GD705A-4 23001 and Up

PEN00266-00
MOTOR GRADER GD705A -4

SERIAL NUMBERS 23001 and up
NOTICE
Komatsu has Operation & Maintenance Manuals written
in some other languages . If a foreign language manual
is necessary , contact your local distributor for
availability .
WARNING
Unsafe use of this machine may cause serious injury or
Death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine .
This manual should be kept near the machine for
reference and periodically reviewed by all personnel
who will come into contact with it .
FOREWORD
11
1-1
FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines, which will help you use this machine safely and effectively. The pre-
cautions 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. Acci-
dents can be prevented by knowing beforehand conditions that may cause danger when performing operation and
maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.
● 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 stuck to the machine thoroughly
and be sure that you understand them fully.
Keep this manual at 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.
This machine has been designed and manufactured to comply with all applicable regulations and stan-
dards for Japan. The regulations and standards of countries other than Japan may be different. When
using this machine in a country other than Japan, so always consult your Komatsu distributor before
operating the machine.
In this manual, the measurement units are shown in international units (SI).
For reference, the units of weight shown in previous manuals are given in ( ).
Place for keeping Operation and Maintenance Manual
Luggage box (1) inside cab
1-2
FOREWORD FOREWORD
1-3
FOREWORD FOREWORD
1-4
FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
DANGER ous injury. This signal word is to be limited to most extreme situations.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
WARNING serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
CAUTION erate injury. It may also be used to alert against unsafe practices.
Example of safety message using signal word
WARNING
To avoid hitting unlocked operation levers, lower work equipment to ground and move SAFETY LOCK
LEVER (located near seat) to LOCK position before starting up from operator's seat.
Sudden and unwanted machine movement can cause serious injury or death.
Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is are useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
NOTICE the life of the machine.
This gives information that is useful to know.

REMARK
1-5
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.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram

Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times.
Safety pictograms show the type of hazardous condition at the

top or left side, and the method of avoiding the hazardous con-
dition at the bottom or right side. In addition, the type of hazard-
ous condition is displayed inside a triangle and the method of
avoiding the hazardous condition is shown inside a circle. Part No.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi-
bility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: → (1))
1-6
FOREWORD INTRODUCTION
INTRODUCTION
INTENDED USE
This machine can be used for the following work.
● Leveling operations
● Repair and maintenance of gravel roads
● Ditch digging
● Cutting slope faces
● Mixed operations
● Spreading operations
● Front wheel offset operations
For details of operating procedures, see "WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER
(PAGE 3-59)" in the operating section.
DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
1-7
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
LOCATION OF PLATES, TABLE TO ENTER SERIAL

NO. AND DISTRIBUTOR
MACHINE SERIAL NO. PLATE POSITION

At the center of the frame on the left side of the machine body.
ENGINE SERIAL NO. PLATE POSITION

This is on the right side of engine cylinder block as seen from the fan.
1-8
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
SERVICE METER POSITION

This is on the machine monitor.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine serial No.:
Distributor name:
Address: Phone:
Service personnel for your machine:
REMARK
1-9
CONTENTS FOREWORD
CONTENTS
FOREWORD
FOREWORD......................................................................................................................................................... 1-2
SAFETY INFORMATION...................................................................................................................................... 1-5
INTRODUCTION................................................................................................................................................... 1-7
INTENDED USE ......................................................................................................................................... 1-7
DIRECTIONS OF MACHINE ...................................................................................................................... 1-7
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ............................................. 1-8
MACHINE SERIAL NO. PLATE POSITION................................................................................................ 1-8
ENGINE SERIAL NO. PLATE POSITION .................................................................................................. 1-8
SERVICE METER POSITION .................................................................................................................... 1-9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR .............................................................................. 1-9
SAFETY
SAFETY LABELS................................................................................................................................................. 2-2
POSITION FOR ATTACHING SAFETY LABELS ....................................................................................... 2-2
SAFETY LABELS ....................................................................................................................................... 2-3
GENERAL PRECAUTIONS ................................................................................................................................. 2-7
PRECAUTIONS DURING OPERATION ............................................................................................................ 2-16

BEFORE STARTING ENGINE ................................................................................................................. 2-16
AFTER STARTING ENGINE .................................................................................................................... 2-18
TRANSPORTATION................................................................................................................................. 2-23
BATTERY ................................................................................................................................................. 2-24
TOWING ................................................................................................................................................... 2-26
PRECAUTIONS FOR MAINTENANCE .............................................................................................................. 2-27

BEFORE CARRYING OUT MAINTENANCE ........................................................................................... 2-27
DURING MAINTENANCE......................................................................................................................... 2-29
PRECAUTIONS WITH TIRES ............................................................................................................................ 2-34
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE ................................................................................................................. 3-2
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-5

METERS AND LAMPS ............................................................................................................................... 3-5
SWITCHES ................................................................................................................................................. 3-9
CONTROL LEVERS, PEDALS ................................................................................................................. 3-14
1-10
FOREWORD CONTENTS
DUST INDICATOR ................................................................................................................................... 3-22

ARTICULATE LOCK PIN.......................................................................................................................... 3-22
FUSE BOX................................................................................................................................................ 3-22
OPERATION....................................................................................................................................................... 3-24
CHECK BEFORE STARTING ENGINE.................................................................................................... 3-24
STARTING ENGINE ................................................................................................................................. 3-38
OPERATIONS, CHECKS AFTER STARTING ENGINE........................................................................... 3-42
STOPPING ENGINE................................................................................................................................. 3-44
CHECK AFTER STOPPING ENGINE ...................................................................................................... 3-45
TRAVELING POSTURE FOR MACHINE ................................................................................................. 3-45
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING.............................. 3-46
TURNING MACHINE ................................................................................................................................ 3-52
OPERATING WORK EQUIPMENT .......................................................................................................... 3-55
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER................................................... 3-59
PRECAUTIONS WHEN OPERATION...................................................................................................... 3-79
ADJUSTING WORK EQUIPMENT POSTURE......................................................................................... 3-82
PARKING MACHINE ................................................................................................................................ 3-89
CHECKS AFTER COMPLETION OF OPERATION ................................................................................. 3-91
LOCKING (if equipped with cab)............................................................................................................... 3-91
HANDLING THE TIRES............................................................................................................................ 3-91
TRANSPORTATION........................................................................................................................................... 3-92
LOADING, UNLOADING WORK .............................................................................................................. 3-92
PRECAUTIONS FOR LOADING .............................................................................................................. 3-92
COLD WEATHER OPERATION ........................................................................................................................ 3-93

PRECAUTIONS FOR LOW TEMPERATURE .......................................................................................... 3-93
CAUTIONS AFTER COMPLETION OF WORK........................................................................................ 3-95
AFTER COLD WEATHER ........................................................................................................................ 3-95
LONG-TERM STORAGE.................................................................................................................................... 3-96

BEFORE STORAGE................................................................................................................................. 3-96
DURING STORAGE ................................................................................................................................. 3-96
AFTER STORAGE.................................................................................................................................... 3-96
TROUBLESHOOTING........................................................................................................................................ 3-97
AFTER RUNNING OUT OF FUEL............................................................................................................ 3-97
WHEN LEANING PIPING IS DAMAGED ................................................................................................. 3-98
TOWING THE MACHINE ......................................................................................................................... 3-99
IF BATTERY IS DISCHARGED.............................................................................................................. 3-101
OTHER TROUBLE ................................................................................................................................. 3-105
MAINTENANCE
GUIDES TO MAINTENANCE............................................................................................................................... 4-2
OUTLINES OF SERVICE ..................................................................................................................................... 4-4

OUTLINE OF OIL, FUEL, COOLANT ......................................................................................................... 4-4
RELATING TO ELECTRIC SYSTEM ......................................................................................................... 4-6
1-11
CONTENTS FOREWORD
WEAR PARTS LIST ............................................................................................................................................. 4-7
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....................... 4-8

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ........................................................... 4-8
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-12

TORQUE LIST .......................................................................................................................................... 4-12
PERIODIC REPLACEMENT OF CRITICAL PARTS ......................................................................................... 4-13

CRITICAL PARTS..................................................................................................................................... 4-13
MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-14

MAINTENANCE SCHEDULE CHART ...................................................................................................... 4-14
SERVICE PROCEDURE .................................................................................................................................... 4-17

INITIAL 250 HOURS SERVICE ................................................................................................................ 4-17
WHEN REQUIRED ................................................................................................................................... 4-18
CHECK BEFORE STARTING .................................................................................................................. 4-28
EVERY 50 HOURS SERVICE .................................................................................................................. 4-29
EVERY 250 HOURS SERVICE ................................................................................................................ 4-30
EVERY 500 HOURS SERVICE ................................................................................................................ 4-43
EVERY 1000 HOURS SERVICE .............................................................................................................. 4-47
SPECIFICATIONS
SPECIFICATIONS ................................................................................................................................................ 5-2
OPTIONS, ATTACHMENTS
HANDLING BLADE ACCUMULATOR ................................................................................................................ 6-2
FEATURES OF BLADE ACCUMULATOR ................................................................................................. 6-2
METHOD OF OPERATING BLADE ACCUMULATOR............................................................................... 6-3
EXPLANATION OF NEGATIVE PARKING BRAKE............................................................................................ 6-4

