KOMATSU GD200A-1 MOTOR GRADER <) 5) SERIAL NUMBERS GD200A-2001 and uoFOREWORD Thank you for purchasing this Komatsu machine. This manual describes procedures for operation, handling, lubrication, main- tenance, checking, and adjustment It will help the operator realize peak perfor- mance through effective, economical and safe machine operation, ¢@ Please read this manual carefully BEFORE operating the machine. © Please continue studying this manual until proper operation is compl reinforced into personal habit. ‘* Operation, inspection, and maintenance should be carefully carried out, and the safety must be given the first priority. Safety precautions are indicated with \, marks inthis manval ely FOREWORD[BREAKING IN YOUR NEW MACHINE BREAKING IN YOUR NEW MACHINE Each machine is carefully adjusted and tested before shipment, However, ‘@ new machine requires careful operation during the first 100 hours to run in various parts. Unreasonably hard use during the run-in period will weaken the machine and reduce its service life. A new machine must be operated with care, particularly with regard to the following items. ‘© After starting, idle the engine for about § minutes to allow proper engine warm-up prior to actual operation ‘© Avoid running the engine at high speed. © Avoid abrupt starting, acceleration, unnecessarily abrupt braking and sharp turning © At the initial 250 hours of operation, the oil and filter elements should both be totally replaced with new oil and new filters. ‘© Be sure to perform periodical maintenance and checking as indicated in this manual, ‘© Be sure to use recommended fuel and lubricant.CONTENTS OPERATION FOREWORD ce 1 BREAKING IN YOUR NEW MACHINE .. 2 SAFETY HINTS ag GENERAL LOCATIONS - 8 OPERATOR'S COMPARTMENT . - 10 INSTRUMENTS AND CONTROLS ...... 12 CHECK BEFORE STARTING ween 23 OPERATING YOUR MACHINE .... 28 WORKS TO BE CARRIED OUT BY AMOTOR GRADER. cee 34 OPERATING OF WORK EQUIPMENT 40 REPLACEMENT OF CUTTING EDGE AND END BIT... sees 45 REPLACEMENT OF TIRES 46 DRIVING ALONG ROAD 48 HANDLING OF BATTERY vee 49 TRANSPORTATION 52 MAINTENANCE PERIODIC MAINTENANCE .... MAINTENANCE TABLE ‘TROUBLE SHOOTING GUIDE COLD WEATHER OPERATION ‘STORAGE SERVICE METER MACHINE AND ENGINE SERIAL NUMBERS .. ‘WEAR PARTS SPECIFICATIONS FUEL AND LUBRICANTS 86 59 104 108 22 4 . 18 116 118 120SAFETY HINTS - SAFETY HINTS: - - A\ For Operators and Maintenance Personnel ¢ Wear a well-fitting helmet, safety shoes and work- ing clothes. When necessary, also wear safety goggles, proteo- tive mask and gloves. Observe the following items without fi machine operation. prior to ‘© Thoroughly read the Operation and Maintenance Manual and the Caution Plates for the operational in- structions and performance of the machine, Operate the machine slowly and in a careful manner Until you are completely familiar with it ‘© Donot attempt to jump off the machine. © Keep fire away from stored fuel, lubricants and anti-freeze. ‘© When removing radiator cap or hydraulic tank cap, loosen the cap carefully and slowly so as to gradual- ly discharge high-pressure vapors. © Use seat belt if equipped,SAFETY HINTS BEFORE OPERATION ¢ Before starting the machine, perform all necessary ‘© Confirm that lighting means and other devices to be checks as stated in the Operation and Maintenance prepared for work during the night work normally Manual and inspect from time to time every section of the ‘© Before starting the engine, place every control lever body of the stopped machine, when you work at in the neutral night time, © Confirm that guards and safety devices operate ‘© Don’t forget to advise the responsible supervisor of property, parts or components to be repaired later which you @ When the engine starts and operation begins, discovered during operation of the machine. sound the horn, eee -5-SAFETYHINTS- = « A OPERATING ‘© During operation of the machine, pay careful atten- tion to any gauges indicating abnormalities, any controls functioning abnormally and any parts emit- ting abnormal sounds. if any are detected, immedi ately stop the machine and engine and call 2 mechanic to check the trouble. ‘© Do not attempt to force the machine to perform any job which exceeds its working capability, or any un- reasonable work deviating from its main application of the machine. ‘© Operate the machine at proper traveling speeds depending on load, Avoid unnecessary heavy-duty operation or rough handling of the machine. ‘@ When operating in a city area, be sure to locate un- derground pipes and cables before starting the ma- chine to prevent them from being broken. ‘© During driving along road: Do not protrude the blade from the side of the machine, © When driving side by side with another vehicle, be careful not to disturb traveling of it by excessive leaning operation, ‘¢ Pay attention to earth laid on the ground and possi- ble collapses of the road shoulder. ¢ Be fully aware of your surroundings when backing your machine. © Never let anyone unauthorized approach the ma- chine while in operation. ‘Always keep your eyes on your work when operat- ing the machine,When a service operation or other operation is to be performed by two or more workers, proceed with each operation step only after confirming that ‘everyone is familiar with all prearranged signals. Confirm that the steering device and brake work normally and properly by slowly moving the machine prior to operation. Be sure to avoid stopping the machine at dangerous places such as weak ground or place beneath an overhang, Never get on or off the miachine while traveling, A SAFETY HINTS AFTER OPERATION '® Park the machine on firm, flat ground. Avoid the dangerous places. @ Lower the work equipment and lock every control lever in neutral when parking the machine. When parking on a slope, lock the machine with the hand brake and chock the wheels. It is safer when the machine is parked with its front facing down- ward, with the blade, or the scarifier biting into the ground. Be sure to apply parking brake, stop the engine, and pull out the starting key before leaving the machine.GENERAL LOCATIONS. GENERAL LOCATIONS Blade lift cylinder Front tire . Front weight Blade Rear tire Fuel filler Auxiliary seat (OP) Operator's seat Exhaust pipe Yellow rotating lamp (OP) Seenoasens 1 (OP): Optional parts 8 kanGENERAL LOCATIONS. eam -9-OPERATOR'S COMPARTMENT OPERATOR'S COMPARTMENT 1. Work equipment contro! lever 2. Parking brake lever 3, Clutch pedal 4. Brake pedal 5. Accelerator pedal 6. Forward-reverse lever 7. Gear shift lever 8 Fuel control lever 9. Turn signal switch (OP) 10. Safety lock (for work equipment control lever) -10- aim(OPERATOR'S COMPARTMENT 11. Articulation lock indicator lamp 12. Ammeter 13. Water temperature gauge 14. Working lamp switch (OP) 18. Engine oil pressure gauge 16. Yellow rotating lamp switch (oP) 17. Parking lamp switch 18 Head lamp switch 19. Starting switch 20. Fuel gauge 21. Speedometer 22. Heater signal 23. Dust indicator 24. Parking brake indicator lamp kuin teINSTRUMENTS AND CONTROLS INSTRUMENTS AND CONTROLS STARTING SWITCH OFF Key can be inserted and pulled ‘out at this position and the switches of all the electric systems are set to off. ‘The parking lamps will remain on, however, when the switch is turned OFF, on When this position ON is reached by rotating clockwise for one step, the charging circuit and the lamp cir- cuit are electrified, The position ON shall be held after the engines started, START Starting motor starts revolution by rotating the switch clockwise fur- ther for one step. And the engine is started. The key will be automatically re- stored to the position ON by releas- ing your hand. So, you shall release your hand once the engine is started eae HEAT Use this position when starting at cold weather. Release the key to allow it to return automatically to OFF and then, without delay, turn it to START. % Never place starting switch key in OFF position while engine is running. This will damage the alternator. ‘* When starting, be sure to use the starting key.ENGINE OIL PRESSURE GAUGE © Engine is normal when indicator ison green range during operation. ‘© When engine is cool, indicator is ‘over geen range, In this case watm up engine until indicator points green range, WATER TEMPERATURE GAUGE ‘© Engine is normal when indicator is ‘on green range during operation © After starting engine, continue to warm up engine until indicator points green range. If indicator is over green range, keep engine in low idling and wait till temperature drops. -12- INSTRUMENTS AND CONTROLS ‘SPEEDOMETER This meter indicates hourly speed of traveling machine. An ‘odometer also incorporated.INSTRUMENTS AND CONTROLS AMMETER FUEL GAUGE LAMP SWITCH Batteries are charged when the When the starting switch is set to. At position 1 indicator stays in the + side (green ON, the amount of existing fuels in- Clearance lamps, tail lamps and li- range). Batteries are discharged dicated by its indicator. cence plate lamps (optional) are when the indicator stays in the — __E indicates that fuel is empty, and it. side (red range) F indicates that fuel is Full At position 2 Batteries are normal when the in- The fuel should be fully filled Head lamps are lit pointing down- dicator stays in the + side while the after completing a work without fail, ward with the lamps being lit at machine is in operation. The indica- position 1 tor goes to “0” in a little while, Atposition 3. Head lamps are lit pointing upward with the lamps being lit at position 1 -14- earnsINSTRUMENTS AND CONTROLS YELLOW WARNING SWITCH — PARKING LAMP SWITCH (OP) HORN BUTTON (oP) ON OFF OFF ON: The yellow warning lamp Pull the switch, and the lamp will This button is used as a warning. lights and rotates. Keep the goon. lamp ON during operation, This lamp is designed to serve as @ warning lamp during parking at night. It works even if starting switch is OFF position, ae -15-INSTRUMENTS AND CONTROLS TURN SIGNAL SWITCH (OP) — HEATER SIGNAL PARKING BRAKE INDICATOR LAMP (oP) Left = Right it ‘The dimmer switch lever is used This glows red in 40 seconds This lamp is lit when the parking for tur signal switch. This lever after the starting switch is set at brake lever is pulled. Check for does not revert to neutral position HEAT position. Use in cold weather. going out of this lamp before start- even if steering wheelis reverted, ing the machine, -16- uaDUST INDICATOR The dust indicator wams the operator of clogging in air cloaner clements, When the elements are clogged, the red piston appears in the transparent part ofthe indicator. In this case, clean the elements immediately. After cleaning, restore the red piston by pushing the indicator button, INSTRUMENTS AND CONTROLS ARTICULATION LOCK INDICATOR LAMP (OP) PARKING BRAKE LEVER 5 When the articulation lock link is. removed, the lamp lights. The brake is applied to the ‘output shaft of transmission by pull ing this lever to limit AdNever remove the lock tink during normal travel. QS when parking oF leaving ma chine, be sure to apply parking brake. -17-INSTRUMENTS AND CONTROLS FUEL CONTROL LEVER Low idling Engine full eee Engine stop position is the posi- tion where the lever is pushed forward, Low idling position is the first rachet from the above position. Engine full running position is the position where the lever is pulled toward you. When stopping the engine, set the lever to engine stop position pressing the button the top of the lever. ACCELERATOR PEDAL Since the accelerator pedal is synchronized with the fuel control lever, the engine is operated freely from tow idling to full running with the accelerator pedal while the fuel control lever is positioned at low idling. -18- BRAKE PEDAL ‘When the pedal is depressed, the brake works on two rear wheels. A\ Keon your foot off the pedal Unless necessary.INSTRUMENTS ANO CONTROLS CLUTCH PEDAL FORWARD REVERSE LEVER GEAR SHIFT LEVER When the pedal is depressed, the The machine travels backwards ‘Five stages of | speed are main clutch is disengaged. This when the lever is pushed forward obtainable. Pedal is used for forward, and and forwards when the lever is reverse shifting, normal gear shifting pulled toward the operator. and stopping the machine, eae ~19-INSTRUMENTS AND CONTROLS WORK EQUIPMENT CONTROL LEVERS 1. Left blade lift cylinder control lever. 