PEN00178-01

MOTOR GRADER

GD555 -3A
SERIAL NUMBERS

11001

and up

.

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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
Operators and maintenance personnel must always do as follows before beginning operation or maintenance. Always be sure to read and understand this manual thoroughly before performing operation and maintenance. Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully. Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners together with the machine. Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.

Storage location for the Operation and Maintenance Manual: Pocket at rear of operator's seat

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FOREWORD

FOREWORD

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. FOREWORD

FOREWORD

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Other signal words In addition to the above. 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. if not avoided. if not avoided. may result in minor or moderate injury. This word is used for information that is useful to know. always place the lock lever in the LOCK position. if not avoided. 1-5 . FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use this machine safely. could result in death or serious injury. If you accidentally touch the control levers when they are not locked. this may cause a serious injury or death.. Indicates a potentially hazardous situation which. Example of safety message using signal word WARNING When standing up from the operator's seat. 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. will result in death or serious injury. Indicates a potentially hazardous situation which. 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 also to alert against unsafe practices that may cause property damage. In this manual and on machine labels. 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. Indicates an imminently hazardous situation which. the following signal words are used to express the potential level of hazard.

it is your responsibility to take the necessary steps to ensure safety. values. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures. (For example: 1 J (1)) 1-6 . SAFETY INFORMATION FOREWORD Safety labels Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. Safety pictograms show the type of hazardous condition at the top or left side. If any procedures or actions not specifically recommended or allowed in this manual are used. Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Example of safety label using words Safety labels using pictogram Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. In addition. Therefore. The explanations. These safety pictograms use pictures in order to let the operator or maintenance worker understand the level and type of hazardous condition at all times. the type of hazardous condition is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside a circle. and the method of avoiding the hazardous condition at the bottom or right side. and illustrations in this manual were prepared based on the latest information available at that time. In no event should you engage in prohibited uses or actions described in this manual.. the safety messages in this manual and on the machine may not include all possible safety precautions.

right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine. FOREWORD INTENDED USE INTENDED USE This Komatsu machine is designed to be used mainly for the following work: Smoothing Repair and maintenance of gravel roads Snow-clearing operations Ditch digging Cutting slope faces Excavating operations Mixed operations Spreading operations Front wheel offset operations See the section "WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER (PAGE 3-69)" for further details. 1-7 . the directions of the machine (front. DIRECTIONS OF MACHINE In this manual. rear. left..

ENGINE SERIAL NO. MACHINE SERIAL NO. 1-8 . TABLE TO ENTER SERIAL NO. PLATE POSITION This is at the front of the rear frame on the left side of the machine. LOCATION OF PLATES. AND DISTRIBUTOR FOREWORD LOCATION OF PLATES. PLATE POSITION This is at the top of the right side of the engine cylinder head as seen from the fan.. AND DISTRIBUTOR When requesting service or ordering replacement parts. TABLE TO ENTER SERIAL NO. please inform your Komatsu distributor of the following items.

FOREWORD LOCATION OF PLATES. AND DISTRIBUTOR SERVICE METER POSITION The meter is installed to the left side of the steering wheel column. TABLE TO ENTER SERIAL NO. Distributor name Address Service Personnel Phone/Fax 1-9 . Engine serial No. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No..

3 3.2 3. CHECKS AFTER STARTING ENGINE STOPPING ENGINE CHECK AFTER STOPPING ENGINE TRAVELING POSTURE FOR MACHINE MOVING MACHINE OFF (FORWARD.24 3.33 3.56 3.18 2.90 3.8 1.9 2.33 3. STOPPING TURNING MACHINE OPERATING WORK EQUIPMENT WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER PRECAUTIONS WHEN OPERATION ADJUSTING WORK EQUIPMENT POSTURE PARKING MACHINE 1.35 3.52 3. SHIFTING GEAR).7 1.4 2.63 3.5 1.6 3.4 2.35 3.10 .69 3.28 2.1 2.8 1.33 3.2 1.54 3.1 1.1 3.55 3.20 2.5 2. AND DISTRIBUTOR MACHINE SERIAL NO.54 3.6 3. PEDALS DUST INDICATOR ARTICULATE LOCK PIN FUSE BOX OPERATION CHECK BEFORE STARTING ENGINE STARTING ENGINE OPERATIONS.26 2.9 2. REVERSE. TABLE TO ENTER SERIAL NO.7 1..35 3.25 2.2 2.2 3.48 3. PLATE POSITION SERVICE METER POSITION TABLE TO ENTER SERIAL NO. CONTENTS FOREWORD CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTENDED USE DIRECTIONS OF MACHINE LOCATION OF PLATES.9 1.60 3.8 1.13 3.18 2.94 3-105 1 .29 2. AND DISTRIBUTOR SAFETY SAFETY INFORMATION SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS PRECAUTIONS DURING OPERATION STARTING ENGINE OPERATION TRANSPORTATION BATTERY TOWING PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WITH TIRES OPERATION GENERAL VIEW GENERAL VIEW OF MACHINE GENERAL VIEW OF CONTROLS AND GAUGES EXPLANATION OF COMPONENTS METERS AND LAMPS SWITCHES CONTROL LEVERS. PLATE POSITION ENGINE SERIAL NO.

13 4.63 4.15 4.2 6.1 5. COOLANT.8 4.13 4.7 4.8 4.3 1 .1 6.49 4.2 6.32 4.18 4.2 4.1 4.16 4. COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS TORQUE LIST PERIODIC REPLACEMENT OF CRITICAL PARTS CRITICAL PARTS MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART SERVICE PROCEDURE INITIAL 250 HOURS SERVICE (only after the first 250 hours) WHEN REQUIRED CHECK BEFORE STARTING EVERY 50 HOURS SERVICE EVERY 250 HOURS SERVICE EVERY 500 HOURS SERVICE EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE EVERY 4000 HOURS SERVICE SPECIFICATIONS SPECIFICATIONS ATTACHMENTS. OPTIONS HANDLING BLADE ACCUMULATOR FEATURES OF BLADE ACCUMULATOR METHOD OF OPERATING BLADE ACCUMULATOR 3-106 3-107 3-107 3-108 3-108 3-109 3-110 3-110 3-111 3-111 3-112 3-112 3-112 3-112 3-113 3-113 3-114 3-115 3-117 3-120 4.16 4.4 4.34 4. FUEL. UNLOADING WORK PRECAUTIONS FOR LOADING COLD WEATHER OPERATION PRECAUTIONS FOR LOW TEMPERATURE CAUTIONS AFTER COMPLETION OF WORK AFTER COLD WEATHER LONG-TERM STORAGE BEFORE STORAGE DURING STORAGE AFTER STORAGE TROUBLESHOOTING AFTER RUNNING OUT OF FUEL WHEN LEANING PIPING IS DAMAGED TOWING THE MACHINE IF BATTERY IS DISCHARGED OTHER TROUBLE MAINTENANCE GUIDES TO MAINTENANCE OUTLINES OF SERVICE HANDLING OIL.4 4. FOREWORD CONTENTS CHECKS AFTER COMPLETION OF OPERATION LOCKING HANDLING THE TIRES TRANSPORTATION LOADING..9 4.69 5.18 4.19 4.33 4.55 4.2 6.11 . AND PERFORMING OIL CLINIC RELATING TO ELECTRIC SYSTEM WEAR PARTS WEAR PARTS LIST USE OF FUEL.15 4.

CONTENTS FOREWORD CAR RADIO EXPLANATION OF COMPONENTS METHOD OF OPERATION PRECAUTIONS FOR USE AIR CONDITIONER LOCATIONS AND FUNCTIONS OF CONTROL PANEL METHOD OF OPERATION PRECAUTIONS WHEN USING TESTING AND MAINTENANCE HANDLING ADJUSTABLE SEAT ADJUST OPERATOR'S SEAT HANDLING AIR-SUSPENSION SEAT ADJUST OPERATOR'S SEAT HANDLING MACHINES EQUIPPED WITH KOMTRAX BASIC PRECAUTIONS INDEX 6666666666666667- 4 4 7 9 10 10 12 12 12 13 13 14 14 16 16 1 1 .12 ..

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. SAFETY INFORMATION SAFETY SAFETY INFORMATION SAFETY LABELS POSITIONS OF SAFETY PICTOGRAMS SAFETY LABELS GENERAL PRECAUTIONS SAFETY RULES IF PROBLEMS ARE FOUND CLOTHING AND PERSONAL PROTECTIVE ITEMS FIRE EXTINGUISHER AND FIRST AID KIT SAFETY FEATURES KEEP MACHINE CLEAN INSIDE OPERATOR'S COMPARTMENT ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT HANDRAILS AND STEPS MOUNTING AND DISMOUNTIN DO NOT GET CAUGHT IN ARTICULATED PORTION PREVENTION OF BURNS FIRE PREVENTION ACTION IF FIRE OCCURS WINDOW WASHER LIQUID PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) PRECAUTIONS FOR ATTACHMENTS UNAUTHORIZED MODIFICATION SAFETY AT WORKSITE WORKING ON LOOSE GROUND DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES ENSURE GOOD VISIBILITY VENTILATION FOR ENCLOSED AREAS CHECKING SIGNALMAN'S SIGNALS AND SIGNS EMERGENCY ESCAPE FROM OPERATOR'S CAB ASBESTOS DUST HAZARD PREVENTION 2222222222222222222222222222224 4 5 9 9 9 9 9 9 10 10 10 11 11 11 12 13 13 14 14 14 14 15 15 16 16 16 17 17 17 2-2 .

35 2..35 2-3 .35 2. ADJUST PRECAUTIONS WHEN STARTING PRECAUTIONS IN COLD AREAS OPERATION CHECKS BEFORE STARTING OPERATION PRECAUTIONS BEFORE MOVING OFF PRECAUTIONS WHEN TRAVELING PRECAUTIONS WHEN TRAVELING ON SLOPES PRECAUTIONS WHEN OPERATIONS ON SLOPES PROHIBITED OPERATIONS PRECAUTIONS WHEN OPERATING OPERATE CAREFULLY ON SNOW PARKING MACHINE TRANSPORTATION LOADING AND UNLOADING SHIPPING BATTERY BATTERY HAZARD PREVENTION STARTING WITH BOOSTER CABLES TOWING WHEN TOWING PRECAUTIONS FOR MAINTENANCE WARNING TAG 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 PROPER TOOLS ACCUMULATOR PERSONNEL ATTACHMENTS WORK UNDER THE MACHINE NOISE PRECAUTIONS WHEN USIN HAMMER REPAIR WELDING REMOVING BATTERY TERMINAL PRECAUTIONS WITH HIGH-PRESSURE OIL HANDLING HIGH-PRESSURE HOSES WASTE MATERIALS MAINTENANCE OF AIR CONDITIONER COMPRESSED AIR PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS PRECAUTIONS WITH TIRES HANDLING TIRES PRECAUTIONS WHEN STORING TIRE 22222222222222222222222222222222222222222222- 18 18 18 18 19 20 20 20 21 22 22 22 22 23 24 25 25 25 26 26 27 28 28 29 29 29 29 30 31 31 32 32 32 32 32 33 33 33 33 34 34 34 34 34 2. SAFETY SAFETY INFORMATION PRECAUTIONS DURING OPERATION STARTING ENGINE CHECKS BEFORE STARTING ENGINE.

POSITION FOR ATTACHING SAFETY LABELS 2-4 .. see this manual or the actual label. be sure that they are in the correct place and always keep them clean. lost. and place an order with Komatsu distributor. do not use organic solvents or gasoline. When cleaning them. To ensure that the content of labels can be read properly. For details of the part numbers for the labels. There are also other labels in addition to the warning signs and safety labels. These may cause the labels to peel off. Handle those labels in the same way. Be sure that you fully understand the correct position and content of labels. replace them with new ones. SAFETY LABELS SAFETY SAFETY LABELS The following warning signs and safety labels are used on this machine. or cannot be read properly. If the labels are damaged.

SAFETY SAFETY LABELS SAFETY LABELS (1) Precautions before operating (09651-A0881) (2) Precautions for opening hydraulic cap (09653-A0641) (3) Precautions when driving in reverse (09802-43000) (4) Warning for high voltage (09801-E0881) 2-5 ..

SAFETY LABELS SAFETY (5) Articulate lock (09161-C0881) (6) Warning for handling accumulator (09659-A057B) (7) Prohibited to walk (23B-53-31740) (8) Precautions when engine running (09667-A0481) 2-6 ..

SAFETY SAFETY LABELS (9) Precautions when handling booster cable and battery cable (09808-A1681) (10) Prohibited to enter (09162-E0881) (11) Precautions when startling and traveling (23B-53-31740) (12) Exhaust pipe is hot ! (09817-K088B) 2-7 ..

SAFETY LABELS SAFETY (13) "Do not approach machine" warning (09806-E1201) (14) Precautions for brake (23B-53-31670) (15) Precautions when handling battery (16) Jump start prohibited (09842-A0481) 2-8 ..

putting yourself and everyone else on your job site in danger. There is a hazard that they may catch on control levers or other protruding parts. CLOTHING AND PERSONAL PROTECTIVE ITEMS Do not wear loose clothing and accessories. Check that all protective equipment functions properly before using it. and safety belt when operating or maintaining the machine. or if you are under the influence of alcohol or medication.. SAFETY FEATURES Be sure that all guards. precautions and instructions in this manual when operating or performing maintenance on the machine. mask. smell. Have guards and covers repaired immediately if they are damaged. incorrect gauges. oil leakage. Always keep them in good operating condition. Always wear a hard hat and safety shoes. Do not operate the machine until the problem has been corrected. 2-9 . Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emergencies. smoke. Never remove any safety features. discuss the content of the operation beforehand and use the determined signals when carrying out the operation. your ability to safely operate or repair your machine may be severely impaired. vibration. wear safety glasses. Follow all safety rules. etc. Carry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used. IF PROBLEMS ARE FOUND If you find any problems in the machine during operation or maintenance (noise. gloves. When working with another operator or with the person on the worksite traffic duty. Provide a first aid kit in the storage point. If you have long hair and it hangs out from your hard hat. covers and mirrors are in their proper position. SAFETY GENERAL PRECAUTIONS GENERAL PRECAUTIONS SAFETY RULES Only trained and authorized personnel can operate and maintain the machine.. Carry out periodic checks and add to the contents if necessary. FIRE EXTINGUISHER AND FIRST AID KIT Always follow the precautions below to prepare for action if any injury or fire should occur. or any abnormal display on the warning devices or monitor). If the nature of the work requires it. there is a hazard that it may get caught up in the machine. If you are not feeling well. Understand the method of use of safety features and use them properly. so tie your hair up and be careful not to let it get caught. ear plugs. report to the person in charge and have the necessary action taken.

set gearshift lever (1) to the P (Parking) position. 2 .. then stop the engine. always lower the work equipment completely to the ground. INSIDE OPERATOR'S COMPARTMENT When entering the operator's compartment. or that dirt or mud will get into your eyes. raise the steering column fully when getting off the machine. take it with you. Do not stick suction pads to the window glass. and keep it in the specified place. your foot may slip and this may cause a serious accident. Use the key to lock all the equipment.10 . Do not use cellular telephones inside the operator's compartment when driving or operating the machine. Always keep the machine clean. If inspection and maintenance is carried out when the machine is still dirty with mud or oil. there is a hazard that it will cause malfunctions or misoperation. GENERAL PRECAUTIONS SAFETY KEEP MACHINE CLEAN If water gets into the electrical system. Do not use water or steam to wash the electrical system (sensors. there is a hazard that you will slip and fall. and this may lead to a serious accident. Do not leave parts or tools lying around the operator's compartment. To ensure that there is enough space to get on or off the machine. If you operate the pedal with mud or oil affixed to your shoes. the machine may move suddenly. always remove all mud and oil from the soles of your shoes. Never bring any dangerous objects such as flammable or explosive items into the operator's compartment. When leaving the machine. Suction pads act as a lens and may cause fire. ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT If the work equipment control levers are touched by mistake. Always remove the key. connectors).

or mud on them. Do not grip the control levers when getting on or off the machine. Do not allow anyone near any of the rotating or telescoping parts. To ensure safety. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine. MOUNTING AND DISMOUNTING Never jump on or off the machine. SAFETY GENERAL PRECAUTIONS HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine. Do not get on or off the machine while holding tools in your hand. or both hands and one foot) with the handrails and steps to ensure that you support yourself. wipe it off immediately. In addition. it will lead to serious injury. and if there is any oil. grease. DO NOT GET CAUGHT IN ARTICULATED PORTION The clearance in the area around the work equipment changes according to the movement of the link. If the machine starts to move when there is no operator on the machine. 2 . always do as follows. always face the machine and maintain three-point contact (both feet and one hand. If you get caught. Never get on or off a moving machine. repair any damage and tighten any loose bolts.. do not jump on to the machine and try to stop it. Before getting on or off the machine. check the handrails and steps.11 . Never climb on the engine hood or covers where there are no non-slip pads.

Even when the coolant has cooled down. Even when the oil has cooled down. loosen the cap slowly to relieve the pressure inside the upper tank before removing the cap. 2 . wait for the water to cool to at temperature where it is possible to touch the upper tank cap by hand before starting the operation. wait for the oil to cool to a temperature where it is possible to touch the cap or plug by hand before starting the operation. Hot oil To prevent burns from hot oil spurting out when checking or draining the oil. loosen the cap or plug slowly to relieve the internal pressure before removing the cap or plug.12 . GENERAL PRECAUTIONS SAFETY PREVENTION OF BURNS Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant..

oil. battery electrolyte. always observe the following: Do not smoke or use any flame near fuel or oil. use a non-flammable oil. Do not leave the machine while adding fuel or oil. If such lighting equipment is not used. Use the handrails and steps to get off the machine. they may vibrate during operation and rub against other parts. exhaust manifold. ACTION IF FIRE OCCURS If a fire occurs. Repair or replace any damaged wiring. Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids. and cushions are securely fixed in position. Use well-ventilated areas for adding or storing oil and fuel.. Put greasy rags and other flammable materials into a safe container to maintain safety at the work place. Diesel oil and gasoline may catch fire. move any flammable materials to a safe place before starting. Stop the engine before refueling.13 . so do not use them. there is danger of explosion that may cause serious injury. Fire caused by accumulation of flammable material. and cause high-pressure oil to spurt out. or inside the undercovers. SAFETY GENERAL PRECAUTIONS FIRE PREVENTION Fire caused by fuel or oil Fuel. escape from the machine as follows. Fire coming from hydraulic line Check that all the hose and tube clamps. After adding fuel or oil. oil. pieces of paper. Explosion caused by lighting equipment When checking fuel. Keep oil and fuel in the determined place and do not allow unauthorized persons to enter. or battery. This may lead to damage to the hoses. Fire coming from electric wiring Short circuits in the electrical system can cause fire. always use lighting with anti-explosion specifications. Remove any dry leaves. window washer fluid. When washing parts with oil. To prevent fire. Turn the start switch OFF to stop the engine. muffler. Always keep electric wiring connections clean and securely tightened. If they are loose. chips. or any other flammable materials accumulated or affixed around the engine. When taking the electrical power for the lighting from the machine itself. When carrying out grinding or welding work on the chassis. Tighten any loose connectors or wiring clamps. 2 . guards. Tighten all fuel and oil caps securely. Check the wiring every day for looseness or damage. dust. or coolant. leading to fire damage or serious injury. Do not spill fuel on overheated surfaces or on parts of the electrical system. and window washer liquid are particularly flammable and can be hazardous. follow the instructions in this manual. wipe up any spilled fuel or oil. antifreeze.

it cannot display its effect. Komatsu will not be responsible for any injuries. Before making a modification. PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) Install ROPS when working in places where there is danger of falling rocks. so do not use it. When modifying. ROPS is installed to protect the operator when machine rolls over. consult your Komatsu distributor. product failures or other property damages resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu. such as in mines and quarries. consult your Komatsu distributor. accidents. Even if ROPS is installed. product failures or other property damages resulting from modifications made without authorization from Komatsu. Any injuries. there may be problems with safety or legal restrictions. GENERAL PRECAUTIONS SAFETY WINDOW WASHER LIQUID Use an ethyl alcohol base washer liquid. its strength may be reduced.. In this case. If ROPS is modified. When machine rolls over. its strength lowers and its design functions cannot be maintained. or in places where there is danger of rolling over. If ROPS is deformed by falling objects or by rolling over. be sure to ask your Komatsu distributor about repair method. and the general information related to attachments in this manual. do not remove it when operating the machine. ROPS supports its weight and absorbs its impact energy. UNAUTHORIZED MODIFICATION Any modification made without authorization from Komatsu can create hazards. always fasten your seat belt properly when operating the machine. PRECAUTIONS FOR ATTACHMENTS When installing optional parts or attachments. read the instruction manual for the attachment. If you do not use your fasten your seat belt properly. Therefore contact your Komatsu distributor for advice. accidents. When installing and using optional attachments. 2 . Methyl alcohol base washer liquid may irritate your eyes.14 . If ROPS is installed.

2 . and deep ditches. If water lines. In order that travel operations can be carried out safely. contact each utility and identify their locations. Take action to prevent unauthorized people from approaching the jobsite. always keep the roads on the jobsite properly maintained. SAFETY GENERAL PRECAUTIONS SAFETY AT WORKSITE Before starting operations.. Be careful not to sever or damage any of these lines. take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling. position flagmen and erect barriers to ensure the safety of passing traffic and pedestrians. When traveling or operating in shallow water or on soft ground. Before starting operations. or high-voltage electrical lines may be buried under the worksite. there is a hazard that the machine may fall or tip over. When working on public roads. Do not operate where there is a hazard of landslides or falling rocks. there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas. check the shape and condition of the bedrock. gas lines. The ground may be weak in such areas. overhangs. If the ground should collapse under the weight or vibration of the machine.15 . and the depth and speed of flow of the water before starting operations. thoroughly check the area for any unusual conditions that could be dangerous. WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs. When working on embankments or near excavated ditches. Check the terrain and condition of the ground at the worksite. and determine the safest method of operation.

If the machine should come too close or touch the electric cable. There is a hazard of electric shock. Lay a rubber sheet on top of the seat. always do as follows. When carrying out operations near high voltage cables. Position a signalman if there are areas at the rear of the machine where the visibility is not good. 275. which may cause serious personal injury or death.000 V Over 5 m (17 ft) and gloves. the operator should not leave the operator's compartment until it has been confirmed that the electricity has been shut off. 2 . do not let anyone near the machine. take steps to ensure that the engine exhaust gas is removed and that ample fresh air is brought in. and ask them to take the necessary action.600 V Over 2 m (7 ft) machine and the electric cable. wear rubber shoes 154. and be careful 187. If the engine or machine must be operated inside a building or under ground. which may cause serious burns or even death. Start or operate the engine in a place where there is good ventilation. Even going close to high-voltage cables can cause electric Voltage of Cables Safety Distance shock. GENERAL PRECAUTIONS SAFETY DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. do not let anyone near the machine.16 . to prevent electric shock. When working in dark places.000 V Over 3 m (10 ft) operations. Before starting work near electric cables. Check with the local power company about safe operating procedure before starting 22. or dust.000 V Over 4 m (14 ft) To prepare for any possible emergencies. On jobsites where the machine may go close to electric cables. and set up additional lighting in the work area if necessary.000 V Over 11 m (36 ft) close to the electric cables.200 V Over 2 m (7 ft) maintain a safe distance (see the table on the right) between the 6. Also. 66. VENTILATION FOR ENCLOSED AREAS The engine exhaust gas contains substances that may damage your health or even cause death. ENSURE GOOD VISIBILITY Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to ensure that operations and travel can be carried out safely.000 V Over 7 m (23 ft) Use a signalman to give warning if the machine approaches too 500. Always 100 V . such as in mist.000 V Over 6 m (20 ft) not to touch the chassis with any exposed part of your body. Stop operations if the visibility is poor. Always do as follows. snow. turn on the working lamp and front lamps installed to the machine. where the ventilation is poor. rain. inform the local power company of the work to be performed..

Only one signalman should give signals. Always observe the rules and regulations for the work site and environmental standards. SAFETY GENERAL PRECAUTIONS CHECKING SIGNALMAN'S SIGNALS AND SIGNS Set up signs to inform of road shoulders and soft ground..17 . If the door on one side does not open. Do not allow other persons to approach during the operation. Make sure that all workers understand the meaning of all signals and signs before starting work. There is danger of inhaling asbestos when working on jobsites handling demolition work or work handling industrial waste. position a signalman if necessary. This machine does not use asbestos. If there is danger that there may be asbestos dust in the air. Spray water to keep down the dust when cleaning. ASBESTOS DUST HAZARD PREVENTION Asbestos dust in the air can cause lung cancer if it is inhaled. If the visibility is not good. Do not use compressed air for cleaning. EMERGENCY ESCAPE FROM OPERATOR'S CAB The cab installed on this machine has doors on the left and right sides. Operators should pay careful attention to the signs and follow the instructions from the signalman. escape through the door on the other side. All workers should use an approved respirator. always operate the machine from an upwind position. 2 . but there is a danger that imitation parts may contain asbestos. so always use genuine Komatsu parts. Always observe the following.

Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake pedal. PRECAUTIONS DURING OPERATION SAFETY PRECAUTIONS DURING OPERATION STARTING ENGINE If there is a warning tag hanging from gear shift lever. do not start the engine or touch the levers. Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. Remove all dirt from the surface of the lens of the front lamps. Before starting the engine. and check that they light up correctly. 2 . below. Remove all dirt from the surface of the window glass to ensure a good view. and check that the control levers are all at the Neutral position. fuel level. When starting the engine. and rear combination lamp. and check for damage to the electric wiring. CHECKS BEFORE STARTING ENGINE. For machines equipped with a back-up alarm. Adjust the operator's seat to a position where it is easy to carry out operations. check the angle of the mirror. PRECAUTIONS WHEN STARTING Start and operate the machine only while seated. Such an act may cause a serious bodily injury or fire.18 . check that the gearshift lever is at the P (Parking) position. Check the operation of the instruments and gauges. and oil level in engine oil pan. Do not allow anyone apart from the operator to ride on the machine. sound the horn as a warning. Refer to "WALK-AROUND CHECK (PAGE 3-35)". Check the coolant level. or in the area around the machine. and check that the pedals work properly. Check that there are no persons or obstacles above. working lamps. ADJUST Carry out the following checks before starting the engine at the beginning of the day's work. check for clogging of the air cleaner. check that the alarm works properly.. and check that there is no damage or wear to the seat belt or mounting clamps. Do not attempt to start the engine by short-circuiting the engine starting circuit.

and this may lead to an accident. do not charge the battery or start the engine with a different power source. control levers.. SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS IN COLD AREAS Carry out the warming-up operation thoroughly. melt the battery electrolyte and check for frost and leakage of battery electrolyte before starting. gearshift lever. Before charging or starting the engine with a different power source. 2 . After warming up the engine. operate at low speed and check the safety while traveling. If the machine is not thoroughly warmed up before the steering wheel.19 . the reaction of the machine will be slow or may suddenly change. There is a hazard that this will ignite the battery. If the battery electrolyte is frozen. or brake pedal are operated.

If the operation requires use of the articulation. move the machine to a wide area where there are no obstructions.20 . and work equipment control system. vibration. sound the horn to warn people in the area. Take special care not to hit other machines or people when turning or swinging the machine. smell. PRECAUTIONS BEFORE MOVING OFF Before travelling. and operate slowly. Before travelling. Always be sure to carry out the above precautions even when the machine is equipped with mirrors. and that there are no obstacles. carry out repairs immediately. Do not allow anyone near the machine. Fix the operator's compartment doors and windows in the closed position securely. If any problem is found. Check for any problem in the sound of the machine. remove articulate lock pin (1). check that articulate lock pin (1) is at the LOCK position. check again that there is no one in the surrounding area. check also that there is no leakage of oil or fuel. Always operate the machine only when seated. Before traveling on roads. Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly. Do not allow anyone apart from the operator to ride on the machine. If there is an area to the rear of the machine which cannot be seen. Check the operation of travel. heat. 2 . or gauges. position a signal person.. PRECAUTIONS DURING OPERATION SAFETY OPERATION CHECKS BEFORE STARTING OPERATION When carrying out the checks. steering and brake systems. Always fasten your seat belt.

because the steering becomes heavy. When traveling continuously. There is danger that the machine may turn over. If you drive the machine at high speed continuously for a long time. or other machines to avoid coming into contact with them. When traveling on rough ground. If you are going to travel continuously. under electric wires. it produces an extremely large destructive force. 2 .2 MPH). The work equipment may hit the ground surface and cause the machine to lose its balance. When passing over bridges or structures. Travel at a maximum speed of 10 km/h (6. then rest for 30 minutes. and this may cause serious injury. or other places where the height is limited. there is danger that the machine may overturn. If the engine stops. structures. If the articulation is used when traveling at a speed of over 10 km/h (6. travel at low speed and do not operate the steering suddenly. Next.2 MPH) when using the articulation.21 . If a tire bursts. Operate carefully when the wheels are leaning. travel for 2 hours or 80 km. operate slowly and be extremely careful not to let the machine body or work equipment hit anything. check first that the structure is strong enough to support the mass of the machine. then rest for 1 hour. or contact your Komatsu distributor. It is prohibited to travel on roads with the wheels leaning. This may cause the tires to burst. depress the brake pedal immediately to stop the machine. always keep a safe distance from people.. SAFETY PRECAUTIONS DURING OPERATION PRECAUTIONS WHEN TRAVELING Never turn the key in the starting switch to the OFF position. under bridges. It is dangerous if the engine stops when the machine is traveling.2 MPH). travel for 2 hours. or may damage the machine or structures in the area. When traveling or carrying out operations. When operating in tunnels. Never use the articulation at speeds of over 10 km/h (6. the tires will overheat and the internal pressure will become abnormally high. please consult your Komatsu distributor.