EXPLANATION OF STRUCTURE.............................................................................................................. 6-4
METHOD OF OPERATING PARKING BRAKE SWITCH........................................................................... 6-4
ACTION IF THERE IS A PROBLEM........................................................................................................... 6-4
1-12
SAFETY
21
WARNING
Please read and make sure that you fully understand the
precautions described in this manual and the safety labels
on the machine. When operating or servicing the machine,
always follow these precautions strictly.
2-1
SAFETY LABELS SAFETY
SAFETY LABELS
This section explains the safety labels used on this machine.
● Be sure that you fully understand the correct position of the safety labels, the details of the danger described
on the message, and the method of avoiding the danger.
● To ensure that the content of these safety labels can be read properly, be sure that they are in the correct
place and always keep them clean. When cleaning them, do not use organic solvents or gasoline. These may
cause the safety labels to peel off.
● If the safety labels are damaged or lost or cannot be read, replace them with new labels.
For details of the part number for the safety label, check this manual or the label itself and order a new one
from your Komatsu distributor.
● There are also other labels in addition to the safety labels. Handle these labels in the same way.
POSITION FOR ATTACHING SAFETY LABELS
2-2
SAFETY SAFETY LABELS
SAFETY LABELS
(1) Precautions before operating (09651-A0641) (2) Prevention of danger when inspecting radiator
(09653-A0481)
(3) Precautions when opening fuel tank cap (4) Precautions when handling booster cable and
(09653-A0481) battery cable (09808-A0881)
2-3
(5) Precautions when driving in reverse (6) Articulate lock (09161-E0641)

(09806-E0883)
(7) Prohibited to enter (09162-E0641) (8) Precautions when handling battery

(235-53-31210)
•
•
•
•
2-4
SAFETY SAFETY LABELS
(9) Precautions for bank control (234-53-31120) (10) Operation prohibited with engine cover open
(09667-A0641)
(11) Caution for spring (09820-E0481) (12) Danger when approaching (09806-E0883)
2-5
(13) Precautions when handling battery

(235-53-31220)
2-6
SAFETY GENERAL PRECAUTIONS
GENERAL PRECAUTIONS
SAFETY RULES
● Only trained and authorized personnel can operate and maintain the machine.
● Follow all safety rules, precautions and instructions when operating or performing maintenance on the
machine.
● If you are under the influence of alcohol or medication, your ability to safety operate or repair your machine
may be severely impaired putting yourself and everyone else on your jobsite in danger.
● When working with another operator or with a person on worksite traffic duty, be sure that all personnel under-
stand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUND

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

● Do not wear loose clothing and accessories. There is a
hazard that they may catch on control levers or other pro-
truding parts.
● If you have long hair and it hangs out from your hard hat,
there is a hazard that it may get caught up in the machine,
so tie your hair up and be careful not to let it get caught.
● Always wear a hard hat and safety shoes. If the nature of

the work requires it, wear safety glasses, mask, gloves, ear
plugs, and safety belt when operating or maintaining the
machine.
● Check that all protective equipment functions properly before using it.
FIRE EXTINGUISHER AND FIRST AID KIT

Always follow the precautions below to prepare for action if any injury or fire should occur.
● Be sure that fire extinguishers have been provided and

read the labels to ensure that you know how to use them in
emergencies.
● Carry out periodic inspection and maintenance to ensure

that the fire extinguisher can always be used.
● Provide a first aid kit at the storage point. Carry out periodic
checks and add to the contents if necessary.
2-7
GENERAL PRECAUTIONS SAFETY
SAFETY FEATURES
● Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately
if they are damaged.
● Understand the method of use of safety features and use them properly.
● Never remove any safety features. Always keep them in good operating condition.
KEEP MACHINE CLEAN

● If water gets into the electrical system, there is a hazard
that it will cause malfunctions or misoperation. Do not use
water or steam to wash the electrical system (sensors,
connectors).
● If inspection and maintenance is carried out when the

machine is still dirty with mud or oil, there is a hazard that
you will slip and fall, or that dirt or mud will get into your
eyes. Always keep the machine clean.
INSIDE OPERATOR’S COMPARTMENT

● When entering the operator’s compartment, always remove all mud and oil from the soles of your shoes. If you
operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious acci-
dent.
● Do not leave parts or tools lying around the operator’s compartment.
● Do not fix any suction pad to the window glass.

The suction pad will act as a lens and may cause a fire.
● Do not use cellular telephones inside the operator’s compartment when driving or operating the machine.
● Never bring any dangerous objects such as flammable or explosive items into the operator’s cab.
2-8
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT

● Before standing up from the operator’s seat to adjust the
operator’s seat, always lower the work equipment, set
safety lock lever to the LOCK position and parking brake
lever to the LOCK position, then stop the engine.
● When leaving the machine, always lower the work equip-

ment to the ground, set safety lock lever to the LOCK posi-
tion and parking brake lever to the LOCK position, then
stop the engine. Lock all places and always take the key
with you and leave it in the specified location.
HANDRAILS AND STEPS

To prevent personal injury caused by slipping or falling off the machine, always do as follows.
● Use the handrails and steps marked by arrows in the dia-

gram on the right when getting on or off the machine.
● To ensure safety, always face the machine and maintain

three-point contact (both feet and one hand, or both hands
and one foot) with the handrails and steps to ensure that
you support yourself.
● Do not grip the control levers when getting on or off the

machine.
● Never climb on the engine hood or covers where there are

no non-slip pads.
● If there is any oil, grease, or mud on the handrails or steps,

wipe it off immediately. Always keep these parts clean.
Repair any damage and tighten any loose bolts.
● Do not get on or off the machine while holding tools in your

hand.
2-9
MOUNTING AND DISMOUNTING

● Never jump on or off the machine. Never get on or off a moving machine.
● If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try
to stop it.
DO NOT GET CAUGHT IN ARTICULATED PORTION

If the clearance at the articulated portion changes, it may lead
to serious personal injury.
Do not let anyone stand in the area of articulation.
PREVENTION OF BURNS
Hot coolant
● To prevent burns from hot water or steam spurting out
when checking or draining the coolant, wait for the water to
cool to a temperature where it is possible to touch the radi-
ator cap by hand before starting the operation. When
removing the radiator cap, lift the lever to relieve the inter-
nal pressure.
Hot oil
● To prevent burns when checking or draining the oil, wait for
the oil to cool to a temperature where it is possible to touch
the plug by hand before starting the operation. Even when
the oil has cooled down, loosen the plug slowly to relieve
the internal pressure before removing the plug.
2-10
FIRE PREVENTION
● Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particu-
larly flammable and can be hazardous. To prevent fire,
always observe the following:
● Do not smoke or use any flame near fuel or oil.
● Stop the engine before refueling.
● Do not leave the machine while adding fuel or oil.
● Tighten all fuel and oil caps securely.
● Do not spill fuel on overheated surfaces or on parts of

the electrical system.
● Use well-ventilated areas for adding or storing oil and

fuel.
● Keep oil and fuel in the determined place and do not

allow unauthorized persons to enter.
● After adding fuel or oil, wipe up any spilled fuel or oil.
● When carrying out grinding or welding work on the

chassis, move any flammable materials to a safe place
before starting.
● When washing parts with oil, use a non-flammable oil. Diesel oil and gasoline may catch fire, so do not
use them.
● Put greasy rags and other flammable materials into a safe container to maintain safety at the work place.
● Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
● Fire caused by accumulation of flammable material.

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

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

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

● When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, use explosion-proof lighting.
If you do not use explosion-proof lighting, there is a hazard of serious injury or damage caused by explo-
sion.
● When taking the electrical power for the lighting from the machine, follow the instructions in this manual.
2-11
ACTION IF FIRE OCCURS

If a fire occurs, escape from the machine as follows.
● Turn the starting switch OFF and stop the engine.
● Use the handrails and steps to get off the machine.
WINDOW WASHER LIQUID

Use an ethyl alchohol base washer liquid. Methyl alchohol base washer liquid may irritate your eyes, so do not use
it.
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)

Install ROPS when working in places where there is danger of
falling rocks, such as in mines and quarries, or in places where
there is danger of rolling over.
● If ROPS is installed, do not remove ROPS when operating

the machine.
● The ROPS is installed to protect the operator if the

machine should roll over. It is designed not only to support
the load if the machine should roll over, but also to absorb
the impact energy.
● If ROPS is modified, its strength may drop. Consult your

Komatsu distributor before carrying out any modification.
● If ROPS is damaged or deformed by falling objects or by

rolling over, its strength will be reduced and it will not be
able to fulfill its function properly. In such cases, always
contact your Komatsu distributor for advice of the method
of repair.
Even if ROPS is installed, always fasten your seat belt
properly when operating the machine. If you do not use
your fasten your seat belt properly, it cannot display its
effect.
PRECAUTIONS FOR ATTACHMENTS

