circuit the starting motor circuit to start the engine. Short circuit can cause fire.
PRECAUTIONS IN COLD AREAS

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

When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.
Check for any abnormality in the sound of the machine, vibration, heat, smell, or gauges; check also that there
is no leakage of oil or fuel.
If any abnormality is found, carry out repairs immediately.
TRANSPORTATION
SHIPPING
When shipping the machine on a trailer, do as follows.
When passing over bridges or structures on private land, check first that the structure is strong enough to support
the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their
instructions.
For details of the shipping procedure, see "TRANSPORTATION (PAGE 3-15)" in the OPERATION section.
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PRECAUTIONS DURING OPERATION SAFETY
BATTERY
BATTERY HAZARD PREVENTION

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

area with large amount of water.
If acid gets into your eyes, flush them immediately with large
amount of water and seek medical attention.
Before working with batteries, turn the starting switch to the OFF position.
Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other
metal objects lying around near the battery.
Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last.
Tighten the battery terminals securely.
Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take
it to a well-ventilated place, and remove the battery caps before charging it.
Tighten the battery caps securely.
Install the battery securely to the determined place.
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SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR MAINTENANCE

WARNING TAG
Hang the DO NOT OPERATE warning tag to the controls. If
necessary, hang additional warning tags around the machine.
If others start the engine, or touch or operate the work
equipment controls while you are performing service or
maintenance, you could suffer serious injury.
KEEP WORK PLACE CLEAN AND TIDY

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

When repairing the machine, appoint a leader and follow his instructions during the operation.
When working with others, there is danger that misunderstandings between workers may lead to serious accidents.
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

Stop the engine.
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent injury, do not carry out maintenance with the engine
running. If maintenance must be carried out with the engine
running, carry out the operation with at least two workers and do as
follows.
One worker must always sit in the operator's seat and be ready
to stop the engine at any time. All workers must maintain contact
with the other workers.
When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts, so
be careful not to come close.
Never drop or insert tools or other objects into the fan or fan belt.
Parts may break or be sent flying.
MIND YOUR STEP WHEN CARRYING OUT MAINTENANCE

When carrying out maintenance at places which are difficult to reach, stand on a work stand that gives you a firm
foothold.
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PRECAUTIONS FOR MAINTENANCE SAFETY
PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.
LIFT ENGINE CAREFULLY

Check the lifting equipment (check that no strands of wire are broken), the method of lifting, and the crane
capacity. Pay careful attention to the surrounding area and carry out the lifting operation slowly.
Make sure that the lifting angle of the wire is less than 60°. If the lifting angle is too large, an excessive load will
be brought to bear on the lifting hook in a horizontal direction, and this may lead to breakage of the bracket.
Use a cloth for protection at points where the wire contacts the engine to prevent damage to the wire.
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
NOISE
When carrying out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers
or ear plugs while working.
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems.
PRECAUTIONS WHEN USING HAMMER

When using a hammer, pieces of metal may fly and cause serious injury. Check that there is no one in the
surrounding area before starting the operation.
REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment.
There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel
to carry out welding.
REMOVING BATTERY TERMINAL

When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the
battery to prevent the flow of current.
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SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS WITH HIGH-PRESSURE OIL

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

When the engine is running, high-pressure is generated in the engine fuel piping. When carrying out inspection or
maintenance of the fuel piping system, stop the engine and wait for at least 30 seconds to allow the internal pressure
to go down before starting the operation.
HANDLING HIGH-PRESSURE HOSES, PIPING

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

When the engine is running or immediately after it has stopped,
high voltage is generated at the injector terminal and inside the
engine controller, so there is danger of electrocution. Never touch
the injector terminal or the inside of the engine controller.
If it is necessary to touch the injector terminal or the inside of the
engine controller, please contact your Komatsu distributor.
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PRECAUTIONS FOR MAINTENANCE SAFETY
WASTE MATERIALS
To prevent pollution, pay careful attention to the method of disposing of waste materials.
Always put oil drained from your machine in containers. Never
drain oil directly onto the ground or dump into the sewage
system, rivers, the sea, or lakes.
Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
COMPRESSED AIR
When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.
When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other protective equipment.
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS

In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service
and maintenance at periodic intervals. In order to further increase safety, components with a strong relationship
to safety, such as hoses, must be replaced at periodic intervals.
Replacement of safety critical parts: See "PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS (PAGE
4-15)".
The material of these components naturally changes over time, and repeated use causes deterioration, wear, and
fatigue. As a result, there is a hazard that these components may fail and cause serious injury or death. It is
difficult to judge the remaining life of these components from external inspection or the feeling when operating,
so always replace them at the specified interval.
Replace or repair safety-critical parts if any defect is found, even when they have not reached the time specified
interval.
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3-1
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GENERAL VIEW OPERATION
GENERAL VIEW
GENERAL VIEW OF ENGINE
3-2
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OPERATION GENERAL VIEW
EXTERIOR VIEW OF FUEL FILTER UNIT
3-3
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EXPLANATION OF COMPONENTS OPERATION
EXPLANATION OF COMPONENTS
The following is an explanation of the devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand the methods of
operating equipment and meanings of the displays.
METER
The indicators on the instruments are provided as a guide when carrying out the daily inspection of the machine to
check that there has been no sudden change to an abnormal condition.
Compare with the record for the previous day and check that there are no sudden changes or abnormalities.
ENGINE WATER TEMPERATURE GAUGE

This gauge (1) indicates the temperature of the engine cooling
water.
It should indicate 60 to 95°C (140 to 203°F) during normal
operation.
If the water temperature rise alarm is actuated during operation,
remove the load, run the engine under no load, wait for the
temperature to go down, then stop the engine. If there is any
abnormality, take the necessary action. For details, see "ENGINE
(PAGE 3-20)".
TACHOMETER
This tachometer (2) shows the engine revolutions per minute.
A service meter is also assembled.
ENGINE OIL PRESSURE GAUGE

This gauge (3) indicates the engine lubricating oil presssure.
It should indicate 0.29 to 0.49 MPa (3.0 to 5.0 kgf/cm2, 42.6 to 71.0
PSI) during normal operation.
If the oil pressure drop alarm is actuated during operations, remove
the load, then stop the engine, and take the necessary action.
For details, see "ENGINE (PAGE 3-20)".
REMARK
The indicator should be in the range from 0.1 to 0.2 MPa (1.0 to 2.0
kgf/cm2, 14.2 to 28.4 PSI) at low idling (750 to 850 rpm).
3-4
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OPERATION EXPLANATION OF COMPONENTS
ENGINE OIL TEMPERATURE GAUGE

This displays the temperature of the engine lubricating oil.
During operations, it should indicate 110 °C (230 °F) or less.
ENGINE EXHAUST TEMPERATURE GAUGE

This displays the temperature of the engine exhaust gas.
3-5
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EXPLANATION OF COMPONENTS OPERATION
SWITCHES
The shape of the component and position or type of installation may differ according to the model.
STARTING SWITCH
This switch (1) is used to start the engine.
OFF position :
At this position, the starting switch key can be inserted or removed.
When the key is turned to this position, electric circuits are
switched off.
ON position :
In this position, electric current flows in the charging circuits.
Keep the starting switch key at the ON position while the engine is
running.
START position :
This is the position to start the engine. Hold the key at this position
while cranking. Release the key immediately after the engine has
been started. The key will return to the ON position when released.
HEAT position :
No heater is installed, so this position is not used. If the key is
turned to this position and is then release, it will return to the OFF
position.
ENGINE STOP BUTTON

This switch (2) is used to stop the engine.
DUST INDICATOR
This device informs the operator that the air cleaner element is
clogged.
When the element is clogged, a red piston appears in transparent
portion (1). Clean the element immediately or replace it.
After cleaning, press indicator button (2) to return the red piston to
its original position. The dust indicator is at the rear of the air
cleaner inside the engine room.
REMARK
For the electric type dust indicator, check the separate alarm lamp
to confirm that the alarm is not being displayed.
3-6
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OPERATION OPERATION
OPERATION
CHECK BEFORE STARTING ENGINE
WALK-AROUND CHECK
WARNING
Leakage of oil or fuel, or accumulation of flammable material around the battery or high temperature parts of the engine, such as
the engine muffler, may cause fire. Check carefully, and if any abnormality is found, repair it or contact your Komatsu distributor.
Be particularly sure to wipe off the dust accumulated on the top surface of the battery with a damp cloth before starting the engine.
Before starting the engine, look around and under the machine to check for loose parts or bolts, or leakage of oil,
fuel, or coolant. Check also for loose wiring, play, and accumulation of dust in places that get very hot and are
exposed to extremely high temperatures.
Always carry out the followin items before starting the engine each day.
1. Remove dirt from around engine, battery, and radiator.