PRECAUTIONS WHEN OPERATIONS ON SLOPES Do not articulate the machine fully on steep slops. Do not turn on slopes or travel across slopes. 2 . depress the brake pedal immediately. and stop the machine. travel slowly. there is danger that the soil may collapse or that rocks may fall. then travel on to the slope again. or other places where the height is limited. always do as follows. or wet steel plates with low speed. The edge of cliffs or road shoulders may easily collapse.22 . Check that there is no person other than the operator within the range of flying objects caused by the operation. When working on slopes. use the braking force of the engine together with the brake pedal to control the travel speed. Avoid sudden starts. Do not go close to such places. Even with slight slopes there is a hazard that the machine may slip. PRECAUTIONS DURING OPERATION SAFETY PRECAUTIONS WHEN TRAVELING ON SLOPES To prevent the machine from tipping over or slipping to the side. When traveling downhill. When traveling downhill. be extremely careful not to let the machine body or work equipment hit anything. Travel on grass. To prevent accidents caused by hitting other objects. Always place the transmission in a low gear before starting to travel downhill. PROHIBITED OPERATIONS When operating at the bottom of a cliff. set the gearshift lever to the P (Parking) position. particular in confined spaces. sudden stops. indoors. Never operate in such places. Always go down to a flat place to change the position of the machine. always operate the machine at a speed which is safe for operation. and there is danger of falling. lower the blade.. under bridges. and in places where there are other machines. never shift gear or place the transmission at neutral. fallen leaves. Always travel straight up or down a slope. and sudden steering. There is danger that the machine may tip over. Traveling at an angle or across the slope is extremely dangerous. PRECAUTIONS WHEN OPERATING When operating in tunnels. If the engine stops. It is dangerous not to use the braking force of the engine. If necessary. under electric wires. control the machine speed with the accelerator pedal.

When clearing snow. lower the blade to the ground to stop the machine. When traveling on snow-covered slopes. so always carry out operations carefully.23 .. Reduce the speed and use the engine as a brake while appling the foot brake intermittently (depress the brake intermittently several times). so be extremely careful when traveling or operating the machine. the road shoulder and objects placed beside the road are buried in the snow and cannot be seen. Even a slight slope may cause the machine to slip. the ground becomes soft when the temperature rises. and do not operate the levers suddenly. always fit tire chains. If necessary. Be careful not to leave the road shoulder or to get trapped in a snow drift. If the machine enters deep snow. With frozen ground surfaces. never apply the brakes suddenly. and this may cause the machine to tip over or make it impossible for the machine to escape. SAFETY PRECAUTIONS DURING OPERATION OPERATE CAREFULLY ON SNOW Snow-covered or frozen surfaces are slippery. 2 . there is a hazard that it may tip over or become buried in the snow. There is a hazard of the machine tipping over or hitting covered objects. When traveling on snow-covered roads. so be particularly careful when working on slopes.

PRECAUTIONS DURING OPERATION SAFETY PARKING MACHINE Park the machine on firm. set gearshift lever (1) to the P (Parking) position. 2 . or flooding. then stop the engine.. and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine. level ground. falling rocks. Select a place where there is no hazard of landslides.24 . Lower the work equipment completely to the ground. Always remove the key. Always close the operator's cab door. and leave it in the specified place. set blocks under the wheels to prevent the machine from moving. take it with you. If it is necessary to park the machine on a slope. When leaving the machine.

check first with the relevant authorities and follow their instructions. so particular care is necessary. drive off the ramps. SAFETY PRECAUTIONS DURING OPERATION TRANSPORTATION LOADING AND UNLOADING When loading or unloading the machine. correct the direction. For machines equipped with a cab. make sure that it has suitable width. Be sure that the ramps are wide. do as follows. SHIPPING When shipping the machine on a trailer. Remove dirt from machine-tracks. always lock the door after boarding the machine.. If necessary. Maintain a safe distance from the edge of the road or cliff. When traveling on public roads. ice and loose materials. Be sure the ramp surface is clean and free of grease. The weight. On a rainy day. For details of the shipping procedure. When passing over bridges or structures on private land. strength. and grade. If this is not done. see "TRANSPORTATION (PAGE 3-108)" in the OPERATION section. Perform loading and unloading on firm. Always do as follows. so be sure to confirm the dimensions. in particular. transportation height. mistaken operation may bring the hazard of the machine tipping over or falling. oil. Always use ramps of adequate strength. 2 . and thick enough to provide a safe loading slope. check first that the structure is strong enough to support the weight of the machine. Run the engine at low speed and travel slowly. and overall length of the machine differ according to the work equipment. the door may suddenly open during transportation. long.25 . level ground only. Refer to "TRANSPORTATION (PAGE 3-108)". Lock the frame with the articulate lock pin to prevent the machine from articulating. be extremely careful since the ramp surface is slippery. Never correct your steering on the ramps. Take suitable steps to prevent the ramps from moving out of position or coming off. When loading or unloading to an embankment or platform. then enter the ramps again.

and batteries generate flammable hydrogen gas. PRECAUTIONS DURING OPERATION SAFETY BATTERY BATTERY HAZARD PREVENTION Battery electrolyte contains sulphuric acid. and remove the battery caps before charging it. For this reason. take it to a well-ventilated place. Before working with batteries. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. When working with batteries. Do not leave tools or other metal objects lying around near the battery. If you spill acid on your clothes or skin. immediately flush the area with large amount of water. and connect the ground last. always wear safety glasses and rubber gloves. Mistaken handling can lead to serious injury or fire.. always observe the following precautions. connect the positive (+) terminal first. As there is a hazard that sparks will be generated. Never smoke or use any flame near the battery.26 . Install the battery securely to the determined place. Tighten the battery caps securely. 2 . Flammable hydrogen gas is generated when the battery is charged. which may explode. If acid gets into your eyes. when installing the battery. Do not let tools or other metal objects make any contact between the battery terminals. Always disconnect the negative (-) terminal (ground side) first when removing the battery. so remove the battery from the chassis. always do as follows. flush them immediately with large amount of water and seek medical attention. Tighten the battery terminals securely. This may cause an explosion. turn the starting switch to the OFF position. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line.

Disconnect the negative (-) cable (ground side) first when removing them. For details of the starting procedure when using booster cables. carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery). 2 . do not allow the two machines to touch.. When starting with a booster cable. be careful not to let the booster cable clips touch each other or to let the clips touch the machine. Always wear safety glasses and rubber gloves when starting the engine with booster cables.27 . see "STARTING ENGINE WITH BOOSTER CABLE (PAGE 3-118)" in the OPERATION section. When removing the booster cables. so always do as follows. When connecting a normal machine to a problem machine with booster cables. When starting from another machine. There is a hazard that the machine will move when the power is connected. always use a normal machine with the same battery voltage as the problem machine. When connecting the booster cables. SAFETY PRECAUTIONS DURING OPERATION STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables. it may cause the battery to explode. turn the starting switch OFF position for both the normal machine and problem machine. Be sure to connect the positive (+) cable first when installing the booster cables.

or kinks (C). Always wear leather gloves when handling wire rope. Never tow a machine on a slope. reduced diameter (B). 2 . There is danger that the rope may break during the towing operation. During the towing operation.. Never use a wire rope which has cut strands (A). see "TOWING THE MACHINE (PAGE 3-115)".28 . For towing. never stand between the towing machine and the machine being towed. PRECAUTIONS DURING OPERATION SAFETY TOWING WHEN TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope.

or touch or operate the work equipment control lever while you are performing service or maintenance. Always keep the work place clean the tidy to enable you to carry out operations safely. If the work place is not kept claen and tidy. If there is no tool box. misunderstandings between workers can lead to serious accidents. slip. or fall over and injure yourself. SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE WARNING TAG Always attach the "DO NOT OPERATE" warning tag to gear shift lever in the operator's cab to alert others that you are performing service of maintenance on the machine. keep the tag in the operation manual pocket. or other substances that will cause you to slip. If others start the engine. APPOINT LEADER WHEN WORKING WITH OTHERS When repairing the machine or when removing and installing the work equipment.. there is the danger that you will trip. oil. Attach additional warning tags around the machine if necessary.09963-03001 Keep this warning tag in the tool box while it is not used. appoint a leader and follow his instructions during the operation. you could suffer serious injury or property damage. KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place. Warning tag Part No. Wipe up all grease.29 . 2 . When working with others.

2 . Lock the frame with articulate lock pin (1) to prevent the machine from articulating. Lower the work equipment completely to the ground and stop the engine. PRECAUTIONS FOR MAINTENANCE SAFETY STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Stop the machine on firm.30 . After stopping the engine. Select a place where there is no hazard of landslides. or flooding. then set gearshift lever (1) to the P (Parking) position. level ground. falling rocks. Put blocks under the front and rear of the tires.. operate the left and right blade lift cylinder control levers fully to the RAISE and LOWER positions 2 or 3 times to release the pressure remaining in the hydraulic circuit.

Using damaged.. there is a hazard of being caught in the parts. or other rotating parts. fan belt. If maintenance must be carried out with the engine running. Parts may break or be sent flying. 2 . faulty. low quality. carry out the operation with at least two workers and do as follows. All workers must maintain contact with the other workers. makeshift tools or improper use of the tools could cause serious personal injury. Never drop or insert tools or other objects into the fan or fan belt. do not carry out maintenance with the engine running. If any control lever must be operated. so be careful not to come close. When carrying out operations near the fan. One worker must always sit in the operator's seat and be ready to stop the engine at any time. give a signal to the other workers to warn them to move to a safe place. Set gearshift lever (1) to the P (Parking) position and take action to prevent the work equipment from moving.31 . SAFETY PRECAUTIONS FOR MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury. Do not touch any control levers. PROPER TOOLS Use only tools suited to the task and be sure to use the tools correctly.

it may cause temporary or permanent hearing problems. weld it. Do not disassemble the accumulator. NOISE If the noise from the machine is too loud. the gas must be released. or use a cutting torch. Please contact your Komatsu distributor to have this work performed. PERSONNEL Do not allow any unauthorized personnel into the area when servicing the machine. careless procedure may cause an explosion which could lead to serious injury or property damage. When carrying out maintenance of the engine and you are exposed to noise for long periods of time. Do not hit or roll the accumulator.. PRECAUTIONS FOR MAINTENANCE SAFETY ACCUMULATOR The accumulator is charged with high-pressure nitrogen gas. always observe the following precautions. When handling the accumulator. 2 . For this reason. And take steps to prevent unauthorized persons from entering the storage area. support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine. employ a guard. WORK UNDER THE MACHINE If it is necessary to go under the work equipment or the machine to carry out service and maintenance. Do not make holes in it. wear ear covers or ear plugs while working. ATTACHMENTS Appoint a leader before starting removal or installation operations for attachments. Place attachments that have been removed from the machine in a stable condition so that they do not fall. If necessary.32 . Do not bring it near flame or dispose of it in fire. or subject it to any impact. When disposing of the accumulator.

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SAFETY

PRECAUTIONS FOR MAINTENANCE

PRECAUTIONS WHEN USING HAMMER When using a hammer, pins may fly out or metal particles may be scattered. This may lead to serious injury. Always do as follows. If hard metal parts such as pins, bucket teeth, cutting edges, or bearings are hit with a hammer, there is a hazard that pieces might be scattered and cause serious personal injury. Always wear safety glasses and gloves. There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area.

REPAIR WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with 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. 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 personal injury, so always do as follows. When carrying out inspection and maintenance of the pressure, release the pressure before starting. For details, see "STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE (PAGE 2-30)". Do not carry out inspection or replacement work with the circuit under pressure. 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.

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SAFETY

HANDLING HIGH-PRESSURE HOSES If oil or fuel leaks from high-pressure hoses, there is danger that it may cause fire or defective operation, which may lead to serious injury or fire. If there are any loose hoses or piping, or any leakage of oil or fuel from the hose or piping mount, stop operation and tighten to the specified torque. If any hoses or pipes are damaged or deformed, please 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. 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.

MAINTENANCE OF AIR CONDITIONER If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite. Never touch refrigerant. COMPRESSED AIR 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 glasses, 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 and seat belts, must be replaced at periodic intervals. Replacement of safety-critical parts: See "PERIODIC REPLACEMENT OF 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 specified replacement time.

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SAFETY

PRECAUTIONS WITH TIRES

PRECAUTIONS WITH TIRES
HANDLING TIRES If tires or rims are handled mistakenly, there is danger that the tire may explode or be damaged, or that the rim may fly off and cause serious personal injury or death. To maintain safety, always do as follows. Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special technology, so always ask your Komatsu distributor to carry out these operations. Always use the tires specified by Komatsu and maintain the specified inflation pressure. Suitable tire inflation pressure: see "CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM (PAGE 4-31)" When pumping up the tires, check that no other person is standing near the tire, and install an air chuck with a clip that can be secured to the air valve. To prevent the tire inflation pressure from becoming too high, measure the pressure from time to time with an air gauge while pumping up the tire. If the tire pressure goes down abnormally or the rim parts do not fit the tire, there is a problem with the tire or rim parts. Always contact your Komatsu distributor for repairs. If the rim parts are not fitted properly when the tire is being pumped up, there is danger that the rim parts may fly off, so set up a protective fence around the tire, and do not stand directly in front of the rim. Stand beside the tread when pumping up the tire. Do not adjust the tire inflation pressure immediately after traveling at high speed or carrying out operations under heavy load. Never carry out welding or light a fire near the tire. PRECAUTIONS WHEN STORING TIRE Tires for construction equipment are extremely heavy, it may lead to serious personal injury or death. As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires must be stored outside, always erect a fence and put up "No Entry" signs. Stand the tire on level ground, and block it securely so that it cannot roll or fall over if any person should touch it. Do not lay the tire on its side. This will deform the tire and cause it to deteriorate. If the tire should fall over, do not attempt to stop it. Get out of the way quickly.

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3-1

GENERAL VIEW OPERATION GENERAL VIEW GENERAL VIEW OF MACHINE The drawing shows the machine with the cab (if equipped) installed (1) Front wheel (4) Head lamp (if equipped) (2) Blade lift cylinder (5) Blade (3) Rear wheel 3-2 ..

. OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES The drawing shows the machine with the cab (if equipped) installed (1) Inching pedal (9) Turn signal lever (2) Steering wheel (10) Accelerator pedal (3) Horn button (11) Gearshift lever (4) Work equipment control lever (12) Fuel control lever (5) Starting aid switch (13) Right side panel (6) Dimmer switch (14) Decelerator pedal (7) Machine monitor (15) Brake pedal (8) Differential lock switch (if equipped) (16) Steering console tilt pedal 3-3 .

GENERAL VIEW OPERATION Machine monitor (1) Engine water temperature gauge (2) Speedometer (if equipped) (3) Turn signal pilot lamp (if equipped) (4) Fuel gauge (5) Message center (6) Battery charge (7) Engine oil pressure (8) Brake oil pressure (9) Transmission system electric circuit monitor (10) Lift arm lock (11) Torque converter oil temperature (12) Differential oil temperature (if equipped) (13) Differential control (if equipped) (14) Blade accumulator (if equipped) (15) Working lamp (if equipped) (16) Blade float (if equipped) (17) Preheating lamp (18) High beam of front lamp (if equipped) (19) Parking brake (20) Articulation gauge (21) Torque converter oil temperature gauge Right panel (22) Starting switch (23) Hazard lamp switch (if equipped) (24) Working lamp switch (if equipped) (25) Blade accumulator/float switch (if equipped) (26) Cigarette lighter (if equipped) (27) Lift arm lock switch (28) Front wiper switch (top) (if equipped) (29) Front lamp switch (if equipped) (30) Transmission mode selector switch (31) Car heater switch (if equipped) (32) Additional car heater switch (if equipped) 3-4 ..

OPERATION GENERAL VIEW Top left inside cab (1) Front wiper switch (bottom) (if equipped) (2) Rear wiper switch (if equipped) (3) Yellow rotating lamp switch (if equipped) (4) Front defroster fan switch (if equipped) (5) Rear defroster fan switch (if equipped) 3-5 ..

. METERS AND LAMPS (1) Engine water temperature gauge (2) Speedometer (if equipped) (3) Turn signal pilot lamp (if equipped) (4) Fuel gauge (5) Message center (6) Battery charge (7) Engine oil pressure lamp (8) Brake oil pressure lamp (9) Transmission system electric circuit monitor (10) Lift arm lock (11) Torque converter oil temperature (12) Differential oil temperature (if equipped) (13) Differential control (if equipped) (14) Blade accumulator (if equipped) (15) Working lamp (if equipped) (16) Blade float (if equipped) (17) Preheating lamp (18) High beam of front lamp (if equipped) (19) Parking brake (20) Articulation gauge (21) Torque converter oil temperature gauge (22) Service meter (to the left side of the steering wheel column) 3-6 . it is important to completely understand methods of operating the equipment. EXPLANATION OF COMPONENTS OPERATION EXPLANATION OF COMPONENTS The following is an explanation of devices needed for operating the machine. To perform suitable operations correctly and safely. and the meanings of the displays.

Fuel tank capacity: 340 liters (89.76 US gal) 3-7 . FUEL GAUGE This gauge (4) indicates the amount of fuel in the fuel tank. carry out the warming-up operation until the indicator enters the white range. add fuel. If the gauge goes into the red range during operation. and wait for the temperature to go down to the white range. SPEEDOMETER (If equipped) This meter (2) displays the travel speed of the machine. the flashing interval becomes shorter. TURN SIGNAL PILOT LAMP (If equipped) This lamp (3) flashes at the same time as the turn signal lamp. During normal operation. E: Little fuel remaining F: Full tank If the gauge comes close to the E mark. REMARK If there is a disconnection in the turn signal lamp. the gauge should be in the white range.. stop the machine. OPERATION EXPLANATION OF COMPONENTS ENGINE WATER TEMPERATURE GAUGE This meter (1) displays the engine cooling water temperature. There is an odometer at the bottom of the meter. After starting the engine. run the engine at a mid-range speed under no load.

If it flashes. the transmission range is displayed for 3 seconds. Stop the engine. REMARK AUTO always shows the engine speed. BATTERY CHARGE This lamp (6) warns of any problem in the charging system when the engine is running. It lights up when the starting switch is turned ON. see "OTHER TROUBLE (PAGE 3-120)". see "OTHER TROUBLE (PAGE 3-120)". see "OTHER TROUBLE (PAGE 3-120)". transmission range. If any problem is found. error code. but when changing to the transmission range. and machine travel speed. press the SCROLL button to change the brightness of the message center as follows: 100% -> 25% -> 50% -> 100%. stop the engine immediately. and check for any problem. and check for any looseness of the V-belt. and goes out after the engine stops. If any failure occurs in the transmission control. The error code always displays [E--0]. check the charging circuit. ENGINE OIL PRESSURE This lamp (7) lights up to warn that the engine lubricating oil pressure has dropped. If it lights up during operation. and then the display returns to the engine speed display. the display changes as follows: AUTO -> engine speed -> transmission range -> error code -> monitor brightness adjustment -> version of software -> machine travel speed (mph display) -> machine travel speed (km/h display). 3-8 . the error code is displayed. If any other display appears. When the "MODE" button is pressed. and contact your Komatsu distributor for repairs. When adjusting the brightness of the monitor. EXPLANATION OF COMPONENTS OPERATION MESSAGE CENTER This meter (5) indicates the engine speed. For details..

and wait for the lamp to go out. If it lights up. Read the error code displayed on the controller and contact your Komatsu distributor for repairs. TORQUE CONVERTER OIL TEMPERATURE This lamp (11) lights up to warn that the torque converter oil temperature has risen.shifting function of the transmission. 3-9 . run the engine at a midrange speed under no load.. OPERATION EXPLANATION OF COMPONENTS BRAKE OIL PRESSURE This lamp (8) lights up to warn that the oil pressure in the brake circuit has dropped. LIFT ARM LOCK This lamp (10) lights up when the lift arm is not locked. stop the machine. stop the engine immediately. or short circuit in the electrical equipment and it has become impossible to carry out the normal gear. TRANSMISSION SYSTEM ELECTRIC CIRCUIT MONITOR This lamp (9) lights up when there is any failure. disconnection. and check for leakage of oil from the brake circuit. If it lights up.

check the oil level in the final drive case. 3 . If it lights up. EXPLANATION OF COMPONENTS OPERATION DIFFERENTIAL OIL TEMPERATURE (If equipped) This lamp (12) lights up to warn that the differential oil temperature has risen. BLADE ACCUMULATOR (If equipped) This lamp (14) lights up when the blade accumulator/float switch is turned ON. WORKING LAMP (If equipped) This lamp (15) lights up when the working lamp switch is turned ON. DIFFERENTIAL CONTROL (If equipped) This lamp (13) lights up when the differential is locked. If there is no problem.10 .. This protects the operator and work equipment when carrying out leveling work on road surfaces where there are many rocks. set the differential to UNLOCK and wait for the lamp to go out.

it shows that the preheating has been completed. 20 seconds.11 .. When the starting switch is turned to the HEAT position. HIGH BEAM OF FRONT LAMP (If equipped) This lamp (18) lights up to indicate that the head lamps are at BEAM. PARKING BRAKE This lamp (19) lights up to indicate that the gearshift lever is at the P (Parking) position. PREHEATING LAMP This lamp (17) displays the preheating time when starting the engine at temperatures of 5°C (41°F) or below. This is effective for snow-clearing operations. 3 . When it goes out. OPERATION EXPLANATION OF COMPONENTS BLADE FLOAT (If equipped) This lamp (16) lights up when the blade accumulator/float switch switch is turned ON. the lamp lights up for approx.

3 . The service meter will advance while the engine is running even if the machine is not moving. The meter is installed to the left side of the steering wheel column. it shows the angle of the machine body. the gauge indicator is at the left side. the oil temperature is normal. EXPLANATION OF COMPONENTS OPERATION ARTICULATION GAUGE This gauge (20) indicates the angle between the front frame and rear frame. REMARK When the engine is running. The service meter reading advances by 1 for every hour that the engine is running. When the key is at the OFF position.12 . and when the switch is at the ON position. SERVICE METER This meter (22) displays the accumulated hours of operation of the machine. regardless of the engine speed. TORQUE CONVERTER OIL TEMPERATURE GAUGE This gauge (21) indicates the torque converter oil temperature. When the pointer of the temperature gauge shows the green range. stop the machine immediately. the operation display at the top of the meter rotates to indicate that the meter is advancing. When the pointer enters the red range.. and run the engine at 1900 rpm with the gear shift lever in neutral until the oil temperature drops to the normal value.

.

OPERATION

EXPLANATION OF COMPONENTS

SWITCHES

The drawing shows the machine with the cab (if equipped) installed (1) Starting switch (10) Transmission mode selector switch (2) Starting aid switch (11) Dimmer switch (if equipped) (3) Front lamp switch (if equipped) (12) Differential lock switch (if equipped) (4) Working lamp switch (if equipped) (13) Turn signal lever (if equipped) (5) Blade accumulator/float switch (if equipped) (14) Horn button (6) Cigarette lighter (if equipped) (15) Car heater switch (if equipped) (7) Lift arm lock switch (16) Additional car heater switch (if equipped) (8) Front wiper switch (top) (if equipped) (17) Fresh/recirc selector switch (if equipped) (9) Hazard lamp switch (if equipped)

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. EXPLANATION OF COMPONENTS

OPERATION

Top right inside cab (18) Room lamp switch

Top left inside cab (19) Front wiper switch (bottom) (if equipped) (20) Rear wiper switch (if equipped) (21) Yellow rotating lamp switch (if equipped) (22) Front defroster fan switch (if equipped) (23) Rear defroster fan switch (if equipped)

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OPERATION

EXPLANATION OF COMPONENTS

STARTING SWITCH
This switch (1) is used to start or stop the engine. OFF position The key can be inserted or with drawn. The switches for the electric system are all turned off and the engine is stopped. ON Electricity flows to the charging circuit and lamp circuit. START This is the position for starting the engine. Keep the key at this position while cranking the engine. When the engine starts, release the key immediately. The key returns automatically to the ON position. HEAT position Set to this position when starting the engine in cold weather. If the key is held at the HEAT position, the electrical heater will be heated and the preheat monitor will light up. When the preheating is completed, the preheating monitor will go out. When the preheating monitor goes out, release the key immediately. If the key is released, it will return to the OFF position. Stop the engine with the key at the OFF position, then turn the key to the START position to start the engine. REMARK When the preheating lamp goes out in cold weather, continue preheating for a further 10 seconds before releasing the key.

STARTING AID SWITCH
Use this switch (2) when starting the engine in cold weather (-21° C (-5.8°F) or below). If this switch (2) is pressed when the engine is being started, the load on the hydraulic pump will be reduced and this will make it easier for the engine to start. When the engine starts and the engine speed rises to a stable condition, release the switch. Position (a) (when pressed): ON Position (b) (when released): OFF This switch functions only when the gearshift lever is at the P (Parking) position.

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. EXPLANATION OF COMPONENTS

OPERATION

FRONT LAMP SWITCH
(If equipped) This switch (3) is used to light up the front lamps, side clearance lamps, tail lamps, and instrument panel. Position (a) (pushed back): OFF Position (b): Side clearance lamps, tail lamps, and instrument panel light up Position (c) (pushed forward): Front lamps light up in addition to lamps at position (b).

WORKING LAMP SWITCH
(If equipped) This switch (4) is used to light up the working lamp. Position (a) (pushed back): OFF Position (b) (pushed forward): Working lamp lights up

BLADE ACCUMULATOR/FLOAT SWITCH
(If equipped) This switch (5) is used to actuate the blade accumulator and float. Position (a) (neutral): OFF Position (b) (pushed forward): Blade float ON Position (c) (pushed back): Blade accumulator ON REMARK The blade accumulator is effective in leveling road surfaces on jobsites where there are many rocks or when clearing compressed snow. The blade float is effective when clearing fresh snow.

CIGARETTE LIGHTER
(If equipped) This cigarette lighter (6) is used to light cigarettes. When the cigarette lighter is pushed in, it will return to its original position after several seconds, so pull it out and use it to light your cigarette.

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OPERATION

EXPLANATION OF COMPONENTS

LIFT ARM LOCK SWITCH

WARNING
Lower the blade to the ground before removing the bank control lock pin. Do not remove it at any other position. There is danger that it will rotate and the blade will fall.

This switch (7) is used to remove or insert the lifter lock pin. This switch is used when setting the blade to the bank cut posture or shoulder reach posture. Press the switch to remove the pin; press the switch again to return the switch and insert the pin.

FRONT WIPER SWITCH (TOP)
(If equipped) This switch (8) is used to operate the wiper at the top of the front glass. Position (a): Washer liquid is sprayed out Position (b): Wiper is operated Position (c): Wiper is operate and washer liquid is sprayed out

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. EXPLANATION OF COMPONENTS

OPERATION

HAZARD LAMP SWITCH
(If equipped)

WARNING
Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine operators.

The emergency lamp is used only in emergencies. This switch (9) is used to make the emergency lamp flash when there is a failure or when the machine has to be parked on the road. Position (a) (pushed back): OFF Position (b) (pushed forward): All turn signal lamps flash

TRANSMISSION MODE SELECTOR SWITCH
This switch (10) switches the gearshifting pattern of the transmission. Position (b) (push forward): Mode 1 When carrying out work with the same operating feeling as the conventional direct power shift (hydroshift), select Mode 1. Use Mode 1 in the following cases: When carrying out work with production efficiency raised to the maximum. When carrying out snow clearing or other work with the gearshift range fixed.

Position (a) (push back): Mode 2 When carrying out work in the torque converter drive with easy-to-operate automatic gearshifting, select Mode 2. When traveling in a high-gear speed range at a speed of 10 km/h (6.2 MPH) or above, this automatically shifts to the lock-up with its more efficient power transmission. Use Mode 2 in the following cases: When carrying out work with big variation in load, where the engine is likely to stall (F1 - F4) When carrying out snow-clearing work in high-gear speed range at a speed of 10 km/h (6.2 MPH) or above When traveling under own power.

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OPERATION

EXPLANATION OF COMPONENTS

z : Manual gearshifting uses the torque converter lock-up from the beginning
With automatic gearshifting, when the travel speed rises and the torque converter slippage is reduced, the transmission is automatically locked up. { : Remains in torque converter drive (torque converter drive is held, regardless of travel speed or engine speed) Manual gearshifting: Transmission is held in same gear range as position of gearshift lever Automatic gearshifting: Transmission is automatically shifted according to travel speed within maximum range set by position of gearshift lever REMARK When Mode 1 is selected, the engine may stall because of the use of direct power shift. When Mode 2 is selected and work is carried out in F1 with the engine at low idle, it becomes easier to perform light load operations, such as finishing work at low travel speed (approx. 1 km/h (0.6 MPH)). When Mode 2 is selected and the gear speed range is set between F5 and F8, the transmission is shifted automatically. With automatic transmission, the transmission starts in F4 torque converter drive, and shifts up automatically as necessary through the gear speeds to the set gear speed range. Even if the gearshift lever is shifted, if there is danger of overrun, the overrun inhibitor is actuated to prevent gearshifting. When the travel speed drops to a speed where there is no danger of overrun, the transmission starts to shift again.

DIMMER SWITCH
(If equipped) This switch (11) is used to switch the head lamps between high beam and low beam. (a) High beam (b) Low beam

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. EXPLANATION OF COMPONENTS

OPERATION

DIFFERENTIAL LOCK SWITCH
(If equipped) This switch (12) is used to actuate the differential lock. Position (a) (pushed back): Differential lock actuated Position (b) (pushed forward): OFF

TURN SIGNAL LEVER
(If equipped) This lever (13) is used to operate the turn signal lamps. (a)Left turn: Operate the lever up (b)Right turn: Operate the lever down The lever does not return to its original position when the steering lever is returned to the straight position. Return the lever by hand.

HORN BUTTON
When horn button (14) in the center of the steering wheel is pressed, the horn will sound.

CAR HEATER SWITCH
(If equipped) Use this switch (15) to turn the heater ON/OFF and to regulate the air flow (3 levels). Position (a): OFF Position (b): ON, low air flow Position (c): ON, medium air flow Position (d): ON, high air flow

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OPERATION

EXPLANATION OF COMPONENTS

ADDITIONAL CAR HEATER SWITCH
(If equipped) Use this switch (16) to increase the heater capacity. Position (a): OFF Position (b): ON, low air flow Position (c): ON, medium air flow Position (d): ON, high air flow

FRESH/RECIRC SELECTOR SWITCH
(If equipped) This switch (17) is used to choose introduction of fresh air from outside or recirculation of the air inside the cab. Pull the switch to position (a) to take in outside air; push the switch to position (b) to circulate the air inside the cab.