● When installing optional parts or attachments, there may be problems with safety or legal restrictions, so con-
tact your Komatsu distributor for advice.
● Any injuries, accidents, or product failures resulting from the use of unauthorized attachments or parts will not
be the responsibility of Komatsu.
● When installing and using optional attachments, read the instruction manual for the attachment, and the gen-
eral information related to attachments in this manual.
2-12
UNAUTHORIZED MODIFICATION
Any modification made without authorization from Komatsu can create hazards.
Before making a modification, consult your Komatsu distributor.
● Komatsu will not be responsible for any injuries, accidents, or product failures resulting from modifications
made without authorization from Komatsu.
SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any
unusual conditions that could be dangerous.
● When carrying out operations near combustible materials

such as thatched roofs, dry leaves or dry grass, there is a
hazard of fire, so be careful when operating.
● Check the terrain and condition of the ground at the work-

site, and determine the safest method of operation. Do not
carry out operations at places where there is a hazard of
landslides or falling rocks.
● If water lines, gas lines, or high-voltage electrical lines may

be buried under the worksite, contact each utility and iden-
tify their locations. Be careful not to sever or damage any
of these lines.
● Take necessary measures to prevent any unauthorized person from entering the operating area.
● When traveling or operating in shallow water or on soft ground, check the shape and condition of the bedrock,
and the depth and speed of flow of the water before starting operations.
● Set and maintain the haul load on the jobsites so that the machine can always travel safely.
WORKING ON LOOSE GROUND

● Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or
after earthquakes is weak in these areas.
● When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of
the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is
safe and to prevent the machine from rolling over or falling.
2-13
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not travel or operate the machine near electric cables.
These is a hazard of electric shock, which may cause serious
injury or property damage. On jobsites where the machine may
go close to electric cables, always do as follows.
● Before starting work near electric cables, inform the local

power company of the work to be performed, and ask them
to take the necessary action.
● Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death.
Always maintain a safe distance (see the table on the right)
between the machine and the electric cable. Check with
the local power company about the voltage of the cables
before starting operations. Min. safety
Voltage
distance
● To prepare for any possible emergencies, wear rubber
shoes and gloves. Lay a rubber sheet on top of the seat, Low 100V•200V 2m
and be careful not to touch the chassis with any exposed voltage
part of your body. 6,600V 2m
22,000V 3m
● Use a signalman to give warning if the machine
approaches too close to the electric cables. 66,000V 4m
● When carrying out operations near high voltage cables, do Very high 154,000V 5m
not let anyone come close to the machine. voltage 187,000V 6m
● If the machine should come too close or touch the electric
275,000V 7m
cable, to prevent electric shock, the operator should not
leave the operator’s compartment until it has been con- 500,000V 11m
firmed that the electricity has been shut off.
Also, do not let anyone come close to the machine.
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. Always do as follows.
● Position a signalman if there are areas at the rear of the machine where the visibility is not good.
● When working in dark places, turn on the working lamp and front lamps installed to the machine, and set
up additional lighting in the work area if necessary.
● Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
2-14
VENTILATION FOR ENCLOSED AREAS

Exhaust fumes from the engine can kill.
● If it is necessary to start the engine within an enclosed

area, or when handling fuel, flushing oil, or paint, open the
doors and windows to ensure that adequate ventilation is
provided to prevent gas poisoning.
CHECKING SIGNALMAN’S SIGNALS AND SIGNS

● Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
● Only one signalman should give signals.
● Make sure that all workers understand the meaning of all signals and signs before starting work.
ASBESTOS DUST HAZARD PREVENTION

Asbestos dust in the air can cause lung cancer if it is inhaled.
There is danger of inhaling asbestos when working on jobsites
handling demolition work or work handling industrial waste.
Always observe the following.
● Spray water to keep down the dust when cleaning.
● Do not use compressed air for cleaning.
● If there is danger that there may be asbestos dust in the

air, always operate the machine from an upwind position.
● All workers should use an approved respirator.
● Do not allow other persons to approach during the operation.
● Always observe the rules and regulations for the work site and environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always
use genuine Komatsu parts.
2-15
PRECAUTIONS DURING OPERATION SAFETY
PRECAUTIONS DURING OPERATION
BEFORE STARTING ENGINE

If there is a warning tag hanging from gear shift lever, do not
start the engine or touch the levers.
CHECKS BEFORE STARTING ENGINE, ADJUST

Carry out the following checks before starting the engine at the beginning of the day’s work.
● Remove all dirt from the surface of the window glass to make it easy to see.
● Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and
check that they light up correctly.
● Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and
check for damage to the electric wiring.
● Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake
pedal, and check that the pedals work properly.
● Adjust the operator’s seat to a position where it is easy to carry out operations, and check that there is no
damage or wear to the seat belt or mounting clamps.
● Check that the gauges work properly, and check that the control levers are all at the neutral position.
● Before starting the engine, check that the safety lock lever is at the LOCK position.
● Adjust the mirrors so that the rear of the machine can be seen clearly from the operator’s seat.
● Check that there are no persons or obstacles above, below, or in the area around the machine.
2-16
SAFETY PRECAUTIONS DURING OPERATION
PRECAUTIONS WHEN STARTING

● When starting the engine, sound the horn as a warning.
● Start and operate the machine only while seated.
● Do not allow anyone apart from the operator to ride on the machine.
● Do not short circuit the starting motor circuit to start the engine. There is danger of fire.
● For machines equipped with a back-up alarm, check that the alarm works properly.
PRECAUTIONS IN COLD AREAS

● Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control
levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents.
● If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check for
frost and leakage of battery electrolyte before starting.
2-17
AFTER STARTING ENGINE
CHECKS AFTER STARTING ENGINE

When carrying out the checks, move the machine to a wide
area where there are no obstructions, and operate slowly. Do
not allow anyone near the machine.
● Always fasten your seat belt (if equipped).
● Check the actuating condition of the work equipment,

travel, and brake systems.
● Check for any abnormality in the sound of the machine,

vibration, heat, smell, or gauges; check also that there is
no leakage of oil or fuel.
● If any abnormality is found, carry out repairs immediately.
● When traveling and operating, check that articulate lock pin

(1) is removed and is set to the STOW position.
● When traveling on roads, check that articulate lock pin (1)

is at the LOCK position.
CHECK WHEN MOVING MACHINE

● Before traveling, check again that there is no one in the
surrounding area, and that there are no obstacles.
● Before traveling, sound the horn to warn people in the

area.
● Always operate the machine only when seated.
● Do not allow anyone apart from the operator to ride on the

machine.
● Check that the back-up alarm (alarm buzzer when machine

travels in reverse) works properly.
● Fix the operator’s compartment doors and windows in position securely.
● If there is any blind spot to the rear of the machine, position a signalman.
Always be sure to carry out the above precautions even when the machine is equipped with mirrors.
2-18
PRECAUTIONS WHEN TRAVELING

● Never turn the key in the starting switch to the OFF position. It is dangerous if the engine stops when the
machine is traveling, because the steering becomes heavy. If the engine stops, depress the brake pedal
immediately to stop the machine.
● When traveling on rough ground, to avoid turning over, travel at low speed, and avoid sudden changes in
direction. There is also danger of the work equipment touching the ground and making the machine lose its
balance, or of hitting other machines or structures in the surrounding area.
● Operate carefully when the wheels are leaning. It is prohib-

ited to travel on roads with the wheels leaning.
● Travel at a maximum speed of 10 km/h (6.2 MPH) when

using the articulation. If the articulation is used when travel-
ing at a speed of over 10 km/h (6.2 MPH), there is danger
that the machine may overturn. Never use the articulation
at speeds of over 10 km/h (6.2 MPH).
● Avoid traveling over obstacles as far as possible. If the machine has to travel over an obstacle, keep the work
equipment as close to the ground as possible and travel at low speed. The machine will also tend to turn over
to the left or right sides, so do not travel over obstacles that make the machine tilt excessively to one side.
● When traveling or carrying out operations, always keep your distance from other persons, machines, or struc-
tures to avoid coming into contact with them.
● When passing over bridges or structures, check first that the structure is strong enough to support the mass of
the machine.
● When operating in tunnels, inside buildings, under bridges, under electric wires, or other places where the
height is limited, operate slowly and be extremely careful not to let the machine or work equipment hit any-
thing.
● If you drive the machine at high speed continuously for a long time, the tires will overheat and the internal
pressure will become abnormally high. This may cause the tires to burst. If a tire bursts, it produces an
extremely large destructive force, and this may cause serious injury or accident.
If you are going to travel continuously, please consult your Komatsu distributor.
2-19
PRECAUTIONS WHEN TRAVELING ON SLOPES

To prevent the machine for tipping over or slipping to the side,
always do as follows.
● Always travel straight up or down a slope. Traveling at an

angle or across the slope is extremely dangerous.
● Do not turn on slopes or travel across slopes. Always go

down to a flat place to change the position of the machine,
then travel on to the slope again.
● Travel on grass, fallen leaves, or wet steel plates with low

speed. Even with slight slopes there is a hazard that the
machine may slip.
● If the engine stops, depress the brake pedal immediately, lower the blade to the ground, and apply the parking
brake to stop the machine.
● When traveling downhill, never shift gear or place the transmission at neutral. It is dangerous not to use the
braking force of the engine. Always place the transmission in a low gear before starting to travel downhill.
● When traveling downhill, travel slowly. If necessary, use the braking force of the engine together with the brake
pedal to control the travel speed.
PROHIBITED OPERATIONS
When using the machine, do not exceed the stability determined from the structure of the machine, maximum
using load and other performance values to prevent the tipping of the machine and breakage of the work equip-
ment caused by an overload.
PRECAUTIONS WHEN OPERATING

● Ordinary cars may travel on the ground that has been leveled by the grader, so always pay attention to the
rear when carrying out operations.
● Be careful when carrying out side cutting or operating with a load on one end of the blade. This may cause the
end of the machine to sway.
● When operating in tunnels, under bridges, under electric wires, or other places where the height is limited, be
extremely careful not to let the work equipment hit anything.
● To prevent accidents caused by hitting other objects, always operate the machine at a speed which is safe for
operation, particularly in confined spaces, indoors, and in places where there are other machines.
● When operating the blade, be careful not to let the blade

contact the tire.
2-20
METHODS OF USING BRAKE

● Do not rest your foot on the brake pedal if you are not using the brake. If you travel with your foot on the pedal,
the brake will always be applied. This will cause abnormal heating of the brake and the brake will not work.
● Do not depress the brake pedal repeatedly if not necessary.