Check that there is no dirt or dust accumulated around the engine, radiator or aftercooler. Check also that there is
no flammable material (dry leaves, twigs, etc.) accumulated around the battery, or engine, muffler, turbocharger, or
other high temperature parts of the engine. Remove any dirt or flammable materials that are found.
2. Check for leakage of water or oil around engine

Check that there is no oil leakage from the engine or coolant leakage from the cooling system. If any abnormality
is found, repair it.
3. Check for damage to gauges, monitor on instrument panel, loose bolts

Check for damage to the gauges and monitor. If any abnormality is found, replace the parts. Clean off any dirt on
the surface.
3-7
.
OPERATION OPERATION
CHECK BEFORE STARTING

Always check the items in this section before starting the engine each day.
CHECK COOLANT LEVEL, ADD COOLANT
WARNING
Under normal conditions, do not open radiator cap (1). When checking the coolant level, wait for the engine to cool down, and
check the reserve tank.
1. Check that the coolant is in the range between the FULL and
LOW marks on reserve tank (2) and (3) (diagram on right). If
the level is low, add water through the water filler port of tanks
(2) and (3) to the FULL level.
2. If the reserve tank is empty, check for water leakage, then
remove radiator cap (1) and check the level of the coolant. If
it is low, add water to the radiator, then add water to the reserve
tanks.
REMARK
If an excessive amount of water must be supplied, adjust the
density of the antifreeze. For details, see "WHEN REQUIRED
(PAGE 4-19)".
WARNING
If the radiator water temperature is high, do not remove the cap. Boiling
water may spurt out. Wait for the temperature to go down, then turn the cap
slowly to release the pressure before removing it.
3-8
.
OPERATION OPERATION
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
Engine parts and oil are at high temperature immediately after the engine is stopped, and will cause serious burns. Wait for the
temperature to cool down before starting the operation.
NOTICE
When adding oil, do not add oil above the H level line. This will cause the oil to spurt out.
1. Remove dipstick (G), and wipe the oil off with a cloth.
2. Completely insert dipstick (G) into the oil filler pipe, then
remove it and check the oil level.
3. Check that the oil is above the halfway mark between the H
and L marks on dipstick (G).
It is below the halfway mark between the H and L marks, add
engine oil through oil filler port (F).
4. If the oil is above the H mark, drain the excess engine oil from
the drain plug, then check the oil level again.
5. If the oil level is correct, tighten the oil filler cap securely.
REMARK
When checking the oil level, wait for at least 15 minutes after stopping the engine.
CHECK FUEL LEVEL, ADD FUEL
WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring flames
near fuel because it is highly flammable and dangerous.
CAUTION
Do not remove the strainer from the fuel tank filler when adding fuel.
Becareful not to let the water accumulated at the bottom of the fuel drum can or dust stuck ti the filling equipment get into the fuel
tank.
REMARK
If the breather hole in the cap becomes clogged, the pressure inside the tank will go down and the fuel may not flow,
therefore clean the breather hole from time to time.
1. Check the fuel level with the fuel level gauge. Always fill the fuel tank after completion of the day's operation.
2. After adding fuel, tighten the cap securely.
3-9
.
OPERATION OPERATION
CHECK FOR WATER IN WATER SEPARATOR, DRAIN WATER

(If equipped)
The water separator separates water mixed in the fuel. If float (2)
is at or above red line (1), drain the water according to the following
procedure:
1. Loosen drain plug (3) and drain the accumulated water until the
float reaches the bottom.
2. Tighten drain plug (3).
3. If air is sucked into the fuel circuit when draining the circuit,
bleed the air. For details, see "REPLACE FUEL FILTER
CARTRIDGE (PAGE 4-33)".
CHECK DUST INDICATOR

1. Check that the red piston cannot be seen in transparent portion
(1) of the dust indicator.
2. If the red piston has appeared, clean or replace the element
immediately.
For details of the method of cleaning the element, see
"CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
(PAGE 4-19)".
3. After checking, cleaning, or replacing, press the knob (2) of
dust indicator to return the red piston to its original position.
DRAIN WATER, SEDIMENT FROM FUEL TANK

Loosen the drain valve and valve, and drain the water and sediment collected at the bottom of the tank together with
the fuel.
CHECK FOR LOOSE BOLT, NUT, TIGHTEN

Check for looseness of nuts and bolts, and tighten if any loose nuts and bolts are found.
Check the following components particularly carefully.
Air cleaner
Muffler mount
Exhaust pipe
3 - 10
.
OPERATION OPERATION
CHECK ELECTRICAL WIRING
WARNING
If the fuses frequently blow or if there are traces of short circuits on the electrical wiring, locate the cause immediately and carry
out repairs, or contact your Komatsu distributor for repairs.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash
the battery cap to clean the breather hole.
Check that there is no damage to the fuses; that fuses of the specified capacity are used; that there is no
disconnection or trace of short-circuiting on the electric wiring and no damage to the covering. Check also that there
is no loosened terminals. If any, tighten them.
Moreover, pay particular attention to the electric wiring when checking the battery, engine starting motor and
alternator.
Be sure to check that there is no inflammable material accumulated around the battery. If present, remove it as soon
as possible.
3 - 11
.
OPERATION OPERATION
STARTING ENGINE
WARNING
Check that there are no persons in the surrounding area before starting the engine.
NOTICE
Do not keep the starting motor rotating continuously for more than 20 seconds.
If the engine does not start, wait for at least 2 minutes before trying to start the engine again.
1. Check that the manual stop switch is not actuated (check that
the circuit is closed).
2. Turn battery switch ON.
3. Turn the key in the starting switch to the START position and
start the engine.
4. After starting the engine, release the key in the starting switch.
The key will return automatically to the ON position.
3 - 12
.
OPERATION OPERATION
OPERATIONS, CHECKS AFTER STARTING ENGINE

After starting the engine, do not start operations immediately. Carry out the following operations and check first.
NOTICE
Do not run the engine at idling continuously for more than 20 minutes.
If it is necessary to continue to run the engine at idling, apply a load from time to time (at least 50% of the rated load).
1. Run the engine for approx. 5 minutes at idling.

2. After completing the warming-up operation, check that all the gauges and caution lamps are working properly.
If any abnormality is found, carry out maintenance and repair.
Operate the engine under light load until the engine water temperature gauge indicates 60 to 80 °C (140 to 176
°F).
3. Check for any abnormal exhaust gas color, sound, or vibration.
If any abnormality is found, repair it.
4. To check the condition of the engine, carry out the following checkitems and record the results. Compare with
the records up to the previous day, and if there is any sudden change or abnormal data, and the cause or remedy
is not known, please contact your Komatsu distributor.
Water temperature
Oil temperature
Oil pressure
EXhaust temperature
5. Run the engine ar rated speed and apply a load.
3 - 13
.
OPERATION OPERATION
STOPPING ENGINE
NOTICE
If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly
stop the engine apart from an emergency.
In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop
it.
1. Run the enigne at low idling speed for about 5 minutes to allow it to gradually cool down.
2. Operate the engine stop switch button to stop the engine.
3. Turn the key of starting switch to the OFF position.
4. Remove the key from starting switch.
With this machine, if the sensors detect any abnormality in the engine, the engine is automatically stopped.
EMERGENCY STOPPING
Keep the engine stop switch button pressed until the engine stops.
If the emergency stop button is a turn-lock type, press the switch once and it will be locked in position.
CHECK AFTER STOPPING ENGINE

1. Walk around the machine and check for leakage of oil and water. If any leakage or abnormality is found, carry
put repairs.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
MAINTENANCE OPERATION OF ENGINE FOR EMERGENCY GENERATOR

SPECIFICATION
NOTICE
Operate the engine periodically to maintain the oil film at the engine bearings and to prevent the engine from seizing up during
emergency operation.
1. Carry out the checks before starting.

2. Operate under no load for approx. 5 to 10 minutes once a week.
3. Operate under no load for approx. 15 to 30 minutes at least once a month (apply at least 50% of the rated load)
REMARK
If the engine is cranked or run continuously under no load, there will be incomplete combustion and the unburnt gas
and lubricant will accumulate in the exhaust pipe and cause problems with the engine.
Run the engine under load to remove any unburnt gas or lubricating oil.
3 - 14
.
OPERATION TRANSPORTATION
TRANSPORTATION
METHOD OF LIFTING ENGINE
WARNING
The wire rope used for the lifting opertion must be of ample strongth for
the weight of the engine.
When lifting the engine, lift the engine as an individual part. So not lift
the engine and generator as an assembly.
When lifting the engine, be careful to maintain the balance of the center
of gravity. Be careful not to subject the engine to any impact load.
Make sure that the lifting angle od the wire is less than 60°. If the lifting
angle is too large, an excessive load will be brougt to bear on the lifting
hook in a horizontal direction, and this may load to breakage od the
bracket.
Use cloth as a protection at points where the wire contacts the engine
to prevent damage to the wire.
3 - 15
.
COLD WEATHER OPERATION OPERATION
COLD WEATHER OPERATION

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

Change the fuel and oil for each component to those of lower viscosity. For the specific viscosity, see "USE OF
FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-8)".
COOLANT
WARNING
Keep antifreeze fluid away from open flames. Never smoke when using antifreeze.
NOTICE
Never use mathanol,ethanol or propanol based antifreeze.
For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM
(PAGE 4-22)".
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the
standard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If
it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for
information.
Standard requirements for permanent antifreeze
SAE J1034
FEDERAL STANDARD O-A-548D
REMARK
In areas where permanent antifreeze is not available, it is possible to use antifreeze whose main component is
ethylene glycol and does not contain any corrosion inhibitor. (Such antifreeze can be used for the winter season
only.) However, in such a case, the cooling water must be changed twice a year (spring and fall), so use permanent
antifreeze when possible.
3 - 16
.
OPERATION COLD WEATHER OPERATION
BATTERY
WARNING
The battery generates flammable gas, so do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts of water, and consult a
doctor.
When the ambient temperature goes down, the battery performance also goes down. If the charging ratio is low,
there is danger that the battery electrolyte may freeze. Always keep the charging ratio as close to 100% as possible,
and take action to maintain the temperature to prepare for starting the machine the following morning.
REMARK
Measure the specific gravity and calculate the rate of charge from the following conversion table.
Temp. of fluid 20°C 0°C -10°C -20°C