2. Scarifier lift cylinder control lever (Option) Blade rotation control lever Blade side shift control lever Articulation control lever Right blade lift cylinder control lever eone Refer to “OPERATING OF WORK EQUIPMENT” 20 WORK EQUIPMENT CONTROL LEVER SAFETY Lock (OP) GE This device is for locking the work equipment control levers. For locking, pull the lock lever down- ward, For unlocking, push it upward. under maintenance, Be sure to lock when the ma. chine is parked, traveling andFUSE BOX Loosen bolt (1) and remove ‘cover (2) + Replace a fuse with another of the same capacity. A\Betore replacing a fuse, be sure to turn off the starting switch. Fuse arrangement -21- INSTRUMENTS AND CONTROLSINSTRUMENTS AND CONTROLS OPERATOR'S SEAT When operating by standing, lean seat as shown. Adjust seat as follows. Forward and adjustment. Move lever (1) backward and seat can be adjusted in § positions (100 mm), backward Upward and downward adjustment Pull lever (2) upward and seat can bbe adjusted in 4 positions (90 mm). Back cushion adjustment Pull lever (3) inward and back cushion can be adjusted in 3 posi- tions (820 mm). SAFETY BELT (OP) Ay Assistant operator should use safety belt during traveling and operation. The assistant opera- tor’s seat is option. Method of use Insert (2) into (1) and adjust the length with (3) 3 2 Method of release Push the portion indicated by an =a:(CHECK BEFORE STARTING CHECK BEFORE STARTING Check before starting shall never be neglected as troubles are prevent- ed beforehand by check. a, Walk around machine and check leakage of oil or water. In particular joint of high pressure hose and hydraulic cylinder. In case leakage is found, stop leakage. When leakage is not stopped, have your Komatsu distributor check it. b. Inspect tightening of bolts and nuts. When loosened fetighten. In particular, air cleaner and muffler should be paid special attention. ©. Inspect disconnection and shortcircuit of electric wirings, and loosened terminal connections. aun —23-(CHECK BEFORE STARTING d. CHECK AND CORRECT ENGINE OIL LEVEL Check oil level of engine oil pan with oil level gauge (G). If cil level is insufficient, add engine oil from oil filler (F). * Make an oil level check before starting engine or 5 minutes or more after the engine is stopped. If oil remains at various portions of the engine, the correct oil evel cannot be measured, * AboveO°C: Use engine oll CLASS-CD SAE 30. Below 10°C: Use engine oil CLASS-CD SAE 10W. + Proper oil level is between “H” and “L" marks. ¢. CHECK AND ADJUST TIRE PRESSURE Standard pressure Front wheel 2.2 kg/cm? Rear Wheel 2.0 kg/cm? Make sure that tire and rim is free from wear and damage, and that hub nuts are not loose. Boatf. CHECK COOLANT Open lid (1) on the hood and remove radiator cap on rear machine body, and check that cooling water is filled up to depth indicated by sha- dowed portion. If not, add water from filler (F). When water has to be added very frequently, this is usually an indication of leakage at some place. Check for a leak and take necessary measures. AXbo not remove the cap while cooling water is hot. Hot water may spout out. When removing radiator cap, lift the lever to r pressure. 26 - CHECK BEFORE STARTING 9. CHECK FUEL LEVEL AND SUPPLY FUEL Check the fuel level with the fuel gauge (G). After a day's work, refill fuel through the fuel filler (F) to fil up the fuel tank,(CHECK BEFORE STARTING h, CHECK PLAY OF STEERING WHEEL The standard play is 150 to 170 Hf play is out of the standard, con- tact your Komatsu distributor. i. CHECK DUST INDICATOR When air cleaner element is clogged, the red piston (1) appears. In that case, clean element refer- ring to section "WHEN REQUIRED" ‘After cleaning element, push button (2) to return red piston i: CHECK BRAKE FUNCTION ‘The function is normal if the braking distance is less than 5 m at 2 speed of 20 km/h. If braking is not sufficiently effective, refer to EVERY 250 HOURS SERVICE (FOOT BRAKE). And also check the pedal travel. Normal travel is 60 to 90 mm from tip of pedal(CHECK BEFORE STARTING k. CHECK BRAKE FLUID LEVEL |. CHECK TRAVELOFPARKING —_m.CHECK LAMPS FOR BURNT Romove the cap (F) from the tanks BRAKE LEVER OUT BULBS, DIRT OR located in the operator's seat and The standard travel is 200 mm, DAMAGE. check the fluid level. ‘Also check its effectiveness. © Specified level is within 40 mm Refer to EVERY 260 HOURS n, CHECK REAR VIEW MIRRORS: below the top of tank. If insuffi- SERVICE for adjustment method. FOR INCORRECT ANGLE, DIRT cient, supply flu. OR DAMAGE. + Check piping for leaks if the fluid decreases abnormally. 0. CHECK LISENCE NUMBER % Use caution to prevent the PLATE FOR DIRT OR DAMAGE. mixing of the mineral oil with the brake flu p. CHECK HORN FOR as this will cause the rubber MALFUNCTION. part of the brake oil line to perish, leading to defective 4. CHECK EXHAUST GAS COLOR. brake operation. The special vessel must be used only for refilling the brake fluid. ©. CHECK GAUGES FOR MALFUNCTION. nun, kame -2-OPERATING YOUR MACHINE OPERATING YOUR MACHINE HANDLING THE ENGINE Before Starting Starting the Engine Perform CHECK BEFORE STARTING. ls the parking brake lever (1) @ Are work equipment control pulled back? levers (3) at neutral position and Is goar shift lever (2) at the neu- locked? tral position? Pull the fuel control lever (4) until it slightly exceeds the idling position. 1. To start the engine, put the key to the START position and turn over the starting motor. 2.As soon as the engine starts, release the starting switch key to allow it to return automatically to ON position. 3. Place the fuel control lever (4) in LOW IDLING position. =28- cams+ Do not leave key in START for more than 20 seconds. If engine will not start, repeat the starting procedure after about 2 minutes. % Never piace starting switch key in OFF position while engine is running. This will damage the alternator. + To start engine in cold weather, refer to COLD WEATHER OPERATION, Check After Start Up When the engine has started, ob- serve the following instructions before putting the machine to work. 1. Run the engine without load, with the fuel control lever kept at LOW IDLING position, until the engine oil pressure gauge indicator reaches the green range. 