If the brake overheats, the brake may have no braking effect when it is needed.
● When traveling downhill, use the braking force of the engine.

If necessary, use the brake pedal at the same time.
OPERATE CAREFULLY ON SNOW

● Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the
machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be
particularly careful when working on slopes.
● With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
● If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be care-
ful not to leave the road shoulder or to get trapped in a snow drift.
● When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot
be seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out opera-
tions carefully.
● When traveling on snow-covered roads, always fit tire chains.
● When traveling on snow-covered slopes, never apply the brakes suddenly. Reduce the speed and use the
engine as a brake while applying the foot brake intermittently (depress the brake intermittently several times).
If necessary, lower the blade to the ground to stop the machine.
2-21
PARKING MACHINE
● Park the machine on firm, level ground.
● Select a place where there is no hazard of falling rocks or

landslides, or of flooding if the land is low.
● Lower the work equipment completely to the ground.
● When leaving the machine, set gear shift lever to the N

(neutral) position and safety lock lever to the LOCK posi-
tion and parking brake to the LOCK position, and stop the
engine.
● Always close the door of the operator’s cab, lock all the equipment to prevent any unauthorized person from
moving the machine, then remove the key and leave it in the specified location.
● When parking on public roads, provide signs, fences, and lights to ensure that passing traffic can see the
machine clearly even at night, and park the machine so that the machine, signs, fences, and lights do not
obstruct traffic or passers-by.
● If it is necessary to park the machine on a slope, set blocks

under the wheels to prevent the machine from moving.
2-22
TRANSPORTATION
LOADING AND UNLOADING

When loading or unloading the machine, mistaken operation
may bring the hazard of the machine tipping over or falling, so
particular care is necessary. Always do as follows.
● Perform loading and unloading on firm, level ground only.

Maintain a safe distance from the edge of the road or cliff.
● Always use ramps of adequate strength. Be sure that the

ramps are wide, long, and thick enough to provide a safe
loading slope. Take suitable steps to prevent the ramps
from moving out of position or coming off.
● Be sure the ramp surface is clean and free of grease, oil,

ice and loose materials. Remove dirt from machine-tires.
On a rainy day, in particular, take extremely careful since
the ramp surface is slippery.
● Run the engine at low idling and operate slowly at low speed.
● Never correct your steering on the ramps. There is danger that the machine may turn over. If necessary, drive
off the ramps, correct the direction, then enter the ramps again.
● When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and
grade.
● For machines equipped with a cab, always lock the door after loading the machine. If this is not done, the door
may suddenly open during transportation.
See "TRANSPORTATION (PAGE 3-92)".
SHIPPING
When shipping the machine on a trailer, do as follows.
● When passing over bridges or structures on private land, check first that the structure is strong enough to sup-
port the weight of the machine.
● Lock the frame with the articulate lock pin to prevent the machine from articulating.
● For details of the shipping procedure, see "TRANSPORTATION (PAGE 3-92)" in the OPERATION section.
2-23
BATTERY
BATTERY HAZARD PREVENTION

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

the area with large amounts of water.
● If acid gets into your eyes, flush them immediately with

large quantities of water and seek medical attention.
● Before working with batteries, turn the starting switch to the

OFF position.
As there is a hazard that sparks will be generated, always do as follows.
● Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or
other metal objects lying around near the battery.
● Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals
securely.
● Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis,
take it to a well-ventilated place, and remove the battery caps before charging it.
● Tighten the battery caps securely.
● Install the battery securely to the determined place.
2-24
STARTING WITH BOOSTER CABLES

If any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.
● When starting with a booster cable, carry out the starting

operation with two workers (one worker sitting in the opera-
tor’s seat and the other working with the battery).
● When starting from another machine, do not allow the two

machines to touch.
● When connecting the booster cables, turn the starting

switch OFF for both the normal machine and problem
machine. There is a hazard that the machine will move
when the power is connected.
● Be sure to connect the positive (+) cable first when install-

ing the booster cables. Disconnect the ground or negative
(-) cable (ground side) first when removing them.
● When removing the booster cables, be careful not to let the

booster cable clips touch each other or to let the clips touch
the machine.
● Always wear safety goggles and rubber gloves when start-

ing the engine with booster cables.
● When connecting a normal machine to a problem machine with booster cables, always use a normal machine
with the same battery voltage as the problem machine.
● For details of the starting procedure when using booster cables, see "STARTING ENGINE WITH BOOSTER
CABLE (PAGE 3-103)" in the OPERATION section.
2-25
TOWING
WHEN TOWING
Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selec-
tion or inspection of the wire rope.
When towing, always use the method given in "TOWING THE MACHINE (PAGE 3-99)" in the OPERATION sec-
tion.
● Always wear leather gloves when handling wire rope.
● During the towing operation, never stand between the tow-

ing machine and the machine being towed.
● Never tow a machine on a slope.
● Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is a hazard that the rope
may break during the towing operation.
2-26
SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR MAINTENANCE
BEFORE CARRYING OUT 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.
Attach additional warning tags around the machine if nec-
essary.
Warning tag Part No.09963-03000
Keep this warning tag in the tool box while it is not used. If
there is no tool box, keep the tag in the operation manual
pocket.
● If others start the engine, or touch or operate the work

equipment control lever while you are performing service
or maintenance, you could suffer serious injury.
KEEP WORK PLACE CLEAN AND TIDY

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

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.
When working with others, misunderstandings between workers can lead to serious accidents.
2-27
PRECAUTIONS FOR MAINTENANCE SAFETY
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

● Stop the machine on firm, level ground.
● Select a place where there is no hazard of falling rocks,

landslides, or flooding.
● Lower the work equipment to the ground and stop the

engine.
● After stopping the engine, operate blade lift cylinder control

lever 2 - 3 times fully to the RAISE and LOWER positions
to release the pressure inside the hydraulic circuit, then set
safety lock lever to the LOCK position.
● Turn parking brake lever to the LOCK position and apply

the parking brake, then put blocks under the front and rear
of the tires.
● Lock the front and rear frames with articulate lock pin (1).
2-28
DURING MAINTENANCE
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with
the engine running, carry out the operation with at least two workers and do as follows.
● One worker must always sit in the operator’s seat and be ready to stop the engine at any time. All workers
must maintain contact with the other workers.
● When carrying out operations near the fan, fan belt, or

other rotating parts, there is a hazard of being caught in the
parts, so be extremely careful.
● Never drop or insert tools or other objects into the fan or

fan belt. Parts may break or be sent flying.
● Set safety lock lever to the LOCK position.

Turn parking brake lever to the LOCK position and apply
the parking brake.
● Do not touch any control levers. If any control lever must

be operated, always give a signal to the other workers to
warn them to move to a safe place.
2-29
PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.
WORK UNDER THE MACHINE

When carrying out inspection and maintenance with the work
equipment raised, or if it is necessary to go under the machine,
use strong supports that can fully withstand the weight of the
machine or work equipment, and be sure to fix the stands in
position securely.
ACCUMULATOR
The accumulator is charged with high-pressure nitrogen gas.
When handling the accumulator, careless procedure may
cause an explosion which could lead to serious injury or prop-
erty damage. For this reason, always observe the following
precautions.
● Do not disassemble the accumulator.
● Do not bring it near flame or dispose of it in fire.
● Do not make holes in it, weld it, or use a cutting torch.
● Do not hit or roll the accumulator, or subject it to any

impact.
● When disposing of the accumulator, the gas must be released. Please contact your Komatsu distributor to
have this work performed.
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
2-30
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 thay do not fall. And
take steps to prevent unauthorized presons from entering
the storage area.
NOISE
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems. When carrying
out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs
while working.
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 fol-
lows.
● If hard metal parts such as pins or bearings are hit with a

hammer, there is danger that pieces might be scattered
and cause serious injury. Always wear safety goggles,
gloves and other protective equipment.
REPAIR WELDING
Welding operations must always be carried out by a qualified welder and in a place equipped with a proper equip-
ment. There is a hazard of fire or electrocution when carrying out welding, so never allow any unqualified person-
nel 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.
2-31
PRECAUTIONS WITH HIGH-PRESSURE OIL

The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always
check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to
serious injury, so always do as follows.
● 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 2-28)".
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 con-
tacts your eyes directly. If you are hit by a jet of high-pres-
sure oil and suffer injury to your skin or eyes, wash the
place with clean water, and consult a doctor immediately
for medical attention.
HANDLING HIGH-PRESSURE HOSES