(68°F) (32°F) (14°F) (-4°F)
Rate of charge
100% 1.28 1.29 1.30 1.31
90% 1.26 1.27 1.28 1.29
80% 1.24 1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the
electrolyte from freezing.
AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as follows.
Replace the fuel and oil for all parts with oil of the viscosity specified.
For details, see "USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
(PAGE 4-8)".
If for any reason permanent antifreeze cannot be used, and an ethylene glycol base antifreeze (winter, one
season type) is used instead, or if no antifreeze is used, drain the cooling system completely, then clean out the
inside of the cooling system thoroughly, and fill with fresh coolant.
3 - 17
.
LONG-TERM STORAGE OPERATION
LONG-TERM STORAGE
BEFORE STORAGE
When putting the machine in storage for a long time, do as follows.
After every part is washed and dried, the machine shall be housed in a dry building. In case it is unavoidable to
leave it outdoors, park the machine on flat ground free from flooding or other disaster and cover it with canvas etc.
Completely fill the fuel tank and change the oil before storage.
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately.
If the ambient temperature is expected to drop below 0°C (32°F), add antifreeze to the cooling water.
If it drops below 0°C (32°F), see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-22)" for the adjustment of
concentration ratio.
DURING STORAGE
WARNING
When it is necessary to perform the rust-preventive operation while the machine is indoors, open the doors and windows to
improve ventilation and prevent gas poisoning.
During storage, operate the engine once a week to maintain the oil film at the lubricated portions. Charge the battery
once a month.
AFTER STORAGE
NOTICE
If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact your Komatsu
distributor.
If the machine is to be used when the monthly rust prevention operation has not been carried out, please contact
your Komatsu distributor.
Remave the oil filler pipe from the turbocharger oil inlet port, ass 0.5 to 1 liters (0.13 to 0.26 US gal) of oil to the
turbocharger, then install the oil filler pipe.
Change the engine oil in the engine oil pan.
Replace all the filters.
Flush the inside of the colling system.
Drain the water from the fuel tank and bleed the air from the fuel system.
After starting the engine, carry out the warming-up operation thoroughly to ensure that all parts are settled.
If one year has passed without carrying out the weekly rust prevention operation, please contact your Komatsu
distributor to have the engine overhauled.
3 - 18
.
OPERATION TROUBLESHOOTING
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
When starting after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting.
IF BATTERY IS DISCHARGED
WARNING
When checking or handling the battery, stop the engine and turn the
starting switch key to the OFF position.
Before starting the engine, wipe off the dust from the top of the battery
with a wet cloth.
The battery generates hydrogen gas, so there is a hazard of explosion.
Do not bring lighted cigarettes near the battery, or do anything that will
cause sparks.
Battery electrolyte is dilute sulphuric acid, and it will attack your clothes
and skin. If it gets on your clothes or on your skin, wash it immediately
off with large amounts of water. If it gets in your eyes, wash it out with
fresh water, and consult a doctor.
When handling batteries, always wear protective goggles and rubber
gloves.
When removing the battery, first disconnect the cable from the ground
(normally the negative (-) terminal). When installing, install the positive
(+) terminal first.
If a tool touches the positive terminal and the chassis, there is danger
that it will cause a spark, so be extremely careful.
If the terminals are loose, there is danger that the defective contact may
generate sparks that will cause an explosion.
When removing or installing the terminals, check which is the positive
(+) terminal and which is the negative (-) terminal.
Green rust around the terminals is a cause of self-discharge of the
battery. Polish the terminals with sandpaper. After removing the rust,
coat the terminals thinly with grease before installing.
3 - 19
.
TROUBLESHOOTING OPERATION
OTHER TROUBLE
ENGINE
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs.
Problem Main causes Remedy

Indicator of oil pressure gauge Defective oil pressure gauge (it is ( Replace oil pressure gauge)
does not return to left side when normal if it returns when power is
engine is stopped turned on)
Indicator of oil pressure gauge is Lack of oil in oil pan Add oil to specific
abnormally low or oil pressure drop Leakage of oil caused by Inspect, repair
alarm is actuated breakage or defective tightening
of oil pipe, pipe joint
Defective oil pressure gauge ( Replace oil pressure gauge)
Indicator of oil pressure gauge is Oil viscosity is too high Change to specified oil
abnormally high Defective oil pressure gauge ( Replace oil pressure gauge)
Water overflow from radiator or Lack of coolant, water leakage, Inspect, add cooling water,
heat exchanger loose clamp or cracks in radiator replace hose, replace clamp
or heat exchanger
Loose V-belt Adjust tension
Dirt or scale accumulated in Change coolant, flush inside of
Indicator of water temperature cooling system cooling system
gauge is abnormally high or water Defective water temperature ( Replace water temperature
temperature rise alarm is avtuated gauge gauge)
Defective thermostat ( Replace thermostat)
Defective thermostat seal ( Replace thermostat seal)
Indicator of water tempoerature Defective thermostat ( Replace thermostat)
gauge is abnormally low Insufficient warming-up or ( Carry out warmimg-up operation
defective water temperature or replace water temperature
gauge gauge)
Starting motor turns but engine Lack of fuel Add fuel
dose not start Air in fuel line Repair location of air leakage
Lack of fuel in fuel filter Fill filter with fuel
Defective fuel pump or injector ( Replace fuel pump or
nozzle nozzle)
Starting motor cracks engine too See ELECTRICAL SYSTEM
slowly
Defective electronic control See ELECTRONIC CONTROL
system SYSTEM
Heater signal does not light up See ELECTRICAL SYSTEM
(When heater is installed)
Exhaust gas is white or bluish Too mach oil in oil pan Reduce oil to specified level
Improper fuel Change to specified fuel
Oil leakage from turbochager Inspect, repair oil pipe
Exhaust gas is sometimes black Clogged air cleaner element Clean or replace air creaner
element (See "Check, clean and
replace air cleaner element")
Defective compression See "Adjust valve clearance"
above
Defective turbocharger ( Inspect, repair turbocharger)
Defective injector nozzle ( Replace nozzle)
There is hunting of engine Air entering from suction end of Repair location of air leakage
fuel line
Defective fuel pump ( Inspect, repair fuel pump)
3 - 20
.

Abnormal noise is generated Low-class fuel being used Change to specified fuel
(Combustion or machanical system) Overheating See "Indicator of water
temperature gauge is abnormally
high or water temperature rise
alarm is avtuated"
Breakage inside muffler ( Adjust valve clearance)
Excessive valve clearance ( Replace muffler)
Dirt in common rail Check, replace
Fuel leakage in common rail Check, replace
3 - 21
.
TROUBLESHOOTING OPERATION
ELECTRICAL SYSTEM
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of abnormalities or causes which are not listed below, contact your Komatsu distributor for repairs.

Ammeter does not move even Defective alternator ( Repalce alternator)
when engine is running (When Defective ammeter ( Replace ammeter)
charging alternator is installed) Defective wiring ( Inspect, repair)
Abnormal noise generatoed from Defective alternator Replace
alternator (When charging
alternator is installed)
Starting motor does not turn when Insufficient battery charge Charg battery
starting switch is turned to START Defective wiring ( Inspect, repair)
Starting motor pinion repeatedly Insufficient battery charge Charg battery
moves in and out (Makes rattling Defective wiring ( Inspect, repair)
sound)
Starting motor cranks engine slowly Insufficient battery charge Charg battery
Defective starting motor ( Replace)
Starting motor disengages before Insufficient battery charge Charg battery
engine starts Defective wiring ( Inspect, repair)
Heater signal does not become red Defective wiring, disconnection in ( Inspect, repair)
(When heater is installed) electric heater
Defective actuation of heater ( Replace)
signal, relay switch
Engine does not stop Defective operation of fuel cut ( Inspect, repair, replace)
solenoid
Defective connection of engine ( Inspect, repair, replace)
stop switch
Disconnection in wiring of engine ( Inspect, repair, replace)
stop switch
3 - 22
.
ELECTRONIC CONTROL SYSTEM

If the warning lamp of the engine electronic control system lights up, please contact your Komatsu distributor and
ask for inspection and repair.
REMARK
The warning lamp is at the top surface of the engine electronic controller.
If any failure occurs, the warning lamp displays the error code with LEDs.
When the system is normal, the display shows "00".
If any failure should occur, the letter "E" is displayed, then numerals or letters or a combination of numerals and
letters display the error code.
Note down the error code, then ask for inspection and repair.
If the warning lamp of the engine electronic control system lights up, take action according to the troubleshooting
table below.
Warning lamp Condition when

Main causes Action
display lamp lights up
Failure in component other See section on engine related parts or
00 Engine stop, etc than electronic control electrical component related parts
system
Stop signal input from Have the generator control panel
A3 Engine stop
generator control panel related parts checked
Defective connection of Have inspection carried out immediately
21 Engine stop
connector
22 Engine stop Overrun Have inspection carried out immediately
23 Engine stop Overheat See section on engine
See section on engine
24 Engine stop Drop in engine oil pressure
A1 Abnormality in power source Turn the power for all components OFF,
A2 system then turn it ON again and to try to start
Engine stop
56 the engine. Even if it starts, still have
57 the engine checked immediately
Abnormality in fuel shut-off Turn the power for all components OFF,
A0 valve system then turn it ON again and to try to start
Engine stop
16 the engine. Even if it starts, still have
the engine checked immediately
Abnormality in actuator Turn the power for all components OFF,
75
power source system then turn it ON again and to try to start
85 Engine stop
the engine. Even if it starts, still have
95
Abnormality in rotation Turn the power for all components OFF,
1B sensor system then turn it ON again and to try to start
Engine stop
1C the engine. Even if it starts, still have
Abnormality in sensor Operation is possible if only the warning
system lamp lights up, but have the system
Display other Abnormality in actuator checked immediately
Normal operation
than above system
Abnormality in adjustment
volume system
3 - 23
.
4-1
.
GUIDE TO MAINTENANCE MAINTENANCE
GUIDE TO MAINTENANCE
Do not carry out any inspection and maintenance operation that is not found in this manual.
CHECK SERVICE METER

Check the service meter reading every day to see if the time has come for any necessary maintenance maintenance
to be performed.
KOMATSU GENUINE REPLACEMENT PARTS

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

For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity
according to the ambient temperature.
ALWAYS USE CLEAN OIL AND GREASE

Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from
oil and grease.
CHECKING FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS

After changing the oil or replacing the filter, check the drained oil and filter for metal particles and foreign materials.
If large quantities of metal particles or foreign materials are found, always report to the person in charge and carry
out suitable action. In addition, when replacing the engine oil filter, fill the new filter with the specified clean oil, then
install it.
OIL CHANGE
If your machine is equipped with a fuel strainer, do not remove it while fueling.
WELDING INSTRUCTIONS
Turn off the engine ignition switch.
Do not apply more than 200 V continuously.
Connect grounding cable within 1 m (3.3 ft) of the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
If a seal or bearing happens to come between the part being welded and grounding point, change the the
grounding point to avoid such parts.
DO NOT DROP THINGS INSIDE MACHINE