2. Run the engine without load for five minutes, with the fuel control lever left at IDLING position, 3. Run the engine with light load until the water temperature gauge indicator reaches the green range. -29- * * (OPERATING YOUR MACHINE This operation is called the warm- up run. In case warm-up run is continued for more than 20 minutes, apply load to the engine at intervals. It it is impossible to apply load, run engine at moderate speed. Low idling for every 20 minutes may cause oil leakage from turbine side of turbocharger. After warm-up run is completed, ‘check engine oil pressure gauge, water temperature gauge and ‘ammeter for proper operation, Check for normal coloration of exhaust, any abnormal sound or vibration, Check for any leakage of oil, fuel or water.OPERATING YOUR MACHINE ‘Stopping the Engine 1 Idle the engine at a low speed for about 5 minutes to cool it ‘gradually Push the fuel control lever fully forward and stop the engine. Retum the starting switch to the OFF position, and withdraw the key. Do not attempt to stop a hot engine immediately unless it is necessary. Such unreasonable operation will cause remarkable shortage of life of the various engine parts. ‘Specially when stopping an over- heated engine, be sure to cool the engine gradually by idling it at a middle idling speed, OPERATING THE MACHINE Run in the machine for the first 100 hours (as indicated on the ser- vice meter) or so. Although the new machine has been thoroughly adjust- ed and inspected before leaving the plant, both performance and life will be reduced if it is subjected to hard use from the beginning, sos Starting the Machine 1. Disengage safety lock for work equipment control lever (1) and bring the blade and the scarifier (option) in the traveling posture, 2. Depress the clutch pedel (2) and put the gear shift lever (3) and forward-reverse lever (4) in the desired position. 3. Release the parking brake lever @). 4. Release the clutch pedal (2), dep- ress the accelerator pedal (6), and machine will start.> If some difficulty is felt for mesh- ing gears, once place the gear shift lever (3) in the neutral posi- Try slightly depressing the clutch pedal repeatedly to vary gear position. Then, move the gear shift lever again to the desired position. Ifa difficulty still remains, do not attempt to engage the gears forcedly, but repeat the above-mentioned procedure, ‘* The clutch pedal is a 2-step type. Consequently, note that the Pedal operating force at the two steps is different. OPERATING YOUR MACHINE Gear Shifting Release the accelerator pedal (1) depress the clutch pedal (2) and move the gear shift lever (3) to the desired position. Adwnen shitting the forward: reverse lever, temporarily stop tho machine to assure safety and to prevent a shock, The forward-reverse change gears do not mesh even If the lever is shifted during traveling of the machine,OPERATING YOUR MACHINE Turning Adjustment of Steering Wheel Tilt Stopping Tum the steering wheel (1) to Adjustttt angle by loosening lock- Release accelerator pedel and desired direction and the machine nuts (1) and (2). Adjusting allowance when machine slows down, step turns in that direction, is 30 mm. brake pedal. When machine stops, shift gear shift lever to “NEUTRAL”. Nit machine isnot operated soon after stopping, stop or keep engine at low idling, tower blade on ground and lock work. equipment control levers and apply parking brake. —32- rumOPERATING YOUR MACHINE CAUTIONS IN OPERATION © When climbing down a slope, When tires are caught in swamp _@ For safe parking of the machine use the same speed used for or by muddy ground, apply artic- at night, turn on the parking lamp climbing up slope, using engine _ulation to get out of the spot. to indicate the location of the ma- as a brake. If speed is still too chine to other workers. ‘ast, use foot brake AN do ‘not attempt to shift the ear shift lever to the neutral position during downhill travel- ing, but always keep the lever avoid disengaging the clutch during downhill traveling. wea -33-WORKS TO BE CARRIED OUT BY A MOTOR GRADER ‘WORKS TO BE CARRIED OUT BY A MOTOR GRADER ¢ LAND GRADING © REPAIRING OF GRAVEL ROADS For levelling ground, blade should be maintained at Mainly blade is used with 2nd or 3rd speed. If travel- a selected height with its blade angle and cutting angle ing speed is too fast, road surface will become uneven. set at fully obtuse angle and 2nd or 3rd speed. If ‘wheels run over the fil, machine moves irregularly, and cuts ground like a wave. And enough propulsion can not be attained, -34- eae© SNOW REMOVING Run machine with high speed (2nd or 3rd speed) so that snow may be thrown out of road. AN Be carotut tor obstructions below snow. When tnow depth Is large, SNOW PLOUGH loption) Is oftctent WORKS TO BE CARRIED OUT BY A MOTOR GRADER ‘© SCARIFYING (With optional scarifier) For hard ground, scarifier is used with 1st or 2nd speed. During operation, keep teeth deep in ground. If ground is too hard, some teeth should be reduced. (Don't reduce teeth less than 3.) 35 —WORKS TO BE CARRIED OUT BY A MOTOR GRADER © MIXING © SPREADING The blade of the grader is available for mixing up The traveling speed of the grader is most suitable in road construction materials by its rolling function. In the 2nd to 3rd speed range, with the blade sliding, 3s this operation, the grader should be driven in the 2nd in the spreading operation. Avoid changing its traveling to 3rd speed range with the blade forward tilted and direction unnecessarily lest the newly flattened surface slightly angled. Too great a volume of mixing materials will be disturbed by the rear wheels of the grader. Bo may prevent sufficient rolling of them, careful that the materials are spread to an adequate thickness. - 36 —‘WORKS TO BE CARRIED OUT BY A MOTOR GRADER © DITCHING © BACKFILLING Ditching should be in the 1st to 2nd speed opera- Operate with 2nd or 3rd speed. Set blade side shift tion. The blade must positioned in such a manner that ‘and traveling angle 45° to 60°. And offset front dug soil is inside the rear wheels. In addition, be sure to ‘wheels to run over fil remove the earth heaped up under the chassis before it reaches the bottom of the machine. ate ~37-WORKS TO BE CARRIED OUT BY A MOTOR GRADER © JOBS EFFECTUATED WITH THE ARTICULATED FRONT FRAME The motor grader can be effectively applied to the following jobs with the articulated front frame. 