ROOM LAMP SWITCH
This switch (18) is used to light up the room lamp. ON position: Lamp lights up OFF position: Lamp goes out

3 - 21

Position (a): OFF Position (b): Rotating lamp lights up REMARK The yellow rotating lamp is used when carrying out operations. EXPLANATION OF COMPONENTS OPERATION FRONT WIPER SWITCH (BOTTOM) (If equipped) This switch (19) actuates the wiper for the bottom of the front glass. but follow the guidance of the supervisor. Position (a): OFF Position (b): Wiper actuated Position (c): Washer fluid sprayed out REAR WIPER SWITCH (If equipped) This switch (20) actuates the wiper for the rear glass. Position (a): OFF Position (b): Wiper actuated Position (c): Washer fluid sprayed out YELLOW ROTATING LAMP SWITCH (If equipped) This switch (21) is used to light up and rotate the rotating lamp.. 3 .22 .

Position (a) (pushed back): OFF Position (b) (pushed forward): Front defroster fan actuated This is the switch installed to the defroster and can be used to stop or start operation of the defroster.. 3 . REAR DEFROSTER FAN SWITCH (If equipped) This switch (23) is used to actuate the rear defroster fan. OPERATION EXPLANATION OF COMPONENTS FRONT DEFROSTER FAN SWITCH (If equipped) This switch (22) is used to actuate the front defroster fan. Position (a) (pushed back): OFF Position (b) (pushed forward): Rear defroster fan actuated This is the switch installed to the defroster and can be used to stop or start operation of the defroster.23 .

24 . PEDALS The drawing shows the machine with the cab (if equipped) installed (1) Left blade lift cylinder control lever (10) Right blade lift cylinder control lever (2) Ripper/Scarifier control lever (if equipped) (11) Inching pedal (3) Blade side shift control lever (12) Steering console tilt pedal (4) Power tilt control lever (13) Brake pedal (5) Blade rotation control lever (14) Accelerator pedal (6) Articulate control lever (15) Decelerator pedal (7) Front attachment control lever (16) Gearshift lever (8) Drawbar side shift control lever (17) Fuel control lever (9) Leaning control lever 3 . EXPLANATION OF COMPONENTS OPERATION CONTROL LEVERS..

OPERATION EXPLANATION OF COMPONENTS LEFT BLADE LIFT CYLINDER CONTROL LEVER This lever (1) operates the left blade lift cylinder. (b) HOLD: The blade stops and is held in the same position. When the machine is equipped with a ripper (a) LOWER: The ripper is lowered. (c) RAISE: The ripper is raised.25 . RIPPER/SCARIFIER CONTROL LEVER (If equipped) This lever (2) is used to operate the ripper or scarifier.. (c) RAISE: The left side of the blade goes up. 3 . (a) LOWER: The left side of the blade goes down. (b) HOLD: The ripper is stopped and held in position.

26 . (b) HOLD: The blade stops and is held in the same position. (b) HOLD: The scarifier is stopped and held in position. (a) LEFT SHIFT: The blade is shifted to the left position. EXPLANATION OF COMPONENTS OPERATION When the machine is equipped with a scarifier (a) LOWER: The scarifier is lowered. (c) RIGHT SHIFT: The blade is shifted to the right. (c) RAISE: The scarifier is raised.. BLADE SIDE SHIFT CONTROL LEVER This lever (3) shifts the blade to the side. 3 .

3 . This is effective when operating on soft ground. (b) HOLD: The blade stops and is held in the same position. (a) Max. This is effective when operating on hard ground. be careful not to let the blade hit the tires when rotating the blade.. (a) RIGHT ROTATION: The blade is rotated to the left. (b) HOLD: The blade stops and is held in the same position.27 . (c) Min. OPERATION EXPLANATION OF COMPONENTS POWER TILT CONTROL LEVER This lever (4) changes the cutting angle of the blade. cutting angle: This makes the blade cutting angle smaller. This lever (5) rotates the blade. cutting angle: This makes the blade cutting angle bigger. (c) LEFT ROTATION: The blade is rotated to the right. BLADE ROTATION CONTROL LEVER NOTICE To prevent damage to the tires.

If the articulation is operated at a speed of over 10 km/h (6. be careful not to let the blade hit the tires when articulating the machine.2 MPH). (b) HOLD: The articulation is kept in the same condition.. (c) RIGHT TURN: The machine articulates to the right. NOTICE To prevent damage to the tires. FRONT ATTACHMENT LEVER This lever (7) is used when an optional front attachment is installed.2 MPH). 3 . (a) LEFT TURN: The machine articulates to the left. there is danger that the machine may overturn. EXPLANATION OF COMPONENTS OPERATION ARTICULATE CONTROL LEVER WARNING Operate this lever only when traveling at a speed of below 10 km/h (6.28 . This lever (6) is used to operate the articulation.

(b) HOLD: The leaning is kept in the same condition. 3 .. (b) HOLD: The drawbar stops and is held in the same position. (c) RIGHT TURN: The tires lean to the right. (a) LEFT TURN: The tires lean to the left. (c) RIGHT SHIFT: The drawbar is shifted to the right. LEANING CONTROL LEVER This lever (9) is used to operate the leaning. (a) LEFT SHIFT: The drawbar is shifted to the left.29 . OPERATION EXPLANATION OF COMPONENTS DRAWBAR SIDE SHIFT CONTROL LEVER This lever (8) shifts the drawbar to the side.

instrument panel. or when shifting the direction between forward and reverse. INCHING PEDAL NOTICE Do not operate continuously for more than 10 seconds. Use this pedal when stopping the machine. 3 . such as abnormal wear or seizure. If the inching operation is used continuously for more than 10 seconds. operating this pedal makes it possible to make fine movements of the machine. When the transmission is in F1 . the power is cut off. then release the pedal. move the steering console to the desired position. Depress the tilt pedal.. REMARK The steering wheel. and work equipment control levers also move forward or backward at the same time. When the pedal is depressed. EXPLANATION OF COMPONENTS OPERATION RIGHT BLADE LIFT CYLINDER CONTROL LEVER This lever (10) operates the right blade lift cylinder. starting the machine off. (c) RAISE: The right side of the blade goes up.F4 or in R2. it will cause serious damage to the clutch. (a) LOWER: The right side of the blade goes down. STEERING CONSOLE TILT PEDAL This pedal (12) can be used to adjust the angle of the steering console steplessly. (b) HOLD: The blade stops and is held in the same position. This pedal (11) cuts off the power from the engine.30 .

the engine speed will go down.. the decelerator pedal rises. It is interconnected with the fuel control lever. It is interconnected with the fuel control lever. 3 . When the decelerator pedal has risen and it is depressed. This pedal (13) is used to apply the wheel brakes. ACCELERATOR PEDAL This pedal (14) adjusts the engine speed. when the fuel control lever is pulled. OPERATION EXPLANATION OF COMPONENTS BRAKE PEDAL WARNING Do not place your foot on this pedal unnecessarily. DECELERATOR PEDAL This pedal (15) is used to adjust the engine speed. and it can be used freely to operate from the position set by the fuel control lever to the full speed position.31 .

3 . always set the gearshift lever to the P (Parking) position. This lever (16) is used to select the transmission speed range. REMARK The gearshift lever must be placed at the P (Parking) position to start the engine. FUEL CONTROL LEVER This lever (17) is used to adjust the engine speed and output. The gearshifting pattern differs according to the position of the transmission mode selector switch. For general travel. EXPLANATION OF COMPONENTS OPERATION GEARSHIFT LEVER WARNING When standing up from the operator's seat. see "TRANSMISSION MODE SELECTOR SWITCH (PAGE 3-18)".32 . The transmission has 8 FORWARD and 4 REVERSE speeds. and the gear is shifted simply by setting the gearshift lever to the desired position. use the accelerator pedal. For details.. (a) Low idling: Lever pushed fully forward (b) High idling: Lever pulled fully back REMARK Use the fuel control lever only when starting the engine or during operations.

After cleaning the element. When the yellow display panel showing the clogging reaches the red line. Always insert the lock pin for general travel. It displays five levels for the amount of clogging.. This pin (1) is used to lock the front frame and rear frame to prevent the machine from bending during normal travel or when servicing or transporting the machine.33 . be sure to turn off the starting switch. replace the fuse. and replace the fuse. please contact your Komatsu distributor. or the fuse is loose in the fuse holder. If the fuse becomes corroded. when traveling with the machine articulated. The fuses protect the electrical equipment and wiring from burning out. NOTICE Before replacing a fuse. ARTICULATE LOCK PIN WARNING When servicing or transporting the machine always use this lock pin. For general travel. FUSE BOX WARNING If the fuse blows again immediately after it is replaced. press the reset button to return the yellow display panel to its original position. Replace the fuse with another of the same capacity. Remove the cover. clean the element. OPERATION EXPLANATION OF COMPONENTS DUST INDICATOR This device checks the condition of clogging of the air cleaner element. or white powder can be seen. 3 . there is danger of the machine turning over if it is turned sharply.

ACC. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Fuse II No.. backup alarm Fog lamp Turn signal lamp Brake lamp. fan Capacity Name of circuit 20A 20A 20A 10A 20A 20A 20A Working lamp (front) Air conditioner Air conditioner Lift arm lock. working lamp (rear) Parking brake. gauge lighting Transmission Name of circuit 3 .34 . accumulator Option Capacity 20A 10A 20A 10A 20A 10A 20A Head lamp Horn. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 10A 10A 20A 20A Working lamp Cigarette lighter Rear wiper Front wiper (top) 10A Working lamp 20A 10A Front wiper (bottom) Yellow rotating lamp. differential Car heater Float. EXPLANATION OF COMPONENTS OPERATION FUSE CAPACITY AND NAME OF CIRCUIT Fuse I No. VHP.

steps. wear to tires. OPERATION OPERATION OPERATION CHECK BEFORE STARTING ENGINE WALK-AROUND CHECK Before starting the engine. engine muffler.. 2. If any dirt or flammable materials are found. Perform the following inspections and cleaning every day before starting engine for the day's work. remove them. check for loose mounting bolts Check that there is no peeling of the tires or cracking of the wheels (side ring. Also check for loose wiring. Check for problems in handrails. engine. oil and coolant. If any problem is found. Check for leakage of oil from brake line Check that there is no leakage of oil. leakage of fuel. play in work equipment. 5.) around the battery. wheels. If any problem is found. linkage. cylinders. hose.35 . tandem drive case. or contact your Komatsu distributor. install a substitute part. Remove dirt and debris from around the engine. 3 . 6. battery. 7. and radiator. cylinders. 1. muffler. or other high temperature engine parts. If any problem is found. wear. repair it. repair it. play. loose bolts. joints. turbocharger. If any problem is found. repair or replace. WARNING Remove any flammable materials from around the battery. Check for damage. Tighten any loose bolts. Check carefully. rim base. 4. If any problem is found. be sure to repair any problem. linkage. If any problem is found. twigs. turbocharger. and hoses. Also check for flammable material (dry leaves. Also check the condition of the work equipment and the hydraulic system. Check that there is no oil leakage. play in wotk equipment. etc. Tighten any loose wheel nuts. repair the place where the oil is leaking. Check for coolant and oil leakage around the engine Check for oil leakage from the engine and coolant leaks from the cooling system. walk around the machine and look at the underside of chassis for anything unusual like loose bolts and nuts. If the valve cap is lost. hoses Check for cracks. hydraulic tank. Check for damage. repair the place where the oil is leaking. circle reverse gear case. Leakage of fuel or oil will cause the machine to catch fire. Check for oil leakage of oil from transmission case. or other high temperature engine parts. 3. repair it. excessive wear. and collection of dust at places that reach high temperature. Check for dirt accumulated around the engine and radiator. final drive case. lock ring).

Clean cab window To ensure a good view during operations. OPERATION OPERATION 8. WARNING Check the rims (wheels) and rings for deformation. 13. lock rings and rim flanges thoroughly. Wear: Tires with a tread grooves of less than 15% of that of a new tire Tires with extreme uneven wear or with stepped-type wear Damage: Tires with damage that has reached the cords. corrosion and cracks. loose mounting bolts Check that there is no damage to the mirror or reflectors. and replace if there is any problem. Repair or replace if any problem is found. check the side rings. do not use the following tires. 12. To ensure safety. If there is any damage. If any problem is found. Check for damaged mirror. they may burst and cause serious injury or death. reflector. 11.36 . which do not seem usable 14. Clean off any dirt from the surface. monitor. 9. Check for problem in gauges. always keep the cab windows clean. 10. deformed or abnormally damaged tires. 3 . Inspect rims. In particular. Check for problem in the gauges and monitor in the operator's cab. Inspect tires. WARNING If worn or damaged tires are used. Is door lock normal? Check that there is no damage to the cab door lock. Seat belt and mounting clamps Check for damage or wear to the seat belt and mounting clamps. replace the parts. replace with new parts. Tighten any loose bolts. or with cracks in the rubber Tires with cut or pulled cords Tires with peeled (separated) surface Tires with damaged bead Leaking or improperly repaired tubeless tires Deteriorated.. Clean all dirt from the surface of the mirror and reflector.

37 . check for possible water leakage. Immediately after the engine is stopped. When checking the coolant. always wait for the engine to cool down and check the sub tank. CHECK COOLANT LEVEL. Check that the cooling water in sub tank (1) is between the H and L marks. If the level is low. After adding coolant. OPERATION OPERATION CHECK BEFORE STARTING Always carry out the item in this section before starting the engine each day. If the cap is removed to check the coolant level in this condition. Confirm that there is no oil in the coolant. tighten the cap securely.. 1. then turn the cap slowly to release the pressure and remove it carefully. open the cover and add water through the water filler of sub tank (1) to between the H and L marks. 3 . the coolant is at a high temperature and the radiator is under high internal pressure. NOTICE If the volume of coolant added is more than usual. there is a hazard of burns. Wait for the temperature to go down. 2. ADD WATER WARNING Do not open the radiator cap unless necessary.

Fuel capacity: 340 liters (89. OPERATION OPERATION CHECK FUEL LEVEL. 3. fill the fuel tank through fuel filler port (F). After completing work.. NOTICE If breather hole (1) in the cap becomes clogged. together with fuel. ADD FUEL WARNING When adding fuel. turn the switch back to the OFF position. Turn the engine starting switch to the ON position and check the fuel level with fuel level gauge (G). 2. After adding fuel. After checking. so clean the breather hole from time to time. This may cause a fire. tighten the cap securely. 3 . If any fuel is spilled.38 .76 US gal) DRAIN WATER AND SEDIMENT IN FUEL TANK Loosen fuel tank drain valve (1) and drain the sediment and water. wipe it up completely. accumulated at the bottom. 1. never let the fuel overflow. the pressure inside the tank will go down and the fuel may not flow. Never bring flames near fuel because it is highly flammable and dangerous.

carry out cleaning. the red ring floats up. Inspect the water separator and check the condition of red ring (1) inside. DRAIN WATER SEPARATOR 1. CHECK WATER SEPARATOR (PAGE 4-26)". Open the engine side cover on the left side of the chassis. 3. 2.. see Section "CLEAN. If the ring floats up to the standard line. loosen drain valve (2) and drain the water. For details. The area below the red ring is water. 4. OPERATION OPERATION CHECK. REMARK If water collects in the water separator. If red ring (1) floats up.39 . 3 .

2. Open the side cover at the front of the rear left side of the machine. ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. wait for at least 15 minutes after stopping the engine before checking. Fully insert dipstick (G) into filler pipe (F). When adding oil. 1. make it horizontal before checking. Wait for the oil temperature to go down before performing this operation. and check the oil level again. The oil level should be between the marks on dipstick (G). REMARK When checking the oil level after the engine has been operated. remove the dipstick from the guide to release the air inside the crankcase. then remove it. OPERATION OPERATION CHECK ENGINE OIL PAN LEVEL. If the machine is at an angle. If the oil level is below the mark. 4. add engine oil through oil filler (F). If the oil is above the H mark. If the oil level is correct. open drain plug (P) at the rear right of the machine. and wipe the oil off with a cloth. 6. Remove dipstick (G). 5. 3 .. tighten the oil filler cap securely and close the engine side cover.40 . 3. drain the excess oil into a container.

clean the element. Keep the top surface of the battery clean and check the breather hole in the battery cap. 2. Moreover. engine starting motor and alternator. 3. or replacing. that fuses of the specified capacity are used. For details of the method of cleaning the element. If the yellow display panel reaches red line (3). tighten them. Check the position of yellow display panel (2) in the transparent portion of dust indicator (1). Be sure to check that there is no inflammable material accumulated around the battery. that there is no disconnection or trace of short-circuiting in the electric wiring and no damage to the covering. If it is clogged with dirt or dust. Standard: 10 mm (0. CHECK AND ADJUST STEERING WHEEL Start the engine and check the steering wheel play. press the button of dust indicator (1) to return the yellow display panel to its original position. 3 .4 in) maximum If the steering wheel play is out of the standard range or the steering wheel waves normally or is abnormally heavy. Check also that there is no loosened terminals. wash the battery cap to clean the breather hole. If any. After inspecting. or contact your Komatsu distributor for repairs.41 . locate the cause and immediately perform repairs. ask your Komatsu distributor for repairs. remove immediately. CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-22)". CHECK ELECTRIC WIRING WARNING If the fuses frequently blow or if there are traces of short circuits in the electrical wiring. OPERATION OPERATION CHECK DUST INDICATOR 1. cleaning.. pay particular attention to the electric wiring when checking the battery. see Section "CHECK. Check that there is no damage to the fuses. If any is found.

6) 250 (2.. set the gearshift lever to the P (Parking) position.1) 300 (3.75. WINDOW WASHER. PSI)] 275 (2. Set the machine on a dry downhill slope.00-24-10PR 14. If any problem is found.6) 3 .00-24-10PR 13. 42.00.75. AND DEFROSTER WORK PROPERLY. CHECK WASHER FLUID LEVEL CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge. please contact your Komatsu distributor. 39. and check if the parking brake can hold the machine in position.00-24-12PR 17. Check for loose wheel hub nuts (bolts). please contact your Komatsu distributor to have the brakes adjusted. Tire size 13.00. 39.42 . CHECK FOR DIRT AND DAMAGE CHECK THAT ALL PROBLEMS FROM PREVIOUS DAY HAVE BEEN REPAIRED CHECK THAT WINDSHIELD WIPER.5R25TGœ Inflation pressure [kPa (kgf/cm2. OPERATION OPERATION CHECK BRAKING EFFECT Drive the machine forward and check the effect of the brakes. Check for damage or wear to the tires and the rims. 35. The proper inflation pressure is shown below. If there is any problem in the actuation of the brakes.1) 300 (3.50. while the tires are cool. CHECK FLASHING OF LAMPS. before starting work. 42. see "CHECK DISC BRAKE (PAGE 4-66)".5) 275 (2. 2. CHECK PARKING BRAKE EFFECT 1. If the braking effect is poor.00-24-12PR 14.

and transportation. Steering wheel and gauges move in the same time.43 . 3 . (A) Fore-and-aft adjustment Move lever (1) to the right. Depress the pedal (1). Fore-and-aft adjustment 140 mm (5. If the articulation is to be used during travel operations. WORK EQUIPMENT CONTROL LEVERS WARNING Do not adjust the instrument panel when traveling. When the steering console is set to a desired position. OPERATION OPERATION REMOVAL OF ARTICULATE LOCK PIN WARNING For general travel.. release the pedal. ADJUSTMENTS ADJUST OPERATOR'S SEAT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. set the seat to the desired position. Adjust to a position that matches your physique and operating posture. Adjust the seat position at the beginning of each shift or when operators change. remove articulate lock pin (1) and keep it in the place shown by the arrow. and then release the lever. always keep the articulate lock pin installed. maintenance. Adjust the seat so that the brake pedal can be depressed all the way down with the operator's back against the backrest.5 in) (8 stages) ADJUSTING POSITION OF STEERING CONSOLE.

3 . OPERATION OPERATION ADJUSTING ANGLE OF INSTRUMENT PANEL WARNING Do not adjust the instrument panel when traveling.44 . Turn knob (1) to the left to release the lock. set the top of the panel to the desired position. then tighten the knob..

Adjust the seat so that the brake pedal can be depressed all the way with the operator's back against the backrest. 2. mid-point of your body. check that there is no problem in the securing brackets or belt. 3 . Always use the seat belt when operating the machine. replace. Adjust and fasten the seat belt before operating the machine.45 . Do not use the seat belt with either half of the belt twisted.. Sit in the seat. FASTEN THE BELT AND REMOVE IT 1. Sit in the seat. When removing the belt. Hold buckle (1) with your left hand and tongue (2) with your right hand. 3. Adjust the lengths of the belt on both the buckle and the tongue sides so that the buckle is located at the front. Fasten the belt along your body without kinking it. Pull the belt to check that the belt has locked. The date of manufacture is woven on the reverse side of the belt. OPERATION OPERATION USING SEAT BELT WARNING Before fastening the seat belt. replace the seat belt once every 3 years. raise the tip of buckle lever (1) to release it. Even if there appears to be no problem in the seat belt. If there is any wear or damage. and put tongue (2) into buckle (1).

46 .. TO LENGTHEN THE BELT Pull the belt while holding it at a right angle to the buckle or tongue. OPERATION OPERATION ADJUST THE BELT LENGTH TO SHORTEN THE BELT Pull the free end of the belt on either the buckle body or tongue side. 3 .

If the control levers are touched by accident when the engine is started.47 . 2. always set the gearshift lever to the P (Parking) position. Check that gearshift lever (1) is at the P (Parking) position. Check that work equipment control lever (2) is at the N (Holding) position. if gearshift lever (1) is not at the P (Parking) position.. regardless of whether the engine is running or stopped. check that the gearshift lever is properly at the P (Parking) position. When standing up from the operator's seat. CHECKS BEFORE STARTING ENGINE WARNING When starting the engine. OPERATION OPERATION OPERATIONS. the engine will not start. When starting the engine. 1. the work equipment may move suddenly and cause a serious accident. 3 .

Do not attempt to start the engine by short-circuiting the engine starting circuit. 2. Such an act may cause serious bodily injury or fire. wait for at least 2 minutes before trying to start the engine again. Set fuel control lever (1) to the half-open position. 3 . Do not start the engine with the fuel control lever and the accelerator pedal depressed to the FULL OPEN position. Turn the key in starting switch (2) to the START position. The engine will start. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds. Exhaust gas is toxic.. 1. Check that there are no persons or obstacles in the surrounding area. OPERATION OPERATION STARTING ENGINE NORMAL STARTING WARNING Sit down in the operator's seat before starting the engine. then sound the horn and start the engine. If the engine will not start. When starting the engine in confined spaces.48 . be particularly careful to ensure good ventilation.

then sound the horn and start the engine. Such an act may cause a serious bodily injury or fire. If the engine fails to start. STARTING IN COLD WEATHER WARNING Start the engine only after sitting down in the operator's seat. When starting the engine in confined spaces.49 . When the engine starts. repeat steps 1 . do not keep the starting motor rotating continuously for more than 20 seconds. Never use starting aid fluids as they may cause explosions. release the key in starting switch (2).3 after waiting for about 2 minutes. 3 . Set fuel control lever (1) to the half-open position. Exhaust gas is toxic.8°F) or below). NOTICE If there is no combustion in the engine (no smoke comes out from the exhaust pipe) when the starting motor is cranked. The key will return automatically to the ON position. 1.. When starting in low temperatures (-21°C (-5. be particularly careful to ensure good ventilation. Check that there are no persons or obstacles in the surrounding area. do as follows. Do not start the engine with the fuel control lever and the accelerator pedal depressed to the FULL OPEN position. OPERATION OPERATION 3. Do not attempt to start the engine by short-circuiting the engine starting circuit.

Keep starting aid switch (4) pressed and turn the key in the starting switch (2) to the START position. keep the key at the HEAT position for approx. 10 seconds. OPERATION OPERATION 2. The key will return automatically to the OFF position. release the key in starting switch (2). The engine will start.50 . 3. continue the preheating for a further 10 seconds. REMARK The preheating lamp goes out after 20 seconds. but in cold weather. When the preheating is completed (approx.. 4. 30 seconds). 3 . Turn the key in the starting switch (2) to the HEAT position. Even after preheating lamp (3) goes out.

release starting aid switch (4). 3 . set fuel control lever (1) to the LOW IDLE position. 6. When the engine starts and the speed rises strongly. 7. When the engine speed rises to a mid-range speed.. release starting switch (2).51 . If the engine speed follows the operation of the accelerator pedal. After carrying out the warming-up operation for approx. depress accelerator pedal (5) several times. The switch will return automatically to the OFF position. Keep starting aid switch (4) pressed. 5 minutes. OPERATION OPERATION 5. The key will return automatically to the ON position.

check that there is coolant in the radiator. Avoid operation with heavy loads or at high speeds. However. then fill the radiator with coolant. 3 . Immediately after starting the engine.52 . OPERATION OPERATION OPERATIONS. follow the precautions described in this manual. operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. If the work equipment is operated without warming up the machine sufficiently. Idle the engine for 5 minutes after starting it up. NOTICE Before operating the machine for the first time. and sudden changes in direction. During break-in operations. avoid sudden starts. run water through the system to flush the system thoroughly. The work equipment may not move as the operator desires. CHECKS AFTER STARTING ENGINE WARNING Emergency stop If the operation is abnormal or any other trouble occurs. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter). Particularly in cold areas. turn the key in the starting switch to the OFF position. sudden acceleration. the response of the work equipment to the movement of the control lever will be slow. Follow all warm-up procedures. BREAKING IN THE MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. make sure to warm up the machine properly. unnecessary sudden stops.. If the machine has been delivered without coolant in the radiator.

If any problem is found. 3. 2. Check for abnormal exhaust gas color. noise. 5 minutes to carry out warming-up. After the warming-up operation. carry out maintenance or repair. do not start operating the machine immediately..range speed for approx. contact your Komatsu distributor. If any problem is found. apply a load from time to time or run the engine at a mid-range speed. Do not run the engine at low idle or high idle continuously for more than 20 minutes. Operate the engine under a light load until the indicator of engine water temperature gauge (2) starts to move. check that the gauges and caution lamps are normal. Pull fuel control lever (1). NOTICE Do not accelerate the engine suddenly until the warming-up operation has been completed. or vibration. carry out the following operations and checks. If it is necessary to continue to run the engine at idle. First. and run the engine at a mid. 1. OPERATION OPERATION NORMAL OPERATION After the engine starts. 3 .53 .

Turn the key in starting switch (2) to the OFF position and stop the engine. do not try to stop it abruptly but run it at medium speed to allow it to cool down gradually. CHECK AFTER STOPPING ENGINE 1. Walk around the machine and check the work equipment. and then stop it. also check for any leakage of oil or coolant. 4. Remove the key from starting switch (2). If any problems are found. 3. Clean out any paper and debris to avoid a fire hazard. 2. and undercarriage.54 . If the engine has overheated. machine exterior. Check the engine compartment for paper and debris. Fill the fuel tank. OPERATION OPERATION STOPPING ENGINE NOTICE If the engine is stopped abruptly. 2. 3 . Do not stop the engine abruptly except in an emergency. Remove any mud affixed to the undercarriage. repair them. Place fuel control lever (1) in the low idle position and run the engine at low idle speed for about 5 minutes to allow it to gradually cool down.. service life of component parts of the engine may be considerably reduced. 1. 3.

3 . If articulation is carried out with the blade at the propulsion angle. when traveling with the machine articulated.. NOTICE Pay careful attention to the clearance between the blade and the front tire. Before moving any work equipment control lever. as shown in the diagram on the right. Always lock the front frame and rear frame with the articulate lock pin. the blade may cut the tire or bend the step. raise the front and rear ends of the blade equally and set so that the blade does not extend outside the machine. During general travel operations. OPERATION OPERATION TRAVELING POSTURE FOR MACHINE WARNING For general travel.55 . check the distance between the blade and tires. 1. there is danger of the machine turning over if it is turned sharply.

OPERATION OPERATION MOVING MACHINE OFF (FORWARD. Depress inching pedal (3).. Use extreme care when reversing the machine. PREPARATIONS FOR MOVING OFF 1. check that the brake oil pressure warning buzzer is not sounding. check that the area around the machine is safe. Always check that parking brake lamp (4) has gone out. Clear all personnel from the machine and the area. STOPPING WARNING When moving off. or 3rd speed. Set the blade to the travel posture. Do not operate the machine when air pressure is abnormal. Before starting operations. and sound the horn before moving. 2nd. REVERSE. check that the seat belt is properly installed. 3 . then set gearshift lever (1) to 1st. 3. NOTICE Before starting the machine off. Note there is a blind spot behind the machine. 2.56 . SHIFTING GEAR).

57 . When shifting gear. Let inching pedal (3) back and depress accelerator pedal (6) to move the machine off. SHIFTING GEAR ON MACHINE WARNING Avoid sudden shifting of gear when traveling at high speed. use the brake to reduce speed before shifting gear. then shift gearshift lever (2) down one range. OPERATION OPERATION 4. When shifting gear. 3 . always shift one gear at a time. INCREASE SPEED Let back accelerator pedal (1) and shift gearshift lever (2) up to the next speed range. NOTICE When shifting gear.. do as follows. REDUCING SPEED Release accelerator pedal (1) to reduce speed.

always stop the machine first. Do not shift between forward and reverse when traveling at high speed. When shifting between forward and reverse. then depress inching pedal (2) to stop the machine. Depress brake pedal (1) to reduce speed. always check that it is safe to travel in the new direction. Let inching pedal (2) back while depressing accelerator pedal (4) to start the machine off. Use extreme care when reversing the machine. to protect the operator and the machine. 2. 3. Note there is an blind spot behind the machine.. Shift gearshift lever (3) to F (FORWARD) or R (REVERSE) and set in 1st or 2nd speed. REMARK When switching between forward and reverse travel when the machine is traveling. OPERATION OPERATION SHIFTING BETWEEN FORWARD AND REVERSE WARNING When shifting between forward and reverse. the speed may gradually be decreased and the direction of travel switched.58 . but this is not a problem. 1. 3 .

then just before the machine stops. 3..59 . Set gearshift lever (1) to the P (parking) position. Give yourself ample room when stopping. the parking brake pilot lamp will light up. At the same time. 1. OPERATION OPERATION STOPPING MACHINE WARNING Avoid stopping suddenly. Release accelerator pedal (2). 3 . depress inching pedal (4) and stop the machine. 2. Depress brake pedal (3) to reduce speed.

turn steering wheel (1) in the direction of the turn. the steering will become heavy. If the engine stops when the machine is traveling. the radius of the turn becomes smaller if the tires are leaned in the direction of the turn. LEANING OPERATION Operate leaning control lever (2) to change the angle of the front tires as follows.. Push FORWARD to lean to LEFT. 3 . Pull BACK to lean to RIGHT. When traveling in reverse and turning the machine. OPERATION OPERATION TURNING MACHINE WARNING It is dangerous to turn the machine suddenly at high speed or to turn the machine on steep slopes. so never stop the engine. so never allow the engine to stop while traveling on slopes under any circumstance. When traveling forward and turning the machine. immediately apply the brake and stop the machine in a safe place. the radius of the turn becomes smaller if the tires are leaned in the opposite direction to the turn.60 . If the engine stops. To turn the machine when traveling. This is particularly dangerous on slopes.

and insert it in the storage position. To carry out articulation operations. OPERATION OPERATION ARTICULATING OPERATION WARNING For general travel. remove the lock pin on the left side of the chassis. there is danger of the machine turning over if it is turned sharply.61 . NOTICE To prevent damage to the tires. The machine can be articulated up to a maximum of 23º to the left or right.9 m (22 ft 8 in). 1. remove pin (1). and the turning radius is 6. Stop the machine. be careful not to let the blade hit the tires when articulating the machine.. when traveling with the machine articulated. Do not remove the lock pin for general travel. 3 .