When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop
nuts, bolts, or tools inside the machine.
If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine, and will
lead to failure. If you drop anything inside the machine, always remove it immediately.
Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.
4-2
.
MAINTENANCE GUIDE TO MAINTENANCE
DUSTY WORKSITES
When working at dusty worksites, do as follows:
Inspect the dust indicator frequently to see if the air cleaner is clogged.
Clean the air cleaner element at a shorter interval than specified.
Clean the radiator core frequently to avoid clogging.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting
into the oil.
AVOID MIXING OILS

If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade
of oil. Never mix different brand or grade of oil.
Unless otherwise specified, the oil used to fill the engine oil pan at the time of shipment from the factory is
SAE15W-40 (API classification CD).
LOCKING INSPECTION COVERS

Lock inspection cover securely into position with the lock bar. If inspection or maintenance is performed with
inspection cover not locked in position, there is a hazard that it may suddenly blown shut by the wind and cause
injury to the worker.
CHECK AFTER INSPECTION AND MAINTENANCE

If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may
lead to serious injury or property damage. Always do the following:
Checks after operation (with engine stopped)
Have any inspection and maintenance points been forgotten?
Have all inspection and maintenance items been carried out correctly?
Have any tools or parts been dropped inside the machine?
Is there any leakage of water or oil? Have all the bolts been tightened?
Check when the engine is running
See "TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING (PAGE 2-9)" in the section on
safety for checking when the engine is running. Pay enough attention for safety.
Check if the inspected and maintenance area is normally operated.
Increase the engine speed to check for the leak of fuel and oil.
4-3
.
OUTLINE OF SERVICE MAINTENANCE
OUTLINE OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
OIL
Oil is used in the engine under extremely severe conditions (high temperature, high pressure), and is deteriorates
with use.
Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual.
Even if the oil is not dirty, always change the oil after the specified interval.
Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of problems with machines are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified amount of oil.
Having too much oil or too little oil are both causes of problems.
If the engine oil is not clear, there is probably water or air getting into the circuit. In such cases, please contact your
Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, please contact your Komatsu distributor.
FUEL
The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
Be extremely careful not to let impurities get in when storing or adding fuel.
Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C (5
°F)). It is necessary to use the fuel that is suitable for the temperature.
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank
after completing the day's work.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from
the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
COOLANT
River water contains large amount of calcium and other impurities, so if it is used, scale will stick to the engine and
radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.
When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual.
Use coolant with at least 30% of Komatsu genuine super coolant (AF-NAC). When not using super coolant, use
a corrosion resistor (if equipped).
Antifreeze is flammable, so be extremely careful not to expose it to flame or fire.
If the engine overheats, wait for the engine to cool before adding coolant.
If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air in the
coolant.
4-4
.
MAINTENANCE OUTLINE OF SERVICE
GREASE
Grease is used to prevent twisting and noise at the joints.
The engine fan hub and tension must be greased.
The grease is to lubricate the bearing.
After greasing, wipe off all the old grease that is pushed out.
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)

KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the
oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other
abnormalities.
Periodic use of KOWA makes the following possible:
It enables abnormalities to be detected early, leading to reduction of repair costs and machine downtime.
It enables repair schedules to be planned, leading to improved machine availability.
KOWA ANALYSIS ITEMS

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

This uses a PQI (Particle Quantifier Index) machine to measure
the quantity of large iron particles in the oil.
Others
Measurements are made of items such as the ratio of water or fuel in the oil, and the dynamic viscosity.
OIL SAMPLING
Sampling interval
250 hours: Engine
500 hours: Other components
Precautions when sampling
Make sure that the oil is well mixed before sampling.
Carry out sampling regularly at fixed intervals.
Do not carry out sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu distributor.
4-5
.
OUTLINE OF SERVICE MAINTENANCE
STORING OIL AND FUEL

Keep indoors to prevent any water, dirt, or other impurities from getting in.
When keeping drum cans for a long period, put the drum on its side so that the filler port of the drums is at the side
to prevent moisture from being sucked in.
If drums have to be stored outside, cover them with a waterproof sheet or take other measures to protect them.
To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use the
oldest oil or fuel first).
FILTER
Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
When replacing oil filters, check if any metal particles are affixed to the old filter. If any metal particles are found,
contact your Komatsu distributor.
Do not open packs of spare filters until just before they are to be used.
Always use Komatsu genuine filters.
OUTLINE OF ELECTRIC SYSTEM

It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This
will cause electrical leakage and may lead to malfunction of the machine. Do not let water get on electrical
components. When washing the machine or during rain, do not let water get into the electrical components.
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and
checking battery fluid level.
Never remove or disassemble any equipment (electrical equipment) installed to the machine.
Never install any electric components other than those specified by Komatsu.
When working at the seashore, carefully clean the electric system to prevent corrosion.
4-6
.
MAINTENANCE WEAR PARTS
WEAR PARTS
Wear parts such as the filter element etc. are to be replaced at the time of periodic maintenance or before their
abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
When changing parts,use Komatsu genuine parts of excellent quality.
When ordering parts, please check the part number in the parts book.
WEAR PARTS LIST

Item Part No. Part Name Q'ty Replacement frequency
Engine oil filter 600-211-1231 Cartridge 2 EVERY 500 HOURS
Fuel filter 600-311-3310 Cartridge 4 EVERY 500 HOURS
Corrosion resistor (if equipped) 600-411-1171 Cartridge 1 EVERY 1000 HOURS
561-02-62530 Element 1
Air cleaner -
561-02-62520 assembly 1
Electrical air-intake heater (if equipped) 6240-11-4820 Gasket 6 -
4-7
.
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO

AMBIENT TEMPERATURE
FUEL, OIL, COOLANT
* Use only diesel fuel.
NOTICE
Use only diesel fuel.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain good fuel
consumption and good exhaust gas characteristics. For this reason, it requires high precision for the parts and good lubrication.
If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability.
Engine oil pan

Specified capacity Liters (US gal) 196 (51.78)
Refill capacity Liters (US gal) 196 (51.78)
4-8
.
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
When starting the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine oil
of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C (50°
F) more or less during the day.
Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add
single grade oil that matches the temperature range in the table.
We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and
hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
Change interval of oil in

Fuel sulphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
4-9
.
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT(Winter, one
EO15-40CD season type)
Diesel sigma S
super dieselmulti-
2 AGIP Rotra MP GR MU/EP -
grade
*Sigma turbo
Multi-purpose gear PYKON premium
3 AMOCO *Amoco 300 -
oil grease
Litholine HEP 2
4 ARCO *Arcofleet S3 pius Arco HD gear oil -
Arco EP moly D
Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP
*RPM delo 400 Universal thuban Marfak all purpose 2
6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -
Universal gear
9 CONOCO *Fleet motor oil Super-sta grease -
lubricant
Multiperformance 3C Tranself EP
10 ELF - Glacelf
Performance 3C Tranself EP type 2
Essolube D3
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
Delvac 1300 Mobilux EP2
Mobilube GX
13 MOBIL *Delvac super Mobilgease 77 -
Mobilube HD
10W-30, 15W-40 Mobilgrease special
4 - 10
.
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
Multi-purpose white
*Superme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease
PETROFIN FINA potonic N
15 FINA kappa TD FINA marson EPL2 FINA tamidor
E FINA potonic NE
Spirax EP
16 SHELL Rimura X Albania EP grease -
Spirax heavy duty
Sunoco ultra prestige Sunoco antifreeze
Sunoco GL5
17 SUN - 2EP and summer
gear oil
Sun prestige 742 coolant
*Ursa super plus Multifak EP2 Coda 2055 startex
18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze
*Rubia X
TM
20 UNION *Guardol MP gear lube LS Unoba EP -
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B - Antifreeze
MDC Multigear C
4 - 11
.
HANDLING WHEN USING A GRADE HEAVY OIL AS FUEL

(Only engine with A heavy oil specification)
This gives the minimum precautions that must be followed when using A heavy oil as the fuel for the diesel engine
for the generator.
USE OF A GRADE HEAVY OIL

When A heavy oil is used to as the fuel, it must fulfill the following conditions. In particular, the water content or
residual carbon content accelerates the wear of sliding parts and causes early clogging of the filters. Note also that
the cetane index also has an effect on the ease of starting in cold weather and the stability of rotation.
Dynamic 10% residual oil, Cetane value

Specific gravity Ignition point Sulphur content*1
viscosity residual carbon (cetane index*2)
15/4°C °C (°F) 50°C (122°F), cSt % % -
0.82 - 0.86 Min. 60 (Min. 140) 2.0 - 3.5 Max. 1.0 Normal: Max. 0.8 Min. 45
*1: See "PRECAUTIONS THAT MUST BE OBSERVED WHEN USING A GRADE HEAVY OIL (PAGE 4-12)".
For normal use, we recommend fuel with a sulphur content of less than 0.5%.
*2: According to JIS K 2280-1996.
The cetane value and the cetane index vary slightly, but they can be considered the same.
PRECAUTIONS THAT MUST BE OBSERVED WHEN USING A GRADE HEAVY OIL

Storing A heavy oil
The water, dirt, and residue in the A heavy oil will sink to the bottom of the tank, so when taking it from an oil
drum or storage tank, use the oil at the top as far as possible.
Drain the water, dirt, and sediment from the fuel tank periodically.
Always keep the fuel tank close to full. This will reduce the condensation forming on the inside wall of the tank
because of the difference between the outside temperature and the temperature inside the tank, and this will
reduce the amount of water mixing with the fuel.
Engine maintenance
As a basic rule, clean the strainer and gauze filter (installed inside the joint bolt at the injection pump fuel inlet
port) every 250 hours.
The cleaning interval varies greatly according to the properties of the fuel and the way the fuel is managed, but
if the engine stops or the output drops because of lack of fuel, carry out cleaning regardless of the cleaning
interval.
A heavy oil contains a large amounts of so far and residual carbon, and it causes deterioration of the engine
oil and clogging of the filter, so change the engine oil and replace the filters at the replacement interval given
below.
4 - 12
.
REPLACEMENT INTERVAL FOR ENGINE OIL AND FILTER