● If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious
injury or fire. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses
are found, stop operations immediately and contact your Komatsu distributor.
Replace the hose if any of the following problems are found.
● Damaged or leaking hydraulic fitting.
● Frayed or cut covering or exposed reinforcement wire layer.
● Covering swollen in places.
● Twisted or crushed movable portion.
● Foreign material embedded in covering.
WASTE MATERIALS
To prevent pollution, pay careful attention to the method of dis-
posing 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.
2-32
MAINTENANCE OF AIR CONDITIONER

If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frost-
bite.
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 goggles, dust mask, gloves,
and other protective equipment.
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS

● In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service
and maintenance at periodic intervals. In order to further increase safety, components with a strong relation-
ship 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 4-13)".
● 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 property
damage. It is difficult to judge the remaining life of these components from external inspection or the feeling
when operating, so always replace them at the specified interval.
● Replace or repair safety critical parts if any defect is found, even when they have not reached the time speci-
fied.
2-33
PRECAUTIONS WITH TIRES SAFETY
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 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 tech-
nology, 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 "HANDLING THE
TIRES (PAGE 3-91)".
● 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, so they
may cause serious personal injury.
● As a basic rule, store the tires in a warehouse which unau-

thorized 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.
2-34
OPERATION
31
WARNING
Please read and make sure that you understand the SAFETY
section before reading this section.
3-1
GENERAL VIEW OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
(1) Front combination lamp (if equipped) (7) Backup lamp (if equipped)
(2) Blade lift cylinder (8) Rear wheel
(3) Cab (if equipped) (9) Articulate cylinder
(4) ROPS (if equipped) (10) Blade
(5) Side panel (if equipped) (11) Front wheel
(6) Rear combination lamp (if equipped)
3-2
OPERATION GENERAL VIEW
GENERAL VIEW OF CONTROLS AND GAUGES
(1) Inching pedal (10) Gearshift lever

(2) Steering wheel (11) Cigarette lighter (if equipped)
(3) Horn button (12) Fuel control lever
(4) Work equipment control lever (13) Safety lock lever
(5) Dimmer switch (14) D.D.V. lever (if equipped)
(6) Meter panel (15) Parking brake lever
(7) Steering wheel tilt lever (16) Brake pedal
(8) Turn signal lever (17) Steering post tilt pedal
(9) Accelerator pedal
3-3
GENERAL VIEW OPERATION
MAIN PANEL RIGHT PANEL

(1) Service meter (10) Air pressure gauge
(2) Engine oil pressure gauge (11) Front wiper switch (if equipped)
(3) Engine water temperature gauge (12) Car heater switch (if equipped)
(4) Fuel gauge (13) Rear wiper switch (if equipped)
(5) Speedometer (14) Accumulator switch (if equipped)
(6) Engine oil temperature warning pilot lamp (15) Rear working lamp switch (if equipped)
(7) Parking brake pilot lamp (16) Bank switch
(8) Head lamp beam pilot lamp (17) Caution lamp switch (if equipped)
(9) Charge level warning pilot lamp (18) Fog lamp switch (if equipped)
(19) Front working lamp switch (if equipped)
(20) Heater signal
(21) Head lamp switch
(22) Starting switch
(23) Hazard lamp switch (if equipped)
3-4
OPERATION EXPLANATION OF COMPONENTS
EXPLANATION OF COMPONENTS
This section explains about the devices needed to operate the machine.
To ensure that you can carry out operations correctly, safely, and in comfort, it is important that you read and
understand thoroughly the operating method and contents of displays for these devices.
METERS AND LAMPS
MAIN PANEL
(1) Engine oil pressure gauge (6) Parking brake pilot lamp
(2) Engine water temperature gauge (7) Head lamp beam pilot lamp
(3) Fuel gauge (8) Charge level warning pilot lamp
(4) Speedometer (9) Service meter
(5) Engine oil temperature warning pilot lamp
3-5
EXPLANATION OF COMPONENTS OPERATION
ENGINE OIL PRESSURE GAUGE

This meter (1) displays the engine lubricating oil pressure.
During normal operations, the gauge should be in the green

range. If the gauge goes into the red range during operations,
stop the machine, run the engine at a mid-range speed under
no load, and wait for the temperature to go down to the green
range.
After starting the engine, carry out the warming-up operation

until the indicator enters the green range.
ENGINE WATER TEMPERATURE GAUGE

This meter (2) displays the engine cooling water temperature.
During normal operation, the gauge should be in the green

range.
If the gauge goes into the red range during operation, stop the
machine, run the engine at a mid-range speed under no load,
and wait for the temperature to go down to the green range.
After starting the engine, carry out the warming-up operation
until the indicator enters the green range.
FUEL GAUGE
This gauge (3) shows the fuel level in the fuel tank.
E shows that the fuel level is low.
F shows that the tank is full.
SPEEDOMETER
This meter (4) displays the travel speed of the machine.
There is an odometer at the bottom of the meter.
ENGINE OIL TEMPERATURE WARNING PILOT LAMP

This lamp (5) lights up to warn the operator of an abnormality in
the engine oil temperature.
If the condition is normal, the lamp remains OFF.
If it lights up, stop the machine, and run the engine at a mid-
range speed to carry out the warming-up operation.
3-6
PARKING BRAKE PILOT LAMP

This lamp (6) lights up to indicate that the parking brake is
applied.
Applied: lights up
HEAD LAMP BEAM PILOT LAMP

This lamp (7) lights up to indicate that the head lamps are at
BEAM.
BATTERY CHARGE WARNING PILOT LAMP

This lamp (8) flashes when the engine is running to inform the
operator that there is an abnormality in the charging circuit.
If it lights up, inspect the charging circuit.
Stop the engine and check for looseness of the V-belt. If any
abnormality is found, see "OTHER TROUBLE (PAGE 3-105)".
REMARK
The monitor may flash and the central warning lamp may also
flash when the engine is running or when it is started. If the
lamp goes out when the engine is briefly accelerated, it does
not indicate any abnormality.
SERVICE METER
This meter (9) displays the accumulated hours of operation of
the machine.
The service meter reading advances by 1 for every hour that

the engine is running, regardless of the engine speed.
The service meter will advance while the engine is running,

even if the machine is not moving.
REMARK
When the engine is running, the operation display at the top of
the meter rotates to indicate that the meter is advancing.
3-7
RIGHT PANEL
(1) Air pressure gauge (2) Heater signal
AIR PRESSURE GAUGE

NOTICE
If the alarm buzzer sounds frequently, the piping connec-
tion may be loose, so investigate the cause.
This meter (1) indicates the air pressure inside the air tank.
During normal operations, it should be in the green range.
If it goes down to the red range during operations, the alarm

buzzer will sound.
If the indicator goes down to the red range, stop the machine, raise the engine speed, and wait for the indicator to
return to the green range.
HEATER SIGNAL
When the heater switch is turned ON and the starting switch is
turned to the HEAT position, this lamp (2) glows red after
approx. 30 seconds to indicate that the electrical intake air
heater is red hot.
The preheating time differs according to the ambient tempera-

ture, so follow the instructions in the section dealing with opera-
tions in cold weather.
3-8
SWITCHES
(1) Horn button (9) Fog lamp switch (if equipped)

(2) Dimmer switch (10) Rear working lamp switch (if equipped)
(3) Cigarette lighter (if equipped) (11) Bank switch
(4) Front wiper switch (if equipped) (12) Caution lamp switch (if equipped)
(5) Car heater switch (if equipped) (13) Head lamp switch
(6) Rear wiper switch (if equipped) (14) Starting switch
(7) Accumulator switch (if equipped) (15) Hazard lamp switch (if equipped)
(8) Front working lamp switch (if equipped)
HORN BUTTON
When horn button (1) in the center of the steering wheel is
pressed, the horn will sound.
DIMMER SWITCH
This switch (2) is used to switch the head lamps between high
beam and low beam.
(a) Low beam

(b) High beam
3-9
CIGARETTE LIGHTER (if equipped)

This cigarette lighter (3) 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 ciga-
rette.
FRONT WIPER SWITCH (if equipped)

This switch (4) is used to operate the front wiper.
Position (a): OFF

Position (b): Wiper moves intermittently
Position (c): Wiper moves continuously
Turn clockwise: Window washer switch is actuated and washer

fluid is sprayed out.
CAR HEATER SWITCH (if equipped)

This switch (5) is used to warm the inside of the operator's cab.
The switch can be used to adjust the air flow to three stages.
Position (a): OFF

Position (b): High
Position (c): Medium
Position (d): Low
REMARK
This system uses the hot water from the engine to carry out
warming, so use it when the engine coolant is heated up.
REAR WIPER SWITCH (if equipped)

This switch (6) is used to operate the rear wiper.
Position (a): OFF

Position (b): Wiper is actuated
3-10
ACCUMULATOR SWITCH (if equipped)

The pressure from the accumulator is sent to the blade lift cyl-
inder to maintain the pushing force of the blade. This switch (7)
is used to open and close the pressure of the accumulator.
FRONT WORKING LAMP SWITCH (if equipped)

This switch (8) lights up the front working lamp.
Press the switch once to light up the lamps; press it again to

turn the lamp off.
FOG LAMP SWITCH (if equipped)

This switch (9) turns on the fog lamp.
Press the switch once to light up the lamp; press it again to turn
the lamp off.
REAR WORKING LAMP SWITCH (if equipped)

This switch (10) lights up the rear working lamp.
Press the switch once to light up the lamp; press it again to turn
the lamp off.
3-11
BANK SWITCH
WARNING
Lower the blade completely to the ground before remov-
ing the pin.
This switch (11) is used when setting the blade to the bank- cut
position.
(a) LOCK: The pin is locked.