Pull BACK to articulate to RIGHT. align the pin holes. set the front frame and rear frame straight. and fix the front and rear frames in the original position with pin (1). Push FORWARD to articulate to LEFT. Operate articulate control lever (2) as follows.62 . 3. When not operating the articulation. OPERATION OPERATION 2.. 3 .

OPERATION OPERATION OPERATING WORK EQUIPMENT (1) Left blade control lever (2) Right blade control lever (3) Blade side shift control lever (4) Blade rotation control lever (5) Power tilt control lever (6) Drawbar side shift control lever (7) Ripper/Scarifier control lever (if equipped) 3 .63 ..

Pull BACK to RAISE right end of blade Push FORWARD to LOWER right end of blade 3 .64 . Pull BACK to RAISE left end of blade Push FORWARD to LOWER left end of blade Operate right blade control lever (2) as follows. OPERATION OPERATION BLADE OPERATION BLADE LIFT OPERATION Operate left blade control lever (1) as follows..

.65 . OPERATION OPERATION OPERATING BLADE SIDE SHIFT Operate blade side-shift control lever (3) as follows. Pull BACK to shift blade to RIGHT Push FORWARD to shift blade to LEFT OPERATING BLADE ROTATION Operate blade rotation control lever (4) as follows. Pull BACK to rotate blade to RIGHT Push FORWARD to rotate blade to LEFT 3 .

The distance between the cutting surface and the blade edge can be changed. Pull BACK to make cutting angle SMALLER Push FORWARD to make cutting angle LARGER Use a larger cutting angle when cutting hard soil and a smaller cutting angle when cutting soft soil. so it is possible to carry out fine adjustment of the height of the cutting surface 3 . OPERATION OPERATION CHANGING BLADE CUTTING ANGLE Operate power tilt control lever (5) as follows..66 .

Pull BACK to shift drawbar to RIGHT Push FORWARD to shift drawbar to LEFT 3 .67 . OPERATION OPERATION OPERATING DRAWBAR SIDE SHIFT Operate drawbar side-shift control lever (6) as follows..

RAISE: Pull lever back LOWER: Push lever forward 3 .. RAISE: Pull lever back LOWER: Push lever forward When the machine is equipped with a scarifier Use ripper/scarifier control lever (7) to operate the scarifier as follows.68 . OPERATION OPERATION OPERATING RIPPER/SCARIFIER When the machine is equipped with a ripper Use ripper/scarifier control lever (7) to operate the ripper as follows.

OPERATION OPERATION WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER LEVELING GROUND TO RIGHT 1.9 in) to the left.) 3 .. Operate the drawbar side shift and move the circle approx.69 . Rotate so that the blade is at the optimum position for the soil. 4. 5. Set the blade so that the earth is discharged outside the rear left wheel. Lean the front wheels to the left. (Be careful not to let the rear left wheel run over the windrow discharged from the blade. Operate the blade lift cylinder so that the blade is at the desired digging depth. 200 mm (7. 2. 3. then set it horizontal. REMARK Leaning the wheels to the left prevents the machine from being pushed to the right by the load acting on the left side of the machine.

3 . thereby reducing the load on the machine. REMARK Generally speaking. 8. then start operation. 7. This makes it easier to steer with the rear wheels. Operate the power tilt so that the top of the blade is slightly in front of the cutting edge. If the tires start to spin. In leveling operations. OPERATION OPERATION 6. carry out operations on flat ground with the frame straight to the blade. Articulate the frame to deal with the force in the side direction caused by the load on the blade. Spread fine crushed loose soil over the ground surface until it is level.70 . Discharge the soil to the side to prevent any excessive load from bearing on the machine. turn the blade to a greater angle to reduce the digging width. discharge the soil outside the rear wheels..

Lean the front wheels to the right.9 in) to the right.. 2. 5. OPERATION OPERATION LEVELING GROUND TO LEFT 1. Set the blade so that the earth is discharged outside the rear right wheel. Operate the blade lift cylinder so that the blade is at the desired digging depth. then set it horizontal. 3 . Carry out the operation in the same way as when leveling to the right.71 . 4. 3. Operate the drawbar side shift and move the circle approx. 200 mm (7.

the side of the tire will be pushed against the opposite slope face (back slope).72 . In addition. Rotate the blade and set at an angle so that the soil will be discharged on the inside of the rear left wheel. Operate the power tilt so that the top of the blade is slightly in front of the cutting edge. and this will cause problems such as leakage of air and flat tires. Operate the left blade lift cylinder and raise the left edge of the blade. 4. OPERATION OPERATION DIGGING RIGHT V-DITCHES NOTICE Set the frame straight. The left end of the blade determines the shape of the ditch. 3. (The right end of the blade determines the depth of the ditch.. If the machine is articulated. mud will be pushed in between the tire and rim.) 3 . Set the right edge of the blade in line with the outside of the front right wheel. 1. and this will cause damage to the side face of the tire. 2.

3 .73 . 8.0 in) to determine the line of the ditch. Align the front right wheel with the bottom of the ditch and dig a ditch of the desired depth. OPERATION OPERATION 5. 6.0 to 3. Operate the right blade lift cylinder and set the right end of the blade to a digging depth of 50 to 100 mm (2. First. dig to depth of 50 mm (2.9 in). 7. so align the front and rear wheels with the bottom of the ditch when carrying out such operations. Operate the right blade lift cylinder while traveling to set the right edge of the blade to the desired digging depth. Lean the front tire to the left to prevent the tire from rubbing against the side face of the ditch. The chassis is in an unstable position when digging ditches..

If the machine is articulated.. 3.) 3 . OPERATION OPERATION DIGGING LEFT V-DITCHES NOTICE Set the frame straight. Rotate the blade and set at an angle so that the soil will be discharged on the inside of the rear right wheel. Set the left edge of the blade in line with the outside of the front left wheel. In addition. 1. and this will cause damage to the side face of the tire. 4. (The left end of the blade determines the depth of the ditch. the side of the tire will be pushed against the opposite slope face (back slope). Operate the power tilt so that the top of the blade is slightly in front of the cutting edge.74 . Operate the right blade lift cylinder and raise the right edge of the blade. and this will cause problems such as leakage of air and flat tires. The right end of the blade determines the shape of the ditch. mud will be pushed in between the tire and rim. 2.

Lean the front tire to the right to prevent the tire from rubbing against the side face of the ditch.9 in). so align the front and rear wheels with the bottom of the ditch when carrying out such operations. Operate the left blade lift cylinder and set the right end of the blade to a digging depth of 50 to 100 mm (2. Align the front right wheel with the bottom of the ditch and dig a ditch of the desired depth. 3 . OPERATION OPERATION 5. 6. 8. First.75 . Operate the left blade lift cylinder while traveling to set the left end of the blade to the desired digging depth. The chassis is in an unstable position when digging ditches. 7. dig to depth of 50 mm (2.0 in) to determine the line of the ditch..0 to 3.

4. 5. Operate the right blade lift cylinder and set the blade to the depth of the ditch. Lean the front wheels slightly to the left. 2. then carry out final finishing with the grader. Spread the soil. a separate pass is needed. Operate the blade lift cylinder and blade rotation to set the blade in position. Be careful not to let the rear left wheel run over the window discharged from the blade. 3 . To push out the soil to the top of the slope face and the road shoulder. Set the right side of the blade behind the front right wheel. 3. OPERATION OPERATION RIGHT DITCH FINISHING 1.76 ..

3. Operate the left blade lift cylinder and set the blade to the depth of the ditch. To push out the soil to the top of the slope face and the road shoulder.. 4. OPERATION OPERATION LEFT DITCH FINISHING 1. 2. Lean the front wheels slightly to the right. Operate the blade lift cylinder and blade rotation to set the blade in position.77 . 5. Be careful not to let the rear right wheel run over the windrow discharged from the blade. then carry out final finishing with the grader. 3 . a separate pass is needed. Set the left side of the blade behind the front left wheel. Spread the soil.

3 . 4.) 2. Align the center of the machine with the line of the soil discharged when digging the ditch. Lean the front wheels slightly to the left. Set so that the right end of the blade is in line with the outside of the right tire.78 . (The soil can be moved more smoothly if the blade is at a small propulsion angle.. Operate the left and right blade lift cylinders to keep the blade horizontal and at the desired digging depth. OPERATION OPERATION FINISHING RIGHT ROAD SHOULDER 1. 3. Set the blade so that the soil is discharged between the two wheels.

OPERATION OPERATION FINISHING LEFT ROAD SHOULDER 1. (The soil can be moved more smoothly if the blade is at a small propulsion angle..79 . 4. 3 . 2. Operate the drawbar shift cylinder to set the circle to the left end. Set so that the left end of the blade is in line with the outside of the left tire.) 3. Operate the left and right blade lift cylinders to keep the blade horizontal and at the desired digging depth. 5. Set the blade so that the soil is discharged between the two wheels. Lean the front wheels slightly to the right. Align the center of the machine with the line of the soil discharged when digging the ditch.

. When carrying out Steps 4 and 7.METHOD OF MAKING V-DITCH The procedure shown in the diagrams is for one side of the road. 50 mm (2. Depth: approx. 1. articulate the frame. Finishing road shoulder 3 .80 . Line of ditch: Light-duty digging Determine the line of the ditch along the measured points.2 MPH) 2. Repeat the same operation on the opposite side of the road. Third digging pass: Heavy-duty digging 4. OPERATION OPERATION CONSTRUCTING ROAD . Second digging pass: Heavy-duty digging 3. 2 km/h (1.0 in) Travel speed: approx.

Spreading to center 9.. OPERATION OPERATION 5. Fourth digging pass: Heavy-duty digging 7. Leveling center 6. Slope face and bank Use the bank cutting posture. 3 .81 . Finishing road shoulder 8.

OPERATION OPERATION 10. Ditch digging pass (finishing and shaping inside of the slope face) 12. Leveling and finishing 3 .82 . Finishing road shoulder 14. Finishing slope face 13.. Finishing bottom of ditch 11.

and set it to the desired angle for the slope face of the road shoulder. 1. The slope face of the road shoulder must be flatter than normal. Operate the left blade lift cylinder to raise the right end of the blade. 2. Operate the power tilt and angle the blade to the front. 6. Place the front right tire in the bottom of the V-ditch. OPERATION OPERATION FLAT-BOTTOMED DITCH When there is no V-ditch. 3 . Set the blade so that the right edge of the blade comes to the inside of the front right tire at the width of the flat-bottomed ditch.. Operate the drawbar shift cylinder and set the circle fully to the left of the machine. 5. Operate the right blade lift cylinder to lower the right end of the blade. and set it to the digging depth. 3. 4. make a V-ditch at the depth of the flat-bottomed ditch.83 .

Set the blade at an acute angle and push up the soil to the top of the ditch slope. 15. Spread the windrow and finish to the final precision. Lean the front wheels to the left. Lower the left lift cylinder to the desired digging depth. 14. Dig the flat bottom.84 . 3 . Set the right blade lift cylinder to the desired depth. Dig the No. Set the right edge of the blade at the bottom of the slope. Set the front right tire at the bottom of the first V-ditch and start the operation. 13. 1 ditch. 9. Operate the left blade lift cylinder as required. OPERATION OPERATION 7.. Lean the front wheels to the left. 10. 11. 2 V-ditch to the same depth or slightly deeper than the No. 8. 12. Lower the right blade lift cylinder so that the tip of the blade is the set precision for the ditch.

METHOD FOR MAKING FLAT-BOTTOMED DITCH The procedure shown in the diagrams is for one side of the road. Repeat the same operation on the opposite side of the road. 4. Dig the width and depth of the bottom of the ditch with the left ditching method. OPERATION OPERATION CONSTRUCTING ROAD . 2. 3.85 .. 3 . 1. Make the slope face on the inside flat. Finish the road shoulder. Spread the soil to the center.

Make the bottom of the ditch flat. 7. Finish the ditch. Finish the slope face on the bank. OPERATION OPERATION 5. 8.. 9. Finishing slope face 3 . Finish the slope face on the inside.86 . 6.

. Steer with the front wheels. Keep the rear wheels on the road shoulder and be careful that the wheels do not slip on the soft weak soil of the ditch.87 . use the accelerator to control the machine speed. LEVELING SLOPE FACE WARNING When operating on slopes where the machine may slip to the side. Leveling and finishing FINISHING WITH GRADER FOR DITCHES WHERE WET ROAD SHOULDER IS LOOSE This method is used when avoiding hanging trees or protruding rocks which are obstacles when cleaning old ditches. Articulate the machine so that the front wheels and blade remain in the ditch. On steep slopes. 3 . 1. make sure that you understand the operation of the machine completely. 2. OPERATION OPERATION 10. When operating on slopes. Do not articulate the machine fully on steep slopes. lower the engine speed and operate in 1st gear.

REMARK The wheels should normally be almost perpendicular. Set to the bank cut posture. rotate the blade so that the top of the blade is at the front. 3. Be careful not to let the blade hit the tires. 1. 2. the blade can be set to the reverse low bank posture. 3 . see "BANK CUTTING POSTURE (RIGHT SIDE) (PAGE 3-99)". a shallow angle slope is needed. The rear right wheel must be in the V at the base of the slope face. 9. 5. REMARK If the top of the blade is rotated to the rear. 7. To scrape up the soil smoothly. The roadbed where the foundation is to be dug must be uniform. This sets it to the low bank posture. and set the tip of the left cutting edge of the blade in line with the outside of the rear wheels at the bottom of the slope face. From the high bank position. which makes it possible to cut the slope face while scraping up the soil. Rotate the blade until the bottom of the blade is close to the front tires.. For details. which is suited for scraping operations. 4. Extend the right blade lift cylinder and set the angle to the desired bank slope face. Rotate the circle and extend or retract the left and right blade lift cylinders to set to the bank slope face posture.88 . Extend the left blade lift cylinder. OPERATION OPERATION BANK CUTTING METHOD . If the soil is hard. angle the roadbed slightly towards the bank to prevent the machine from sliding to the side away from the bank.RIGHT SIDE WARNING Lower the blade to the ground before removing the bank control lock pin. 8. 6. Gradually progress with the cutting.

Discharge the soil from the slope face to the outside of the rear wheels. angle the wheels away from the slope face. For the left side. If the digging is comparatively light duty. 3 . OPERATION OPERATION 10. REMARK The procedure in the diagram is for the right side.89 . For details. see "SHOULDER REACH POSTURE (RIGHT SIDE) (PAGE 3-101)". If the digging is comparatively heavy duty. SHOULDER REACH METHOD ..RIGHT SIDE Set to the shoulder reach posture and carry out operations. 11. angle the wheels towards the slope face. set the blade in the opposite position.

However. So when operating the switch.90 . Do not switch from Mode 2 (torque converter mode) to Mode 1 (lockup mode). but this does not indicate any problem.. use the same speed range as when traveling uphill. and make full use of the braking force of the engine. a short warning will be sounded and the transmission will automatically shift up to the next speed range. REMARK If there is danger of overrunning. keep to the following instructions. To prevent overrun. set the gearshift lever to the P (Parking) position. even when the pedal is depressed with the same force. If the engine stops on a slope. IF ENGINE STOPS CAUTION If the engine stops. always shift down one gear at time. as the engine cannot be used to brake the machine. shift the gear speed to lower than F3 speed (3rd forward). possibly causing damage to it. immediately depress the brake pedal fully to stop the machine. 3 . When the travel speed is reduced. use the foot brake. then start the engine again. and the transmission mode selector switch can change a transmission mode between Mode 1 (lockup mode) and Mode 2 (torque converter mode). When running uphill with the switch in Mode 1 (lockup mode). the transmission will automatically return to the speed range set by the gearshift lever. the brake booster will not work. so the operating effort of the pedal will become heavier and the effect of the brake will become lower. TRAVELING DOWNHILL When traveling downhill. while the torque converter is stalling. OPERATION OPERATION PRECAUTIONS WHEN OPERATION PRECAUTIONS WHEN TRAVELING UPHILL OR DOWNHILL WARNING Never shift gear or place the transmission in neutral when traveling on a slope. improper operation of the switch can cause an excess load on the lockup clutch. When starting up the machine with the switch in Mode 1 (lockup mode) and the blade holding earth (a load is applied to the blade). Always place the transmission in the appropriate speed range before starting to travel down a hill. select an optimum gear speed matching the slope grade before coming up to the slope. PRECAUTION FOR OPERATION CAUTION This machine is mounted with a torque converter equipped with a lockup clutch. It is dangerous to do this. If the machine travel speed is still too fast.

PRECAUTIONS WHEN USING ARTICULATED STEERING When the articulation is used to steer the machine. contact your Komatsu distributor to have the parking brake checked for any abnormality. For this reason. stop the machine and rest for 30 minutes after traveling 80 km or 2 hours (whichever comes sooner). rest for one hour. and for the cycle after that.2 MPH). Repeat this and be sure not to exceed the conditions. NOTICE If the parking brake has been used as an emergency brake. do not let the machine enter water or mud that is greater than the permitted water depth (up to the bottom surface of the axle housing). WHEN BRAKES DO NOT WORK If the machine does not stop even when the brake pedal is depressed. so at high speed there is a danger that it will turn over. 3 ..91 . set the gearshift lever to the P (Parking) position to apply the parking brake and stop the machine. After completion of operations. For the following cycle. PRECAUTIONS WHEN TRAVELING ON ROADS When moving the machine to another place and traveling at high speed. rest for 30 minutes. wash the machine and grease the parts that were under water or mud. OPERATION OPERATION PERMITTED WATER DEPTH When operating in water or on muddy ground. only use the articulation at speeds of less than 10 km/h (6. the machine will turn sharply.

. always pay careful attention to the movement of the work equipment and do not move it more than necessary as the work equipment or the hydraulic cylinder may hit and damage other parts. When the work equipment is operated.92 . Blade and front wheel Blade and step Blade and frame Blade and operator's cab 3 . special attention should be given to avoiding contact between the following parts. OPERATION OPERATION CAUTIONS IN OPERATION OF WORK EQUIPMENT When operating the work equipment control lever.

2 to 2. use 3 to 5 shanks.93 . 2 to 4 km/h (1. carry out ripping downhill to use the weight of the machine. For heavy-duty conditions. Keep the ripper at a depth where there is no tire slip and where the engine horsepower can be used to its full. OPERATION OPERATION RIPPER OPERATIONS .5 MPH). NOTICE To prevent damage. When breaking up a paved surface. 3 . and gradually insert the points into the ground. For general soil condition. Carry out cross ripping only when there is a special purpose. On slopes. Travel in a straight line at approx. use 1 to 3 shanks. raise the ripper from the ground before turning the machine.WITH FRAME STRAIGHT CAUTION When using the ripper. set the frame straight.. raise the ripper after digging up the ground under the surface.

2. When the soil is hard. 5. Install the lock washer and bolt. Loosen the bolt holding the blade to the bracket at the tip of the cylinder rod. 4. Protrusion to right: Position (1) Protrusion to left: Position (2) Standard position: Center BLADE PROPULSION ANGLE The angle between the blade and the center line of the machine body is called the blade propulsion angle. Pull in the cylinder rod. When the soil accumulated in front of the blade dose not flow smoothly. Align the bolt hole in the bracket with a hole in another place on the blade. OPERATION OPERATION ADJUSTING WORK EQUIPMENT POSTURE Move the work equipment to the most suitable position for each operation and carry out operations efficiently.. Lower the blade to the ground. then tighten the bolt. Set the blade propulsion angle to about 60° for general cutting work. stop the grader for a while and change the installing position of the blade horizontal shifting cylinder piston rod. 3 .94 . then remove the bolt and lock washer. If further protrusion is needed. but set it narrower in the following situations. When the cutting resistance is high. 3. BLADE PROTRUSION The degree of protrusion is controlled by the control lever during operation. 1. as follows.

the operating efficiency is better if the blade cutting angle is large when cutting hard soil and small when cutting soft soil. 3 .. and it can be freely changed within the range below. It is possible to keep the cutting edge sharp for operations. so this blade can display its power when removing frozen ice during snow-clearing operations. OPERATION OPERATION ADJUSTING BLADE CUTTING ANGLE Generally.95 . and also has the following advantages. Cutting angle Minimum: 32º Maximum: 81º The power tilt blade can carry out normal blade operation. It is possible to set to the optimum blade cutting angle to match the type of soil simply by operating one lever. The blade cutting angle is installed to the power tilt blade.

OPERATION OPERATION It is possible to change the distance between the cutting edge and cutting surface. 3 .96 . so work can be carried out efficiently. When scooping up soil or snow with the low bank posture. the optimum blade cutting angle is selected. so fine adjustment can be made in the height of the cutting surface and cutting edge..

3. remove shear pin (2) from lock plate (3). then knock in the shear pin to a position where lock plate (3) can be installed. then tighten bolt (4). Operate the blade rotation lever slowly until pin (1) enters the concave part and the blade begins to rotate.97 . 5. Hit portion A of pin (1) several times with a hammer to knock it in. OPERATION OPERATION SAFETY DEVICE OF BLADE A shear pin and slip clutch are installed to the circle to prevent accidents when an abnormal impact load is applied to the end of the blade during work. then remove the broken shear pin. SHEAR PIN TYPE If the shear pin breaks. DRIVING SHEAR PIN IN WARNING Check that the surrounding area is safe before replacing the shear pin. (Hit the pin so that portion B of pin (1) enters securely. 3 . Install lock plate (3). Insert a new shear pin. Loosen bolt (4). Raise the blade slightly from the ground. 6.) 4.. replace it as follows. 2. 1.

but the clutch slips and the circle does not turn. -> The condition is normal. it may cause damage. the following problems may appear. but if the slip torque is at the maximum. The motor is turning. so please contact your Komatsu distributor for repairs and adjustment. the circle does not rotate. -> There is serious danger of the clutch burning out. The hydraulic pressure is relieved and the circle does not turn. so it must be adjusted.98 .. 3 . OPERATION OPERATION SLIP CLUTCH TYPE If any problem occurs in the slip clutch. Examples of problems Even when the circle rotation lever is operated.

If lock pin (1) is held by lifter (2) and will not come out. On machines equipped with a scarifier. NOTICE When shifting to the bank cut posture. 2. There is danger that it will rotate and the blade will fall. operate the blade lift cylinder to make it possible to remove the pin. Check that the protrusion of indicator pin (3) has been removed and that the lock pin is completely locked. 3 . be careful not to let the scarifier contact the drawbar when the machine is in the bank cut posture. Do not remove it at any other position. then lock with lock pin (1). When banking to the left. 1. do not rotate the lifter any further. Extend the blade and drawbar fully to the right. use with the tip of the scarifier teeth approx. Push the bank control lock pin switch and remove lock pin (1). there is danger that the bushing or lifter ring will be damaged. rotate the circle and set the end of the blade at the side of the front right wheel. then lock the lock pin. Rotate the lifter to the specified counter mark. Operate lifter (2) to the desired counter mark (A). Check that indicator pin (3) at the rear of the lock pin has come out fully and that the lock pin has been removed.9 in) above the ground. then lower the blade so that it is lightly in contact with the ground. 3. NOTICE If the lock pin switch is kept pushed in the pin lock direction while the lifter is being rotated. If the bank pin passes over the hole in the lifter guide. There is danger that the frame and bank pin case will come into contact and that the bank pin case will be broken. then extend the right blade lift cylinder and retract the left blade lift cylinder to rotate lifter (2) counterclockwise. be particularly careful to avoid contact with the scarifier puller plate. 150 mm (5. be careful not to let the blade hit any other part of the machine. When banking to the right..99 . OPERATION OPERATION BANK CUTTING POSTURE (RIGHT SIDE) WARNING Lower the blade to the ground before removing the bank control lock pin.

then raise the blade and rotate it to the right side of the machine to set the blade to the bank cut position. but in the opposite direction.. When setting to the bank cut posture on the left side. Retract the right lift cylinder and extend the left lift cylinder repeatedly.100 . 3 . REMARK The banking performance can be improved by changing the mounting position of the piston rod of the blade side shift cylinder to the left for right side banking and to the right for left side banking. OPERATION OPERATION 4. use the same procedure as above.

Check that the protrusion of indicator pin (3) has been removed and that the lock pin is completely locked.101 . Extend the blade and drawbar fully to the right. then lower the blade so that it is lightly in contact with the ground. operate the blade lift cylinder to make it possible to remove the pin. then lock the lock pin. Do not remove it at any other position. there is danger that the bushing or lifter ring will be damaged. rotate the circle and set the end of the blade at the side of the front right wheel. then extend the right blade lift cylinder and retract the left blade lift cylinder to rotate lifter (2) counterclockwise. do not rotate the lifter any further. Check that indicator pin (3) at the rear of the lock pin has come out fully and that the lock pin has been removed. NOTICE If the lock pin switch is kept pushed in the pin lock direction while the lifter is being rotated. NOTICE When shifting to the shoulder reach posture. Rotate the lifter to the specified counter mark.. OPERATION OPERATION SHOULDER REACH POSTURE (RIGHT SIDE) WARNING Lower the blade to the ground before removing the bank control lock pin. There is danger that the frame and bank pin case will come into contact and that the bank pin case will be broken. If lock pin (1) is held by lifter (2) and will not come out. There is danger that it will rotate and the blade will fall. 3 . Push the bank control lock pin switch and remove lock pin (1). Operate lifter (2) to the desired counter mark (A). 1. then lock with lock pin (1). If the bank pin passes over the hole in the lifter guide. 3. 2. be careful not to let the blade hit any other part of the machine.

102 . see "BLADE PROTRUSION (PAGE 3-94)". Shift the blade fully to the right.. Shift the blade to the side as shown in the diagram. When setting to the shoulder reach posture on the left side. but in the opposite direction. change the mounting position of the piston rod for the blade side shift cylinder. use the same procedure as above. Shift the drawbar fully to the right. REMARK If it is desired to make the shoulder reach posture even larger. OPERATION OPERATION 4. Rotate the circle and set to the desired position. 3 . 5. For details.

ADJUSTING DIGGING DEPTH The digging depth can be adjusted as follows at 2 places to match the operation. The angle can be adjusted to 3 positions: 63º. Adjusting with teeth Remove the cotter pin. the larger the cutting angle is. on hard ground. pull out wedge (1). then change the notch of tooth (2). the positions are 53º. 61º. 71º is the standard position. then move the position of the hole to the desired position. and 69º. OPERATION OPERATION ADJUSTING SCARIFIER ADJUSTING CUTTING ANGLE In general.. Adjustment Remove bolt (1).103 . For the point tooth type. the more efficient the operation becomes. 3 . 71º. 78º.

and the drawbar will be damaged. and the top of the blade will be damaged. there is danger that the scarifier may contact the drawbar. the blade and scarifier will hit. OPERATION OPERATION PRECAUTIONS WHEN HANDLING OR OPERATING SCARIFIER If the scarifier is fully raised and the blade is lowered to raise the body. If the blade is raised a few centimeters from the ground surface and rotated..104 . If the blade is set within the machine width and the scarifier is lowered. When using the bank cut posture. the scarifier and drawbar will hit. 3 . the top of the blade and the scarifier will hit. and the blade will be damaged.

the work equipment may move unexpectedly. always set the gearshift lever to the P (Parking) position. Depress brake pedal (3) to reduce speed. If the control levers are not locked and they are touched by accident when starting the engine. OPERATION OPERATION PARKING MACHINE WARNING Avoid stopping suddenly. put blocks under the tires. If the machine has to be parked on a slope. 2. give yourself ample room when stopping. then just before the machine stops. Do not park the machine on slopes. and dig the blade into the ground surface to prevent the machine from moving. When standing up from the operator's seat. depress inching pedal (4) and stop the machine. 3 .105 . Release accelerator pedal (2).. and this may lead to a serious accident. set it at right angles to the slope. 1.

and lower the blade and the ripper to the ground. Operate the work equipment control lever. 3 . OPERATION OPERATION 3. engine oil pressure. At the same time.. 4. do not stop the engine suddenly. Run the engine at a mid-range speed and allow it to cool down before stopping it. the parking brake pilot lamp will light up. CHECKS AFTER COMPLETION OF OPERATION Check the engine water temperature. and fuel level on the main panel.106 . Set gearshift lever (1) to the P (parking) position. If the engine has overheated.

deformation. right) (2) Front side cover (left. right) (4) Fuel filler cap REMARK The starting switch key is used also for locks (1). and (4). It is dangerous to jack up the machine without taking due care. 3 . or greatly deformed Excessively worn tires where more than 1/4 of the circumference of the carcass ply (excluding the breaker) is exposed Tires where damage to the carcass exceeds 1/3 of the tire width Tires where ply separation has occurred Tires where radial cracks extend to the carcass Tires where there is abnormal deterioration. right) (3) Rear side cover (left. and damage. (3).. (1) Cab door (left. Please contact your Komatsu distributor when replacing the tires. OPERATION OPERATION LOCKING Always lock the following parts. broken. HANDLING THE TIRES PRECAUTIONS WHEN HANDLING TIRES WARNING To ensure safety.107 . the defective tires given below must be replaced with new tires. and the tire cannot withstand use. Tires where the bead wire has been cut. (2).