Engine for stationary generator
If the sulphur content of the fuel exceeds 0.5%, always carry out analysis of the oil to be used (new oil) and
determine the oil change interval according to the diagram below.
Check the total base number (TBN) of the fresh oil and is a sulphur content in the fuel beforehand, and determine
the oil change interval according to the diagram above.
In particular, CE and CF-4 class oil has a low total base number (TBN), so it may be impossible to use it together
with fuel that has a high sulphur content. Be careful of this point. (The total base number is a characteristic value
that expresses the amount of the components that have an effect on neutralizing the acid generated by combustion
and a cleaning and dispersion effect.)
4 - 13
.
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS MAINTENANCE
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

TORQUE LIST
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
Tightening torque
Item Thread size x pitch Remarks
N·m kgf·m lbft
M6 x 1 11.8 - 14.7 1.2 - 1.5 8.7 - 10.8
M8 x 1.25 27 - 34 2.8 - 3.5 20.3 - 25.3
M10 x 1.5 59 - 74 6.0 - 7.5 43.4 - 54.2
M12 x 1.75 98 - 123 10.0 - 12.5 7T bolt with seat is 70%
72.3 - 86.8
Hexagonal bolt (10.9T)
of value on left
Nut M14 x 2 157 - 196 16.0 - 20.0 115.7 - 144.7 (Applicable to M6 - M12)
M16 x 2 245 - 309 25.0 - 31.5 180.8 - 227.8
M18 x 2.5 343 - 427 35.0 - 43.5 253.2 - 314.6
M20 x 2.5 490 - 608 50.0 - 62.0 361.7 - 448.4
1/8 2.9 - 5.9 0.3 - 0.6 2.2 - 4.3
PT plug
(Plug: SS material) 1/4 4.9 - 9.8 0.5 - 1.0 3.6 - 7.2
(Female thead quality: 3/8 13.7 - 21.6 1.4 - 2.2 10.1 - 15.9
casting)
1/2 26.5 - 43.1 2.7 - 4.4 19.5 - 31.8
M8 7.8 - 9.8 0.8 - 1.0 5.8 - 7.2
M10 9.8 - 12.7 1.0 - 1.3 7.2 - 9.4
Piping connection bolt M12 19.6 - 29.4 2.0 - 3.0 14.5 - 21.7
M14 24.5 - 34.3 2.5 - 3.5 18.1 - 25.3
M16 34.3 - 44.1 3.5 - 4.5 25.3 - 32.5
NOTICE
When tightening panels or other parts having tightening fixtures made of plastic, do not use excessive tightening torque. Doing
so will damage the plastic parts.
Be extremely vareful when tightening such parts.
4 - 14
.
MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out
periodic maintenance. In addition, to further improve safety, please contact your Komatsu distributor for periodic
replacement of parts related to safety and fire prevention in the SAFETY CRITICAL PARTS list.
Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However,
it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is required
to replace them with new ones regardless of their condition after a certain period of usage. This is important to
ensure that these parts maintain their full performance at all times.
Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the periodic
replacement time for the part has not yet arrived.
If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as
the hoses.
Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose
clamps and replace defective hoses, as required.
When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.
SAFETY CRITICAL PARTS

No. Safety critical parts for periodic replacement Replacement interval
1 Fuel hose (fuel tank - fuel pump)
2 Fuel hose (engine - fuel cooler)
3 Fuel hose (fuel cooler - fuel tank) Every 2 years or 8000
hours, whichever comes
4 Engine breather hose sooner
5 Engine cooling water hose
6 Boost piping hose
4 - 15
.
MAINTENANCE SCHEDULE CHART MAINTENANCE
MAINTENANCE SCHEDULE CHART

MAINTENANCE SCHEDULE CHART
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
LUBRICATE FAN HUB, FAN TENSION PULLEY 4- 36
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 32
REPLACE FUEL FILTER CARTRIDGE 4- 33
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 4- 19
CLEAN INSIDE OF COOLING SYSTEM 4- 22
CHECK ELECTRIC HEATER (IF EQUIPPED) 4- 24
CLEAN, INSPECT RADIATOR WITH AIR-COOLED FUEL COOLER, AIR-COOLED AFTERCOOLER 4- 25
EVERY 500 HOURS SERVICE

CHECK LEVEL OF BATTERY ELECTROLYTE 4- 30
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 32
REPLACE FUEL FILTER CARTRIDGE 4- 33

REPLACE CORROSION RESISTOR CARTRIDGE (IF EQUIPPED) 4- 35
CHECK FOR LOOSE ELECTRONIC GOVERNMENT, CONTROLLER MOUNTING BOLTS 4- 35

CLEAN ENGINE BREATHER ELEMENT 4- 36
LUBRICATION 4- 36
CHECK FAN BELT TENSION, ADJUST 4- 37
CHECK ALTERNATOR, STARTING MOTOR 4- 37
CHECK PLAY OF TURBOCHARGER ROTOR 4- 37
CHECK HOSES 4- 37
CHECK, ADJUST INJECTOR 4- 37
CHECK MOUNTING BOLTS 4- 37
CHRCK ENGINE VALVE CLEARANCE, ADJUST 4- 37

CHECK WATER PUMP 4- 38
CHECK VIBRATION DAMPER 4- 38
CHECK FOR CRACKS 4- 38
REPLACE FAN BELT 4- 38
4 - 16
.
MAINTENANCE MAINTENANCE SCHEDULE CHART

CHECK EXHAUST MUFFLER, EXHAUST MANIFOLD, EXHAUST FLEXIBLE PIPE, INTAKE
MANIFOLD 4- 39
CHECK BATTERY SWITCH, STARTING MOTOR, EMERGENCY RELAY 4- 39
CHECK COOLANT HEATER 4- 39
CHECK, MAINTAIN INTAKE VALVE SEAT, EXHAUST VALVE SEAT 4- 39
CLEAN, CHECK TURBOCHARGER 4- 39
REPLACEMENT OF PARTS 4- 39

COMPLETE OVERHAUL OF ENGINE 4- 40

REPLACEMENT OF FUEL PUMP 4- 41
4 - 17
.
SERVICE PROCEDURE MAINTENANCE
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
Carry out the fillowing maintenance only after the first 250 hours.
Lubricate fan hub, fun tension pulley
Change oil in engine oil pan, replace engine oil filter cartridge
Replace fuel filter cartridge
For details of the method of replacing or maintaining, see the section on EVERY 500 HOURS and 2000 HOURS
SERVICE.
4 - 18
.
MAINTENANCE SERVICE PROCEDURE
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
WARNING
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it.
Always stop the engine before carrying out these operations.
When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Always use safety glasses, dust mask, and other protective equipment.
CHECKING
NOTICE
Do not clean the air cleaner element before the dust indicator becomes red.
If the element is cleaned frequently before the dust indicator becomes red, the performance of the air cleaner is not used perfectly
and the cleaning effect is lowered. In addition, dust sticking to the element falls into the inner element each time the element is
cleaned.
Whenever the red piston in dust indicator (1) appears, clean the air
cleaner element.
CLEANING OR REPLACING OUTER ELEMENT

1. Loosen wing bolt (2), remove dust cup (3), then remove wing
nut (4) and take out the element.
2. Clean the air cleaner body interior and dust cup.
4 - 19
.
3. Direct dry compressed air (less than 0.69MPa (7kgf/cm2,

99.4PSI)) to the outer element(4) from inside along its folds,
then direct it from outside along its folds and again from inside.
1) Remove one seal from the element whenever the element
has been cleaned.
2) Replace the outer element if it has been cleaned 6 times
repeatedly or used throughout a year. Replace the inner
element at the same time.
3) Replace both inner and outer elements when the dust
indicator red piston appears soon after installing the
cleaned outer element even though it has not been
cleaned 6 times.
4) Check inner element mounting nuts for looseness and, if
necessary, retighten.
5) If seal washer (5) is damaged or the threads of wing nut (4)
are damaged, replace them.
6) Remove vacuator valve (6) and clean it with compressed
air.
Then, install it again.
NOTICE
If small holes or thinner parts are found on the element when it is checked
with an electric bulb after cleaning and drying, replace the element.
Do not use an element whose folds or gasket or seal are damaged.
When cleaning the element, do not hit it or beat it against something.
4. Install the cleaned element, then install dust cup.
5. Press the button of dust indicator (1) to return the red piston to
its original position.
4 - 20
.
REPLACING INNER ELEMENT

1. First remove the dust cup and the outer element, and then remove the inner element.
2. To prevent dust from getting in, use a clean cloth or tape to cover the air connector (outlet side).
3. Clean the air cleaner body inside, then remove the cover installed in Step 2.
4. Fit a new inner element to the connector and tighten it with nuts.
NOTICE
The inner element must not be used again even after its cleaning. When replacing the outer element, replace the outer element at
the same time.
5. Install the outer element and dust cup.
4 - 21
.
CLEAN INSIDE OF COOLING SYSTEM
WARNING
Immediately after the engine is stopped, the engine coolant is hot and the pressure inside the radiator is high. Removing the
cap and draining the water under this condition could cause burns. Allow the engine to cool down, then turn the cap slowly
to release the pressure.
For details of starting the engine, see "STARTING ENGINE (PAGE 3-12)" in the OPERATION section of the Operation and
Maintenance Manual.
Clean the inside of the cooling system, change the coolant and replace the corrosion resistor (if equipped) according
to the table below.
Cleaning inside of cooling system

Kind of coolant Replacing corrosion resistor
and changing coolant
Every year (autumn) or
Permanent type antifreeze
every 2000 hours,
(All season type)
whichever comes first
Every 1000 hours and when
Non permanent type antifreeze Every 6 months (spring, autume)
cleaning the inside of the
containing ethylene glycol (Drain antifreeze in spring,
cooling system and
(winter, one season type) add antifreeze in autumn)
when changing coolant
Every 6 months or
When no using antifreeze every 1000 hours,
whichever come first
Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol.
Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect.
The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect,
a minimum ratio of 30% by volume is necessary.
When mixing Super Coolant (AF-ACL) at a ratio of more than 30%, there is no need to use a corrosion resistor (if
equipped). If the engine is already equipped with a corrosion resistor, close the valve of the corrosion resistor (if
equipped).
When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing
rate table given below.
It is actually better to estimate a temperature about 10°C (18°F) lower when deciding the mixing rate.
Mixing rate of water and antifreeze
Min atomspheric °C above -10 -15 -20 -25 -30

temperature °F above 14 5 -4 -13 -22
Proportion of anti-freeze % 30 36 41 46 50
Amount of anti-freeze = Total amount of coolant x proportion of anti-freeze
4 - 22
.
WARNING
Antifreeze is flammable, so keep it away from flame.
Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on you. If it gets in your eyes,
flush your eyes with large amount of fresh water and see a doctor at once.
Use city water for the cooling water.