(b) INDEX: Set to this position when aligning the position
before securing the pin.
(c) RETRACT: The pin securing the frame and blade raise cyl-
inder mount is removed.
CAUTION LAMP SWITCH (if equipped)

This switch (12) is used to light up and rotate the yellow rotat-
ing lamp installed to the cab.
HEAD LAMP SWITCH

This switch (13) is used to light up the head lamp, side clear-
ance lamp, tail lamp, and panel lighting.
Position (a): OFF

Position (b): Clearance lamp, tail lamp, panel lamp light up
Position (c): Head lamp lights up in addition to lamps in (b).
3-12
STARTING SWITCH
This switch (14) is used to start or stop the engine.
OFF
The starting key can be inserted and removed at this position.
When the key is turned to this position, the electric circuit is
turned off and the engine stops.
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
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 monitor flashes and then goes out, release the key immediately.
If the key is released it will return to the OFF position, so turn it
immediately to the START position to start the engine.
HAZARD LAMP SWITCH (if equipped)
WARNING
Never use the hazard lamp except in emergencies. If it is
used while traveling when there is no abnormality, it may
cause misunderstanding for drivers of other vehicles.
Use this switch (15) in emergencies, such as when the

machine has to be stopped on the road because of a failure.
When the switch is pressed, all the turn signal indicator lamps
start to flash. Press again to cancel.
3-13
CONTROL LEVERS, PEDALS
(1) Left blade lift cylinder control lever (11) Accelerator pedal
(2) Drawbar side shift control lever (12) Gearshift lever
(3) Blade rotation control lever (13) Fuel control lever
(4) Articulate control lever (14) Safety lock lever (for gearshift lever)
(5) Steering wheel tilt lever (15) D.D.V. lever (if equipped)
(6) Power tilt control lever (if equipped) (16) Parking brake lever
(7) Blade side shift control lever (17) Brake pedal
(8) Leaning control lever (18) Steering post tilt pedal
(9) Right blade lift cylinder control lever (19) Inching pedal
(10) Turn signal lever (if equipped)
3-14
LEFT BLADE LIFT CYLINDER CONTROL LEVER

This lever (1) operates the left blade lift cylinder.
(a) LOWER : The left side of the blade goes down.

(b) HOLD : The blade stops and is held in the same position.
(c) RAISE : The left side of the blade goes up.
DRAWBAR SIDE SHIFT CONTROL LEVER

This lever (2) shifts the drawbar to the side.
(a) LEFT SHIFT : The drawbar is shifted to the left.

(b) HOLD : The drawbar stops and is held in the same
position.
(c) RIGHT SHIFT: The drawbar is shifted to the right.
3-15
BLADE ROTATION CONTROL LEVER

NOTICE
To prevent damage to the tires, be careful not to let the
blade hit the tires when rotating the blade.
This lever (3) rotates the blade.
(a) RIGHT ROTATION: The blade is rotated to the left.

(b) HOLD : The blade stops and is held in the
same position.
(c) LEFT ROTATION : The blade is rotated to the right.
ARTICULATE CONTROL LEVER
WARNING
Operate this lever only when traveling at a speed of below
10 km/h (6.2 MPH). If the articulation is operated at a
speed of over 10 km/h (6.2 MPH), there is danger that the
machine may overturn.
NOTICE
To prevent damage to the tires, be careful not to let the
blade hit the tires when articulating the machine.
This lever (4) is used to operate the articulation.
(a) RIGHT TURN:

(b) HOLD : The articulation is kept in the same condi-
tion.
(c) LEFT TURN :
STEERING WHEEL TILT LEVER

This lever (5) can be used to adjust the angle of the steering
wheel and instrument panel steplessly up to 7º to the front and
rear.
3-16
POWER TILT CONTROL LEVER (if equipped)

This lever (6) changes the cutting angle of the blade.
(a) Max. cutting angle : This makes the blade cutting angle
bigger.
This is effective when operating on
hard ground.
(b) HOLD : The blade stops and is held in the
same position.
(c) Min. cutting angle : This makes the blade cutting angle
smaller.
This is effective when operating on
soft ground.
REMARK
The distance between the cutting surface and the blade edge
can be changed, so it is possible to carry out fine adjustment of
the height of the cutting surface.
BLADE SIDE SHIFT CONTROL LEVER

This lever (7) shifts the blade to the side.
(a) LEFT SHIFT : The blade is shifted to the left position.

(b) HOLD : The blade stops and is held in the same
position.
(c) RIGHT SHIFT: The blade is shifted to the right.
3-17
LEANING CONTROL LEVER

This lever (8) is used to operate the leaning.
(a) LEFT TURN:

(b) HOLD: The leaning is kept in the same condition.
(c) RIGHT TURN:
RIGHT BLADE LIFT CYLINDER CONTROL LEVER

This lever (9) operates the right blade lift cylinder.
(a) LOWER: The right side of the blade goes down.

(b) HOLD: The blade stops and is held in the same position.
(c) RAISE: The right side of the blade goes up.
TURN SIGNAL LEVER (if equipped)

This lever (10) 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 steer-
ing lever is returned to the straight position. Return the lever by
hand.
3-18
ACCELERATOR PEDAL
This pedal (11) adjusts the engine speed.
It is interconnected with the fuel control lever, and it can be

used freely to operate from the position set by the fuel control
lever to the full speed position.
GEARSHIFT LEVER
This lever (12) is used to shift the transmission speed range.
There are 8 speeds in FORWARD and REVERSE, and the

gear can be shifted simply by moving the gearshift lever to the
desired position.
REMARK
When starting the engine, if the gearshift lever is not at the N
position, the engine will not start.
FUEL CONTROL LEVER

This lever (13) is used to adjust the engine speed and output.
(a) Low idling: Lever pushed fully forward

(b) High idling: Lever pulled fully back
REMARK
Use the fuel control lever only during operations. For general
travel, use the accelerator pedal.
SAFETY LOCK LEVER (FOR GEARSHIFT LEVER)
WARNING
● When leaving the operator's seat, always be sure to
lock the shift lock lever securely.
If it is not locked, and anyone touches the gearshift
lever by mistake, it may lead to a serious accident.
● If the shift lock lever is not placed securely in the

LOCK position, the shift lever may not be locked.
This lever (14) locks the gearshift lever.
Set the gearshift lever to N, and push the lever down to set it to the LOCK position.
3-19
D.D.V. LEVER
(if equipped)
CAUTION
Except when starting the engine, do not place the D.D.V. lever in the NO LOAD position. It creates danger
because the work equipment cannot be operated.
This lever (15) is used to control the flow from the hydraulic
pump.
(a) Constant speed position:

The work equipment can be operated at a constant speed,
regardless of the engine speed.
(b) Engine speed proportional position:

The work equipment speed changes in proportion to the
engine speed.
(c) NO LOAD position:

Use this position when starting the engine in cold weather.
The circuits are unloaded, so it becomes impossible to
operate the work equipment.
PARKING BRAKE SWITCH
WARNING
When parking the machine or when leaving the machine, always apply the parking brake.
This lever (16) is used to apply the parking brake.
Pull the lever fully to apply the parking brake.
BRAKE PEDAL
WARNING
Do not put your foot on this pedal unless necessary.
This pedal (17) is used to apply the wheel brakes.
3-20
STEERING POST TILT PEDAL

This pedal (18) can be used to set the steering post to five
positions.
Press down the tilt pedal, set the steering post to the desired
position, then releases the pedal.
REMARK
The steering wheel, instrument panel, and work equipment
control levers also move forward or backward at the same time.
INCHING PEDAL
NOTICE
Do not use this pedal continuously for more than 10 sec-
onds.
This pedal (19) disconnects and connects the power from the
engine. Use this pedal when stopping or starting the machine,
or when switching between FORWARD and REVERSE.
When the pedal is depressed, the power is cut.
In 1st, 2nd, and 3rd speeds, the pedal can be used to make
fine control of the machine possible.
3-21
DUST INDICATOR
This device indicates clogging of the air cleaner element. When
red piston (1) appears in the transparent part of this indicator,
the element is clogged. Immediately clean the element.
After cleaning, push indicator button (2) to return the red piston
to the original position.
ARTICULATE LOCK PIN
WARNING
● When servicing or transporting the machine always
use this lock pin.
● For normal travel, always use the lock pin.
This pin is used to lock the front frame and rear frame to pre-
vent the machine from bending during normal travel or when
servicing or transporting the machine.
FUSE BOX
WARNING
If the fuse blows again immediately after it is replaced,
please contact your Komatsu distributor.
NOTICE
Before replacing a fuse, be sure to turn off the starting
switch.
The fuses protect the electrical equipment and wiring from

burning out.
If the fuse becomes corroded, or white powder can be seen, or

the fuse is loose in the fuse holder, replace the fuse.
Remove the cover, and replace the fuse.
Replace a fuse with another of the same capacity.
3-22
FUSE CAPACITY AND NAME OF CIRCUIT

