Procedure Manual

for
Visual Machine Check
[Motor Grader]

This manual is based on GD705-5.

 1
Preparation These items are safety precautions.
(3) Move to the safe place
(1) Clothes of the worker

Before moving, check that there are no people or

Check that you are wearing the proper gear. Check the chin strap obstructions in the surrounding area and sound the
of your helmet, your work clothes, work gloves, safety boots, and so horn to warn everyone. Then move the machine to a
on. Only start work when everything has been checked. level place.

(2) 3 point contact (4) Set the machine position

Always face the machine

and maintain at least 3-
point contact with the
handrail and steps to
ensure that you are fully
supported.
This means using both feet
and one hand, or both
hands and one foot. Never
Set the machine in the position for a "Visual Machine
jump on or off the machine.
check” in order to check the hydraulic oil level. Return the
leaning front tires to the upright position and face the
wheels straight to the front. NEXT →
 2
These items are safety precautions.

Also set the front frame and the rear frame to a forward- To drain the oil from the accumulator on machines equipped
facing position. (articulated angle = 0 deg.) with a blade accumulator, turn the blade accumulator switch
ON and raise the blade to the maximum height.
After doing this, turn the accumulator switch OFF and lower
the blade to the ground.
(5) Use a warning tag

Return the blade side shift to the center of the

machine, set the blade at right angles to the chassis,
and lower it lightly to the ground. Use a warning tag to warn inform others of the danger.
Do not start the engine or touch the levers while the
inspection is being carried out.
 3
These items are safety precautions.

(6) Insert the articulate lock pin (8) Set the blocks

First, check for damage. We recommend replacing the pin if it is

damaged. Then insert the pin at the lock position to prevent the
machine from articulating.

(7) Insert the leaning stopper

Set blocks under the 3 wheels on the left side to prevent

the machine from moving.

First, check for damage. We recommend replacing the

stopper if it is damaged. Then insert the stopper to
prevent the machine from leaning.
Check procedure of GD705-5 4

⑧
⑥
⑦
⑤
⑨ ⑪ ④
③
①
②
⑩
① The left side of the cabin ⑦ The right side of the cabin
② The left rear tires ⑧ The front right side
③ The left rear side ⑨ The front
④ The rear ⑩ The front left side
⑤ The right rear side ⑪ Inside the cabin
⑥ The right rear tires
 5
Check point 1 The left side of the cabin
(1) Machine serial number plate (4) Working light below the cabin

Check for damage, dirt, or

loose mounting bolts. Clean
the light if it is dirty. Tighten
any loose bolts.

Check the model, type and serial number.

(2) Articulate cylinder

Check for oil leaks or
damage. If any leakage is
found, take a photograph
and report the situation to
an experienced
serviceperson.

(3) Hoses

Check for oil leaks or damage. We recommend

replacing hoses if necessary.
(5) Washer tank (9) Wiper 6

Check the fluid level and Check for damage. If the

make sure there is no blade rubber is cracked or
damage. Add fluid if cut, we recommend
necessary. replacing it.

(6) Steps (10) Mirror

Check for damage, dirt, or

Check for damage or loose loose mounting bolts. Clean
mounting bolts. Tighten any the mirror if it is dirty. Tighten
loose bolts. any loose bolts.

(7) Cabin frame (11) Working light above the cabin

Check for damage, dirt, or

Check for damage. loose mounting bolts. Clean
the light if it is dirty. Tighten
any loose bolts.

(8) Door (12) Handrail

Check for damage and
make sure that the door
Check for deformation or
opens, closes and locks
loose mounting bolts. Tighten
properly. If any problems
any loose bolts.
are found, correct them if
they can be adjusted.

Check point 2 The left rear tires
(1) Bolts (4) Tires
Check for damage or
missing bolts. We
recommend installing
bolts if necessary.
7
Check for cracks or wear. We
recommend replacing tires if
necessary. Here is an
example of worn tires.
We recommend replacing all
worn tires.

(2) Air valves

Check for damage. We recommend replacing any

damaged valves.