If river water, well water or other such water supply must be used, contact your Komatsu distributor.
We recommend use of an antifreeze density gauge to control the mixing proportions.
NOTICE
When changing the coolant, if a coolant heater is used to maintain the temperature, always switch off the heater power before
draining the coolant.
If electricity runs through the heater when is no coolant, the heater will burn out.
1. Stop the engine and tighten valve (1) of the corrosion resistor
(if equipped).
2. Turn water filler cap (2) slowly and remove it.
4 - 23
.
3. Prepare a container to catch the coolant, then open drain plug

(3) of the radiator or heat exchanger and drain plug (4) of
engine, and drain the coolant.
4. After draining the coolant, close drain plugs (3) and (4), and fill
with tap water.
5. When the water level is near the mouth of water filler, open
drain plugs (3) and (4), start the engine, and run at low idling.
Keep the engine running at low idling for 10 minutes until the
water temperature reaches more than 90°C (194°F).
6. Stop the engine, open drain plugs (3) and (4) drain the water.
After draining the water, close it.
7. After draining the water, clean the cooling system with cleaning
agent.
For the cleaning method, see the instructions for the cleaning
agent.
8. After flushing, open drain plugs (3) and (4), and drain all the
water.
9. Close drain plugs (3) and (4).
10. If the engine is equipped with an optional corrosion resistor,
replace the corrosion resistor cartridge, then open the valve
(1).
For the replacing procedure of the corrosion resistor, see "REPLACE CORROSION RESISTOR CARTRIDGE
(PAGE 4-35)".
11. Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze.
12. To remove the air contained in the coolant, run the engine at low idle for 5 minutes, then run for a another 5
minutes at high idle. (When doing this, leave the water filler cap OFF.)
13. Stop the engine. About 3 minutes later, supply city water up to the water filler, then close radiator cap.
CHECK ELECTRIC HEATER

(If equipped)
Before starting in cold weather (once a year), please contact your
Komatsu distributor for inspection. Remove electric heater (1) from
the engine intake manifold and check for disconnections or dirt.
When checking or installing the electric heater, replace the gasket
with a new part.
4 - 24
.
CLEAN, INSPECT RADIATOR WITH AIR-COOLED FUEL COOLER, AIR-COOLED AFTERCOOLER

An air-cooled aftercooler and air-cooled fuel cooler are installed inside the shroud to the radiator assembly on this
engine. Normally, the dirt clogs the upstream side of each cooler, so it is enough to clean the two coolers, but if there
is no improvement when both coolers are cleaned, clean the radiator. If the front face of the air-cooled aftercooler
at the rear of the air-cooled fuel cooler is extremely dirty (the dirt clogs the upstream side of the air-cool aftercooler,
so check visually), remove the air-cooled fuel cooler, then clean the air-cooled aftercooler.
REMARK
When removing the hoses of the air piping or fuel piping, block the hoses and piping after removing to prevent any
dirt or dust entering the piping.
WARNING
There is danger of personal injury if compressed air, steam, or water hits your body directly.
Always wear protective glassws, mask, and safety shoes.
Check for damaged or clogged radiator fins and clean them.

(We recommend that you clean the fins before the summer season (once a year).)
Metal brush (brass, brush length: 15 to 20 mm (0.6 to 0.8 in), soft brush)
Air compressor
Washing gun (nozzle)
Washing liquid (approx. 4 liters (1.06 US gal)/machine)
Thin vinyl sheet (to cover radiator when blowing with air)
Newspaper or absorbent paper (to prevent inside of package from becoming dirty)
Plastic can
Brush for washing automobile (used to apply liquid when washing front surface of radiator)
Cloth belt for lifting fan
1. Removal of side plate of radiator shroud

Remove the 3 side plates of the shroud.
4 - 25
.
2. Clean the air-cooled fuel cooler.

1) Fit a vinyl sheet between air-cooled fuel cooler (1) and
air-cooled aftercooler (2) to separate the coolers and
prevent dirt from sticking to the rear of air-cooled
aftercooler (2).
2) Put cleaning fluid on a brush, then brush the upstream side
(A face) of the air-cooled fuel cooler to dissolve and
remove the dirt.
3) Spread newspaper or absorbent paper to absorb the dirt
washed out on the floor around the radiator and under
bottom (3) inside the shroud.
4) Use a spray gun from the upstream side (A face) of the
air-cooled fuel cooler to wash out the dirt. When doing this,
keep the spray gun away from the core and spray the
cooler directly to prevent damage to the fins of air-cooled
fuel cooler (1). When spraying, cover all the core with
cardboard to prevent damage to the fins of air-cooled
aftercooler (2).
5) Remove the vinyl sheet after completing the cleaning
operation.
3. Removal of air-cooled fuel cooler
1) Removal hose (6) between the engine and air-cooled fuel
cooler (1) and the hose at the outlet port of air-cooled fuel
cooler (1). When removing the hoses, secure the inlet and
outlet port mouthpieces of air-cooled fuel cooler (1), and
loosen joint bolt (7). If joint bolt (7) is loosened without
securing air-cooled fuel cooler (1), air-cooled fuel cooler (1)
may be broken. In addition, when hose (6) is removed, fuel
may spill out from hose (6) and air-cooled fuel cooler (1), so
prepare a container to catch the fuel and be careful not to
spill the fuel in the surrounding area.
2) Remove lock bolts (8) and (9), and remove air-cooled fuel
cooler (1) (including the bracket). When removing the
air-cooled fuel cooler, always carry out the operation with
at least 2 people on the left and right to lift it up.
3) After removing air-cooled fuel cooler (1) stand it at the fan
the end at the bottom of the shroud or remove it from the
side to the outside of the shroud. When standing
air-cooled fuel cooler (1), fit shock-absorbing material (soft
cloth or cardboard can be used) to protect the core from
damage, and replace it in position carefully.
Weight of air-cooled fuel cooler (1) including bracket:
Approx. 30 kg (66 lb)
4 - 26
.
4. Clean air-cooled aftercooler
CAUTION
When tilting the air-cooled aftercooler, it may tilt under its own weight. Be careful not to get your fingers caught.
If the air-cooled aftercooler is tilted by force, there is danger that it might fall off.
1) Remove air-cooled aftercooler lock bolts (4) (4 each on left

and right: total 8).
2) Slide air-cooled aftercooler (2) towards the engine.
Distance of movement: approx. 143 mm (5.6 in)
3) Fit a vinyl sheet between air-cooled aftercooler (2) and
radiator (5) to separate the cooler and radiator, and prevent
dirt from sticking to radiator (5).
washed out on the floor around the radiator (5) and under
5) Put cleaning fluid on a brush, then brush the upstream side
(A face) of the air-cooled aftercooler to dissolve and
remove the dirt.
6) Use a spray gun from the upstream side (A face) of the
air-cooled aftercooler to wash out the dirt. When doing
this, keep the spray gun away from the core and spray the
cooler directly to prevent damage to the fins of radiator (5).
7) Remove the vinyl sheet after completing the cleaning
operation.
5. Clean radiator
1) Carry out Steps 3. 1), 2) to tilt air-cooled aftercooler (2).
washed out on the floor around the radiator (5) and under
3) Use a metal brush and brush in the left-to-right direction to
remove the dirt stuck to the radiator fins.
4) Fit a vinyl sheet between air-cooled aftercooler (2) and
radiator (5).
5) Use a spray gun from the front face (B face) of radiator (5)
to blow out the dirt. When spraying, keep the spray gun
away from the core to prevent damage to the fins caused
by the air pressure.
6) Put cleaning fluid on a brush, then brush the front face of
the radiator core to remove the oil and grease.
7) Use a spray gun from the front face (B face) of radiator (5)
to spray out the cleaning fluid and wash the inside of the
fins.
8) Use a spray gun to spray out water and carry out cleaning.
9) After completing the cleaning operation, shine a flashlight
on the fins and check visually that the fins are not clogged.
4 - 27
.
6. Installation
1) If air-cooled aftercooler (2) has been tilted, push in the tank
portion of air-cooled aftercooler (2) in the direction of
radiator (5), then secure it to radiator (5) with lock bolt (4).
2) If air-cooled fuel cooler (1) has been removed, install it.
Always carry out the operation with at least two workers.
3) If the air piping hoses have been removed, connect the
hoses and tighten them with the clamps. When doing this,
install the clamps so that they are in alternating positions.
4) If the air piping hoses have been removed, connect the
hoses. When tightening the joint bolt, there is danger that
air-cooled fuel cooler (1) may be damaged, so secure the
mouthpiece portion of air-cooled fuel cooler (1).
Tightening torque for joint bolt: 49.0 to 63.7 N·m (5.0 to 6.5
kgf·m)
5) Install the side plate of the shroud.
4 - 28
.