1. When performing land leveling, repairing of gravel road or snow removing operation on @ narrow and sharply curved road, the 5.5 m reduced turning 2. During land teveling, allowing the front wheels to run on the previously leveled track adjacent to the track being leveled is effective in minimizing the radius of the machine equipped with the articulated vertical vibration of the machine, thus increasing front frame allows the operator to drive the machine the smoothness of the finished ground surface. easilyWORKS TO BE CARRIED OUT BY A MOTOR GRADER 3. By concurrent use of blade side shift and front 4, When removing snow from bridge or side walk, use wheel offset, road corners are made easy for offset steering to prevent railing or building from operations. being damaged by the end of V-plough. eau -39-OPERATING OF WORK EQUIPMENT OPERATING OF WORK EQUIPMENT OPERATION OF CONTROL LEVERS. Six control levers (including an Left side control levers optional lever) are equipped and controled as illustrated. Unlock the safety lever before operation and lock it unless necessary, pull down the lever shown by an arrow for —— locking and push it up for unlocking, P | 4 ie ie Wien optional equipment is used -40— rea‘OPERATING OF WORK EQUIPMENT ‘* When operating control levers, ay attention to the work equip- ‘ments’s movements. Otherwise, the work equipment or hydraulic cylinders may hit other things, re- sulting in damage. Therefore avoid unnecessary movement of the work equipment. fe control levers xara, =a(OPERATING OF WORK EQUIPMENT. ARTICULATION Perform articulation with the ar- ticulation control lever after removal Of the lock link on the left side of the machine body. Articulation is ob- tained 30° to the right and left Turing radius becomes 4.5 m. Remove the snap pin (1) and pin (2). Turn the lock fink forward and fix it with the bracket with the pin (2) and snap pin (1), A\Never remove the lock tink during normal travel. CAUTIONS FOR OPERATING BLADE If machine is articulated in run- ring posture (blade Is lifted all the way with an angle), blade will touch rear frame. Therefore if articulation is desired, lower blade or select proper blade angle,ADJUSTMENT OF BLADE CUTTING ANGLE Generally speaking, lean blade forward when material is hard and as it becomes sof, lean blade back- ward for better efficiency. Adjust cutting angle to match to job. Adjustment i) Rotate blade not to touch frame, then set blade in same direction as that of machine and lower blade on ground. i) Loosen bolt (1), remove lock plate (2) and nut (3) and extract bolt (4), using appropriate tools from too! kit. Pay attention to the other lock on the opposite side. -43— OPERATING OF WORK EQUIPMENT iil) Operate right and left side lift cylinders simultaneously and when blade attains desired angle, lock it into position.OPERATING OF WORK EQUIPMENT BLADE ANGLE For ordinary operation, keep blade angle at approximately 60°. ‘When cutting resistance is large or ‘material is hard or when materials in front of blade is hard to flow side- ways, make blade angle smaller. j\ Xi ia BLADE TRAVELING POSITION During traveling keep blade in parallel with frame and lift fully, ‘SAFETY DEVICE OF BLADE Circle reverse gear case is provid- ed with a shear pin to protect mechanism from abnormal shock at the end of blade during operation. If sheer pin is cut during operation, remove shear pin and replace it by removing bolt (2) and lock plate (1). The shear pin is capable of two failures.[REPLACEMENT OF CUTTING EDGE AND END BIT REPLACEMENT OF CUTTING EDGE AND END BIT Replace cutting edges and end bits before their blades’ end faces wear out. When wear is extended to the mounting faces, their repair must be done prior to replacing. TURNING AND REPLACING 1 Lift the blade to a suitable height 2. Clean the mounting face after + The tightening torque for the and put a block underneath the detaching the cutting edge and mounting nuts is 23 to 30 kom. blade rail to prevent its falling. the end bits. % Tighten the nuts again after $\Do not raise the blade unne- 3. Mount the cutting edges after in- several hours’ operation. cessarily high. verting it, or replacing it with a If both ends of the cutting edge Be sure not to put your body un- new one. and side edges are worn out, re- derneath the blade when block- 4. Mount the end bits after inverting _ place them with new ones. ing it. ‘and switching right for left, or replacing with new ones. rams easleREPLACEMENT OF TIRES. REPLACEMENT OF TIRES When replacing tires, park the ‘machine on the hard level ground, 1. FRONT WHEEL ') Lower the work equipment and apply the parking brake. ii) Attach the provided socket to ‘the hub nuts and loose the nuts by 3/4 to 1 turn. iil) When the lift cylinder is lowered and the front tires are raised, lock the work equipment control lever and remove the. hub nuts and replace tires. iv) Install tires and lightly tighten the hub nuts with the tires lifted. Then lower the tires on the ground and retighten the hub nuts with the specified torque in the order shown in the picture below. Specified tightening torque: 45 to 55 kgm, 2. REAR WHEEL ') Follow steps i) and ii) for the front wheel. iil Place @ garage jack under the joining section of the final drive case and raise the rear tires, Remove the hub nuts and replace the tires, iil) Follow step iv) for the front wheel Specified tightening torque: 45 to 55 kgm. 46 —REPLACEMENT OF TIRES. Zdwhen using a jack, try to get maximum contact on the lifting part of the jack to prevent slip- ping. Do not raise the tires un- necessarily high, Do not get under the tires while they are raised. kane fae)DRIVING ALONG ROAD DRIVING ALONG ROAD In addition to strict observance of traffic laws and rules concerned, keep the following in mind: To relieve operator's fatigue, take a rest by 30 minutes — 1 hour = 30 minutes mode, every 80 kilometers or every 2 hours of trav- eling (whichever term expires earlier aeHANDLING OF BATTERY HANDLING OF BATTERY PRECAUTIONS FOR CHARGING BATTERY, 1. Before charging, disconnect the cable from the negative (—) terminal of the battery. Other- wise, an unusually high voltage will damage the alternator. 