(3) Rims
(5) Hubs

Check for damage. Check for oil leaks or damage.

If any leakage is found, take
a photograph and report the
situation to an experienced
serviceperson.
 8
Check point 3 The left rear side
(1) Exterior
(4) Steps

Check for deformation

or damage.

(2) Tandem drive case Check for deformation or loose mounting bolts.
Tighten any loose bolts.
Check for oil leaks or damage. Here is an example of deformed steps.
If any leakage is found, take a
photograph and report the
situation to an experienced
(5) Handrail
serviceperson.

Check for deformation

(3) Fuel tank cap & Strainer or loose mounting bolts.
Tighten any loose bolts.

If the sound of sucking air is heard when opening the cap, dirt may be clogging the vent
hole of the cap. Check the installation of the strainer for dirt clogging the strainer.
If the strainer is not installed properly or broken, dirt may enter into the tank.
Check and clean the cap and packing of the cap.
If the vent hole of the cap is clogged, the pressure in the tank becomes negative and the
engine will stop.
(6) Mirror (8) Brake hoses 9

Check for damage, dirt, or Check for oil leaks or cracks.

loose mounting bolts. Clean We recommend replacing a
the mirror if it is dirty. damaged hose.
Tighten any loose bolts.

(7) Radiator cap (9) Grease pump

Check for damage. If there is

no grease gun, lubrication
may not have been performed
properly.

Check for cracks in the radiator cap seal. If the cap seal is
cracked, pressurization is disabled, resulting in overheating.
We recommend replacing the radiator cap assembly. We recommend the Komatsu
genuine grease.
Please refer to page 34.

(10) Wiper

If the blade rubber is cracked

or cut, we recommend
replacing it.

(11) Air conditioning filter of the
outside air intake
Check for damage or dirt. We recommend replacing the filter
with a new one every year or when it is extremely dirty.
-Attention-
Take care inside and outside of filter when installing.
(12) Battery
First, check for damage and
check the operation of the
cover and lock. Then check
the battery.
Remove any combustible
materials or dust on the
battery surface.
NEXT
10
Check for loose battery
terminals. Tighten any loose
terminals.
Open the caps and check the level of
the battery electrolyte.
There is diluted sulfuric acid inside.
Be very careful not to splash any
sulfuric acid on your clothes or skin
when refilling the battery.
If your clothes or skin are exposed to
sulfuric acid, rinse thoroughly with
plenty of flowing water.
If the electrolyte surface reaches the
end of the cap, the level is high. Fill
with distilled water if the level is low.
(13) Engine room cover
Check for damage to the
rubber and check the
operation of the lock.

(14) Cooling cores
Check for damage or clogging.
There are 5 kinds of cores:
the power train oil cooler,
after cooler, radiator,
condenser, and hydraulic oil
cooler.
Clean the cores with
compressed air if necessary.
If any damage is found, take
a photograph and report the
situation to an experienced
serviceperson.
(15) Hoses
Check for cracks or oil leaks.
We recommend replacing any
damaged hoses.
(16) Receiver
Check for damage.
11
(17) Alternator
Check for damage,
cracks in the belt, or
loose terminals.
(18) Air conditioner compressor
Check for damage, and
check the tension of
the belt. If the belt is
loose, it will slip and it
will become impossible
to carry out cooling
properly. Adjust the
tension of the belt if
necessary.
(19) Engine oil filter
Check for oil leaks or
damage. We
recommend replacing
the filter every 500
hours or if there are
any oil leaks. Also,
check that only
Komatsu genuine parts
are fitted.
 12
(20) Turbocharger (22) Starter motor
Check for cracks or oil leaks.
Check for damage or
If any leakage is found, take
looseness in the
a photograph and report the
terminal. Tighten the
situation to an experienced
terminal if it is loose.
serviceperson.

(21) Final drive oil level & Breather (23) Transmission oil filter
Check for oil leaks or
damage. We
recommend replacing
the filter every 1,000
hours or if there are
any oil leaks. Also,
check that only
Komatsu genuine parts
are fitted.