For the following items, see "CHECK BEFORE STARTING (PAGE 3-8)".
Check coolant level, add coolant
Check oil level in engine oil pan, add oil
Check fuel level, add fuel
Check for water in water separator, drain water (if equipped)
Check dust indicator
Drain water, sediment from fuel tank
Check for loose bolt, nut, tighten
Check electrical wiring
4 - 29
.
CHECK LEVEL OF BATTERY ELECTROLYTE

Carry out this check before operating the machine.
WARNING
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the
inside of the battery and reduce the service life of the battery. In addition, it may also cause an explosion.
The battery generates flammable gas and there is danger of explosion, so do not bring fire or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the
electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts.
NOTICE
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from
freezing.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY

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

U.L. and L.L. lines, remove cap (1) and add distilled water to
the U.L. line.
3. After adding distilled water, tighten cap (1) securely.
REMARK
If distilled water is added to above the U.L. line, use a syringe to
lower the level to the U.L. line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), then flush it away with a large
amount of water or consult your Komatsu distributor or battery
maker.
4 - 30
.
WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY

If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER
LEVEL line on the side of the battery, check as follows.
1. Remove cap (1) at the top of the battery, look through the water
filler port, and check the electrolyte surface. If the electrolyte
does not reach the sleeve, add distilled water so that the level
reaches the bottom of the sleeve (UPPER LEVEL line) without
fail.
Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.
2. After adding distilled water, tighten cap (1) securely.
REMARK
If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the
sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount
of water or consult your Komatsu distributor or battery maker.
WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL

If it is possible to use and indicator to check the electrolyte level, follow the instructions given.
4 - 31
.
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
WARNING
The parts and oil is at high temperature after the engine has been operated, and it can result in a burn. Wait for the oil to cool down
before changing it.
Filter wrench
1. Set a container directly under drain plug (P) of the oil pan.
2. Remove drain plug (P) slowly to avoid getting oil on yourself,
and drain the oil.
3. Check the drained oil, and if there are excessive metal
particles or foreign material, please contact your Komatsu
distributor.
4. Install drain plug (P).
5. Using a filter wrench, turn filter cartridge (1) counterclockwise
to remove it.
A large amount of oil will come out if this procedure is carried
out immediately after stopping the engine, so wait for 10
minutes before starting the maintenance.
6. Clean the filter holder, fill the new filter cartridge with engine oil, coat the packing face and thread with engine
oil (or coat thinly with grease), then install the filter cartridge.
REMARK
Check that there is no old packing affixed to the filter holder. If there is any old packing affixed to the filter, it will cause
leakage of oil.
7. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it a
further 3/4 to 1 turn.
8. After replacing the filter cartridge, add engine oil through oil
filler port (F) so that the oil level is between the H and L marks
on dipstick (G).
NOTICE
Never start the engine before filling with oil. This will cause seizure of the
engine.
9. Run the engine at low idling for some time and stop it. Then,
referring to the section of "CHECK OIL LEVEL IN ENGINE OIL
PAN, ADD OIL (PAGE 3-9)", check that the engine oil amount
is at the H-L level in the engine oil level gauge.
Change the oil and replace the cartridge once every 6 months, even if the engine has not been operated for 500
hours.
In the same way, change the oil and replace the cartridge once every 500 hours, even if the engine has not been
operated for 6 months.
4 - 32
.
REPLACE FUEL FILTER CARTRIDGE
WARNING
Immediately after the engine is stopped, all parts are at high temperature, so do not replace the filter immediately.
Wait for the engine to cool down before starting the operation.
The inside of fuel piping system of the engine is under high-pressure when the engine is running. When replacing the filter,
wait for at least 30 seconds after the engine stops to let the internal pressure go down before replacing the filter.
Do not bring any fire or spark close.
This engine consists of higher precision parts than on the conventional fuel injection pump and nozzle, so if dirt gets in, it will
cause problems. If there is any dirt stuck to the fuel line, use fuel to wash it off completely.
Always use a Komatsu genuine part for the fuel filter cartridge. If filters other than genuine filters are used, problems may occur
in the injection system, so never use substitute parts.
Container to catch the oil

Filter wrench
DIESEL SPECIFICATION
1. Center a container to catch the fuel under the filter cartridge.
to remove it.
3. Clean the filter holder, fill the new filter cartridge with fuel, coat
the packing surface with the engine oil, and install to the filter
holder.
4. When installing, tighten until the packing surface contacts the
seal surface of the filter holder, then tighten a further 3/4 of a
turn.
If the filter cartridge is tightened too far, the packing will be
damaged and this will lead to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing, so
always tighten to the correct amount.
5. After replacing the filter cartridge, bleed the air as follows.
A GRADE HEAVY OIL AND POOR FUEL SPECIFICATION

When replacing fuel filter cartridge (1), follow the instructions for
the diesel specification.
Fuel filter cartridge (1) is built into the fuel filter unit.
It is not necessary to bleed the air after replacing fuel filter cartridge
(1).
4 - 33
.
PROCEDURE FOR AUTOMATIC AIR BLEEDING

1. Check that there is fuel in the fuel tank.
2. If the valves are installed to the fuel outlet port of the fuel tank
and the return piping, open the valves.
3. Check that the fuel filter is filled with fuel.
4. Remove quick coupler (2) at the fuel pump outlet port, then add
30 cc (1 oz) of clean fuel.
REMARK
Do not supply fuel from the coupler at the fuel pump inlet port
end.
Do not use force when supplying fuel. The fuel seal may break.
5. Install quick coupler (2).

6. Turn the key in the starting switch to the ON position and start the engine.
REMARK
A longer period of cranking than normal may be necessary to bleed the air.
After the engine is started, there is still air remaining in the fuel system, so for a short time, the engine rotation
may be unstable, but this does not indicate any abnormality. Continue running the engine at low idling until the
engine rotating speed becomes stable.
4 - 34
.

Carry out the maintenance for EVERY 500 HOURS SERVICE at the same time.
REPLACE CORROSION RESISTOR CARTRIDGE

(If equipped)
WARNING
All the engine parts are at high temperature after the engine has been operated, so never replace the cartridge immediately after
finishing operations.
Wait for the oil to cool down before replacing the cartridge.
Filter wrench
1. Close valve (2) at the top of the corrosion resistor.

to remove it.
3. Clean the filter holder, coat the seal surface of the new
cartridge thinly with engine oil, then install the cartridge.
4. When installing, screw in cartridge until seal comes in contact
with sealing surface, then tighten approx. 2/3 turn.
5. After replacement, open the valve (2).
CHECK FOR LOOSE ELECTRONIC GOVERNMENT, CONTROLLER MOUNTING BOLTS

Check for loose electrical wiring and controller mounting bolts. Tighten if any loose bolts or wires are found.
4 - 35
.

Carry out the maintenance for EVERY 500 HOURS, and EVERY 1000 HOURS SERVICE at the same time.
CLEAN ENGINE BREATHER ELEMENT

1. Loosen the clamp, remove the hose, then remove breather (1).
2. Rinse the whole breather in diesel oil or flushing oil. Dry with
compressed air, then install it.
3. Inspect the hose, and if there is any deteriorated oil (sludge)
stuck inside the hose, replace it with a new part.
Wipe off the dirt around the breather before removing it.
Check the O-ring, and replace it with a new part if necessary.
Coat with engine oil when installing.
LUBRICATION
1. Using a grease pump, pump in grease through the grease fittings shown by arrows.
2. After greasing, wipe off any old grease that was pushed out.
Lubricate fan hub (1 place)
Lubricate fan tension pulley (2 places)
4 - 36
.
CHECK FAN BELT TENSION, ADJUST
CHECKING
The belt shouled deflect by approx. 3 mm (0.118 in) when pressed
with the finger [with a force of approx. 58.8 N (6kgf)] at a point
midway between the fan pulley and crank pulley.
ADJUSTING
1. Loosen tension pulley lock bolt (1) and adjustment bolt locknut
(2).
2. Tighten adjustment bolt (3) to move the tension pulley and
adjust so that the deflection of the belt is approx. 3 mm (0.1 in)
at a finger force of approx. 58.8 N (6 kgf).
3. Tighten bolts and nuts (1) and (2) to hold the tension pulley in
position.
4. Check each pulley for damage, wear of the V-groove, and wear
of the V-belt. In particular, be sure to check that the V-belt is not
touching the bottom of the V-groove.
If any abnormality is found, please ask your Komatsu distributor to replace the pulley.
5. If the V-belt is so lengthened that it cannot be adjusted any more or if it has any cuts or cracks, replace it.
6. After replacing the V-belt, operate for one hour, then adjust again.
CHECK ALTERNATOR, STARTING MOTOR

The brushes mat be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspection
and repairs.
If the engine is started frequently, have this inspection carried out every 1000 hours.
CHECK PLAY OF TURBOCHARGER ROTOR

Contact your Komatsu distributor to have the rotor play checked.
CHECK HOSES
Check the fuel hoses, oil hoses, radiator hoses and all other hoses. If any clacks, wear, or damage are found,
replace the hose.
CHECK, ADJUST INJECTOR

As special tool is required for checking and adjusting the parts, request Komatsu distributor for service.
CHECK MOUNTING BOLTS

Check for any loodeness in the mounting bolts of the intake and exhaust manifolds and the turbocharger.
Tighten any loose bolts.
CHRCK ENGINE VALVE CLEARANCE, ADJUST

Special tools are needed for inspection and maintenance, please contact your Komatsu distributor.
4 - 37
.