2.While charging the battery, remove all battery plugs for satis factory ventilation. To avoid gas explosions, do not bring fire or sparks near the battery. 3. If the electrolyte temperature ex- ceeds 45°C, stop charging for a while 4, Turn off the charger as soon as the battery is charged. Overcharging the battery may cause followings: 1) Overheating the battery. 2) Decreasing the quantity of electrolyte, 5. If the electrolyte gets on your skin or clothes, immediately wash with plenty of clean water. =49- 6. Do not mix up cables (positive (4) to negative (—) or negative (=) to positive (+), as it will damage the alternator. 7. When inspecting or servicing a battery, be sure to stop the engine and tu the starting switch key to “OFF” position. 8. When performing any service to bottery besides checking the electrolyte level or measuring the specific gravity, disconnect cables from the battery.HANDLING OF BATTERY REMOVAL AND INSTALLATION OF BATTERY ‘® When removing battery, first dis- connect the cable from the ‘ground (normally, from the nega- tive (=) terminal. If a tool touches a cable connecting the positive terminal and the chassis, there is a danger of sparks being emitted, @ When installing battery, the ground cable should be connect- fed to the ground terminal as the last step. ‘STARTING ENGINE WITH A BOOSTER CABLE ‘When starting up the engine with a booster cable, do as follows: 1. Before connecting the booster cable, 1) Size of booster cable and clip should be suitable for the bat- tory size. 2) Check cables and clips for breaks, corroded surfaces, otc. 3) Make sure cables and clips are firmly secured. 4) Keep the starting switch key in OFF position. 5) The battery of the running engine must be the same capacity as that of engine to be started —50- 2. Connect the booster cables in the following manner: 1) Connect one clip of booster cable A to the positive (+) terminal of the engine to be started. Connect the other clip to the positive (+) terminal to the engine which is running, 2) Connect one clip of booster cable B to the negative (-) terminal of the engine which is running. Connect the other clip to the negative (—) termi- ‘nal of the engine to be started, 3) Make sure the clips are firmly connected to battery termi- nals. Then, start the engine, Bauery for Battery for runningengine a engine tobe staredHANDLING OF BATTERY Adatter the engine has started, ‘the booster cables should be dis: connected in the reverse order in which they were connecte, 3. Starting the engine 1, Disconnecting the booster cables, 1) Turn the starting switch key to 1) Disconnect the clip of booster _—2) Disconnect the clip of booster START position and start up cable B from the negative (—) cable A from the positive (+) the engine. terminal on the engine which terminal of the running engine 2)if the engine doesn’t start at was started and disconnect and disconnect the other clip first, try again after 2 minutes the other clip from the negative from the positive (+) terminal oso. (=) terminal of the running of the engine which was engine. started, Batty for running engine g Battery for engine tobe started, ve —s1-TRANSPORTATION In addition to strict observance of traffic laws and rules concerned, it is desirable to provide a special platform for loading and unloading of the motor grader. If itis necessary to use a ramp when loading a motor grader on a trailer or unloading it from a trailer, observe the following instructions to assure safety: TRANSPORTATION 1 * Securely brake the trailer and chock trailer tires. Securely fix the ramp boards in place so that the center of motor grader being loaded coincides with the center line of the trailer. Width, length and thickness of ramp boards must large enough to assure safe loading and unload- ing of the motor grader. —52- 2. Slowly travel the motor grader on the ramp straight. Never attempt to change the ;ction of travel on the ramp. I it is necessary to change the ction of travel, once return to the original3. Properly load the motor grader n the trailer at the specified po- sition. To prevent the grader on the trailer from moving back and forth during transportation, apply @ chock to front and rear of each wheel and fix the motor grader with chains and wire ropes. Pay special care to prevent the motér grader from slipping sideward. 4. Rest the work equipment on the trailer deck and observe the following: ‘© Pull the parking brake lever. © Place the gear shift lever in the neutral position. ‘© Pull the starting switch key out, * A ‘TRANSPORTATION Determine the optimum transpor- tation route, taking width of road and permissible overhead clear- ance and weight limitation into consideration. Do not leave the front wheels raised off the trailer deok using ‘the scarifier as a jack. The front wheels will fall gradually during transportation. —53-MaintenancePERIODIC MAINTENANCE Proper lubrication and maintenance assure trouble-free operation and long machine life. Time and money spent for scheduled periodic mainte- nance will be amply compensated by prolonged machine operation and re- duced operating cost. All hourly figures given in the following descriptions are based on service ‘meter readings. In practice, however, it is recommended to rearrange all of them into units of days, weeks and months to make the maintenance schedule more convenient. Under rough job site or operating conditions, itis necessary to somewhat shorten the maintenance intervals stated in this ‘manual —55— PERIODIC MAINTENANCEPERIODIC MAINTENANCE GENERAL PRECAUTIONS FOR MAINTENANCE General © Wear a safety helmet, safety shoes and gloves. Wear goggles if the nature of the inspection work so requires. © When working in a team of more than two persons, arrange @ set of signals beforehand and coordi- nate joint