Fuse I
No. Capacity Name of circuit
(1) 30A Spare

(2) 20A Spare
Diffused light type rotating lamp or cau-
(3) 30A
tion lamp
(4) 20A Spare
(5) 15A Spare
(6) 15A Spare
(7) 10A Car heater
(8) 10A Spare
(9) 20A Spare
(10) 30A Spare
(11) 20A Spare
(12) 10A Cigarette lighter
(13) 20A Air conditioner
Fuse II
No. Capacity Name of circuit

Head lamp, gauge lighting, clearance
(1) 20A
lamp
(2) 15A Rear working lamp, cab work lamp
(3) 10A Front working lamp
(4) 15A Spare
(5) 10A Horn, turn signal, hazard
(6) 10A Accumulator, differential indicator
(7) 10A Stop lamp, parking brake
(8) 10A Spare
(9) 10A Air dryer, bank
(10) 20A Spare
(11) 20A Spare
(12) 20A Top front wiper, rear wiper, room lamp
(13) 10A Buzzer, air gauge, fog lamp
(14) 10A Backup lamp
(15) 20A Starting switch, engine stop motor, radio
3-23
OPERATION OPERATION
OPERATION
CHECK BEFORE STARTING ENGINE
WALK-AROUND CHECK
Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leak-
age of oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Check also for loose wiring, play, and collection of dust at places which reach high temperatures.
WARNING
Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as the
engine muffler or turbocharger may cause fire. Check carefully, and if any abnormality is found, always
repair it or contact your Komatsu distributor.
Carry out the checks in this section before starting the engine each day.
1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses
Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If
any abnormality is found, repair it.
2. Remove dirt and dust from around engine, battery, radiator

Check if there is any dirt or dust accumulated around the engine or radiator. Check also if there is any flamma-
ble material (dead leaves, twigs, grass, etc.) accumulated around the battery or high temperature engine
parts, such as the engine muffler or turbocharger. Remove all such dirt or flammable material.
3. Check for leakage of water or oil around engine

Check that there is no leakage of oil from the engine or leakage of water from the cooling system. If any abnor-
mality is found, repair it.
4. Check for oil leakage of oil from transmission case, final drive case, tandem drive case, hydraulic tank,
circle reverse gear case, hose, joints.
Check that there is no oil leakage. If any abnormality is found, repair the place where the oil is leaking.
5. Check for leakage of air from brake line

Check that there is no leakage of air. If any abnormality is found, repair the place where the air is leaking.
6. Check for damage, wear to tires, wheels, check for loose mounting bolts
Check that there is no peeling of the tires or cracking of the wheels (side ring, rim base, lock ring). Tighten any
loose wheel nuts. If any abnormality is found, repair or replace.
If the valve cap is lost, install a substitute part.
7. Check for damage to handrail, steps, loose bolts

Repair any damage and tighten any loose bolts.
8. Check for damage to gauges, instrument panel, loose bolts

Check that there is no damage to the panel, gauges in the operator’s compartment. If any abnormality is found
replace the parts. Clean off any dirt on the surface. Tighten any loose bolts.
3-24
OPERATION OPERATION
9. Check for damaged mirror, reflector, loose mounting bolts

Check that there is no damage to the mirror or reflectors, and replace if there is any abnormality. Tighten any
loose bolts.
Clean all dirt from the surface of the mirror and reflector.
10. Check seat belt and mount

Check that there is no abnormality in the seat belt and mount. If any damage is found, replace with a new
part.
11. Is door lock normal? (machine equipped with cab)

Check that there is no damage to the cab door lock. Repair or replace if any abnormality is found.
12. Clean cab window (machine equipped with cab)

To ensure a good view during operations, always keep the cab windows clean.
13. Inspection of tires
WARNING
If worn or damaged tires are used, they may burst and
cause serious injury or death.
To ensure safety, do not use the following tires.
Wear:
● Tires with a tread groove of less than 15% of that of a

new tire
● Tires with extreme uneven wear or with stepped-type

wear
Damage:
● Tires with damage which has reached the cords, 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, deformed or abnormally damaged tires

which do not seem usable
14. Inspection of rims
WARNING
Check the rims (wheels) and rings for deformation, corrosion and cracks.
In particular, check the side rings, lock rings and rim flanges thoroughly.
3-25
OPERATION OPERATION
CHECK BEFORE STARTING

Carry out the items in this section before starting the engine each day.
CHECK COOLANT LEVEL, ADD WATER
WARNING
Do not remove the cap while cooling water is hot. Hot
water may spout out.
When removing the radiator cap, lift the lever to relieve
the internal pressure.
1. Remove radiator cap (1) at the rear of the machine and

check that the coolant is above the hatched portion
marked in the diagram on the right. If the coolant level is
low, add more water.
2. After adding water, tighten the cap securely.
NOTICE
If the volume of coolant added is more than usual, check
for possible water leakage.
Confirm that there is no oil in the coolant.
3-26
OPERATION OPERATION
CHECK FUEL LEVEL, ADD FUEL
WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If you spill any fuel, thoroughly clean
up all the spillage.
NOTICE
If breather hole (1) in the cap becomes clogged, the pres-
sure inside the tank will go down and the fuel may not
flow, so clean the breather hole from time to time.
1. Turn the engine starting switch to the ON position and

check the fuel level with fuel level gauge (G).
After checking, turn the switch back to the OFF position.
2. After completing work, fill the fuel tank through fuel filler
port (F).
3. After adding fuel, tighten the cap securely.

Fuel capacity:400 liters (105.6 US gal)
DRAIN WATER, SEDIMENT FROM FUEL TANK

Loosen fuel tank drain valve (1) and drain the sediment and
water, accumulated at the bottom, together with fuel.
3-27
OPERATION OPERATION
DRAIN WATER FROM AIR TANK

Stop the engine, open 2 drain valves (1), and drain the water.
Do this after completion of the day's work.
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
WARNING
The parts and oil are at high temperature after the engine
is stopped, and may cause serious burns. Wait for the
temperature to go down before starting the operation.
1. Open the cover at the rear of the machine.
2. Remove dipstick (G) and wipe the oil off with a cloth.
3. Insert dipstick (G) fully in the oil filler pipe, then take it out
again.
4. The oil level should be between the H and L marks on

dipstick (G).
If the oil level is below the L mark, add engine oil through
oil filler (F).
5. If the oil is above the H mark, drain the excess engine oil
from drain plug (P), and check the oil level again.
6. If the oil level is correct, tighten the oil filler cap securely
and close the engine side cover.
REMARK
When checking the oil level after the engine has been oper-
ated, wait for at least 15 minutes after stopping the engine
before checking. If the machine is at an angle, make it horizon-
tal before checking.
When adding oil, remove the dipstick from the guide to release
the air inside the crankcase.
3-28
OPERATION OPERATION
CHECK DUST INDICATOR

1. Check that the red piston has not appeared in the trans-
parent portion of dust indicator (1).
2. If the red piston has appeared, clean or replace the ele-

ment immediately.
For details of the method of cleaning the element, see

"CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
(PAGE 4-21)".
3. After checking, cleaning, and replacing, press the knob of

dust indicator (1) to return the red piston to its original
position.
CHECK AND ADJUST STEERING WHEEL

Start the engine and check the steering wheel play.
Standard: 10 - 12 mm (0.4 - 0.5 in) maximum
If the steering wheel play is out of the standard range or the

steering wheel waves normally or is abnormally heavy, ask
your Komatsu distributor for repairs.
3-29
OPERATION OPERATION
CHECK ELECTRIC WIRING
WARNING
● If fuses are frequently blown or if there are traces of short circuit on the electrical wiring, locate the
cause and carry out repair.
● Accumulation of flammable material (dead leaves, twigs, grass, etc.) around the battery may cause
fires, so always, check and remove such material.
● Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is
clogged with dirt or dust, wash the battery cap to clear the breather hole.
Check for damage and wrong capacity of the fuse and any sign of disconnection or short circuit in the electric wir-
ing. Check also for loose terminals and tighten and loose parts.
Check the wiring of the "battery", "starting motor" and "alternator" carefully, in particular.
When carrying out walk-around checks or checks before starting, always check if there is any accumulation of
flammable material around the battery, and remove such flammable material.
Please contact your Komatsu distributor for investigation and correction of the cause.
CHECK BRAKING EFFECT

Drive the machine forward and check the effect of the brakes.
If there is any abnormality in the actuation of the brakes, please contact your Komatsu distributor to have the
brakes adjusted. If the braking effect is poor, see "CHECK DISC BRAKE (PAGE 4-24)".
CHECK STROKE OF PARKING BRAKE LEVER

When the parking brake lever is pulled by 3 or 4 clicks, if the
machine is braked securely, the lever stroke is normal. If the
lever is pulled to the 6 clicks, see "CHECK PARKING BRAKE
LEVER STROKE, ADJUST (PAGE 4-41)".
NOTICE
● If the machine travels with the parking brake lever
pulled, the lining will burn and the braking efficiency
will be lowered. The drum is generally discolored in
such cases.
● Once the lining is burnt and the braking efficiency is
lowered, braking efficiency is not restored unless the
burnt thin layer of the lining is removed with sandpa-
per.
3-30
OPERATION OPERATION
CHECK THAT RISE IN AIR PRESSURE IS NORMAL