(24) Remove any combustible materials

The oil level should be between the H and L marks on the

dipstick. If the oil level is below the L mark, add oil through
the oil filler.
Check the oil level, and check for oil leaks from the breather.
We recommend the Komatsu genuine oil. (Refer to page 35.)
Accumulation of dirt around the breather may cause clogging Remove any combustible materials, such as dry leaves,
of the breather. In such cases, we recommend replacing it. chips, pieces of paper, coal dust, or other materials
accumulated around or affixed to the engine, exhaust
manifold, muffler, and so on.
 13
Check point 4 The rear
(1) Light (4) Fuel breather
Check for damage or
Check for damage, dirt,
dirt. We recommend
or loose mounting bolts.
replacing the fuel
Clean the light if it is
breather every 2,000
dirty. Tighten any loose
hours or if there is
bolts.
damage or extreme dirt.

(2) Fan & Cooling cores (5) Back alarm

Check for damage or clogging

of the cores. Clean the cores
with compressed air if
necessary.

Check for damage.

(3) Fan motor (6) Ripper mounting bolts

Check for oil leaks or damage. Check for damage,
If any leakage is found, take a looseness, or missing
photograph and report the bolts. In such cases,
situation to an experienced we recommend
serviceperson. replacing the bolts.

(7) Ripper cylinder
Check for oil leaks, damage,
or cracks in the hose. If any
oil leaks and cracks are
found in the hose, we
recommend replacing it. If an
oil leak is found in the
cylinder rod head, take a
photograph and report the
situation to an experienced
serviceperson.
(8) Ripper rod & Link
Check for damage, dislocated
pins, or broken locks. Check
the opposite side in the same
way. We recommend installing
bolts or replacing the pin if
necessary.
(9) Ripper bracket
Check for damage.
14
(10) Shank pin & Ripper point
Check for damage or
wear of the ripper
point. If the ripper
point has become worn,
we recommend
replacing it.
(11) Under the body
Check for oil or water
leaks. If any leakage is
found, check where it
comes from. Depending
on the situation, take a
photograph and report
the situation to an
experienced
serviceperson.
 15
Check point 5 The right rear side (2) Exhaust pipe

Check these items in the same way as for the

left rear side in “Check point 3”.
Check for damage.
・ Exterior
・ Tandem drive case
・ Step
・ Handrail
・ Brake hoses (3) Rain cap
・ Cooling cores
・ Remove combustible materials

(1) Draining fuel Check for damage.

Prepare a bottle for draining
the fuel. Drain the fuel until it
comes out clean and then
check the drained fuel.
Layers of water containing (4) Hydraulic oil level & Breather
rust, water, and fuel have this
order of specific gravity.
Water and dirt will damage the
engine injector and the supply
pump. We recommend filling
the tank with fuel after
completion of your work every
day in order to prevent water
from condensing in the fuel Check for dirt around the breather.
tank. We recommend replacing the breather
every 2,000 hours or if there is
extreme dirt.
Check the oil level. It should come up
to the window of gauge. And, we
recommend the Komatsu genuine oil.
(5) Transmission oil level
-Attention-
Check the oil level and add
oil while the engine is running
at low idling speed.
The oil level should be between
marks H and L on dipstick marked
with ENG IDLING side. We
recommend the Komatsu genuine oil.
(6) Coolant sub tank
Check that the coolant level
is between FULL and LOW. If
the coolant level is low, we
recommend refilling the
Komatsu genuine coolant.
(Refer to page 35.)
16
(7) Hoses
Check for hardening or
breakage. In such
cases, we recommend
replacing the hoses.
(8) Fuel prefilter & Water separator
Check for fuel leaks, damage, and any water or
sediment in the water separator. If water or
sediment has accumulated, drain it. Also, check
that only Komatsu genuine parts are fitted.
(9) Fuel supply pump & Piping
Check for fuel leaks or
breakage. If any leakage or
breakage is found, we
recommend replacing the
parts. Depending on the
situation, take a
photograph and report the
situation to an experienced
serviceperson.
 17
(10) Engine oil level (12) Dust indicator
Check that the oil level is
between the marks on the
dipstick. Also check for dirt in
the oil. We recommend
replacing the oil every 500
hours or if the oil is extremely
dirty.