work for safety. © Keep unauthorized persons away during inspection or maintenance service. © Use genuine Komatsu parts for replacement parts. @ Use genuine Komatsu grease and oil or products recommended by Komatsu. Depending on tempera- ture, use grease and oil of recom- mended viscosity. © Use only clean grease and oil ‘Also use clean containers for lubricants to prevent foreign matter from entering oil, @ Inspect or change oil in a place where it is not dusty so that dust will not enter ol oc Before Starting Mai Work @ Park machine on firm, level ground and lock it with parking brake lever. jenance © When working indoors, pay extra care to ventilation. @ Wash machine and particularly clean greasing and oiling holes to Prevent dirt and dust from mixing with lubricants.During Maintenance Work © Unless specifically instructed, conduct maintenance work with engine stopped. When perform- ing work with engine running, work should be performed by ‘two people. One operator should sit on operator's seat; the other performs service work. They should closely cooperate to aon maximum safety. @ Hang a warning sign (eg, "Do not Start” or "Under Maintenance Work"? on operator's seat to pre- vent some other person from inadvertently starting or operat- ing machine. © Drain oil after heating it to proper temperature (about 30°C to 40°C). Before removing the radiator cap, raise the lever to discharge in pressure, Do not attempt to remove the hy- draulic tank cap and the drain plug while oil is stil hot After replacement of oll filter ele- ment, strainer, etc. as well as cleaning, bleed air from circuits. For oiling parts with strainers, do not remove strainer from port to fill with oil, Lubricating oil should never be ‘more or less than amount re- quired. At time of inspection or refiling, check that oil is at proper level. SS PERIODIC MAINTENANCE After greasing, wipe clean any old grease forced out. ‘When changing oil and replacing filter, check used oil and filter for any abnormal amounts of iron chips or other foreign objects. ‘When removing assemblies con- taining O-rings, gaskets, or seals, clean their mounting surfaces and replace with new seals. Do not smoke while refueling or when handling fuel containers. When changing the mounting tips tire never stand over or stand directly beside, a tire and rim.PERIODIC MAINTENANCE PERIODICAL REPLACEMENT OF SAFETY PARTS ‘The users of our machine should carry out periodical ‘maintenance in order to ensure the working and opera- tion safety. Those parts, as listed on the right, which are closely convected with safety, must be replaced Periodically so that the highest safety standard can be maintained. ‘These parts with the passage of time have a great tendency to deteriorate in quality, and to wear ratter, soar. Furthermore, their defective condition is difficult to detect during periodical maintenance. These parts must, therefore, be replaced with new ones after a pre- determined service period even though there is no ap- parent abnormality Wt goes without saying that if any abnormality should be found, there parts must be replaced or repaired even before the predetermined period expires. The periodical replacement is completely different from the replacement due to the claim against the guarantee by the manufacturer. So they must be treat- ed separately, Period 1 | Brake nove Yeety 2. | Rubber parts of brake mester evlinder | Yearly Fibber pars et. of brake wh 8 | evinder cam 4 | Brake oi Yeery Packing veal, Oring ofthe seri 5 | Packing ofthe eerog Every 2 yea 6 | rubber hose for tering cylinder Every 2 year 7. | Tab of brake ot spy tank Every 2 yea 8 | stopaniten Every 2 yeas Eset[MAINTENANCE TABLE ‘+ For new machine, change all |, replace oil filter MAINTENANCE TABLE elements and adjust engine valve clearance at the first 250 hours ser No. ITEM SERVICE PAGE CHECK BEFORE STARTING @ | Oitandwaterleak Check - 23 b | Boltsand nuts (Check and retighten 23 cc | Electric wiring hack and retighten Ey | Engine oit pan Check oil level and supply 24 | Tires (Check air pressure 28 1 | Goolant Check water level and supply 5 a | Fuol tank ‘Check fuel level and supply 25 h_| Steering wheel - Check play = 26 i | Dust indicator | Cheek 26 i | Brake Gheck efficiency 26 | Brake fluid Check fluid level and supply 27 1 | Parking brake heck stroke 7 m_[ Lamps and instrument | Check function 27 n_| Rearview mivor [check position 27 —69-MAINTENANCE TABLE No. ITEM SERVICE PAGE (CHECK BEFORE STARTING) © | tisonce number plate heck 27 | Horn ‘Check function 7 2 @_[ Engine exhaust color hack 2 F | Gauges ~~) Cheek a EVERY 50 HOURS SERVICE a | Greasing 6 4 | Circle pinion gear Greasing 2 points 66 2_| Tiextod, pin and link (Front axle) Greasing 8 points 66 “3 | Blade guide rai 7 Greasing surface 67 4 | Power steering (O.P.) Arm bushing Greasing 1 point 67 4 | Power steering (0.P.) Connecting pin bu Greasing 2 points 7 4 | Power steering (0.P.) Ball stud Greasing 2 points a7 b | Fuottank Drain water and sediment 68 -60-MAINTENANCE TABLE No. | ITEM ‘SERVICE PAGE EVERY 250 HOURS SERVICE a | Check oil level 7 oo 1 | Final drive case Check oil level and supply 69 2. | Bevel gear case ~ | check oft evel and supply 6 “3 | Blade rotation gear case ‘Check oil level and supply 70 4_|_Steoring gear case {check oit evel and supply 7 5 | Hydraulic tank (Check oil level and supply m1 8 _| Transmission case (Main) Check ol level and supply a -7_| Transmission case (Sub) 7 [ check oit level and supply 2 >| Greasing ae 73 -1_| Universal joint (Upper) | Greasing 2 points 73 2_| Universal join (Lower) |" Greasing 3 points 73 “3_| Main cluteh shifter block Greasing 1 point 3 <4 | Steering shaft “} Greasing 2 points 73 5 | Articulation center pin Greasing 2 points 73 metMAINTENANCE TABLE No. TEM SERVICE PAGE (EVERY 250 HOURS SERVICE) 6 | Drawbar ball joint Greasing 1 point 74 7_| Transmision linkage - Greasing 2 points 74 8 | Clutch linkage Greasing 1 point 74 <9 | Brake linkage ~ | Greasing 1 point 74 | Batteries Check fui level 7 d | Foot brake |” Check and adjustment 75 | Parking brake 7 | @heck and adjustment 78 4 | Wheet hub nut 7 (Check and retighten 79 Fan belt ~ Check