1. This makes it easier to load or unload the machine. Remove the mud stuck to the undercarriage to prevent the machine from slipping to the side on the ramps. length. return to the ground surface or the trailer platform. Never change direction on the ramps. 3. and there is danger of the machine losing its balance. Use ramps of ample width. then raise it fully. Make the angle of the ramps a maximum of 15º. observe all related laws and regulations. Be sure that the two sides are at the same height as one another. keep well away from the road shoulder. stop the trailer on firm level ground. always use ramps or a platform and carry out the operations as follows. and install them securely at an angle of less than 15°. The position of the center of gravity of the machine will change suddenly at the connection of the ramp and trailer. LOADING. When using an embankment. Set the machine in line with the ramps. There is danger that the machine may tip over. If the ripper teeth make it difficult to load the machine. compact the fill soil thoroughly and make sure that the slope face does not collapse. REMARK When loading or unloading the machine. This makes loading easier. remove any water. rotate the blade from the travel posture. then drive the machine slowly to load or unload it. and strength. grease. and operate slowly.108 . and start again. In addition.. Load the machine correctly in the specified position on the trailer. If it is necessary to change direction. Then fix the ramps in line with the centers of the trailer and the machine. run the engine at low speed. thickness. When loading or unloading the machine. remove the ripper teeth or install them so that they face the top inside. Always drive slowly over this point. 3 . Set the distance between the ramps to match the center of the tires. or oil from the ramps. In addition. correct the direction. Apply the brakes on the trailer securely and insert blocks under the tires to ensure that the trailer does not move. snow. When loading or unloading. travel at low speed. and be careful to assure safety. UNLOADING WORK WARNING When loading or unloading the machine. ice. TRANSPORTATION OPERATION TRANSPORTATION When transporting the machine. 2.

place wooden blocks underneath the front and rear tires to prevent the machine from moving about. 4. 5. hole in the frame under the operator's platform. 2. secure it according to the following procedure. Set the gear shift lever at the P (parking) position. When transporting the machine. Lower the work equipment slowly and set it securely in contact with the platform. and stop the engine. 3 . hold it down with chain or rope. REMARK The towing pin. 3. Also.. Lock the front frame and rear frame with the articulate lock pin. 1.109 . and the drawbar hole can be used to hold the machine in position. OPERATION TRANSPORTATION PRECAUTIONS FOR LOADING After placing the machine on the specified position of the trailer. Turn the starting switch to the OFF position. then remove the key.

ethanol or propanol based antifreeze. 3 . so use permanent antifreeze when possible.110 . Avoid using any leak-preventing agent. COLD WEATHER OPERATION OPERATION COLD WEATHER OPERATION PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low. For details of the antifreeze mixture when changing the coolant. the coolant must be changed twice a year (spring and autumn). If it is doubtful that an available antifreeze meets the standard requirements. For details of the specified viscosity..) However. Never smoke when using antifreeze. it becomes difficult to start the engine. 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. antifoam agent. in such a case. no change of coolant is required for a year. COOLANT WARNING Keep antifreeze fluid away from open flames. Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor. see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-19)". NOTICE Never use methanol. Standard requirements for permanent antifreeze SAE J1034 FEDERAL STANDARD O-A-548D REMARK In areas where permanent antifreeze is not available. With permanent antifreeze. FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components.) meeting the standard requirements as shown below. see "USE OF FUEL. ask the supplier of that antifreeze for information. and the coolant may freeze. etc. Do not mix one brand of antifreeze with a different brand. COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-9)". so do as follows. regardless if it is sold separately or in antifreeze.

Battery electrolyte is dangerous. For details. Measure the specific gravity and calculate the rate of charge from the following conversion table. If this is impossible.24 -10 1.30 1. CAUTIONS AFTER COMPLETION OF WORK To prevent mud. As the battery capacity drastically drops in low temperatures. The boards help protect the tracks from being frozen in soil and the machine can start next morning. dry ground. observe the following precautions. Maintain the battery charge as close as possible to 100%. Park the machine on hard. Thoroughly flush out the cooling system and fill it with fresh coolant. 3 . Battery electrolyte dissolves paint. COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-9)". cover or remove the battery from the machine. AFTER COLD WEATHER When the season changes and the weather becomes warmer. the capacity of the battery will also drop. Battery electrolyte is toxic. When the ambient temperature drops.26 1. the battery electrolyte may freeze. Be particularly careful to remove mud and drops of water from the surface of the hydraulic cylinder rod. Insulate it against cold temperature to ensure the machine can be started easily the next morning.25 -20 1.31 1. and an ethylene glycol base antifreeze (winter.29 1. Charging Rate (%) Electrolyte Temperature (°C) 100 90 80 75 20 1. store the battery in a warm place. OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas.28 1. If it gets in your eyes or on your skin.26 When adding distilled water in cold weather. If it gets on the bodywork.24 1. Replace the fuel and oil for all parts with oil of the viscosity specified. do as follows. or if no antifreeze is used. one season type) is used instead. If the battery charge ratio is low.29 1. drain the cooling system completely.27 1. park the machine on wooden boards. Do not let it flow into drainage ditches or spray it on to the ground surface. If the battery electrolyte is frozen. see "USE OF FUEL. Remove all the mud and water from the machine. water.26 1. wash it off immediately with water. There is danger that the battery may explode.27 1.25 1.. Do not bring fire or sparks near the battery. If for any reason permanent antifreeze cannot be used. do not charge the battery or start the engine with a different power source. This will prevent the mud from getting inside the seal and causing damage to the seal. wash it off with a large amount of water and consult a doctor.111 . Open the drain valve and drain any water collected in the fuel system to prevent it from freezing. or the undercarriage from freezing and making it impossible for the machine to move on the following morning. and install it the next morning.23 0 1. add it before starting operations in the morning to prevent the electrolyte from freezing.28 1.

If the ambient temperature is expected to drop below 0ºC (32°F). do as follows. change all the oil. see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-19)". Add oil and grease to all places. also charge the battery. AFTER STORAGE NOTICE If the machine has been stored without carrying out the monthly rust-prevention operation. Wipe off the grease from the hydraulic cylinder rods. For details. If the temperature goes below -10ºC (14°F).. Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately. After every part is washed and dried. check the refrigerant level twice a year. Coat the exposed portion of the hydraulic cylinder piston rod with grease. always add antifreeze to the cooling water. Always run the engine at low idle when doing this. In case it is indispensable to leave it outdoors. operate the air conditioner for 3 to 5 minutes once a month to lubricate all parts of the air conditioner compressor. If the machine is equipped with an air conditioner. Komatsu genuine Super Coolant (AF-ACL) is added to the cooling water. At the same time. Place gear shift levers at the P (parking) position. DURING STORAGE WARNING If it is necessary to perform the rust-prevention operation while the machine is indoors. When the machine is stored for a long period. Check the oil before and after starting the engine. do as follows before using it. moisture in the air will mix with the oil.112 . operate and move the machine for a short distance once a month so that a new film of oil will coat moving parts. house the machine in a dry building. wipe off all the grease from the hydraulic cylinder rods. If there is water in the oil. LONG-TERM STORAGE OPERATION LONG-TERM STORAGE BEFORE STORAGE When putting the machine in storage for a long time. consult your Komatsu distributor before using it. When using the machine after long-term storage. During storage. jack up the tires from the ground. Never leave it outdoors. adjust the density. so there is no need to change the density for temperatures down to -10ºC (14°F). then put a block under the blade and lower it on top of the block. Fit a block under the center of the front wheel and the tandem case. In addition. lubricate and change the oil before storage. open the doors and windows to improve ventilation and prevent gas poisoning. Completely fill the fuel tank. 3 . When operating the work equipment. park the machine on the flat ground and cover it with canvas etc.

2 lbft) 7. go on to Step 3. taking care not to let dirt or dust get in. PROCEDURE FOR BLEEDING AIR CAUTION Be careful when unscrewing the air bleeding plug on the fuel filter head.2 lbft) Fuel filter: 7. When doing this.113 . Oil may spurt out due to the residual pressure inside the tank. Perform this operation a maximum of 4 times. wait for at least 2 minutes.8 to 1 kgm . Always watch the fuel level and be careful not to run out of fuel. 8. Remove water separator (1).31 kgm . 5. 5. fill the inside of the strainer with clean fuel. Loosen air bleed plug (3) at the water separator head and air bleed plug (4) at the fuel filter head. then try again. Remove fuel filter cartridge (2). Tighten air bleed plug (3) and (4). it is necessary to use the priming pump to bleed the air completely from the fuel circuit. taking care not to let dirt or dust get in. followed by fuel. then install it again. OPERATION TROUBLESHOOTING TROUBLESHOOTING AFTER RUNNING OUT OF FUEL When starting after running out of fuel..1 to 2. fill the inside of the filter with clean fuel. fill the water separator and fuel filter cartridge with clean fuel. then fill the fuel tank with fuel and bleed the air from the fuel system before starting the engine. Tightening torque Water separator: 2. 3 . Fill the fuel tank with fuel. do not crank the starting motor continuously for more than 20 seconds.8 to 9. 1. then install it again.8 to 7. repeat the operation from Step 4. Add fuel from small hole (A) (dirty side) at eight places. Bleed air with priming pump (5) and check that air bubbles come out of air bleeding plug (3) and (4). Turn the key in the starting switch to the START position and start the engine.1 Nm (0. 4.9 to 3. If the engine does not start. If clean fuel is not available.29 to 0. 3. 6.8 Nm (0. Do not add fuel from hole (B) (clean side) at the center. 2. If the engine has stopped because of lack of fuel. If the engine does not start. 2.

METHOD OF USING LEANING STOPPER Fix the front axle and hole (1) in the leaning rod with the bolt in the tool box.114 . call your Komatsu distributor for repair. dangerously unstable steering and excessively worn tires will result. Repair the faulty leaning pipe quickly. If the leaning piping is broken. TROUBLESHOOTING OPERATION WHEN LEANING PIPING IS DAMAGED WARNING If the machine is driven with the leaning cylinder piston rod fluctuating or the front wheels leaning on one side because of damaged leaning piping. 3 ..

use a towing machine of about the same capacity as the machine being towed. Tow the machine properly according to the instructions given below. NOTICE Towing is to be used only for moving the machine to a safe place where it is possible to carry out inspection and maintenance. Check that both machines can be controlled on slopes and on the tow road.0 MPH) or less. OPERATION TROUBLESHOOTING TOWING THE MACHINE WARNING If there is a failure in the brake system.. The parking brake is automatically applied. It must be moved a maximum of 600 m (1968 ft) and at a maximum speed of 8 km/h (5. check that the tow rope or bar are in good condition. Normally. be sure to use a trailer for transportation. put blocks under the tires. so that the steering and braking can be used. If the wrong method of towing is used. then do not have anyone sitting in the operator's seat. If it is impossible to use the steering or brakes on the machine being towed. or if more than one day has elapsed since the engine trouble. install a protector plate to the machine being towed. To protect the operator if the towrope or bar should break. so this may cause them to be damaged. Do not use towing to move a machine for a long distance. weight. the brakes will not work. Before towing. If the machine being towed may get stuck in mud or may have to be towed uphill. The explanation given here is only to be used for a machine that has failed and is to be moved to a safe place for repairs. so be extremely careful. Start the machine gradually and travel at a constant speed. and it may break.) It is necessary to release the parking brake. If the distance is more than the above mentioned. If the machine must be moved a long distance. the tow rope or bar must be of a strength of at least 1. WHEN ENGINE CANNOT BE USED When towing a disabled machine the distance should be within 600 m (1968 ft) at a speed of 8 km/h (5. (A fixed time after the engine stops. Do not apply any load suddenly to the wire rope. NOTICE If the machine is towed without the engine running. This procedure is only for emergency purposes. use a transporter. but the brake will then have no effect at all. and that they have ample strength for the towing operation. so it is necessary to take special measures to ensure safety when moving the machine. 3 . the towrope or bar will be subjected to an excessive load. Please consult your Komatsu distributor for details of the method of towing a machine that has broken down. The gears and bearings are rotated.115 . Operate the machine so that the angle does not become greater than 30° from the straight line. WHEN ENGINE CAN BE USED Always keep the engine running when towing the machine. If the machine is moved suddenly. The rope used for towing should be of ample strength for the weight of the machine being towed. This is particularly important on slopes. and rimpull. Keep the angle of the towing line to the minimum. there is danger that it may cause serious injury or death. no lubrication oil will be supplied to the transmission.5 times greater than the weight of the machine being towed. Before releasing the brakes.0 MPH). The towing machine must have ample brake capacity.

3 . but the maximum drawbar pull is needed on slopes or on rough roads. When towing a failed machine. 2. use the following methods to release the parking brake and tow the machine. the brake cannot be used. 3. This will release parking brake (1). If the parking brake is released. Please contact your Komatsu distributor to have the parking brake adjusted. it is possible to prevent the failed machine from going out of control and turning over. a larger towing machine must be used to ensure ample control and braking power. In this way. stop the machine on level ground and check that the surrounding area is safe. 1. It is impossible to determine the drawbar pull needed for various conditions. block the tires before starting the operation. please contact your Komatsu distributor. it is necessary to adjust the parking brake again. flat ground. NOTICE After releasing the parking brake and moving the machine. TROUBLESHOOTING OPERATION When moving a failed machine on a downhill slope. Loosen adjustment bolt (4) and locknut (3) inside the spring chamber until a clearance is formed between the disc and pad. If it is necessary to release the brake on a slope in an emergency. The minimum drawbar pull may be sufficient on horizontal. If the engine will not run for some reason.. Another method is to use a second towing machine at the rear of the failed machine.116 . METHOD OF RELEASING PARKING BRAKE WARNING When releasing the parking brake. Remove cover plug (2) of parking brake (1) at the rear of the final drive case. so check the safety carefully when moving the machine.

or do anything that will cause sparks. If the terminals are loose. remove the ground cable (normally connected to the negative (-) terminal). so there is a hazard of explosion. there is danger that the defective contact may generate sparks that will cause an explosion. Battery electrolyte is dilute sulfuric acid. If it gets on your clothes or on your skin. first disconnect the cable from the ground (normally the negative (-) terminal). When handling batteries. always wear safety glasses and rubber gloves. so be extremely careful. The battery generates hydrogen gas. OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING It is dangerous to charge a battery when mounted on a machine. wash it out with fresh water and consult a doctor. If it gets in your eyes.117 . immediately wash it off with a large amount of water. 3 . When installing the battery. If a tool touches the positive terminal and the chassis. Make sure that it is dismounted before charging. there is danger that it will cause a spark. Do not bring lighted cigarettes near the battery. there is a hazard of sparks being generated. and it will attack your clothes and skin. check which is the positive (+) terminal and which is the negative (-) terminal. When removing or installing the terminals. REMOVAL AND INSTALLATION OF BATTERY Before removing the battery. If any tool touches between the positive terminal and the chassis. When removing the battery. connect the ground cable last. stop the engine and turn the starting switch key to the OFF position. install the positive (+) terminal first.. When installing. When checking or handling the battery.

so connect to a place as far as possible from the battery. 3 . Set the voltage of the charger to match the voltage of the battery to be charged. If the correct voltage is not selected. Follow the precautions in "IF BATTERY IS DISCHARGED (PAGE 3-117)" and the instructions given in the charger manual. set it to less than the rated battery capacity. the electrolyte will leak or dry up. When disconnecting the booster cable. wear safety glasses and rubber gloves. Check that the work equipment lock levers and parking brake levers of both machines are in the LOCK position. and always do as follows. Connect the positive (+) charger clip of the charger to the positive (+) terminal of the battery. If the charger current is too high. This may cause an explosion. Check the cables and clips for damage or corrosion. Be careful not to let the normal machine and problem machine contact each other. Be sure to attach the clips securely. Check that each lever is in the NEUTRAL position. The battery of the normal machine must be the same capacity as that of the engine to be started. if the battery is mistakenly handled.118 . STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable. There is a danger that this will ignite the battery electrolyte and cause the battery to explode. take care not to bring the clips in contact with each other or with the machine body. If the battery electrolyte is frozen. the charger may overheat and cause an explosion. TROUBLESHOOTING OPERATION PRECAUTIONS WHEN CHARGING BATTERY When the charging the battery. Make sure that the cables and clips are firmly connected. Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. Set the charging current to 1/10 of the value of the rated battery capacity. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line. This prevents sparks from generating near the battery which could ignite the hydrogen gas given off by the battery. NOTICE The size of the booster cable and clip should be suitable for the battery size. do not charge the battery or start the engine with a different power source. and this may cause the battery to catch fire and explode. Make sure that there is no mistake in the booster cable connections. when carrying out rapid charging. When starting the engine with a booster cable. PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING When connecting the cables. but sparks will be generated when this is done.. do as follows. there is danger of explosion. never contact the positive (+) and negative (-) terminals. The final connection is to the engine block of the problem machine. then connect the negative (-) charger clip of the charger to the negative (-) terminal of the battery.

OPERATION TROUBLESHOOTING CONNECTING THE BOOSTER CABLES Keep the starting switch of the normal machine and problem machine in the OFF position. 2. Make sure the clips are firmly connected to the battery terminals. DISCONNECTING THE BOOSTER CABLES After the engine has started. 3. 1. 2. Connect one clip of booster cable (B) to the negative (-) terminal of the normal machine. 3. Connect one clip of booster cable (A) to the positive (+) terminal of the problem machine. Turn the starting switch of the problem machine to the START position and start the engine. Connect the other clip of booster cable (A) to the positive (+) terminal of the normal machine. 3 . 1. Remove one clip of booster cable (B) from the engine block of the problem machine. disconnect the booster cables in the reverse of the order in which they were connected. 4. Connect the booster cable as follows. 2. STARTING THE ENGINE CAUTION Check that the gearshift levers on both the normal machine and problem machine are at the P (Parking) position.119 . Remove the other clip of booster cable (A) from the positive (+) terminal of the problem machine. in the order of the numbers marked in the diagram. Connect the other clip of booster cable (B) to the engine block of the problem machine. 3. 4.. Check also that all levers are at neutral. Remove the other clip of booster cable (B) from the negative (-) terminal of the normal machine. Start engine of the normal machine and run it at high idle speed. try again after 2 minutes or so. If the engine doesn't start at first. Remove one clip of booster cable (A) from the positive (+) terminal of the normal machine. 1.

see EVERY 250 HOURS SERVICE Replace) Replace) Check. TROUBLESHOOTING OPERATION OTHER TROUBLE ELECTRICAL SYSTEM ( ): Always contact your Komatsu distributor when dealing with these items. repair) Replace) Replace) Replace) Check. contact your Komatsu distributor for repairs. repair) Replace) Replace heater relay switch) ( ( ( ( ( ( ( ( Defective wiring Disconnection in electrical intake ( air heater ( Defective operation of heater relay switch intake air heater 3 . repair) Replace) Check. replace For details. Problem Lamp does not glow brightly even when the engine runs at high speed Lamp flickers while engine is running Charge lamp do not go out even when engine is running Abnormal noise is generated from alternator Starting motor does not turn when starting switch is turned to ON Pinion of starting motor keeps going in and out Starting motor turns engine sluggishly Starting motor disengages before engine starts Preheating monitor does not goes out Charge lamp does not light up while engine is stopped (with starting switch at ON position) Outside of electrical intake air heater is not warm when touched by hand Main causes Defective wiring Defective adjustment of fan belt tension Defective lamp Defective alternator Defective wiring Defective alternator Defective wiring Insufficient battery charge Defective starting motor Insufficient battery charge Insufficient battery charge Defective starting motor Defective wiring Insufficient battery charge Defective wiring Defective heater relay Defective monitor Defective monitor Defective wiring ( ( ( ( ( ( Remedy Check. repair) Check. repair) Charge Check.120 . In cases of problems or causes which are not listed below. repair) Charge ( Replace) Charge Charge Replace) Check.. repair loose terminals. disconnection) Check fan belt wear.

Clean. For details. adjust Lack of inflation pressure Heat generated from front wheel hub Loose bearing preload adjustment ( Check. Adjust. Inflate tires to same air pressure Install again. see EVERY 250 HOURS SERVICE.121 . replace) Check. For details. replace. machine moves slowly. scuffing of transmission pump Leakage of oil from oil line Clogged transmission filter element Add oil to specified level. contact your Komatsu distributor for repairs. OPERATION TROUBLESHOOTING CHASSIS ( ): Always contact your Komatsu distributor when dealing with these items. repair) Add oil to specified level. ( Check. lacks power Lack of oil in transmission Clogged transmission oil filter cartridge Defective return of parking brake Improper adjustment of engine More noise than usual is generated from power train Abnormal wear of front tires Lack of oil in transmission case. Check. For details. see EVERY 1000 HOURS SERVICE. repair) Check. adjust [adjust bearing nut for front wheel preload]) Lack of grease Supply grease Incorrect adjustment of toe-in. tandem case Incorrect adjustment of toe-in Add oil to specified level. repair) ( ( Check. Front wheels wobble when traveling Steering wheel is heavy 3 . In cases of problems or causes which are not listed below. For details. For details. loose tie rod Inflation pressure of left and right tires not same Wheel not properly installed Loose front wheel bearing mounting nut Defective Orbit-roll Defective adjustment of priority valve Lack of hydraulic oil Adjust. see EVERY 250 HOURS SERVICE. control valve Defective return of parking brake Even when engine is run at full throttle. adjust) Wear. ( Check. repair) Clean. replace. Problem Even when engine is running.. repair) Check. repair) ( Check. ( Check. see EVERY 250 HOURS SERVICE. see HANDLING TIRES. repair) ( Defective operation of transmission. For details. see EVERY 1000 HOURS SERVICE. For details. see EVERY 500 HOURS SERVICE. repair) Add oil to specified level. For details. see EVERY 1000 HOURS SERVICE. machine does not move Main causes Gearshift lever has not been shifted properly Gouging of lever linkage Transmission oil pressure does not rise Lack of oil in transmission case Remedy Shift lever properly ( ( Check. ( Adjust) ( ( Adjust) Check.

shim Correct blade rail Adjust position of guide connector. clean) Adjust shim. For details. repair) Check.. TROUBLESHOOTING OPERATION Problem Even when brake pedal is depressed. see EVERY 250 HOURS SERVICE. braking effect is poor Main causes Worn lining Oil leakage in brake piping Defective brake valve Defective piston seal Defective adjustment of brake shoe Oil on lining surface Seized lining Sand.122 . ( Adjust clearance) Blade moves up and down excessively during operation Play in lift cylinder ball joint Excessive clearance between sliding surface of circle and drawbar Worn blade rail guide bushing Rotation of blade during operation is excessive Excessive clearance in circle in radial direction Work equipment does not move properly when work equipment control lever is operated Heat generated from parking brake disc Lack of oil Lining in contact with disc 3 . For details. see EVERY 250 HOURS SERVICE. repair) Check. Adjust shim at circle guide connector. repair) Replace) Adjust) Poor braking effect of parking brake Finish surface of lining with sandpaper) ( Finish surface of lining with sandpaper) ( Disassemble. For details. see EVERY 500 HOURS SERVICE. For details. mud inside brake ( ( ( ( ( ( Remedy Check. Replace guide bushing. see EVERY 500 HOURS SERVICE. water. Add oil to specified level.

Problem After warming-up operation.123 . For details. see CHECK BEFORE STARTING. see WHEN REQUIRED. replace spring) Loose fan belt Dirt or scale accumulated in cooling system Radiator fins clogged or bent Water temperature gauge is in top of red range Defective thermostat Loose radiator filler cap (high altitude operations) Defective water temperature gauge Broken shroud or not installed Defective pressure cap Excessive load Check. engine oil pressure monitor lights up even when engine speed is raised Main causes Oil level in engine oil pan is low (sucking in air) Clogged oil filter element Remedy Add oil to specified level. see EVERY 250 HOURS SERVICE. clean cooling system. see EVERY 250 HOURS SERVICE. pipe joint Defective monitor Defective oil pressure switch Diluted with fuel. In cases of problems or causes which are not listed below. water temperature gauge does not work even when engine speed is raised Defective thermostat Defective water temperature gauge 3 . repair) Leakage of oil due to damage. ( Replace thermostat) Tighten cap or replace packing ( Replace) Check. water Defective pressure adjustment valve Steam spurts out from top of radiator sub-tank (pressure valve) Coolant level is low ( ( ( ( Replace) Replace) Check. repair. For details. defective tightening of oil pipe. check defective return of parking brake) ( ( Replace thermostat) Replace water temperature gauge) ( After warming-up operation. For details. add cooling water. contact your Komatsu distributor for repairs. see EVERY 500 HOURS SERVICE. ( Check. Replace element. OPERATION TROUBLESHOOTING ENGINE ( ): Always contact your Komatsu distributor when dealing with these items. For details. Clean or repair. Change cooling water.. Adjust tension. repair cooling system. For details. For details. install) Replace ( Check brake. repair) Check valve. see WHEN REQUIRED.

For details. For details. see WHEN REQUIRED. ( Repair place where air is sucked in) ( Replace pump or nozzle) See ELECTRICAL SYSTEM See ELECTRICAL SYSTEM Air in fuel system Defective fuel injection pump or nozzle Starting motor cranks engine sluggishly Preheating monitor does not light up Defective compression Defective valve clearance Defective fuel shut-down solenoid Clogged fuel filter Defective wiring in charge prevention circuit when starting Defective actuation of charge prevention solenoid valve when starting Exhaust gas is white or blue Too much oil in oil pan ( Adjust clearance) ( Replace) Replace filter ( Check. see CHECK BEFORE STARTING. replace) ( Check. repair wiring of solenoid valve) 3 . repair) Lack of fuel Improper fuel Exhaust gas sometimes turns black Clogged air cleaner element Defective nozzle Defective compression Defective turbocharger Engine water temperature too low Combustion noise occasionally makes breathing sound Defective nozzle Defective fuel injection pump Air in fuel line Defective fuel injection timing Clogged fuel filter Low-grade fuel being used Overheating Reduce oil to specified level. adjust) ( Repair.. repair) ( Check. Clean or replace. see CHECK BEFORE STARTING. see CHECK BEFORE STARTING. TROUBLESHOOTING OPERATION Problem Engine does not start when starting motor is turned Main causes Lack of fuel Remedy Add fuel. Replace nozzle) See "Defective compression" above) Wash or replace turbocharger) Check. replace thermostat) Replace nozzle) Replace pump) Repair location of air entry) Adjust timing) Replace fuel filter ( ( ( ( ( ( ( ( Abnormal noise generated (fuel system or mechanical system) Damage inside muffler Excessive valve clearance Air in fuel line Defective timing Defective nozzle Engine does not stop Defective actuation of shut-down valve Change to specified fuel See "Engine water temperature gauge is in red range top". For details. Add fuel. For details.124 . Replace muffler ( Adjust clearance) Bleed air ( Check.

repair) Check. See CHECK BEFORE STARTING ( Repair location of air entry) ( Replace) Replace filter Replace transmission controller) Replace) ( ( Adjust to correct level Clean. replace) Add fuel. nozzle Clogged fuel filter Output of variable output selector signal not given (machines with variable output engine) Defective variable output selector valve (machines with variable output engine) Oil level too high Clogged air cleaner Leakage of intake or exhaust from turbocharger Use of poor quality fuel Defective thermostat Defective timing ( ( Remedy Check. repair. OPERATION TROUBLESHOOTING Problem Does not reach rated speed when there is load Main causes Defective adjustment of link Defective actuation of tachometer Lack of fuel Air in fuel line Defective fuel injection pump. adjust) ( ( 3 . replace) Change fuel Replace) Check.. replace ( Check.125 .

then contact your Komatsu distributor for repairs. [E--0] is displayed. 2. If there is no problem.126 . After checking the error code. Press the "MODE" button of message center (2). After checking the error code. set to the AUTO display or error code display. TROUBLESHOOTING OPERATION ERROR CODES If any problem occurs. Stop the machine immediately at a safe place and set gearshift lever (1) to the P (Parking) position. REMARK If multiple failures occur at the same time. 3. set the gearshift lever to the P (Parking) position. please contact your Komatsu distributor for repairs. 1. Check the error code as follows. 3 . and check the error code. each service code is displayed in turn for 2 seconds each. stop the engine immediately. check the error code. stop the machine at a safe place..

4-1 ..

Objects in your pockets: When opening inspection windows or the oil filler port of the tank to carry out inspection. Carry only things which are necessary for inspection. If a seal or bearing happens to come between the part being welded and grounding point. Welding instructions: Turn off the engine starting switch. etc. If such things are dropped inside the machine. be careful not to drop nuts. Also. GUIDES TO MAINTENANCE MAINTENANCE GUIDES TO MAINTENANCE Do not perform any inspection and maintenance operation that is not found in this manual. Do not apply more than 200 V continuously. use the Komatsu genuine lubricants. Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point. check the old oil and filters for metal particles and foreign materials. If large quantity of metal particles or foreign materials are found. or tools inside the machine.. Moreover use oil of the specified viscosity according to the ambient temperature. If you drop anything inside the machine. Do not put unnecessary things in your pockets. do not remove it while fueling. it may cause damage and/or malfunction of the machine.3 ft) of the area to be welded. Be careful of hot water and oil: If your machine is equipped with a fuel strainer. Komatsu genuine oils: For lubrication of the machine. If grounding cable is connected near instruments. Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Checking foreign material in drained oil: After oil is changed or filters are replaced. Keep foreign materials away from oil and grease. connectors. keep the containers of the oil and grease clean. the instruments may malfunction. bolts. Connect grounding cable within 1 m (3. Clean oil and grease: Use clean oil and grease. 4-2 . always report to the person in charge. Always use clean washer fluid: Use automobile window washer fluid. and carry out suitable action. change the grounding point to avoid such parts. always remove it immediately. and be careful not to let any dirt get into it.. and will lead to failure. Check service meter: Check the service meter reading every day to see if the time has come for any necessary maintenance to be performed.