We recommend the Komatsu genuine oil.

Press the button on the dust indicator after cleaning

(11) Fuel main filter the element and then return the yellow line to the
original position.

Check for fuel leaks or damage. We recommend replacing

the filter every 1,000 hours or if leakage is found. Also,
check that only Komatsu genuine parts are fitted.
 18
(13) Air cleaner

Check for damage or clogging

of the evacuator valve.

Open the air element cap and

check that the O-ring is set
properly.

[Outer element]
Check that only Komatsu genuine parts are fitted. Do not remove
the inner element when cleaning the outer element. We strongly
recommend replacing the air element assembly, both the outer
and inner elements together, after the outer element has been
cleaned six times or has been used for a year.

[Inner element]
 19
Check point 6 The right rear tires
Check these items in the same way as for the
left rear tires in “Check point 2”.
・ Bolts
・ Air valves
・ Rims
・ Tires
・ Hubs
 20
Check point 7 The right side of the cabin
Check these items in the same way as for the left side of the cabin in
“Check point 1”.
・ Articulate cylinder ・ Door
・ Hoses ・ Wiper (Include “Front wiper”)
・ Working light below the cabin ・ Mirror
・ Steps ・ Working light above the cabin
・ Cabin frame ・ Handrail

⑩
 21
Check point 8 The front right side
(1) Lifter bracket (3) Drawbar side shift cylinder, Ball joint

Check for damage or oil leaks. If any leakage is found, take Check for damage or oil leaks. If any leakage is
a photograph and report the situation to an experienced found, take a photograph and report the situation
serviceperson. to an experienced serviceperson.

(2) Blade lift cylinder, Pin, Ball joint (4) Circle gear
Check for damage. If any
cracks or deformation are
found, take a photograph and
report the situation to an
experienced serviceperson.

Check for damage or oil leaks.

If any leakage is found, take a
photograph and report the
situation to an experienced
serviceperson.
(5) Power tilt cylinder
Check for damage or oil leaks.
If any leakage is found, take a
photograph of it and report the
situation to an experienced
serviceperson.
 (7) Front frame & Drawbar frame 22
(6) Blade cutting edge & End bit
Check for damage, loose
mounting bolts, and wear. Drawbar
Here’s an example of a
Front frame
damaged bolt. In such
cases, we recommend frame
replacing the bolt.
Check for cracks or deformation. If any problems are found,
take a photograph and report the situation to an
experienced serviceperson.

(8) Light

Check for damage, dirt, or

loose mounting bolts. Clean
the light if it is dirty. Tighten
any loose mounting bolts.

(9) Circle rotation motor & Gear case

[Example]

Check for damage or oil leaks. If any leakage is found, take

a photograph and report the situation to an experienced
Here is an example of a loose mounting bolt. serviceperson.
In such cases, we recommend replacing the bolts.
 (3) Leaning cylinder, Rod, Steering linkage 23
Check point 9 The front
Check these items in the same way as for the
left rear tires in “Check point 2”.
・ Bolts Check for damage
or oil leaks.
・ Air valves
・ Rims
・ Tires

(1) Drawbar ball joint

(4) Light

Check for damage, dirt, or

loose mounting bolts. Clean
the light if it is dirty. Tighten
any loose mounting bolts.
Check for damage. If any problems are found, take a
photograph and report the situation to an experienced
serviceperson. (5) Horn
(2) Front axle center pin,
Steering cylinder, Tie rod
Check for damage.

(6) Front weight mounting bolts

Check for loose or missing mounting
bolts. Tighten any loose mounting
bolts. We recommend replacing
Check for damage or oil leaks. missing bolts.
 24
Check point 10 The front left side

Check these items in the same way as for the

front right side in “Check point 8”.
・ Lifter bracket
・ Blade lift cylinder, Pin, Ball joint
・ Blade cutting edge & End bit
・ Front frame & Drawbar frame
・ Light

(1) Blade side shift cylinder

Check for damage or oil leaks. If any leakage is

found, take a photograph and report the
situation to an experienced serviceperson.
 25
Check point 11 Inside the cabin
(1)Air conditioning filter for inside (3) Seat
air circulation

Check for damage.