tension 20 bh | Lift eylinder ball joint Check clearance 80 ~62-MAINTENANCE TABLE No. TEM SERVICE PAGE EVERY 500 HOURS SERVICE a | Engine oil pan Change oil om | Fuel iter Replace filter | 2 © | Circe guide shoes Check clearance and adjustment 83 a@_| Terod Check wear and looseness e4 @ | _Breathers (Transmission) Check and cleaning ea 4 | Blade guide rail a Check clearance and adjustment 85 Radiator fn = Cleaning 85 | Clutch pedal Check play and adjustment 36 EVERY 1000 HOURS SERVICE _ a | change ot - 37 “1,2. | Transmission (Main, Sub) Change oil 87 3 | Final drive ose a Chenge ol 38 ~4_ | Bevel gear case 7 Change ol 39 oun -63-MAINTENANCE TABLE No ITEM SERVICE PAGE (EVERY 1000 HOURS SERVICE) 5 | Steering gear case Change oil 0 Circle reverse goar caso ~ | Change eit 20 Hydraulic tank Change oil a Hydraulic fitter Replace filter o1 Greasing | Steering splined shaft ~_|_ Grossing 1 point Front axle center pin Greasing 2 points 2 3 | Articulation eylindor pin Groasing 2 points 2 4 | Blade lift oylinder yoke ~ | Greasing 6 points 92 “8 | Blade lif eylindor ball joint Greasing 2 points ~ 2 6 | Blade side shift joint Grossing 2points —SS*«dY'«C« “7 | Drawbar side shift rod ball joint | Greasing 2 points 93 | Drawbar front ball joint ‘Gheck and retighten| | 8 Check and adjust 98 64 asaMAINTENANCE TABLE No. ieM SERVICE PAGE + _| Front wheel bearing play Check 6 EVERY 2000 HOURS SERVICE a | Engine breather Replace strainer 7 | Akternator, Starting motor Check 97 © | Engine valve clearace ‘Adjustment 97 EVERY 4000 HOURS SERVICE a_| Water pump Check 98 WHEN REQUIRED - a _ | Cleaning coolant and change “Twice @ year or every 1000 hours 9 | Air cleaner element Check, lean oF replace 100 | Ribbon heater and coil heater Check 103 | Engine breather hose Check and clean 103 —65-EVERY 60 HOURS SERVICE EVERY 50 HOURS SERVICE a. GREASING Grease up the indicated points. 1.Girele, pinion gear (2 points) 2. Tierod, Pin, Link __(® points) Apply grease on entirely. 66 — easEVERY 50 HOURS SERVICE 3, Blade guide rail 4, Power steering (opt) ‘Arm bushing (1 point) Connecting pin bush (2 points) Ball stud (2 points) wa -67-EVERY 50 HOURS SERVICE b. FUEL TANK Open fuel tank and allow water and sediment to drain. Shut drain valve. EreoeEVERY 250 HOURS SERVICE a. CHECK OIL LEVEL 1. Final drive ease Remover the plug (F) and check to see if oll level is near the lowest edge of the plug hole. if short, supply gear oil through the plug hole up to the specified level. EVERY 250 HOURS SERVICE % For new machine, change all oil and replace oil filter elements at the first 260 hours servic + Perform 50 hours service at the same time. % Select and use gear cil depending ‘on temperatures. ‘Above +30°C: Use SAE 140 +35°C to 10°C: Use SAE90 Below — 10°C: Use SAE 80 eo 2. Bevel gear case Remove the plug (F) and check to ‘06 if oil level is near the lowest edge of the plug hole. I short, supply gear oil through the plug hole.EVERY 250 HOURS SERVICE 3. Blade rotation gear case ‘* Select and use gear oil depending “Remove the level plug (G) and * Above O°C: Use engine oil on temperatures, check to see if the engine oil level CLASS-CD SAE 30. Above +30°C: UseSAE140 _is near the lowest edge of the Below 10°C: Use engine oll +35°C to-10°C: UseSAE90 —_plug hole. If short, supply engine CLASS-CD SAE 10W. Below — 10°C: UseSAE80 oil through fillerEVERY 250 HOURS SERVICE 4. Steering gear case 5. Hydraulic tank 6. Main transmission case Remove the plug (F) and supply Check oil level with the level Check oil level with the dipstick engine oil through the plug hole if gauge (G). I short, supply engine (Gi). If short, supply gear oil the oil evel is below 42 mm from oil through the filler (). through the dipstick hole. the plug hole. + Check oil level with the ma- * Select and use gear oil * Use CLASS-CD SAE 10W chine held at travel position. depending on temperatures. engine oil for ali seasons. + Use CLASS-CD SAE 10W Above +30°C: Use SAE 140 engine oil forall seasons. +35°C to 10°C: Use SAE 90 Below —10°C: Use SAE80 AX nen moving the filler cap, re lieve inner pressure by loosing the cap slowly. 420m ane -n-EVERY 250 HOURS SERVICE 7. Subtransmission case Remove the level plug () and —* Select and use gear oil depending check to see if oil level is near the on temperatures. lowest edge of the plug hole. if Above +30°C: Use SAE 140 short, supply gear oil through the «-+35°C to 10°C: Use SAE 90, filler (F), Below — 10°C: Use SAE 80 -2- avEVERY 250 HOURS SERVICE b. GREASING Grease the following grease fit- tings shown by arrows. 2. Lower universal oint (3 points) 4. Steering shaft (2 points) yt 1. Upper universal joint (2 points) kame -73-EVERY 250 HOURS SERVICE ©. BATTERY ELECTROLYTE LeveL ‘Add distilled water to battery if electrolyte level is below the speci- 6. Drawberballjoint (1 point) 8. Clutch controllinkage (1 point) _fied level (10 to 12 mm high above the platel. I electrolyte has been spilled and decreased, have the bat- tery supplied with dilute sulphuric acid by a battery shop. ‘When checking electrolyte level, also clean the air hole of the battery cap % Nover use a metal funnel for adding water: 7. Transmission control linkage (2 points) ~ Fo Z ao Top view Side ssetion view Sie euEVERY 250 HOURS SERVICE 4d. FOOT BRAKE Check Adjustment ‘When the pedal is depressed if 1. Insert a screwativer in the hole at 2. If the clearance cannot be adjust- the height of the mounting bolt the bottom of the back plate. ed properly by step 1., adjust the center of brake pedal above the Turn the adjustment gear in the camshaft as follows. floor is 90 mm or less, perform the direction of the arrow to bring Loosen lock nut (21, turn camsh- following adjustment. the lining and drum into close aft (1) in the direction of the contact. Then turn the gear back arrow and adjust the top clear- 4105 teeth. In this way the clear- ance on both right and left sides ance between the lining and 00.14 t0.0.17 mm. drum is adjusted to the following «To increase clearance, turn values. camshaft CLOCKWISE. a ee To decrease clearance, turn = eo camshaft ‘At upper inspection hole [0.14 ~ 0.17 mm ‘COUNTERCLOCKWISE. Ss &. 7 ‘aivsingasor ues — 75 ~