If inspection or maintenance is performed with inspection cover not locked in position. clean the mounting surface. When doing this. When installing the hoses.. Avoid mixing oils: If a different brand or grade of oil has to be added. to avoid accumulation of dust. or the hydraulic piping has been removed and installed again. Checks after inspection and maintenance: If you forget to perform the checks after inspection and maintenance. their service life will be shortened extremely and they may be damaged. Locking inspection covers: Lock inspection cover securely into position with the lock bar. drain the old oil and replace all the oil with the new brand or grade of oil. unexpected problems may occur. and replace with new parts. do as follows: Inspect the air cleaner clogging monitor frequently to see if the dust indicator is clogged. Bleeding air from hydraulic circuit: When hydraulic equipment has been repaired or replaced. there is a danger that it may be suddenly blow shut by the wind and cause injury to the worker. MAINTENANCE GUIDES TO MAINTENANCE Dusty worksites: When working at dusty worksites. Are there any leakage of coolant or oil? Have all nuts and bolts been tightened? Checks when operating engine For details of the checks when operating the engine. Clean the air cleaner element at a shorter interval than specified. Never mix different brand or grade of oil. Clean and replace the fuel filter frequently. When inspecting or changing the oil. the air must be bled from the circuit. see "TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING (PAGE 2-31)" and pay careful attention to safety. especially the starting motor and alternator. be careful not to forget to assemble the O-rings and gaskets. Clean the radiator core frequently to avoid clogging. and this may lead to serious injury or property damage. do not twist them or bend them sharply. Precautions when installing hydraulic hoses: When removing parts at locations where there are O-rings or gasket seals. If they are installed so. move the machine to a place that is free of dust to prevent dirt from getting into the oil. 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 performed correctly? Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped inside the machine and get caught in the lever linkage mechanism. Clean electrical components. Are the inspection and maintenance items working properly? Is there any leakage of oil when the engine speed is raised and load is applied to the oil pressure? Is there any leakage of oil or fuel when the engine speed is raised? 4-3 .

always fill the fuel tank after completing the day's work. or if the filters have been replaced. so be extremely careful not to expose it to flame or fire. Antifreeze is flammable. When using antifreeze. If the oil in the work equipment is not clear. Oil corresponds to blood in the human body. Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C (5 °F)). To prevent the moisture in the air from condensing and forming water inside the fuel tank. FUEL The fuel pump is a precision instrument. please contact your Komatsu distributor. AND PERFORMING OIL CLINIC OIL Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature. For details of the anti-freeze. If the engine runs out of fuel. or when 10 minutes have passed after adding fuel. and this will cause defective heat exchange and overheating. Be extremely careful not to let impurities get in when storing or adding fuel. scale will stick to the engine and radiator. Even if the oil is not dirty. Take particular care not to let any impurities get in when storing or adding oil. metal particles. It is necessary to use the fuel that is suitable for the temperature. always be careful when handling it to prevent any impurities (water.) from getting in. When changing the oil. always change the oil after the specified interval. For those who wish to use this service. and will also cause problems with corrosion due to air entering the coolant. COOLANT. wait for the engine to cool before adding coolant. it cannot work properly. COOLANT River water contains large amount of calcium and other impurities. We recommend you have an analysis made of the oil periodically to check the condition of the machine. there is probably water or air getting into the circuit. so if it is used. The majority of problems with the machine are caused by the entry of such impurities. FUEL. see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-19)". Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. dirt. always observe the precautions given in the Operation and Maintenance Manual. etc. In such cases. Do not use water that is not suitable for drinking. it is necessary to bleed the air from the circuit. If the coolant level is low. see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-19)". and deteriorates with use. please contact your Komatsu distributor. If the engine overheats. Never mix oils of different grades or brands. This anti-freeze is effective in preventing corrosion of the cooling system. The proportion of anti-freeze to water differs according to the ambient temperature. Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual. always replace the related filters at the same time. Before starting the engine. and if fuel containing water or dirt is used. OUTLINES OF SERVICE MAINTENANCE OUTLINES OF SERVICE HANDLING OIL. Always add the specified amount of oil. drain the sediment and water from the fuel tank. it will cause overheating. Always use the fuel specified in the Operation and Maintenance Manual. high pressure).. For details of the mixing proportions. Having too much oil or too little oil are both causes of problems. 4-4 .

. Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. The nipples not included in the MAINTENANCE section are nipples used when overhauling. 4-5 . grease it. Always wipe off all of the old grease that is pushed out when greasing. so they do not need grease. If any part becomes stiff or generates noise after being used for a long time. MAINTENANCE OUTLINES OF SERVICE GREASE Grease is used to prevent seizure and noises at the joints.

. 4-6 . and dynamic viscosity. The oil analysis is carried out at actual cost. This enables early detection of wear of the machine drive parts and other problems. KOWA ANALYSIS ITEMS Measurement of density of metal wear particles This uses an ICP (Inductively Coupled Plasma) analyzer to measure the density of iron. For further details of KOWA. Perform sampling at regular fixed intervals. density of the antifreeze coolant. and other metal wear particles in the oil. enabling a highly precise diagnosis of the machine's health. OIL SAMPLING Sampling interval 250 hours: Engine 500 hours: Other components Precautions when sampling Make sure that the oil is well mixed before sampling. so the cost is low. please contact your Komatsu distributor. ratio of fuel in the oil. We strongly recommend you to use this service. and the results of the analysis are reported together with recommendations which will reduce repair costs and machine downtime. Measurement of quantity of particles This uses a PQI (Particle Quantifier Index) measurer to measure the quantity of iron particles of 5µm or more. the oil is periodically sampled and analyzed. Do not perform sampling on rainy or windy days when water or dust can get into the oil. OUTLINES OF SERVICE MAINTENANCE CARRYING OUT KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. copper. Others Measurements are made of items such as the ratio of water in the oil. With KOWA. enabling early detection of failures.

be careful not to let water get into the electrical components. This will cause an electrical short circuit and may lead to malfunction of the machine. 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. carefully clean the electric system to prevent corrosion. before installing a radio receiver or other wireless equipment. However. Always replace with new filters. When washing the machine. dirt. RELATING TO ELECTRIC SYSTEM It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. When keeping drum cans for a long period. For details. Never try to clean the filters (cartridge type) and use them again. contact your Komatsu distributor. When installing an operator's cab cooler or any other electrical equipment. 4-7 . Do not wash the inside of the operator's cab with water. FILTERS Filters are extremely important safety parts. connect it to an independent power source connector. MAINTENANCE OUTLINES OF SERVICE STORING OIL AND FUEL Keep indoors to prevent any water. check if any metal particles are attached to the old filter. They prevent impurities in the fuel and air circuits from entering important equipment and causing problems. replace the filters at shorter intervals according to the oil and fuel (sulfur content) being used. When working at the seashore. or battery relay. If drums have to be stored outside. The cables to supply power to the optional equipment must never be connected to the fuse. cover them with a waterproof sheet or take other measures to protect them. Never install any electric components other than those specified by Komatsu.. Always use Komatsu genuine filters. If any metal particles are found. checking damage or wear to the fan belt and checking battery fluid level. or other impurities from getting in. when working in severe conditions. Replace all filters periodically. When replacing oil filters. contact your Komatsu distributor. see the Operation and Maintenance Manual. To prevent any change in quality during long-term storage.first out (use the oldest oil or fuel first). External electro-magnetic interference may cause malfunction of the control system controller. be sure to use in the order of first in . Service relating to the electric system is checking fan belt tension. starting switch. Do not open packs of spare filters until just before they are to be used.

For part change. The wear parts should be changed correctly in order to use the machine economically. Komatsu genuine parts of excellent quality should be used.. edge. are to be replaced at the time of periodic maintenance or before their abrasion limits. air cleaner element. Item Engine oil filter Fuel filter Corrosion resistor Transmission oil filter Hydraulic filter Air cleaner Part No. When ordering parts. please check the part number in the parts book. 6736-51-5142 6732-71-6112 600-411-1191 714-07-28711 07063-51100 (07000-15155) 600-185-3100 23B-70-31310 23B-70-31660 (232-70-12550) 23B-70-31340 (232-70-12560) 23B-70-31331 23B-735-3320 23B-70-31630 23B-70-51560 234-71-13443 232-71-51320 113-78-21140 (113-78-21170) Part Name Cartridge Cartridge Cartridge Cartridge Element (O-ring) Element ass'y Edge Side edge (Bolt) End bit Bolt Guide bushing Guide bushing Wear plate Wear piece Shear pin Tooth Tooth (Pin) Q'ty 1 1 1 1 1 (1) 1 2 2 (34) 2 (10) 4 1 6 6 1 11 3 (3) Replacement interval Every 250 hours Every 500 hours Every 1000 hours Every 1000 hours Every 1000 hours - Blade - Scarifier Ripper - 4-8 . WEAR PARTS LIST The parts in parentheses are to be replaced at the same time. etc. WEAR PARTS MAINTENANCE WEAR PARTS Wear parts such as the filter element.

. 1 4-9 . COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE *: ASTM D975 No. MAINTENANCE USE OF FUEL. COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE USE OF FUEL.

0 4.2 3.0 4.14 Final drive case Standard 17.49 17.0% Above 1. SAE10W-30 and SAE15W-40.62 REMARK When fuel sulphur content is less than 0.5%. but be sure to add single grade oil that matches the temperature range in the table.89 Tandem drive case (each) 80.32 Slip clutch type 7..89 Fuel tank 340 89. be sure to use engine oil of SAE10W. Change oil according to the following table if fuel sulfur content is above 0.49 With differential lock 14.0 1. When starting the engine with an atmospheric temperature of lower than 0°C (32°F). change oil in the oil pan according to the periodic maintenance hours described in this manual. COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE Reservoir Engine oil pan Capacity Specified Refill Liters US gal Liters US gal 16.5%. There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30.0 21.23 14. Specified capacity: Total amount of oil including oil for components and oil in piping. even though the atmospheric temperature goes up to 10°C (50° F) more or less during the day.85 Capacity Specified Refill Reservoir Hydraulic system Liters US gal Liters US gal 85 22.46 45 11.10 .70 14.70 Circle reverce gear case Shear pin type 5.0% Engine oil change interval 1/2 of regular interval 1/4 of regular interval 4 .32 5.62 44 11. 15W-40).76 – – Cooling system 44 11. USE OF FUEL.0 1.0 3. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.0 21.85 7.75 Transmission case 60.85 45. Use API classification CD as engine oil and if API classification CC. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute Fuel sulfur content 0.5 to 1.14 80.0 11.0 3.0 1. reduce the engine oil change interval to half.0 4.0 1. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications.0 15.

MAINTENANCE USE OF FUEL. 15W40 (The 15W40 oil marked * is CE.) EO10-CD EO30-CD EO10-30CD EO15-40CD Diesel sigma S super dieselmultigrade *Sigma turbo *Amoco 300 *Arcofleet S3 pius Vanellus C3 *RPM delo 400 RPM delo 450 *Turbomax *RX super CRD Gear Oil [GL-4 or GL-5] SAE80. Supplier Engine Oil [CD or CE] SAE10W. 15W-40 Glacelf 10 ELF 11 EXXON (ESSO) Gear oil GP Gear oil GX Multi-purpose gear lubricant Mobilube GX Mobilube HD Beacon EP2 All season coolant 12 GULF 13 MOBIL Gulfcrown EP2 Gulfcrown EP special Mobilux EP2 Mobilgease 77 Mobilgrease special Antifeeze and coolant - 4 . COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE No..11 . one season type) - 1 KOMATSU GO90 GO140 G2-LI G2-LI-S 2 AGIP Rotra MP Multi-purpose gear oil Arco HD gear oil Gear oil EP Hypogear EP GR MU/EP PYKON premium grease Litholine HEP 2 Arco EP moly D Energrease LS-EP2 3 4 5 6 AMOCO ARCO BP CALTEX Antifreeze AF engine coolant Universal thuban Marfak all purpose 2 Universal thuban EP Ultra-duty grease 2 EP EPX Hypoy Hypoy B Hypoy C Universal gear Universal gear lubricant MS3 Spheerol EPL2 Ultra-duty grease 2 Super-sta grease Tranself EP Tranself EP type 2 7 CASTROL Anti-freeze 8 9 CHEVRON *Delo 400 CONOCO *Fleet motor oil Multiperformance 3C Performance 3C Essolube D3 *Essolube XD-3 *Essolube XD-3 Extra *Esso heavy duty Exxon heavy duty Super duty motor oil *Super duty plus Delvac 1300 *Delvac super 10W-30. 90. 30. 40 10W30.2 Anti-freeze Coolant [Ethylene Glycol Base] Permanent Type AF-ACL AF-PTL AF-PT(Winter. 140 Grease [Lithium-Base] NLGI No.

140 Grease [Lithium-Base] NLGI No. 30.12 .) Gear Oil [GL-4 or GL-5] SAE80. Supplier Engine Oil [CD or CE] SAE10W.2 Multi-purpose white grease 705 707L White-bearing grease FINA marson EPL2 Albania EP grease Sunoco ultra prestige 2EP Sun prestige 742 Multifak EP2 Starplex 2 Multis EP2 Unoba EP - Anti-freeze Coolant [Ethylene Glycol Base] Permanent Type Anti-freeze and summer coolant FINA tamidor Sunoco antifreeze and summer coolant Coda 2055 startex antifreeze coolant Antigal/antifreeze Antifreeze *Superme duty 14 PENNZOIL fleet motor oil 15 PETROFIN FINA kappa TD E Rimura X *Ursa super plus Ursa premium Rubia S *Rubia X *Guardol *Turbostar *Diesel star MDC Multi-purpose 4092 Multi-purpose 4140 FINA potonic N FINA potonic NE Spirax EP Spirax heavy duty Sunoco GL5 gear oil Multigear Total EP Total Transmission TM MP gear lube LS Multigear Multigear B Multigear C 16 SHELL 17 SUN 18 TEXACO 19 TOTAL 20 UNION 21 VEEDOL 4 . 90. USE OF FUEL. 15W40 (The 15W40 oil marked * is CE.. COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE No. 40 10W30.

12.0-1085.3-90.0 .5 83.1.7 147.0 159.0 15.0 1121.0 22.7 .5 117.35 3.8 159.137.3 1808.284.0-20.0 175..1 Nm 11.0 200.5 16.5 117.5 39 56 76 94.7-144.0 120.0-195.14.7-448.3 86.0 kgm 1.98.0 lbft 8.2 607.7 57.0 9.0 lbft 10.1 405.8 23.7 29.5 976.0-370.3-2242.5 .5-84. it will cause looseness or damage to the tightened parts.3 43.0-150.0 67.2 2423.8 1627. Thread diameter of bolt (a)(mm) 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 Width across flats (b)(mm) 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Tightening torque Target value Nm 13.2 130.5 18 28.5 50.1 88.7 27-34 59-74 98-123 157-196 245-309 343-425 490-608 662-829 824-1030 1180-1470 1520-1910 1960-2450 2450-3040 2890-3630 Service limit kgm 1.0 6.16.10.0-310.7 255.3 .8 .2 31 66 113 177 279 382 549 745 927 1320 1720 2210 2750 3280 kgm 1.8 20.8 108.28.7-2676.4 22.3 .5 10.1 48.0 .0-105.9 43.4 2025.0 25. always use a Komatsu genuine part of the same size as the part that was replaced.2 2133.4 .0 lbft 9.1 176. If it is necessary to replace any nut or bolt.0 4 .1 .5 12.3 65.0 .0 12. Unless otherwise specified.7 2.7-10.2 58.4 .1 .0 280.2-611.6-1808.0 549.8 .5 35. or other parts are not tightened to the specified torque.0 . Always pay careful attention when tightening parts.2 6.8-227.7 683.8 .25. MAINTENANCE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS TORQUE LIST CAUTION If nuts.8-3.209.0-12.0-31.18.7 11.2-1.5 3.3 Permissible range kgm 1.0 250.5 2.13 .0 .2 Apply the following table for Hydraulic Hose.6 361.7 180.3 .4 78.130.101.5 1265.5 135.245.8 21.9 86.2-314.8 253.6-759.5 84.180.0 335.3 20.72.1 215.2 18.0-7. Taper seal Thread diameter a (mm) 10 14 18 22 24 30 33 Width across flats b (mm) 14 19 24 27 32 36 41 Tightening torque Target value Nm 14. tighten the metric nuts and bolts to the torque shown in the table below.5 6.2 206.0-43. and this will cause failure of the machine or problems with operation.0 225.0 155.176.0-250. bolts.4.0 lbft 9.4-54.5 868.0 8.8-14.0 188.5 .7 .7 27.1 215.2 130.3-25.6 Nm 12.1-1410.29.4 1446.1 282.4 115.0 295.0-62.0 26.7 .39.4 488.2 72.2 .

0 39.0 .8 .4 216 22.5 25.0 94.68.7 128 .9 84 .5 32.47.5 7.5 .5 .180.93 3.186 13.8 4 .5 .0 130.14 .1 177 .0 .6 103 10.245 18. of threads (a) 9/16 -18UNF 11/16 -16UN 13/16 -16UN 1 -14UNS 13/16 -12UN Width Tightening torque across Target value Permissible range flats (b) Nm kgm lbft (mm) Nm kgm lbft 19 22 27 32 36 44 74 4.132 8.0 115.9.137.2 35 .5 75.0 159.7 61.5 157 16..25.3 .5 5.5 54.5 .63 54 .0 .2 .13. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS MAINTENANCE Face seal Nominal No.97.6.19.

of leaning cylinder 13 O-ring for leaning cylinder 14 Brake circuit rubber hose (governor valve ..steering cylinder) O-ring for steering valve O-ring. If any of the hose clamps show deterioration like deformation or cracking.steering valve) Steering circuit rubber hose (steering valve . always replace O-rings. and other such parts at the same time. Hence. These parts are particularly closely connected to safety and fire prevention. When replacing hoses. so please contact your Komatsu distributor to have them replaced. 1 2 3 4 5 6 7 8 9 Safety critical parts for periodic replacement Fuel hose (fuel tank . of steering cylinder Dust seal for steering cylinder O-ring for steering cylinder Steering circuit rubber hose (steering pump . MAINTENANCE PERIODIC REPLACEMENT OF CRITICAL PARTS PERIODIC REPLACEMENT OF CRITICAL PARTS To ensure safety at all times when operating or driving the machine. the parts in the safety-critical parts list on the next page must also be replaced at the specified interval. gaskets. the user of the machine must always carry out periodic maintenance. replace the clamps at the same time as the hoses.slack adjuster) 16 Brake circuit rubber hose (slack adjuster . Replacement interval 10 Dust seal for steering valve 11 12 Packing.brake) 17 Seat belt 4 . This is important to ensure that these parts maintain their full performance at all times.fuel filter) Fuel spill hose (nozzle . of steering valve Leaning circuit rubber hose (right side of work equipment control valve . should anything abnormal be found on any of these parts. Also perform the following checks with hydraulic hoses which need to be replaced periodically. Furthermore.leaning cylinder) Q'ty 1 1 4 2 4 1 8 3 2 1 4 4 2 2 5 4 1 Every 3 years Every 2 years or every 4000 hours. dust seals. it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. In addition. Tighten all loose clamps and replace defective hoses. piston seals. seals.fuel tank) Rod packing. it is required to replace them with new ones regardless of their condition after a certain period of usage.accumulator) 15 Brake circuit rubber hose (accumulator . Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However. as required. to further improve safety. replace it with a new one even if the periodic replacement time for the part has not yet arrived. CRITICAL PARTS No. piston seals.15 . whichever comes sooner.

49 4. ADJUST 4444444449 57 58 64 63 58 65 68 4444444444- 19 22 26 27 27 27 28 29 29 30 4.51 4. MAINTENANCE SCHEDULE CHART MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (only after the first 250 hours) REPLACE FUEL FILTER CARTRIDGE CHANGE OIL IN TRANSMISSION CASE CHANGE OIL IN FINAL DRIVE CASE CHANGE OIL IN CIRCLE REVERSE GEAR CASE CHANGE OIL IN HYDRAULIC TANK REPLACE HYDRAULIC TANK FILTER ELEMENT CHANGE OIL IN TANDEM DRIVE CASE CHECK ENGINE VALVE CLEARANCE.33 444444444444- 34 40 41 42 43 43 44 45 47 47 47 48 4. ADD OIL CHECK LEVEL OF BATTERY ELECTROLYTE CHECK BALL JOINT CLEARANCE. ADD OIL CHECK OIL LEVEL IN HYDRAULIC TANK.16 . ADD OIL CHECK OIL LEVEL IN TANDEM DRIVE CASE. ADJUST EVERY 500 HOURS SERVICE REPLACE FUEL FILTER CARTRIDGE CLEAN.. ADD OIL CHECK OIL LEVEL IN FINAL DRIVE CASE. LOCK RING AND SIDE RING FOR CORROSION AND WEAR CHECK FAN BELT TENSION. ADJUST CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT CHECKING WHEEL RIM. ADD OIL CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE.52 4 . CLEAN AND REPLACE AIR CLEANER ELEMENT CLEAN. ADJUST WHEN REQUIRED CLEAN INSIDE OF COOLING SYSTEM CHECK. CHECK RADIATOR FINS CHECK CIRCLE GUIDE CLEARANCE. REPLACE ENGINE OIL FILTER CARTRIDGE CHECK OIL LEVEL IN TRANSMISSION CASE. CHECK WATER SEPARATOR CHECK ELECTRICAL INTAKE AIR HEATER REPLACE THE CUTTING EDGES. REVERSE AND REPLACE END BIT CHECK INCHING PEDAL CLEAN AIR CONDITIONER AIR FILTER CHECK REFRIGENT (GAS) LEVEL CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT SELECTION AND INSPECTION OF TIRES CHECK BEFORE STARTING EVERY 50 HOURS SERVICE LUBRICATING EVERY 250 HOURS SERVICE LUBRICATING CHANGE OIL IN ENGINE OIL PAN.

.

MAINTENANCE

MAINTENANCE SCHEDULE CHART

EVERY 1000 HOURS SERVICE LUBRICATING REPLACE TRANSMISSION OIL FILTER CARTRIDGE CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER CHANGE OIL IN FINAL DRIVE CASE REPLACE HYDRAULIC TANK FILTER ELEMENT CHECK LOOSENESS, PLAY OF BALL JOINT AT FRONT OF DRAWBAR CHECK TOE-IN, ADJUST CHECK FRONT WHEEL BEARING PLAY, ADJUST REPLACE CORROSION RESISTOR CARTRIDGE EVERY 2000 HOURS SERVICE CHANGE OIL IN HYDRAULIC TANK CHANGE OIL IN CIRCLE REVERSE GEAR CASE CHANGE OIL IN TANDEM DRIVE CASE CHECK DISC BRAKE CHECK ALTERNATOR, STARTING MOTOR CHECK ENGINE VALVE CLEARANCE, ADJUST CHECK VIBRATION DAMPER CLEAN, CHECK TURBOCHARGER CHECK ACCUMULATOR GAS PRESSURE CHANGE GREASE IN FRONT WHEEL BEARING EVERY 4000 HOURS SERVICE CHECK WATER PUMP CHECK AND ADJUST AIR COMPRESSOR CHECK FAN PULLEY

444444444-

55 56 57 58 58 59 60 61 62

4444444444-

63 64 65 66 68 68 68 68 68 68

4- 69 4- 69 4- 69

4 - 17

. SERVICE PROCEDURE

MAINTENANCE

SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (only after the first 250 hours)
Carry out the following maintenance only after the first 250 hours of operation on new machines. REPLACE FUEL FILTER CARTRIDGE CHANGE OIL IN TRANSMISSION CASE CHANGE OIL IN FINAL DRIVE CASE CHANGE OIL IN CIRCLE REVERSE GEAR CASE CHANGE OIL IN HYDRAULIC TANK REPLACE HYDRAULIC TANK FILTER ELEMENT CHANGE OIL IN TANDEM DRIVE CASE Check engine valve clearance, adjust For details of the method of replacing or maintaining, see the section on EVERY 250 HOURS, EVERY 500 HOURS, 1000 HOURS AND 2000 HOURS SERVICE.

4 - 18

.

MAINTENANCE

SERVICE PROCEDURE

WHEN REQUIRED
CLEAN INSIDE OF COOLING SYSTEM

WARNING
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to drain the coolant in this condition, there is a danger of burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure before removing it. The cleaning is carried out with the engine running. When standing up or leaving the operator's seat, set the gearshift lever to the P (Parking) position. For details of starting the engine, see "CHECK BEFORE STARTING ENGINE (PAGE 3-35)", "STARTING ENGINE (PAGE 3-48)" in the OPERATION section. There is danger of touching the fan if the undercover is left removed. Never enter the area behind the machine when the engine is running.

Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the table below. Kind of coolant Permanent type antifreeze (All season type) Non permanent type antifreeze containing ethylene glycol (winter, one season type) When not using antifreeze Cleaning inside of cooling system and changing coolant Every year (autumn) or every 2000 hours, whichever comes first Every 6 months (spring, autumn) (Drain antifreeze in spring, add antifreeze in autumn) Every 6 months or every 1000 hours, whichever come first Replacing corrosion resistor

Every 1000 hours and when cleaning the inside of the cooling system and when changing coolant

Stop the machine on level ground when cleaning or changing the coolant. 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 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 (50°F) lower when deciding the mixing rate. Mixing rate of water and antifreeze Min. ambient temperature Amount of antifreeze Amount of water °C °F Liters US gal Liters US gal - 10 14 13 3.43 31 8.19 - 15 5 16 4.23 28 7.39 - 20 -4 18 4.76 26 6.86 - 25 - 13 20 528 24 6.34 - 30 - 22 22 5.81 22 5.81

4 - 19

. SERVICE PROCEDURE

MAINTENANCE

WARNING
Antifreeze coolant is flammable, so keep it away from flame. Antifreeze coolant is toxic. When removing the drain plug, be careful not to get water containing antifreeze coolant 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 coolant. 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. 1. Stop the engine and close the valve (1) of corrosion resistor cartridge.

2. Open cover (2), turn cap (3) of the upper tank slowly, then remove it.

4 - 20

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MAINTENANCE

SERVICE PROCEDURE

3. Set a container in position to catch the coolant, then open drain valve (4) at the bottom of the radiator. 4. After draining the water, close drain valve (4), then add water from water filler (3) of the upper tank to between the H and L marks. 5. When the radiator is full, start the engine, and run it at low idle. Keep the engine running at low idle for 10 minutes until the coolant temperature reaches more than 90°C (194°F). 6. Stop the engine, then open drain valve (4) to drain the water. 7. After draining the water, clean the cooling system with cleaning agent. For the cleaning method, see the instructions for the cleaning agent. 8. Close drain valve (4). 9. Replace the corrosion resistor and set valve (1) to the ON position to open it. For details of replacing the corrosion resistor, see "REPLACE CORROSION RESISTOR CARTRIDGE (PAGE 4-62)". 10. Add antifreeze and water slowly through the water filler port of the upper tank. 11. After adding water to the middle of the level gauge, tighten cap (3). 12. Run the engine idle at a low speed for 5 minutes, then at a high speed for 5 minutes to bleed air mixed in the cooling water. 13. Stop the engine, wait until the engine cools down to normal temperature, then check that the coolant is between the H and L marks. If the water level is low, open cap (3) of the upper tank, add water to between the H and L marks, then close the cap.

4 - 21

there is danger that dirt may be blown around and cause serious injury. the air cleaner will not be able to display its performance fully and the cleaning efficiency will also go down. more dirt stuck to the element will fall inside the inner element. clean the air cleaner element.. If the element is cleaned frequently before the yellow display panel of the dust indicator reaches the red line. NOTICE Do not clean the element before the yellow display panel of the dust indicator reaches the red line. 4 . Always use protective glasses. CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING If inspection. or maintenance is carried out with the engine running. and other protective equipment. Always stop the engine before carrying out these operations. If yellow display panel (2) in the transparent portion of dust indicator (1) reaches red line (3). Open engine side cover.22 . dust mask. dirt will get into the engine and damage it. SERVICE PROCEDURE MAINTENANCE CHECK. during the cleaning operation. 2. CHECKING 1. When using compressed air. cleaning. In addition.

dust will enter and cause engine trouble. Remove outer element (6). Replace the inner element at the same time. Direct dry compressed air (less than 0. then remove dust cup (5). Open engine side cover.4 PSI)) to the element from inside along its folds. do not remove evacuator valve (8). Clean the inside of the air cleaner body and dust cup.. then direct it from outside along its folds and again from inside. MAINTENANCE SERVICE PROCEDURE CLEANING OR REPLACING OUTER ELEMENT 1. If it is removed. replace both the inner and outer elements. 1) Replace the outer element if it has been cleaned 6 times repeatedly or used throughout a year. 5. 2) If the yellow display panel of the dust indicator reaches the center of the scale (5 kPa) immediately after the outer element has been cleaned. 4.23 . even when the outer element has not been cleaned 6 times. Remove clips (4).69 MPa (7 kg/ cm2. 99. 2. 4 . NOTICE Never remove inner element (7). 3. NOTICE When cleaning the dust cup.

then secure them with clips (4). always replace O-ring (9) with a new part. 4 . Do not operate the machine with the inner element removed. the clip or air cleaner body will be damaged. NOTICE When cleaning the element. replace the element. so push it in straight when installing it. Close engine side cover.24 . 9. CAUTION If the inner and outer element have been replaced. SERVICE PROCEDURE MAINTENANCE 6. This will damage the engine. do not hit it or beat it against something.. Press the button on dust indicator (1) to return the yellow display panel to its original position. Set the cleaned outer element and install dust cup (5). If small holes or thinner parts are found on the element when it is checked by shining a light through it after cleaning. Do not use an element whose folds or gasket or seal are damaged. If force is used when assembling. 8. 7.

MAINTENANCE SERVICE PROCEDURE REPLACING INNER ELEMENT NOTICE The inner element must not be used again even after cleaning. however. always replace O-ring (9) with a new part. Press the button on dust indicator (1) to return the yellow display panel to its original position. Do not remove inner element (7) at this time. then install a new inner element immediately. 3. 4 . Set new outer element (6) and install dust cup (5). 5.. Close engine side cover. Remove clips (4). 6. NOTICE When cleaning the dust cup. Remove outer element (6).25 . do not remove evacuator valve (8). then secure them with clips (4). Remove inner element (7). When replacing the outer element. 8. Open engine side cover. then remove dust cup (5). 2. 7. 1. Clean the inside of the air cleaner body and dust cup. 4. CAUTION If the inner and outer element have been replaced. replace the inner element at the same time.