Carry out the maintanance for EVERY 500 HOURS, EVERY 1000 HOURS, and EVERY 2000 HOURS SERVICE
at the same time.
CHECK WATER PUMP

Check for olay in the pulley, leakage of oil or water, and cloging of
drain hole (2). If any abnormality is found, contact your Komatsu
distributor for disassembly and repair or replacement.
CHECK VIBRATION DAMPER

Check that there is no reduction in the amount of fluid in damper
(1), or any dents or face runout. If any abnormality is found, please
contact your Komatsu distributor for replacement.
CHECK FOR CRACKS

Check the following parts for cracks or breakage. If any abnormality is found, please contact your Komatsu
distributor.
Radiator mount rubber
Exhaust muffler
Exhaust flexible pipe
Battery switch
Starting relay
Emergency relay
REPLACE FAN BELT

4 - 38
.
CHECK EXHAUST MUFFLER, EXHAUST MANIFOLD, EXHAUST FLEXIBLE PIPE, INTAKE MANIFOLD
Check for any cracks, deformation, or other abnormality. If any abnormality is found, contact your Komatsu
distributor for repair or replacement.
CHECK BATTERY SWITCH, STARTING MOTOR, EMERGENCY RELAY

Check the appearance of there parts, and if any deformation, damage, or other abnormality is found, contact your
Komatsu distributor for repair or replacement.
CHECK COOLANT HEATER

Check the cble for disconnection or damage and the heaterfor
disconnection. Check for corrosion and scale ib the heater
protection pipe. If any abnormality is found, contact your Komatsu
distributor for repair or replacement.
CHECK, MAINTAIN INTAKE VALVE SEAT, EXHAUST VALVE SEAT

CLEAN, CHECK TURBOCHARGER

REPLACEMENT OF PARTS
Please contact your Komatsu distributor for replacement of the following parts.
Engine oil pressure switch, engine water temperature switch
Hoses (fuel, oil, radiator, etc.)
Cylinder head gasket
Seal rings for exhaust parts
Coolant thermostat
Exhaust valve, intake valve, valve guide
4 - 39
.

Carry out the maintenance for EVERY 500 HOURS, EVERY 1000 HOURS, EVERY 2000 HOURS, EVERY 4000
HOURS, and EVERY 8000 HOURS SERVICE at the same time.
COMPLETE OVERHAUL OF ENGINE

Please request your Komatsu distributor to carry out a complete overhaul of the engine.
CARRY OUT MAINTENANCE ON THE FOLLOWING PARTS IN ACCORDING WITH THE KOMATSU MAINTENANCE STANDARDS
Cylinder head, cylindser block

Rocker arm, crosshead
Push rod
Crankshaft (carry out magnetic inspection)
Camshaft, cam follower
Gears
Timing gear bearing
Pulleys (crankshaft, fan tension)
Oil cooler, aftercooler
Air cleaner body
REPLACE THE WEAR PARTS ASSEMBLED INSIDE THE FOLLOWING PARTS

Turbocharger
Starting motor
Alternator (if equipped)
Lubrication pump
Fuel pump
Valve assembly
Water pump
PLEASE CONTACT YOUR KOMATSU DISTRIBUTOR FOR REPLACEMENT OF THE FOLLOWING PARTS
Fuel injector assembly
Valve assembly
4 - 40
.

Carry out the maintenance for EVERY 500 HOURS, EVERY 1000 HOURS, EVERY 2000 HOURS, EVERY 4000
HOURS, and EVERY 8000 HOURS SERVICE at the same time.
REPLACEMENT OF FUEL PUMP

4 - 41
.
5-1
.
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
Engine model Type Cylinder No. - Bore x stroke Firing order
4-cycle, water cooled,
Air-cooled aftercooler
SAA6D170E-3 straight, vertical type, 6 - 170 mm x 170 mm 1-5-3-6-2-4
With turbocharger
direct injection system
5-2
.
INDEX
INDEX
<C> OPERATIONS, CHECKS AFTER

CHECK AFTER STOPPING ENGINE 3- 14 STARTING ENGINE 3- 13
CHECK BEFORE STARTING ENGINE 3- 7 OUTLINE OF ELECTRIC SYSTEM 4- 6
COLD WEATHER OPERATION 3- 16 OUTLINE OF SERVICE 4- 4
AFTER COLD WEATHER 3- 17
PRECAUTIONS FOR LOW <P>
TEMPERATURE 3- 16 PERIODIC REPLACEMENT OF SAFETY
CRITICAL PARTS 4- 15
<D> PRECAUTIONS DURING OPERATION 2- 7
DUST INDICATOR 3- 6 BATTERY 2- 8
OPERATION 2- 7
<E> STARTING ENGINE 2- 7
EMERGENCY STOPPING 3- 14 TRANSPORTATION 2- 7
ENGINE SERIAL NO. PLATE POSITION 1- 6 PRECAUTIONS FOR MAINTENANCE 2- 9
EXPLANATION OF COMPONENTS 3- 4 PRODUCT INFORMATION 1- 6
EXTERIOR VIEW OF FUEL FILTER UNIT 3- 3
<S>
<F> SAFETY CRITICAL PARTS 4- 15
FOREWORD 1- 2 SAFETY INFORMATION 1- 5
<G> SERVICE PROCEDURE 4- 18
GENERAL PRECAUTIONS 2- 3 CHECK BEFORE STARTING 4- 29
GENERAL VIEW 3- 2 EVERY 1000 HOURS SERVICE 4- 35
GENERAL VIEW OF ENGINE 3- 2 EVERY 16000 HOURS SERVICE 4- 40
GUIDE TO MAINTENANCE 4- 2 EVERY 2000 HOURS SERVICE 4- 36
<H> EVERY 4000 HOURS SERVICE 4- 38
HANDLING OIL, FUEL, COOLANT, AND EVERY 500 HOURS SERVICE 4- 30
PERFORMING OIL CLINIC 4- 4 EVERY 8000 HOURS SERVICE 4- 39
INITIAL 250 HOURS SERVICE (ONLY
<L> AFTER THE FIRST 250 HOURS) 4- 18
LONG-TERM STORAGE 3- 18 WHEN REQUIRED 4- 19
AFTER STORAGE 3- 18 SPECIFICATIONS 5- 2
BEFORE STORAGE 3- 18 STANDARD TIGHTENING TORQUES
DURING STORAGE 3- 18 FOR BOLTS AND NUTS 4- 14
<M> STOPPING ENGINE 3- 14
MAINTENANCE OPERATION OF SWITCHES 3- 6
ENGINE FOR EMERGENCY
GENERATOR SPECIFICATION 3- 14 <T>
MAINTENANCE SCHEDULE CHART 4- 16 TABLE TO ENTER SERIAL NO. AND
MAINTENANCE SCHEDULE CHART 4- 16 DISTRIBUTOR 1- 6
METER 3- 4 TORQUE LIST 4- 14
METHOD OF LIFTING ENGINE 3- 15 TRANSPORTATION 3- 15
TROUBLESHOOTING 3- 19
<O> AFTER RUNNING OUT OF FUEL 3- 19
OPERATION 3- 7 IF BATTERY IS DISCHARGED 3- 19
6-1
.
INDEX
OTHER TROUBLE 3- 20
<U>
USE OF FUEL, COOLANT AND
LUBRICANTS ACCORDING TO
AMBIENT TEMPERATURE 4- 8
FUEL, OIL, COOLANT 4- 8
HANDLING WHEN USING A GRADE
HEAVY OIL AS FUEL 4- 12
<W>
WEAR PARTS 4- 7
WEAR PARTS LIST 4- 7
6-2
.
SAA6D170E-3 DIESEL ENGINE (for generator)
Form. No. SEAM062700P
©
2003 KOMATSU
All Rights Reserved
Printed in Japan 12-03

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Read this manual thoroughly and understand its contents fully.

FOREWORD SAFETY INFORMATION

Example of safety message using signal word

Other signal words

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

PRODUCT INFORMATION FOREWORD

ENGINE SERIAL NO. PLATE POSITION

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Service personnel for your engine:

SAFETY INFORMATION SAFETY

PRECAUTIONS DURING OPERATION 2- 7

PRECAUTIONS FOR MAINTENANCE 2- 9

SAFETY GENERAL PRECAUTIONS

IF ABNORMALITIES ARE FOUND

CLOTHING AND PERSONAL PROTECTIVE ITEMS

FIRE EXTINGISHER AND FIRST AID KIT

GENERAL PRECAUTIONS SAFETY

KEEP MACHINE CLEAN

SAFETY GENERAL PRECAUTIONS

Fire caused by accumulation of flammable material

Fire coming from electric wiring

Fire coming from hydraulic line

Explosion caused by lighting equipment

GENERAL PRECAUTIONS SAFETY

PRECAUTIONS RELATED TO VENTILATION OF EXHAUST GAS

SAFETY PRECAUTIONS DURING OPERATION

PRECAUTIONS DURING OPERATION

CHECK BEFORE STARTING ENGINE, ADJUST

PRECAUTIONS WHEN STARTING

PRECAUTIONS IN COLD AREAS

CHECK BEFORE STARTING OPERATION

PRECAUTIONS DURING OPERATION SAFETY

BATTERY HAZARD PREVENTION

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

SAFETY PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS FOR MAINTENANCE

KEEP WORK PLACE CLEAN AND TIDY

APPOINT LEADER WHEN WORKING WITH OTHERS

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

MIND YOUR STEP WHEN CARRYING OUT MAINTENANCE

PRECAUTIONS FOR MAINTENANCE SAFETY

LIFT ENGINE CAREFULLY

PRECAUTIONS WHEN USING HAMMER

REMOVING BATTERY TERMINAL

SAFETY PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WITH HIGH-PRESSURE OIL

PRECAUTIONS FOR HIGH-PRESSURE FUEL

HANDLING HIGH-PRESSURE HOSES, PIPING

PRECAUTIONS FOR HIGH VOLTAGE

PRECAUTIONS FOR MAINTENANCE SAFETY

PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS

GENERAL VIEW OPERATION

OPERATION GENERAL VIEW

EXTERIOR VIEW OF FUEL FILTER UNIT

EXPLANATION OF COMPONENTS OPERATION

ENGINE WATER TEMPERATURE GAUGE

ENGINE OIL PRESSURE GAUGE

OPERATION EXPLANATION OF COMPONENTS

ENGINE OIL TEMPERATURE GAUGE

ENGINE EXHAUST TEMPERATURE GAUGE

EXPLANATION OF COMPONENTS OPERATION