(4) Seat belt

Check for damage or dirt. We recommend replacing the

filter every year or when it is extremely dirty.

(2) Fuse box

Check for breaks in the belt or damage to the lock. We
recommend replacing the seat belt every 3 years after
beginning to use or every 5 years after manufacture or if
it is damaged, whichever comes sooner.

(5) Mirror
Check for damage,
dirt, or loose
mounting bolts.
Check for burn out or loss in the fuse. Please refer to the Clean the mirror if it
check fuse position on the chart on the back side of the is dirty. Tighten any
cover. loose bolts.
(6) Door lock (8) Replacement time 26
Check that the door opens, Now, the SMR and
closes and locks properly. If odometer are
any problems are found, displayed on the
correct them if they can be monitor. Use the
adjusted. If a replacement is “Machine monitor
required, take a photograph mode selector
and report the situation to an switch” to check
experienced serviceperson. “Replacement time”.

Press the ◇ button

once and
“OPERATION INFO”
is displayed.

(7) SMR

Press the ＞ button

Turn the starting
twice and
switch key to the ON
“MAINTENANCE
position.
MONITOR” is
In this example, the
displayed.
SMR is 528.2 hours.

Press the ◇ button

once and the
replacement time for
each part can be
checked.
(9) Switches 27
Check the working of these 17 switches.

① Hazard lamp switch

② Fog lamp switch, if equipped
③ Front lamp switch ② Fog lamp switch, if equipped
④ Side clearance lamps and tail lamps
⑤ Front working lamp switch, if equipped
⑥ Rear working lamp switch
⑦ Cab-mounted working lamp switch, if equipped
⑧ Yellow rotating lamp switch, if equipped
⑨ Brake lamp
⑩ Back lamp
⑪ Front wiper switch
⑫ Door wiper switch
⑬ Rear wiper switch
⑭ Intermittent wiper switch
⑮ Dimmer switch
⑯ Turn signal lever (Right)
⑰ Turn signal lever (Left)

① Hazard lamp switch ③ Front lamp switch

 28

④ Side clearance lamps and tail lamps ⑥ Rear working lamp switch

⑤ Front working lamp switch, if equipped ⑦ Cab-mounted working lamp switch, if equipped
 29

⑧ Yellow rotating lamp switch, if equipped ⑩ Back lamp

⑨ Brake lamp ⑪ Front wiper switch

Check the injection of washer fluid by pressing and

holding the switch.
 30
⑫ Door wiper switch ⑭ Intermittent wiper switch

Check the injection of washer fluid by pressing and Check this switch while pressing the other wiper
holding the switch. switch.

⑬ Rear wiper switch ⑮ Dimmer switch

Check the injection of washer fluid by pressing and Check this switch while pressing the other working
holding the switch. lamp switch.
 31
⑯ Turn signal lever (Right)

⑰ Turn signal lever (Left)

 32
(10) Levers ② Leaning control lever
Check the working of these 9 items.

① Steering wheel
② Leaning control lever
③ Articulate control lever
④ Blade lift control lever(Left & Right)
⑤ Power tilt control lever
⑥ Blade side shift control lever
⑦ Blade rotation control lever
⑧ Drawbar side shift control lever
⑨ Ripper/scarifier control lever, if equipped

① Steering wheel ③ Articulate control lever

 33
④ Blade lift control lever ⑥ Blade side shift control lever

⑤ Power tilt control lever ⑦ Blade rotation control lever

 34
⑧ Drawbar side shift control lever (11) Accelerator & Brake

Check acceleration and

deceleration. Sound the
horn to warn people before
moving.

⑨ Ripper/Scarifier control lever

End.
 35
Reference 1 Komatsu Genuine Grease
 36
Reference 2 Use of Fuel, Coolant and Lubricants
[Example]
 37
Reference 3 Capacity of Fuel, Coolant and Lubricants