Clean the water separator base. 1. 29. bleed air in the following manner. 4. float. so check and clean the water separator as follows. CHECK WATER SEPARATOR WARNING Each part of the engine is still highly heated immediately after the engine is stopped. Do not bring fire close. 4 . Install element (4) in the reverse sequence to the removing process mentioned in the Step 6 nad 7.2 lbft) If the ring is loose.26 . Check the water separator to see that a red ring inside has come up to the standard line.3 kgm . Wash the interior of filter element (4) and element cup (3) with clean fuel. 11. so always tighten it to the specified torque. REMARK Be careful not to lose the O-ring. After installing filter element cup (3). 2. 9. 10. then remove element cup (3). 12. 5. it will cause leakage of fuel. there is probably water mixed in the fuel. 7. Loosen ring nut (2). Prepare a container to catch the drained fuel and set it under the water separator. Check element (4) and replace it if it is damaged. If red ring (1) has come up to the standard line. SERVICE PROCEDURE MAINTENANCE CLEAN.1 ± 0. carry out the operation from Step 4 below.. Wait for more than 30 seconds after the engine stop for the engine to sufficiently cool down. If the engine does not run smoothly. Loosen drain valve (1) at the bottom of the water separator and drain the water and fuel into the container. Be sure to assemble them after washing. Open the engine side cover on the right side of the chassis. Do not attempt to drain cooling water or remove the filter element cup. 6. The specified tightening torque of ring nut (2): 40 ± 3 Nm (4. while the engine is running. Be sure to use clean fuel for filling the element cup and take care so that no dust will mix with it. 8. Then start with draining cooling water or removing the filter element cup.7 ± 2. Remove element (4) from the separator base. 3. then fill washed element cup (3) with clean fuel and install it on the water separator base. or spring. High pressure is generated inside the engine fuel piping.

1. Clean the mounting face for cutting edge. REVERSE AND REPLACE END BIT WARNING Do not raise the blade unnecessarily high.8 to 1 kgm . reverse the side edges and install them on the opposite side. 15. 5.2 lbft) CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year). 2.1 Nm (0. Replace the cutting edge before it wears to the end face of the blade.3 Nm (26. If the mounting surface is worn.31 kgm . 2. CHECK INCHING PEDAL If any of the following problems have occurred.8 Nm (0. After several hours of running. 14. Install a new cutting edge to the blade. MAINTENANCE SERVICE PROCEDURE 13. 4. 3. or replace the side edges. contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections. If the machine does not stop even the inching pedal is depressed. Tighten air bleed plug (5) and (6). Tightening torque of mounting nut : 260 ± 34. Lift the blade to a suitable height and put a block underneath the blade rail to prevent it from falling.3 lbft) 6. If the machine does not move or lacks power even the inching pedal is released. Remove bolts and nuts (1).27 .8 to 7. REPLACE THE CUTTING EDGES.9 to 3. please contact your Komatsu distributor for inspection and adjustment.7 ± 25. 5.2 lbft) Fuel filter: 7. Tightening torque Water separator: 2. 191. then remove end bit and the cutting edge. Be sure not to put any part of your body underneath the blade when blocking it. Loosen air bleed plug (5) of the water separator and air bleed plug (6) of the fuel filter.4 in).8 to 9.1 to 2.. If the cutting portion (outside) of the side edge is worn. 4 .5 ± 3. Always replace the cutting edge and side edge when the distance from the blade holder is less than 10 mm (0.5 kgm . Operate priming pump (7) up and down until no more bubbles come out with the fuel from air bleed plugs (5) and (6). correct it before turning or replacing the end bits. retighten the nuts.29 to 0.

Use a weak jet of compressed air to remove the dust stuck to the fresh air filter. 2.28 . SERVICE PROCEDURE MAINTENANCE CLEAN AIR CONDITIONER AIR FILTER If the recirculation air filter at the suction port of the air conditioner unit or the fresh air filter at the external air suction port become clogged. so clean the filter. Remove the cover at the bottom of the operator's compartment. 3. 1. Pull out recirculation air filter (1) and clean it with a weak jet of compressed air. 4. Pull up the fresh air filter under the left rear of the operator's seat to remove it.. the heating or cooling performance will drop. 4 .

4 .29 . use a wrench. wear of the V-groove. and wear of the V-belt. Never loosen any part of the refrigerant circuit. replace it with a new belt. If the cooling effect is poor. 98 N (10 kg). it will slip and it will become impossible to carry out cooling properly.75 in) (new belt: 15 to 16 mm (0. the refrigerant level is low. If the belt is stretched and there is no allowance for adjustment. so please contact your Komatsu distributor to have it refilled. When the belt is new. MAINTENANCE SERVICE PROCEDURE CHECK REFRIGERANT (GAS) LEVEL WARNING If the refrigerant used in the cooler gets into your eyes or on your hands. Be particularly careful to check that the V-belt does not contact the bottom of the V-groove. From time to time.67 to 0. If this is the case. Do not bring any flame close to any point where the refrigerant gas is leaking. Press the belt at a point (A) midway between the drive pulley and compressor pulley and check that the deflection is 17 to 19 mm (0. Check each pulley for damage. CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT If the belt is loose. or it is cut or cracked. it may cause loss of sight or frostbite. and if bubbles appear in the sight glass when the air conditioner is set to cooling..63 in)) when pushed with a finger force of approx.59 to 0. so it must be adjusted again after 2 to 3 days. check the sight gauge of the receiver dryer under the right side of the cab. Do not touch the refrigerant. REMARK Run the engine at idle. When adjusting the V-belt. check the belt tension. do not push the compressor directly with a bar. the refrigerant (gas) level may be low. it is particularly likely to stretch at the initial stages.

30 .. and that can cause serious injury or death. Since maintenance. the tire may burst or may be damaged and the rim may be broken and scattered. consult your Komatsu distributor when using optional tires.00-24-10PR 13.00-24-12PR 17.5R25TGœ Remarks 4 . SELECTION OF TIRES WARNING Select the tires according to the conditions of use and the weight of the attachments on the machine. disassembly.00-24-10PR 14. Select the tires according to the conditions of use and the weight of the attachments of the machine.00-24-12PR Optional tires 14. Do not heat or weld the rim to which the tire is installed. Do not make a fire near the tire. repair and assembly of the tires and rims require special equipment and skill. be sure to ask a tire repair shop to do the work. Since the travel speed indicated on the speedometer varies with the tire size. Tire size Standard tires 13. SERVICE PROCEDURE MAINTENANCE SELECTION AND INSPECTION OF TIRES WARNING If a tire or a rim is handled improperly. Use only specified tires and inflate them to the specified pressure. Use the following table.

Do not work in front of the rim but work on the tread side of the tire.75. before starting work. PSI)] 275 (2.00. Abnormal drop of inflation pressure and abnormal fitting of the rim indicate trouble in the tire or rim. If the rim is not fitted normally.5R25TGœ Inflation pressure [kPa (kgf/cm2. 4 . 39. The proper inflation pressure is shown below. INFLATION OF TIRES Adjust the inflation pressure properly. be sure to ask a tire repair shop to carry out repairs.1) 300 (3. 42.6) NOTICE The optimum inflation pressure differs according to the type of work.00-24-12PR 17. 39.00. place a guard around the tire and do not work in front of the rim but work on the tread side of the tire. use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not adjust the inflation pressure of the tires just after high-speed travel or heavy-duty work. Tire size 13. For details.. While inflating the tire. 35. When inflating a tire.50. while the tires are cool. MAINTENANCE SERVICE PROCEDURE CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM WARNING When inflating a tire.00-24-10PR 13. check that no one will enter the working area.6) 250 (2. check the inflation pressure occasionally so that it will not rise too high. 42. Be sure to observe the specified inflation pressure.00-24-10PR 14. In this case.5) 275 (2. see "HANDLING THE TIRES (PAGE 3-107)".31 .75. Use an air chuck which has a clip and which can be fixed to the air valve.00-24-12PR 14. CHECK Measure the inflation pressure with a tire pressure gauge.1) 300 (3. To ensure safety. it may be broken and scattered while the tire is inflated.

add oil Check dust indicator Check and adjust steering wheel Check electric wiring Check breaking effect Check parking brake effect Check flashing of lamps. and defroster work properly. check for dirt and damage Check that all problems from previous day have been repaired Check that windshield wiper. SERVICE PROCEDURE MAINTENANCE CHECK BEFORE STARTING For details of the following items.. drain water separator Check engine oil pan level. check washer fluid level Check inflation pressure of tire 4 . see "CHECK BEFORE STARTING (PAGE 3-37)" in the OPERATION section. add fuel Drain water and sediment in fuel tank Check.32 . window washer. add water Check fuel level. Check coolant level.

Sliding surface at top of circle. Apply grease to the grease fittings shown by arrows.33 . 1.. and secure the front and rear frame with the articulate lock pin. sliding surface on inside of circle. MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE LUBRICATING WARNING Apply the parking brake. and stop the engine. face of circle gear teeth 4 . Set the work equipment in a stable condition.

SERVICE PROCEDURE MAINTENANCE EVERY 250 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATING WARNING Set the gearshift lever to the P (Parking) position. and secure the front and rear frame with the articulate lock pin. Front axle center pin (2 places) 4 . and stop the engine. After greasing.34 . Using a grease pump.. Set the work equipment in a stable condition. wipe off any old grease that was pushed out. 2. 1. pump in grease through the grease fittings shown by arrows.

MAINTENANCE SERVICE PROCEDURE Steering linkage (6 places) Steering cylinder pin (4 places) Tie rod (2 places) Articulate pin (2 places) 4 .35 ..

SERVICE PROCEDURE MAINTENANCE Articulate cylinder pin (4 places) Blade lift cylinder yoke (6 places) Blade lift cylinder ball joint (2 places) Drawbar ball joint (1 place) Drawbar side shift cylinder ball joint (2 places) 4 .36 ..

.37 . MAINTENANCE SERVICE PROCEDURE Adjuster bracket (2 places) Power tilt cylinder pin (2 places) Lifter bracket (3 places) Leaning rod end (2 places) 4 .

. SERVICE PROCEDURE MAINTENANCE Leaning cylinder pin (2 places) Ripper linkage pin (2 points) Ripper cylinder pin (3 places) Scarifier shaft (2 places) 4 .38 .

MAINTENANCE SERVICE PROCEDURE Scarifier ball joint (4 places) Scarifier cylinder pin (2 places) 4 ..39 .

When removing the oil filler cap. 8.2 liters (3. then remove it.40 . and if there are excessive metal particles or foreign material. Set the container to catch the oil immediately under drain plug (P) on the rear right side of the machine. please contact your Komatsu distributor. 6. Wait for the temperature to go down before starting the work. Loosen drain plug (P). and drain the oil. turn it slowly to release the internal pressure.75 US gal) Prepare a filter wrench 1. When installing. SERVICE PROCEDURE MAINTENANCE CHANGE OIL IN ENGINE OIL PAN. Install drain plug (P).. and may cause burns. Check the drained oil. 3. then tighten a further approx. REPLACE ENGINE OIL FILTER CARTRIDGE WARNING The parts and oil are at high temperature immediately after the engine is stopped. Open oil filler (F). 3/4 turn of a turn. turn filter cartridge (1) counterclockwise to remove it. a large amount of oil will come out. 2. 4 . 5. Refill capacity: 14. 4. so wait for 10 minutes before starting the operation. coat the Sealing surface of a new filter cartridge with engine oil. then install it to the filter holder. bring the seal surface into contact with the filter holder. 7. if this operation is carried out immediately after stopping the engine. Using a filter wrench. In particular. Clean the filter holder.

6. then wipe the oil off with a cloth. see "CHECK ENGINE OIL PAN LEVEL. After replacing the filter cartridge. After starting the engine. Remove dipstick (G) from oil filler port (F). 4 . then remove it. and check that all the levers are at the neutral position. add engine oil through oil filler port (F). then carry out the inspection. then stop the engine. Before starting inspection. 4. 2. set the gearshift lever to the P (Parking) position. add engine oil through oil filler (F) until the oil level is between the marks on the dipstick (G). 3. Wait for the temperature to go down before starting the operation. then leave in this condition for at least 5 minutes. 5. to prevent the machine from moving. If the oil is below the bottom mark.41 . For details. then check the oil level again. CHECK OIL LEVEL IN TRANSMISSION CASE. ADD OIL WARNING The parts and oil are at high temperature after the engine is stopped. Fully insert dipstick (G) into filler pipe (F). and check that the oil level is between the marks on the dipstick. drain the excess oil from drain plug (P). 1. Remove the transmission case oil filler cap. then install the oil filler cap. 10. run at idle for at least 5 minutes to make the oil level stable. Check that the oil is between the marks on dipstick (G). If the oil level is correct. Start the engine and run at low idle. ADD OIL (PAGE 3-40)".. insert dipstick (G) in the oil filler guide. If the oil is above the top mark. Run the engine at idle for a short time. MAINTENANCE SERVICE PROCEDURE 9.

Fully insert dipstick (G) into filler pipe (F). Remove the oil filler cap. If the oil level is correct. remove the cover. then check the oil level again. then remove it. insert dipstick (G) in the oil filler pipe. 6. If the oil level is above the H mark. 3. Stop the engine. ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped. and may cause burns. 4. then install the oil filler cap. SERVICE PROCEDURE MAINTENANCE CHECK OIL LEVEL IN FINAL DRIVE CASE. Wait for the temperature to go down before starting the work. then wipe the oil off with a cloth. 1. then take out dipstick (G). 5. 4 . and leave it for 5 minutes. and drain the excess gear oil from drain plug (P). If the oil level is below the L mark. The oil level should be between the H and L marks on dipstick (G). add oil through oil filler (F).42 .. 2.

3. Stop the engine and leave for at least 5 minutes. add gear oil through oil filler port (F). REMARK There may be wear particles in the oil. If the oil level is low.43 . but there is no problem using the oil as it is. CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE. 1. Wait for the temperature to go down before starting the work. Stop the engine and leave for at least 5 minutes. If the oil level is low. and may cause burns. Wait for the temperature to go down before starting the work. and may cause burns. MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN TANDEM DRIVE CASE. Remove plug (G) and check that the oil leaks slowly. 3. 4. 1. 4 . ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped. 2. If the oil level is correct. ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped. 4.. the pressure inside the blade rotation gear case will become high when the oil temperature rises. 2. install plug (G). Remove plug (G) and check that the oil level is near the bottom of the plug hole. install plug (G). If the oil level is correct. add oil through oil filler port (F). and this will cause leakage of oil. NOTICE If the oil level is too high.

turn the accumulator switch OFF and lower the blade to the ground. and may cause burns. If the oil level is too high. then drain the excess oil from the drain plug. turn it slowly to release the internal pressure. NOTICE If oil has been added to above the window in the gauge. If the oil is above the window of the gauge. Check with sight gauge (G). The oil should be up to the window of gauge (G). 5. stop the engine. When removing the oil filler cap. it will damage the hydraulic circuit and cause the oil to spurt out. drain the excess oil from drain plug (P). Set the front frame and rear frame facing straight (articulated angle = 0°). 4 . set the blade at right angles to the chassis and lower it lightly to the ground. If the oil is not up to the window of gauge (G). then check the oil level again. 3. 1. Return the blade sideshift to the center of the machine. To drain the oil from the accumulator on machines equipped with a blade accumulator. wait for the hydraulic oil to cool. then remove it. SERVICE PROCEDURE MAINTENANCE CHECK OIL LEVEL IN HYDRAULIC TANK. ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped. add engine oil through oil filler port (F). turn the blade accumulator switch ON and raise the blade to the maximum height. After doing this. Start the engine and run at low idle. 4.44 .. Set the machine in position as follows to check the oil level. Install the articulate lock pin. Return the leaning of the front tires to the upright position and face the wheels straight to the front. Wait for the temperature to go down before starting the work. 2.

When adding distilled water to the battery. 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. line. commercially available replenishment water for a battery). If the electrolyte level is too high. do not allow the battery electrolyte to go above the UPPER LEVEL line. wash it off with a large amount of water and consult a doctor. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery.L. In addition. remove cap (1) and add distilled water to the U. Neutralize the removed fluid with baking soda (sodium bicarbonate). it may leak and cause damage to the paint surface or corrode other parts.L line. NOTICE If there is a fear that the battery water may freeze after refilling with purified water (e. If the battery is wiped with a dry cloth. Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.L lines. it may cause an explosion. check as follows. MAINTENANCE SERVICE PROCEDURE CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this procedure before operating the machine. tighten cap (1) securely. 1. 2.L. do the replenishment before the day's work on the next day. If it gets in your eyes or on your skin. use a syringe to lower the level to the U.L and L. line.L. After adding distilled water. The battery generates flammable gas and there is danger of explosion.) and LOWER LEVEL (L. Battery electrolyte is dangerous. WARNING Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. static electricity may cause a fire or explosion. WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is possible to check the electrolyte level from the side of the battery.g. REMARK If distilled water is added to above the U. 3. do not bring fire or sparks near the battery.) lines.. 4 .L.45 . then flush it away with a large amount of water or consult your Komatsu distributor or battery maker. If the electrolyte level is below the midway point between the U.

WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level. add distilled water so that the level reaches the bottom of the sleeve (UPPER LEVEL line) without fail. and check the electrolyte surface. 2.. use a pipette to remove electrolyte.46 . and check if the electrolyte reaches the bottom of the sleeve. If necessary. tighten cap (1) securely. then flush it away with a large amount of water. SERVICE PROCEDURE MAINTENANCE 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. look through the water filler port. Remove cap (1) at the top of the battery. After adding distilled water. contact your Komatsu distributor or your battery maker. 1. Use the diagram below for reference. or there is no display of the UPPER LEVEL line on the side of the battery. Neutralize the removed electrolyte with sodium bicarbonate. REMARK If water is added to above the bottom tip of the sleeve. 4 . If the electrolyte does not reach the sleeve. follow the instructions given. check as follows.

then insert one shim more than this dimension. ask the tire manufacturer or your Komatsu distributor for inspection.1 to 564.2 mm (0. replace all the hub bolts. Tighten the caps with bolts (1) to make the same clearance on the left and right. and if the axial play is more than 1 mm (0.5 to 78. LOCK RING AND SIDE RING FOR CORROSION AND WEAR If the wheel rim.0 kgm .. Carefully check for loose bolts (1). Measure the clearance with a thickness gauge. When checking for loose borts (1). adjust as follows. 452. Tightening torque: 610 to 765 Nm (62. ADJUST Check and adjust all locations with ball joints at the links of the work equipment. lock ring and side ring are heavily corroded.020 in) CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT NOTICE Loose wheel hub nuts and hub bolts (1) will result in shortened life of tires or other troubles. Remove all the shims from the ball joint. Check for any play in the ball joint. Prepare a thickness gauge 1. 3. 2.039 in).2 lbft) 2. 4 .5 mm (0. MAINTENANCE SERVICE PROCEDURE CHECK BALL JOINT CLEARANCE. always turn the borts (1) in the tightening direction to check. Thickness of one shim : 0.47 . and tighten the cap. If a hub bolt is broken.008 in). 0. CHECKING WHEEL RIM. 1.

3. 4. Be particularly careful to check that the V-belt is not in contact with the bottom of the V-groove. loosen nuts (1) and (2). 4 .48 . ADJUST TESTING Check the belt tension.51 in)) when pushed with a finger force of approx. and wear of the V-groove and V-belt. Check for damage to the pulleys.63 in) (new belt: 12 to 13 mm (0. then adjust again. Press the belt at a point (A) midway between the tension pulley and fan pulley and check that the deflection is 14 to 16 mm (0. If the belt has elongated and there is no more allowance for adjustment. When the position is fixed. tighten the other nut and the fulcrum nut (3) to hold tesion pulley (4) in position. After replacing the V-belt. ADJUSTING 1. then move tension pulley (4) to adjust. or if the belt is cut or cracked. When adjusting the V-belt. 98 N (10 kg). When adjusting. then move tesion pulley (4).55 to 0.47 to 0. 5. replace the belt. tighten nut (1) or (2) (the nut in the opposite direction from the direction to move the tesion pulley). 2. SERVICE PROCEDURE MAINTENANCE CHECK FAN BELT TENSION. and the nut at the fulcrum of the tension pulley.. operate for one hour.

loosen air bleed plugs (3). 4 . Clean the filter head. Tighten filter cartridge (2) 2/3 turns. Be sure to use genuine Komatsu fuel filter cartridge. 2. Be careful when unscrewing the air bleeding plug on the fuel filter head. so do not replace the filter immediately. then tighten another 3/4 turn.. tighten it so its surface comes into contact with the filter holder. fuel will also leak from the packing. There is the danger that a trouble occurs in the fuel injection system. Filter cartridge (2) and plug (5) are installed only on the optional low-quality fuel specification machine. REPLACE FUEL FILTER CARTRIDGE WARNING After the engine is stopped. if a non-genuine product is used. If the filter cartridge is tightened too far. Filter cartridge (2) is installed only on the optional low-quality fuel specification machine. Oil may spurt out due to the residual pressure inside the tank. Prepare a filter wrench 1. Using a filter wrench. Add fuel from small hole (A) (dirty side) at eight places. 4. Wait for the parts to cool down before carrying out the replacement. fill the new filter cartridge with clean fuel. the packing will be damaged and this will lead to leakage of fuel. and install it to the filter holder.49 . and be careful not to let any dirt or dust get in. so always tighten to the correct amount. Use of non-genuine parts must be definitely avoided. wait for at least 30 seconds after stopping the engine to let the internal pressure go down before replacing the filter. The engine fuel piping line is under high pressure when the engine is running. coat the packing surface thinly with oil. Do not add fuel from hole (B) (clean side) at the center. Set the container under the filter cartridge to catch the drained oil. (4). and (5). 5. all parts are at high temperature. After replacing filter cartridges (1) and (2). When installing the seal. If the filter cartridge is too loose. Always use clean fuel when filling with fuel. MAINTENANCE SERVICE PROCEDURE EVERY 500 HOURS SERVICE Maintenance for every 50 and 250 hours service should be carried out at the same time. turn filter cartridges (1) and (2) to the left to remove. 3. When replacing the filter. Never bring any flame close.

.29 to 0.8 to 9. and that fuel comes out. and (5).50 . After replacing the filter cartridge. 7.8 to 1 kgm .2 lbft) Fuel filter: 7. then repeat Steps 3 . follow Step 1 and 2 to remove the filter cartridge. If there is still leakage of fuel.2 lbft) 8. replace the cartridge with a new part. Operate priming pump (6) up and down and check that bubbles are discharged from air bleed plugs (3). If there is any leakage of fuel. 5. Tighten air bleed plug (3).9 to 3. Tightening torque Water separator: 2.8 Nm (0.8 to install the filter cartridge. 2. check the tightening of the filter cartridge.1 Nm (0.31 kgm . then check the packing surface for damage or foreign material. (4). (4) and (5). SERVICE PROCEDURE MAINTENANCE 6.1 to 2.8 to 7. If any damage or foreign material is found in the packing. 4 . start the engine and check that there is no leakage of fuel from the filter seal surface.

2. (4). direct the nozzle at right angles to the radiator and aftercooler. When cleaning. Remove bolts (5) at the bottom of the aftercooler. 4 . Steam or water can be used instead of compressed air. check hose clamps for looseness. there is danger of injury. (3). be careful not to put the nozzle in contact with the fin. or water hit your body directly. 6.2 MPa (2. 1. Check the rubber hose. then remove panel (4). and (5). then use compressed air to blow out the mud. Remove bolts (3) at the top of the aftercooler.0 kg/cm2. 3. Always wear protective glasses. mask. Insert cleaning nozzle (9) in the gap between radiator core (7) and aftercooler core (8). MAINTENANCE SERVICE PROCEDURE CLEAN. and leaves clogging the core.51 .. steam. NOTICE When cleaning. 28. Replace with a new one if the hose is found to have cracks or to be hardened by aging. 4. then remove panel (6). and (6) with bolts (1). Install panels (2). dirt. CHECK RADIATOR FINS WARNING If compressed air. use a maximum pressure of less than 0.4 PSI). When cleaning. and safety shoes. 5. Also. Remove bolts (1) to remove panel (2).

(Q) R = 1.059 in). (Q) F = 0 mm. ADJUST WARNING If there is no clearance between the root of the teeth (or the tip of the teeth) of the pinion gear of the circle rotator and the tip of the teeth (or the root of the teeth) of the circle gear after maintenance has been carried out. or (Q) F = (Q) R = 1 mm (0.5 mm (0. replace the guide. replace the circle guide.039 in).020 in). do not raise it higher than necessary.039 in) 4 .52 .. 2 types) CHECKING 1.020 in). NOTICE If the condition remains as below even after maintenance is carried out. Keep the blade raised and use a feeler gauge to measure clearance (Q) F (front) and (Q) R (rear) between the circle and circle guide as shown in the diagram when force is applied at the rear.5 mm (0.059 ± 0. Prepare the following: Feeler gauge Shims (thickness: 1 mm (0. 0. 2. Raise the blade and use a feeler gauge to measure clearance (P) between the bottom face of the drawbar and the top face of the swing circle as shown in the diagram. The standard clearance is 1. When there is no clearance between the root of the teeth (or the tip of the teeth) of the pinion gear of the circle rotator and the tip of the teeth (or the root of the teeth) of the circle gear. When raising the blade.5 ± 0. SERVICE PROCEDURE MAINTENANCE CHECK CIRCLE GUIDE CLEARANCE.5 mm (0. When there is no clearance (R) between the circle and circle guide. Standard clearances (Q) F and (Q) R are as follows.

2 types) 4 . (Shim thickness: 1 mm (0. then adjust the shim thickness. 0.53 . remove bolts (1) and (5) for clearance (P). remove circle guides (2) and (6).020 in). Raise the blade.5 mm (0.. MAINTENANCE SERVICE PROCEDURE ADJUSTING Adjusting top and bottom position 1.039 in).

push open the left and right bolts uniformly. then tighten bolt (5). Check that it rotates 90º to the left and right at high bank.22 mm (0.54 . push open circle guide (2). SERVICE PROCEDURE MAINTENANCE Adjusting front and rear position 2. When (Q) R = 0. loosen bolt (1). and make (Q) R = 0.) 6. 4 .5 . (When doing this. Lower the blade lightly to the ground.0. turn back bolt (3). then tighten bolt (1).17 mm (0. The clearance between the tip of the teeth of the circle gear and the root of the teeth of the pinion gear should be 1. tighten locknut (8).. then loosen locknut (4).059 .0 mm (0. push open circle guide (6). (When doing this. 4. 8. Adjust the circle to the front or rear so that clearance (D) between the sliding surface on the inside circumference of the circle and the flange surface of the bottom of the circle rotator is 15 .0.6 . return circle guide (6) until it contacts bolt (7). 7. and make (Q) F = 0.) 3. push open the left and right bolts uniformly. turn back bolt (7). Loosen bolt (5).3. then loosen locknut (8). When (Q) F = 0.8 . tighten locknut (4). turn back bolt (7) 1/4 of a turn.0.9 in)). Adjusting left and right position 5.7 in)(slip clutch type: 20 .118 in).

Drive shaft (2 places) Final drive (2 places) (Machine equipped with differential lock only) 4 . and secure the front and rear frame with the articulate lock pin. pump in grease through the grease fittings shown by arrows. 250 and 500 hours should be carried out at the same time. Set the work equipment in a stable condition. Using a grease pump. After greasing. 2. LUBRICATING WARNING Apply the parking brake. 1. wipe off any old grease that was pushed out. and stop the engine.. MAINTENANCE SERVICE PROCEDURE EVERY 1000 HOURS SERVICE Maintenance for every 50.55 .

3. turn filter cartridge (1) counterclockwise to remove it. Clean the filter holder. 4 . 2. Wait for the temperature to go down before starting the work. coat the seal surface of the new filter cartridge thinly with clean engine oil. Set the container under the filter cartridge to catch the drained oil.56 . and may cause burns. then install to the filter holder. Using a filter wrench.. Prepare a filter wrench 1. SERVICE PROCEDURE MAINTENANCE REPLACE TRANSMISSION OIL FILTER CARTRIDGE WARNING The parts and oil are at high temperature immediately after the engine is stopped.

After draining the oil. 2. 43.9 lbft) 4.4 to 57. 3. Remove all the dirt stuck to the strainer. After washing the strainer. 4 . Wait for the temperature to go down before starting the work. After refilling.88 US gal) 1. MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TRANSMISSION CASE. 9. install it. then install tube (2) with bolts (1). and may cause burns. take out the strainer. check that the oil is at the specified level. loosen drain plug (P). Refill capacity: 45 liters (11. 5. For details. Remove bolt (1). Tightening torque: 58. 6.57 . Refill the specified quantity of engine oil through oil filler (F).4 Nm (6 to 8 kgm . To prevent the oil from spurting out. then remove tube (2). replace it with a new part. then gradually remove it. To prevent getting oil on yourself.. Check that there is no leakage of oil from the transmission case or oil filter.8 to 78. install drain plug (P). then wash it in clean diesel oil or flushing oil. loosen drain plug (P) and drain the oil. 7. see "CHECK OIL LEVEL IN TRANSMISSION CASE. 8. Set a container under the transmission case to catch the oil. If the strainer is damaged. ADD OIL (PAGE 4-41)". and wash it. CLEAN STRAINER WARNING The parts and oil are at high temperature immediately after the engine is stopped.

After draining the oil. Install cover (2) and bolt (1).9 lbft) 4. 43. 1. 4 .4 Nm (6 to 8 kgm . check that the oil is at the specified level. then remove cover (2). 3. 5.8 to 78. 2. Refill capacity: 14 liters (3. After refilling. 2. install drain plug (P). loosen drain plug (P) and drain the oil. 3. 6.4 to 57. loosen drain plug (P). Take out the element. Wait for the temperature to go down before starting the work.49 US gal) (with differential lock) 1. Refill the specified quantity of engine oil through oil filler (F). ADD OIL (PAGE 4-42)". see "CHECK OIL LEVEL IN FINAL DRIVE CASE. To prevent the oil from spurting out. For details.58 . and may cause burns. Remove bolt (1)..70 US gal) (standard) 17 liters (4. Wait for the temperature to go down before starting the work. Tightening torque: 58. To prevent getting oil on yourself. Set a container under the final drive case to catch the oil. and may cause burns. REPLACE HYDRAULIC TANK FILTER ELEMENT WARNING The parts and oil are at high temperature immediately after the engine is stopped. clean the removed parts and the inside of the filter case. then install a new element. Check for oil leakage from the final drive case. SERVICE PROCEDURE MAINTENANCE CHANGE OIL IN FINAL DRIVE CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped. then gradually remove it.

PLAY OF BALL JOINT AT FRONT OF DRAWBAR Turn nut (1) at the mounting portion of the ball joint at the front of the drawbar to check if it is loose.079 in). there is danger that the ball joint will break.59 .5 to 2 mm (0. MAINTENANCE SERVICE PROCEDURE CHECK LOOSENESS.020 to 0.079 in). and if the play to the front and rear is more than 2 mm (0. If it is tightened without any clearance. Check for play of the ball joint. tighten it. remove a shim and adjust to 0. If it is loose.. 4 .

4 . Mark the same dimension as measured in step 2 at about the center position of the tire width.039 in) of standard range. Measure the distance between the two marks. 5. ADJUST HOW TO MEASURE TOE-IN: Check toe-in and adjust it so that no side slip is caused. adjust toe-in using the following procedure. When no side slip tester is available. 7. Next. If any value other than the standard range is measured.60 .A) is adjusted to -5 ± 1 mm (-0. Measure the height from the ground to the center of the front wheel axle. 2. 4.197 ± 0. Measure the distance between the two marks. and stop the machine when the marks come to the same position as the height from the ground to the center of the front axle. 1. Use the same procedure to mark both the left and right tires. 3.. Be sure to drive straight at least a few meters before parking. 6. When toe-in (B . SERVICE PROCEDURE MAINTENANCE CHECK TOE-IN. side slip is decreased to zero. drive the machine forward slowly to move the marks on the tire to the rear. Always travel forward when doing this. Park the grader on a level ground without steering and leaning the wheels. This distance is called "A". This distance is called "B". use the following procedure.

ADJUST Please ask your Komatsu distributor to carry out this inspection and adjustment. Loosen tightening nut (1). tighten tightening nut (1). make sure that the front axle is horizontal and that the front wheels are not leaning.61 . turn in OPPOSITE DIRECTION Amount of extension for 1/3 turn of left or right tie rod in direction of extension: 6 mm (0. turn in DIRECTION OF ARROW To DECREASE toe-in. MAINTENANCE SERVICE PROCEDURE HOW TO ADJUST TOE-IN: NOTICE When adjusting.. After adjusting.236 in) 2. then turn the left and right tie rods as shown in the diagram on the right to adjust as follows. fit a wrench to corner (2) of the tie rod. 4 . CHECK FRONT WHEEL BEARING PLAY. 1. To INCREASE toe-in.

5. then tighten a further 2/3 turns. 6. 4. Set the container to catch the water under the cartridge. coat the steel surface of the new filter cartridge with clean engine oil.62 . remove cartridge (2). then install it. water will also leak from the gap at the gasket. Clean the filter holder. SERVICE PROCEDURE MAINTENANCE REPLACE CORROSION RESISTOR CARTRIDGE WARNING All the engine parts are at high temperature after the engine has been operated. tighten until the gasket contacts the seal surface of the filter holder. Turn valve (1) at the top of the corrosion resistor to close it. Wait for the oil to cool down before replacing the cartridge. so always tighten the correct amount. If there is any leakage of water. the gasket will be damaged and this will lead to leakage of water. Turn valve (1) to open it. 7. Using a filter wrench. If the filter is too loose. Prepare a filter wrench 1. 4 . 2. so never replace the cartridge immediately after finishing operations. When installing. start the engine and check that there is no leakage of water from the filter seal surface. If the filter cartridge is tightened too far. check the tightening of the filter cartridge.. After replacing the cartridge. 3.

then gradually remove it. set the blade at right angles to the chassis and lower it lightly to the ground. 7. 4 . When removing the oil filler cap. stop the engine. Set the front frame and rear frame facing straight (articulated angle = 0°). After filling with oil. 500 and 1000 hours service should be carried out at the same time. then depress the brake approx. turn it slowly to release the internal pressure. ADD OIL (PAGE 4-44)". 20 times. and operate the blade lift lever to release the pressure. For details. To prevent getting oil on yourself. and may cause burns. then stop the engine. Return the leaning of the front tires to the upright position and face the wheels straight to the front. Wait for the temperature to go down before starting the work.. turn the accumulator "ON". Return the blade sideshift to the center of the machine. check that the oil is at the specified level. loosen drain plug (P). see "CHECK OIL LEVEL IN HYDRAULIC TANK. 9. Refill the specified quantity of engine oil through oil filler (F). Refill capacity: 45 liters (11. To return the oil inside the accumulator to the tank. 3. Set the machine in position as follows to check the oil level. 8.88 US gal) 1. For machines equipped with a blade accumulator. Install oil filler (F). 5. 250.63 . install drain plug (P). then remove it. loosen drain plug (P) and drain the oil. Install the articulate lock pin. CHANGE OIL IN HYDRAULIC TANK WARNING The parts and oil are at high temperature immediately after the engine is stopped. After draining the oil. MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50. Loosen oil filler port (F) slowly to completely release the air inside the hydraulic tank. 6. 4. 2. Put an oil container under drain plug (P) to catch the oil. To prevent the oil from spurting out.

Refill capacity: 5 liters (1. check that the oil is at the specified level. and may cause burns. ADD OIL (PAGE 4-43)" 6. clean drain plug (P) and install it again. Set the container under drain plug (P) to catch the oil. Wait for the temperature to go down before starting the work. Remove drain plug (P) and drain the oil. 5. 4.32 US gal) (Shear pin type) 7 liters (1. After adding the oil.. Remove oil filler plug (F) and add gear oil to the specified level. For details. 3. SERVICE PROCEDURE MAINTENANCE CHANGE OIL IN CIRCLE REVERSE GEAR CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped.85 US gal) (Slip clutch type) 1. 2. After draining the oil.64 . Install oil filler plug (F). see "CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE. 4 .

see "CHECK OIL LEVEL IN TANDEM DRIVE CASE. Refill the specified quantity of engine oil through oil filler (F). 3. After refilling the oil. check that the oil is at the specified level. ADD OIL (PAGE 4-43)".. 5. and may cause burns. 2. Remove drain plug (P) and drain the oil. clean drain plug (P) and install it again. After draining the oil.65 . 4.14 US gal) 1. For details. Put an oil container under drain plug (P) to catch the oil. MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TANDEM DRIVE CASE WARNING The parts and oil are at high temperature immediately after the engine is stopped. Wait for the temperature to go down before starting the work. Refill capacity: Each 80 liters (21. 4 .

SERVICE PROCEDURE MAINTENANCE CHECK DISC BRAKE WARNING A small amount of oil will come out from the inspection plug hole. METHOD OF INSPECTING PISTON SEAL FUNCTION 1. 3. PERIODICAL REPLACEMENT OF DISC BRAKE Inspection: Every 12 months or 2000 hours. and measure the amount of oil that leaks out from the piston chamber. If the amount of oil leaking is more than 20 cc. Remove drain plug (2) from the cage (1).66 . 4 . Depress the brake pedal and keep the brake applied. 2. Disassembly: If the disc brake has reached the wear limit or there is any problem in the brake system.. judge if it is necessary to carry out disassembly or maintenance. disassemble and replace the seal. so do not look through the plug hole when the brake is applied.

67 . 2.. If the tip of pin (2) is level with the end face of guide (3). so please contact your Komatsu distributor for replacement. the disc wear limit has been reached. Remove cap (1) from the wear indicator. then push in pin (2) of the wear indicator. MAINTENANCE SERVICE PROCEDURE METHOD OF CHECKING BRAKE DISC WEAR 1. Depress the brake pedal and keep the brake applied. 4 . Depress the brake pedal. 3. 4.

68 .. CHECK TURBOCHARGER Contact your Komatsu distributor for cleaning or inspection. If any cracks or peeling are found. CLEAN. CHECK VIBRATION DAMPER Check that there are no cracks or peeling in the outside surface of the rubber. 4 . CHECK ENGINE VALVE CLEARANCE. contact your Komatsu distributor to have the parts replaced. SERVICE PROCEDURE MAINTENANCE CHECK ALTERNATOR. ADJUST Special tools are needed for inspection and maintenance. STARTING MOTOR The brushes may be worn or the bearing may have run out of grease. CHECK ACCUMULATOR GAS PRESSURE Please contact your Komatsu distributor to have the gas pressure checked when making periodically replacement of safety parts or carrying out the legally required 2000 hour or every year service. have this inspection carried out every 1000 hours. CHANGE GREASE IN FRONT WHEEL BEARING Please contact your Komatsu distributor for inspection and adjustment. contact your Komatsu distributor for inspection and repairs. If the engine is started frequently. so contact your Komatsu distributor.

250. If any problem is found. water leakage. CHECK AND ADJUST AIR COMPRESSOR Please contact your Komatsu distributor for inspection and adjustment. 500. If any problem is found. or clogging of the drain hole. contact your Komatsu distributor for disassembly and repair or replacement. water leakage. 1000 and 2000 hours service should be carried out at the same time. 4 . or clogging of the drain hole. MAINTENANCE SERVICE PROCEDURE EVERY 4000 HOURS SERVICE Maintenance for every 50.. contact your Komatsu distributor for disassembly and repair or replacement.69 . CHECK FAN PULLEY Check that there is no play in the pulley or any grease leakage. CHECK WATER PUMP Check that there is no play in the pulley or any grease leakage.

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5-1 ..

6 (9.000 8.8 (3.980 (9' 9") 3.6 (12.2) 39 (24. ground clearance (to bottom surface of final drive case) Min.3) 29.2) 5-2 .9 (26..3 (2.8 (4.525 (8' 3") 350 (1' 2") 6. SPECIFICATIONS SPECIFICATIONS SPECIFICATIONS Item Operating weight (including operator 75 kg (165 lb)) Engine model Flywheel horsepower A Overall length B Overall height (Tail pipe) C Overall height (with cab) D Overall width Min.8 (6.1) 4. turning radius (outermost part of chassis) 1st 2nd 3rd Forward Travel speeds 4th 5th 6th 7th 8th 1st Reverse 2nd 3rd 4th Unit kg (lb) kW(HP)/rpm mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) km/h (MPH) 13.800 (22' 4") 3.119 (140 .7) 8.6 (18.160)/2.2) 9.330 (10' 11") 2.4 (2.9 (9.9 (5.7) 4.100 (28820) Komatsu SAA6D102E-2 diesel engine 104 .5) 19.4) 42.3) 21.1) 14.0) 6.350 (27' 5") 2.

SPECIFICATIONS SPECIFICATIONS 5-3 ..

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. 6-1 .

OPTIONS HANDLING BLADE ACCUMULATOR FEATURES OF BLADE ACCUMULATOR IMPROVEMENT IN EASE OF SNOW-CLEARING OPERATION No need to operate blade No need to employ experienced operator (relief of condition) SAFETY. HANDLING BLADE ACCUMULATOR ATTACHMENTS.. safety of front wheels) IMPROVEMENT IN EASE OF OPERATION Good pushing of blade Good avoidance by blade 6-2 . PROTECTION Reduction in shock on road surfaces with many rocks or boulders (protection of operator and machine) Protection of buried structures (mounts and avoids protruding objects) IMPROVEMENT IN STEERING ABILITY Improvement in steering when operating on curves Reduction in side slippage when operating on curves Ease of steering when using leaning Reduction in side slippage when using leaning No pulling of front wheels (floating.

there is no need to operate the blade lift cylinder when starting operations.. retaining pressure is generated at the bottom of the blade lift cylinders. The oil at the bottom end of the left and right blade lift cylinders will flow into the accumulator. Turn the accumulator switch ON and start the accumulator. ATTACHMENTS. In actual fact. and bleed the remaining pressure inside the accumulator and hydraulic circuit. by operating the blade lift cylinder lever in a suitable way. OPTIONS HANDLING BLADE ACCUMULATOR METHOD OF OPERATING BLADE ACCUMULATOR 1. the left and right blade cylinders will retract. Turn the accumulator switch OFF. 50 mm (2. 5.0 in). work is carried out within a certain updown follow-up range with a small pushing pressure. 6-3 . Lower the blade to the ground and stop the engine. If the operation is stopped and the switch is turned OFF. (When doing this.0 in) in the ground surface. 3. 2. Turn the starting switch to ON position (electricity flows in the electrical circuit). so uniform accumulator operations can be carried out. the pressure is maintained at the bottom end of the blade lift cylinder so the blade pushes at a certain pressure. 4. operate the left and right blade lift levers to the front and rear. raise the blade and put the blade in contact with the ground again. Maintain the condition in Step 2. the blade will be able to follow a rise or fall of approx. 50 mm (2. then turn the switch ON to make it possible to set the accumulator to the same setting. If operations are carried out in the condition in Step 6. REMARK In the condition Step 6. Maintain the condition in Step 4.) 6. and extend the left and right blade lift cylinders approx. and the front wheels will come into contact with the ground. then turn the accumulator switch ON. then start the engine. Once the accumulator is set.

it clicks and the power is turned on. If it is turned further. the speaker volume is adjusted. OPTIONS CAR RADIO EXPLANATION OF COMPONENTS (1) Power switch/Volume (2) Tone control knob (3) Display (4) Clock button/Displaying frequency (5) AST (6) Preset switch (7) Seek (8) Band selector switch (9) Tuning switch POWER SWITCH/VOLUME When this switch (1) is turned to the right. CAR RADIO ATTACHMENTS. 6-4 ..

the preset stations are called up in turn. If the button is kept pressed continuously for 2 seconds. When the desired broadcasting station is reached. ATTACHMENTS. OPTIONS CAR RADIO TONE CONTROL KNOB If this knob (2) is turned to the right. 6-5 . it is set to auto memory. if it is turned to the left. CLOCK BUTTON/DISPLAYING FREQUENCY When this button (4) is pressed. the display changes to the time. If it is pressed again. DISPLAY This display (3) shows the radio reception frequency and the operating mode. it displays the frequency. press the button again to stop it. the high tone is reduced. AST When this button (5) is pressed. the high tone is emphasized..

If it is kept pressed. 6-6 . the frequency goes down.) SEEK When this switch (7) ("SEEK") is pressed. CAR RADIO ATTACHMENTS. OPTIONS PRESET SWITCH With this switch (6). and when it receives a station. the band is switched between FM and MW (AM). it stops. the frequency changes continuously. see "METHOD OF PRESET (PAGE 6-8)". The reception band and frequency are displayed on the display. each button can be set to one station each for FM and MW (AM). the frequency goes up. TUNING SWITCH When the "TUNE" button U of switch (9) is pressed. BAND SELECTOR SWITCH When this switch (8) ("BAND") is pressed. (For details of the method of resetting.. when the V button is pressed. it automatically searches for stations that can be received.

6-7 . If it is kept pressed. it moves up to higher frequencies and when it finds a station that can be received. it stops automatically. 2. OPTIONS CAR RADIO METHOD OF OPERATION LISTENING TO RADIO 1. turn VOL knob (1) to the left until a click is heard. 5.. METHOD OF MANUAL TUNING When the TUNE button U is pressed. METHOD OF AUTOMATIC TUNING When the "SEEK" switch is pressed. Use the preset switch or tuning switch (3) to select the station. "BAND" switch (2) is used to select MW (AM) or FM. To turn the radio OFF. the frequency goes up. when the V button is pressed. This switches on power (1) for the radio. the frequency changes continuously. 4. ATTACHMENTS. Adjust the volume and tone as desired. 3. the frequency goes down.

and the broadcasting stations are automatically saved in the preset memory. the radio is automatically switched from stereo to monaural to reduce the interference. 2. It is possible to preset 6 AM (MW) stations and 6 FM stations. CAR RADIO ATTACHMENTS. If the battery is replaced or the power is switched off.. When the stereo broadcast becomes stronger. OPTIONS METHOD OF PRESET 1. repeat Steps 1 to 2. Select the desired preset station. Repeat Steps 1 to 2 to preset other broadcasting stations. it automatically switches back to stereo broadcasting. and use the "TUNE" button to select the frequency of the broadcasting station. AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO If the reception of the FM stereo broadcast being received is weak (when you are far from the broadcasting station or are surrounded by hills). To change the setting of a preset switch to another station. Carry out the presetting operation again. Decide the number of the button to be preset. The number of the button will be displayed and the presetting is completed. Use the "BAND" button to select MW (AM) or FM. and keep it pressed for 2 seconds. 3. the broadcasting stations that can be received in the area are called up in turn. all the preset settings are deleted. 6-8 . METHOD OF AUTOMATIC MEMORY If the "AST" button is pressed for 2 seconds.

Wipe with a dry soft cloth. 6-9 . so be careful not to get water on the equipment. If the display shows the frequency. To ensure safety. To set the time. soak the cloth with alcohol. set the CLOCK button to the time display.. always keep the sound to a level where it is possible to hear outside sounds during operation. If water gets into the speaker case or radio. Do not wipe the scales or buttons with solvent such as benzene or thinner. keep the CLOCK button pressed and Press the U button to change the minutes Press the V button to change the hours PRECAUTIONS FOR USE Stow the antenna when traveling in places with low overhead clearance. 2. Turn the radio power ON. ATTACHMENTS. OPTIONS CAR RADIO ADJUSTING TIME 1. If the dirt cannot be removed easily. it may lead to an unexpected failure.

6 . OFF: When this switch is pressed. the lighted display moves one position to the right.. OPTIONS AIR CONDITIONER LOCATIONS AND FUNCTIONS OF CONTROL PANEL (1)Fan switch (2)FRESH/RECIRC selector switch (3)Temperature control (4)Air conditioner switch FAN SWITCH This switch (1) is used to adjust the air flow to 4 levels.10 . the air conditioner stops. AIR CONDITIONER ATTACHMENTS. <: When this switch is pressed. the lighted display moves one position to the left. >: When this switch is pressed. It also acts as the main switch for the air conditioner.

REMARK If the air conditioner is used at the FRESH position. The higher the position of the fan switch.. OPTIONS AIR CONDITIONER FRESH/RECIRC SELECTOR SWITCH This switch (2) is used to choose introduction of fresh air from outside or recirculation of the air inside the cab. the inside of the cab will be pressurized and this will prevent the entry of dust. air conditioner display lamp (B) will light up. If the air conditioner is used for a long period at RECIRC. so normally use the air conditioner at FRESH. The LED lights up at the top of the switch to indicates FRESH or RECIRC. This switch (4) is used to stop and start the cooling and dehumidification functions. When the switch is pressed. If the fan switch is turned ON and air conditioner switch (A) is pressed. the lighted display moves one position to the right and the temperature goes up. contact your Komatsu distributor as soon as possible. If the air conditioner temperature is set too low. condensation may form on the outside of the window glass and reduce the visibility. the more effective the pressurizing becomes. <: When this switch is pressed. the air conditioner display will go out. always turn the air conditioner off and stop the engine. the lighted position changes and the air intake is changed. the window glass may mist up and reduce the visibility. AIR CONDITIONER SWITCH CAUTION When leaving the machine. 6 .11 . The temperature level LEDs display the temperature of the air as a guideline. ATTACHMENTS. so adjust the temperature of the air flow. If any problem is found in the operation of the air conditioner. >: When this switch is pressed. It is pressed again. the lighted display moves one position to the left and the temperature goes down. TEMPERATURE CONTROL SWITCH This switch (3) is used to adjust the temperature steplessly between low temperature and high temperature.

When smoking. If you are smoking when using the cooling your eyes may sting. OPTIONS METHOD OF OPERATION Switch Fan switch Condition of use Cooling High speed Normal High speed Normal HI HI-LO HI-LO HI HI-LO 1 lamp lights up Less than half lamps light up More than half lamps light up All lamps light up More than half lamps light up Temperature control switch FRESH/RECIRC selector switch RECIRC FRESH FRESH RECIRC FRESH Dehumidification + heating Heating If the outside air is dirty or it is desired to carry out cooling quickly. The air conditioner will be run. REMARK If the temperature inside the cab is low. TESTING AND MAINTENANCE Even when not using the air conditioner. it is recommended that the cooling temperature in the cab should not vary more than 5 to 6 ºC (41 to 42. set to the RECIRC position. For health reasons.) For details of the procedure for cleaning the air filter and checking the refrigerant. AIR CONDITIONER ATTACHMENTS. open the window slightly or switch to FRESH to clear the smoke from the operator's cab. use the recirculated air to warm up the inside of the cab. PRECAUTIONS WHEN USING WHEN NOT USING THE COOLING Run the air conditioner in cooling or dehumidification + heating mode for several minutes from time to time to prevent the loss of the oil film in various parts of the compressor. To enable the air conditioner to perform to the full and to maintain a pleasant working environment.8°F) from the outside temperature. run the compressor at low speed for several minutes once a week to prevent the loss of the oil film at various parts of the compressor. 6 . always contact your Komatsu distributor to have the air conditioner refilled with refrigerant and to carry out other checks.12 . Be careful. then turn the air conditioner switch on. do not set the cooling temperature too low. the air conditioner may not work. In such cases. see "CLEAN AIR CONDITIONER AIR FILTER (PAGE 4-28)" and "CHECK REFRIGERANT (GAS) LEVEL (PAGE 4-29)".. (Run the engine at low speed and set the temperature control lever to the central position. Do not use the FACE mode for long periods with the setting at RECIRC.

(A) Adjustment of seat height Pull up lever (1) and when it is at the desired position.5 in). (B) Fore-and-aft adjustment of seat Pull lever (2) up. then release the lever.. OPTIONS HANDLING ADJUSTABLE SEAT HANDLING ADJUSTABLE SEAT ADJUST OPERATOR'S SEAT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. move the seat to the desired position. Adjust the seat position at the beginning of each shift or when operators change. release the lever. ATTACHMENTS. Adjust the seat so that the brake pedal can be depressed all the way down with the operator's back against the backrest. Fore-and-aft adjustment: 140 mm (5.5 in)(7 stages) 6 . The height adjustment is 165 mm (6.13 .

Use the front (rear) tilt operation to set the seat to the desired height. Rear tilt Pull lever (3) up and adjust the angle of the rear of the seat. Adjust the seat position at the beginning of each shift or when operators change. Height adjustment: 60 mm (2. keep the lever pushed down and apply your weight to the rear of the seat. OPTIONS HANDLING AIR-SUSPENSION SEAT ADJUST OPERATOR'S SEAT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. (C) Adjusting seat tilt Front tilt Push lever (3) down and adjust the angle of the front of the seat. keep the lever pulled up and raise yourself slightly from the rear of the seat. Fore-and-aft adjustment: 160 mm (6.3 in) (16 stages) (B) Adjusting reclining angle Pull lever (2) up. keep the lever pulled up and apply your weight to the rear of the seat.. To lower the front of the seat. To lower the rear of the seat. then release the lever. then release the lever. the seat back may spring back suddenly. move the seat to the desired position. To raise the rear of the seat. To raise the front of the seat. keep the lever pulled up and apply your weight to the front of the seat. the available reclining angle becomes smaller.14 . when the seat is pushed back. down 13° Adjusting seat height It is possible to raise or lower the seat by combining the front tilt and rear tilt. return the seat back to its original position before moving the seat. When moving the seat back. NOTICE When the seat is pushed forward. When doing this. (A) Fore-and-aft adjustment Pull lever (1) up. HANDLING AIR-SUSPENSION SEAT ATTACHMENTS. Adjust the seat so that the brake pedal can be depressed all the way down with the operator's back against the backrest. set the seat back to a position where it is easy to carry out operations. then use the rear (front) tilt to make the seat horizontal.4 in) 6 . If your back is not against the seat back. keep your back pressed against the seat back. the available reclining angle becomes greater. Amount of tilt: Up 13°.

by turning the bottom (5) of the armrest by hand it is possible to make fine vertical adjustments of the armrest angle.. 6 . OPTIONS HANDLING AIR-SUSPENSION SEAT (D) Adjusting armrest angle Armrest (4) can be made to spring up by hand approx. Turn CLOCKWISE to make HARDER Turn COUNTERCLOCKWISE to make SOFTER REMARK To adjust to the optimum setting. 90°. (E) Adjusting suspension To select the optimum suspension. turn knob (6) so that the indicator in the transparent portion inside the knob indicates the same as the operator's weight (kg). Armrest adjustment angle: 25°. the armrest will rise automatically.15 . turn knob (6) to adjust the dial for the suspension to the operator's weight as follows. In addition. ATTACHMENTS. REMARK If the seat back is tipped to the front without raising the armrest(4).

so it cannot be used inside tunnels. or cables. make sure that the communications antenna is at least 22 cm (8. Any customers desiring to use the KOMTRAX system should consult their Komatsu distributor. Always contact your Komatsu distributor before selling or exporting any machine equipped with KOMTRAX. it may be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to stop communications. do not damage or pull cables or cords by force. or in mountain areas where radio waves cannot be received. There is absolutely no need to inspect or operate the KOMTRAX communications terminal.. BASIC PRECAUTIONS WARNING Never disassemble. inside buildings. A contract with your Komatsu distributor is necessary before the KOMTRAX system can be used. NOTICE Even when the key in the starting switch of the KOMTRAX system is at the OFF position. 6 . (Your Komatsu distributor will carry out removal and installation of KOMTRAX. This may cause failure or fire on the KOMTRAX equipment or the machine itself. The radio waves may have an adverse effect on the operation of the pacemaker. but if any abnormality is found. Please contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof. When putting the machine into long-term storage.7 in) from the pacemaker. For anyone wearing a pacemaker. so it is necessary to obtain authorization and conform to the laws of the country or territory where the machine equipped with KOMTRAX is being used. or move the communications terminal. neither Komatsu nor your Komatsu distributor can take any responsibility for any problem that is caused or for any loss that results. underground. When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary. take the action given in "LONG-TERM STORAGE (PAGE 3-112)". REMARK The KOMTRAX system uses wireless communications. The KOMTRAX equipment is a wireless device using radio waves. Short circuits or disconnected wires may cause failure or fire on the KOMTRAX equipment or the machine itself. Even when the machine is outside. it cannot be used in areas where the radio signal is weak or in areas outside the wireless communication service area. a small amount of electric power is consumed.16 . If you do not obey the above precautions. OPTIONS HANDLING MACHINES EQUIPPED WITH KOMTRAX KOMTRAX is a machine management system that uses wireless communications. HANDLING MACHINES EQUIPPED WITH KOMTRAX ATTACHMENTS. modify. please consult your Komatsu distributor.) Do not allow cables or cords to become caught. Be careful not to get water on the communications terminal or wiring. antenna. repair.

STOPPING <O> OPERATING WORK EQUIPMENT OPERATION 6666613 13 14 14 2 3.35 7-1 .4 3-107 6.33 23334- 9 2 3 2 2 3.24 4. SHIFTING GEAR).16 3. AND DISTRIBUTOR ENGINE SERIAL NO. PLATE POSITION MACHINE SERIAL NO. REVERSE. AND PERFORMING OIL CLINIC HANDLING THE TIRES <I> INTENDED USE DIRECTIONS OF MACHINE <L> LOCATION OF PLATES. TABLE TO ENTER SERIAL NO. PLATE POSITION SERVICE METER POSITION TABLE TO ENTER SERIAL NO.7 6.15 11- 7 7 1111- 8 8 8 9 3.16 6.63 3.54 3.94 6.2 1.9 3-107 3-112 3-112 3-112 3-112 3- 6 4.16 4. AND DISTRIBUTOR LOCKING LONG-TERM STORAGE AFTER STORAGE BEFORE STORAGE DURING STORAGE <M> MAINTENANCE SCHEDULE CHART METERS AND LAMPS METHOD OF OPERATING BLADE ACCUMULATOR MOVING MACHINE OFF (FORWARD.6 63 6.2 3. COOLANT.56 3.4 6.33 1.9 3. INDEX INDEX <A> ADJUSTING WORK EQUIPMENT POSTURE AIR CONDITIONER LOCATIONS AND FUNCTIONS OF CONTROL PANEL METHOD OF OPERATION PRECAUTIONS WHEN USING TESTING AND MAINTENANCE ARTICULATE LOCK PIN <C> CAR RADIO EXPLANATION OF COMPONENTS METHOD OF OPERATION PRECAUTIONS FOR USE CHECK AFTER STOPPING ENGINE CHECK BEFORE STARTING ENGINE CHECKS AFTER COMPLETION OF OPERATION COLD WEATHER OPERATION AFTER COLD WEATHER CAUTIONS AFTER COMPLETION OF WORK PRECAUTIONS FOR LOW TEMPERATURE CONTROL LEVERS. FUEL.35 3-106 3-110 3-111 3-111 3-110 3.4 6.10 6666310 12 12 12 33 6.. PEDALS CRITICAL PARTS <D> DUST INDICATOR <E> EXPLANATION OF COMPONENTS <F> FEATURES OF BLADE ACCUMULATOR FOREWORD FUSE BOX <G> GENERAL PRECAUTIONS GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES GENERAL VIEW OF MACHINE GUIDES TO MAINTENANCE <H> HANDLING ADJUSTABLE SEAT ADJUST OPERATOR'S SEAT HANDLING AIR-SUSPENSION SEAT ADJUST OPERATOR'S SEAT HANDLING BLADE ACCUMULATOR HANDLING MACHINES EQUIPPED WITH KOMTRAX BASIC PRECAUTIONS HANDLING OIL.

.4 3-105 4222223215 18 26 28 25 29 90 35 TRAVELING POSTURE FOR MACHINE TROUBLESHOOTING AFTER RUNNING OUT OF FUEL IF BATTERY IS DISCHARGED OTHER TROUBLE TOWING THE MACHINE WHEN LEANING PIPING IS DAMAGED TURNING MACHINE <U> USE OF FUEL.52 4.18 4. INDEX OPERATIONS. COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE <W> WEAR PARTS WEAR PARTS LIST WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER 3.2 433313 48 54 13 4. CHECKS AFTER STARTING ENGINE OUTLINES OF SERVICE <P> PARKING MACHINE PERIODIC REPLACEMENT OF CRITICAL PARTS PRECAUTIONS DURING OPERATION BATTERY TOWING TRANSPORTATION PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN OPERATION PRECAUTIONS WITH TIRES <R> RELATING TO ELECTRIC SYSTEM <S> SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS SERVICE PROCEDURE CHECK BEFORE STARTING EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE EVERY 250 HOURS SERVICE EVERY 4000 HOURS SERVICE EVERY 50 HOURS SERVICE EVERY 500 HOURS SERVICE INITIAL 250 HOURS SERVICE (only after the first 250 hours) WHEN REQUIRED SPECIFICATIONS STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS STARTING ENGINE STOPPING ENGINE SWITCHES <T> TORQUE LIST TRANSPORTATION LOADING.69 1222244444444- 5 2 4 4 5 18 32 55 63 34 69 33 49 4.13 3-108 3-108 3-109 7-2 .55 3-113 3-113 3-117 3-120 3-115 3-114 3.60 4- 9 4- 7 44- 8 8 3.19 5. UNLOADING WORK PRECAUTIONS FOR LOADING 3.

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. GD555-3A MOTOR GRADER Form No. PEN00178-01 ©2007 KOMATSU All Rights Reserved Printed in Japan 06-07 .