If the pressure inside the air tank is 0, charge the tank with air to raise the indicator of the air pressure gauge to the
green range by running the engine at low idling for approx. 3 minutes, or by running it at full throttle for less than
1.5 minutes.
CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE
CHECK THAT ALL ABNORMALITIES FROM PREVIOUS DAY HAVE BEEN REPAIRED
CHECK THAT WINDSHIELD WIPER, WINDOW WASHER, AND DEFROSTER WORK

PROPERLY, CHECK WASHER FLUID LEVEL
CHECK INFLATION PRESSURE OF TIRES

Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.
Check for damage or wear to the tires and the rims.
Check for loose wheel hub nuts (bolts).
The proper inflation pressure is shown below.
Tire size Inflation pressure
Front 16.00-24-12PR 0.22 MPa (2.2 kgf/cm2, 31.24 PSI)
Rear 16.00-24-12PR 0.22 MPa (2.2 kgf/cm2, 31.24 PSI)
3-31
OPERATION OPERATION
REMOVAL OF ARTICULAR LOCK PIN
WARNING
For general travel, maintenance, and transportation,
always keep the articulate lock pin installed.
If the articulation is to be used during travel operations, remove

the articulate lock pin and keep it in the place shown by the
arrow.
ADJUSTMENTS BEFORE OPERATION
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.
● Adjust the seat position at the beginning of each shift

or when operators change.
● Adjust the seat so that the brake pedal can be

depressed all the way with the operator’s back against
the backrest.
(A) Adjustment of seat height

Turn knob (1) to the right to lower the seat, or to the left to
raise the seat.
Height adjustment: 190 mm (7.5 in)
(B) Fore-and-aft adjustment of seat

Move lever (2) to the right, set the seat to the desired posi-
tion, and then release the lever.
Fore-and-aft adjustment: 125 mm (4.9 in)(5 stages)
3-32
OPERATION OPERATION
ADJUSTING POSITION OF STEERING POST, WORK EQUIPMENT CONTROL LEVERS
WARNING
Do not carry out adjustments while traveling.
Depress the pedal (1). When the steering post is set to a

desired position, release the pedal.
Adjust to a position that matches your physique and operating

posture.
Steering wheel and gauges move in the same time.
ADJUSTING POSITION OF STEERING WHEEL TILT LEVER
WARNING
Do not adjust the steering wheel when the machine is
traveling.
Turn tilt lever (1) to the left to loosen the lock, set the steering
wheel to the desired position, then tighten the lever again.
3-33
OPERATION OPERATION
USING SEAT BELT

When operating a machine equipped with ROPS, be sure to use the seat belt.
WARNING
● Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions.
Replace any worn or damaged seat belt or the securing brackets.
● Even if no abnormality can be seen in the seat belt, always replace the seat belt every 3 years.
The date of manufacture of the seat belt is woven into the back of the seat belt.
● Adjust and fasten the seat belt before operating the machine.
● Always use seat belt when operating the machine.
● Do not use seat belt with either half of the belt twisted.
Fasten the belt and remove it in the following manner

Install the belts so that it fits you exactly without being too tight.
1. Adjust the seat so that the brake pedal can be depressed

all the way with the operator’s back against the backrest.
2. Sit in the seat. Hold buckle (1) with your left hand and
tongue (2) with your right hand, and put tongue (2) into
buckle (1). Pull the belt to check that the belt has locked.
3. When removing the belt, raise the tip of the lever of

buckle (2) to release it.
Fasten the belt along your body without twisting it. Adjust the
lengths of the belt on both the buckle and the tongue sides so
that the buckle is located at the mid-point of the front of your
body.
3-34
OPERATION OPERATION
Adjust the belt length in the following manner

To shorten the belt: Pull the free end of the belt on either the
buckle body or tongue side.
To lengthen the belt: Pull the belt while holding it at a right

angle to the buckle or tongue.
HANDLING SAFETY BELT
WARNING
Fit a safety belt to the assistant's seat during general
travel and operation travel.
This is installed to the assistant's seat.
Method of installing safety belt

Insert lock plate (2) into buckle (1), then adjust the length with
strap (3).
Method of removing safety belt

Push the portion marked by the arrow to release the belt.
3-35
OPERATION OPERATION
OPERATIONS, CHECKS BEFORE STARTING ENGINE
WARNING
● When starting the engine, check that the safety lock
lever is securely at the LOCK position.
If the control levers are not locked and they are
touched by accident when starting the engine, the
work equipment may move unexpectedly, and this
may lead to a serious accident.
● When standing up from the operator's seat, always set

the safety lock lever to the LOCK position, regardless
of whether the engine is running or stopped.
1. Check that parking brake lever (1) is at the LOCK posi-

tion.
2. Check that gear shift lever (2) is at the N (Neutral) posi-

tion and locked with safety lock lever (3).
If gear shift lever (2) is not at the N (Neutral) position, the
engine will not start.
3-36
OPERATION OPERATION
3. Check that work equipment control lever (4) is at the N

(Holding) position.
3-37
OPERATION OPERATION
STARTING ENGINE
NORMAL STARTING
WARNING
● Check that there are no people or obstacles in the sur-
rounding area, then sound the horn and start the
engine.
● Exhaust gas is toxic. When starting the engine in a

confined space, be extremely careful to ensure that
there is good ventilation.
NOTICE
Do not keep the starting motor rotating continuously for
more than 20 seconds.
If the engine will not start, wait for at least 2 minutes
before trying to start the engine again.
Do not start the engine with the accelerator pedal
depressed to the FULL OPEN position.
1. Set fuel control lever (1) to the low idling position.
2. Turn the key in starting switch (2) to the START position.

The engine will start.
3-38
OPERATION OPERATION
3. After the engine starts, release the key in starting switch

(2). The key will return automatically to the ON position.
STARTING IN COLD WEATHER
WARNING
● Check that there are no people or obstacles in the sur-
rounding area, then sound the horn and start the
engine.
● Never use starting aid fluids as they may cause explo-

sions.
NOTICE
Do not keep the starting motor rotating continuously for
more than 20 seconds.
If the engine fails to start, repeat steps 1 - 3 after waiting
for about 2 minutes.
When starting is low temperatures, do as follows.
1. Set fuel control lever (1) to the half-open position.
3-39
OPERATION OPERATION
2. For machines equipped with the D.D.V. lever, set D.D.V.

lever (2) to the NO LOAD position.
3. Turn the key in starting switch (3) to the HEAT position

and keep it in this position until heater signal (4) flashes.
4. When heater signal (4) lights up, turn the key in starting
switch (3) to the START position. The engine will start.
5. After the engine starts, release the key in starting switch

(3). The key will return automatically to the ON position.
3-40
OPERATION OPERATION
6. Set fuel control lever (1) to the low idling position.
7. For machines equipped with the D.D.V. lever, set D.D.V.

lever (2) to the constant speed position or engine speed
proportional position.
3-41
OPERATION OPERATION
OPERATIONS, CHECKS AFTER STARTING ENGINE
WARNING
● Emergency stop
If the operation is abnormal or any other trouble occurs, turn the key in the starting switch to the OFF
position.
● If the work equipment is operated without warming up the machine sufficiently, the response of the
work equipment to the movement of the control lever will be slow, and the work equipment may not
move as the operator desires, so always carry out the warming-up operation. Particularly in cold
areas, be sure to carry out the warming-up operation fully.
BREAKING IN THE MACHINE
CAUTION
● Your Komatsu machine has been thoroughly adjusted and tested before shipment.
However, operating the machine under severe conditions at the beginning can adversely affect the
performance and shorten the machine life.
● Be sure to break in the machine for the initial 100 hours (as indicated by the service meter).
During breaking in, pay particular attention to the following points.
NOTICE
● Idle the engine for 5 minutes after starting it up.
● Avoid operation with heavy loads or at high speeds.
● Avoid sudden starts, sudden acceleration, sudden steering, and sudden stops except in cases of
emergency.
NORMAL OPERATION
After starting the engine, do not start operations immediately.
Carry out the following operations and checks first.
NOTICE
Do not accelerate the engine suddenly until the warming-
up operation has been completed.
Do not run the engine at low idling or high idling continu-
ously for more than 20 minutes.
If it is necessary to continue to run the engine at idling,
apply a load from time to time or run the engine at a mid-
range speed.
3-42
OPERATION OPERATION
1. Pull fuel control lever (1), and run the engine at a mid-
range speed for approx. 5 minutes to carry out warming-
up.
2. After the warming-up operation, check that the gauges

and caution lamps are normal.
If any abnormality is found, carry out maintenance or
repair.
Operate the engine under a light load until engine water
temperature gauge (2) enters the green range.
3. Check for any abnormal exhaust gas color, sound, or

vibration. If any abnormality is found, repair it.
3-43
OPERATION OPERATION
STOPPING ENGINE
NOTICE
If the engine is abruptly stopped before it has cooled down
the engine life may be greatly shortened. Consequently, do
not abruptly stop the engine apart from an emergency.
In particular, if the engine has overheated, do not abruptly
stop it but run it at medium speed to allow it to cool gradu-
ally, then stop it.
1. Place fuel control lever (1) in the low idling position and
run the engine at low idling speed for about 5 minutes to
allow it to gradually cool down.
2. Turn the key in starting switch (2) to the OFF position and
stop the engine.
3. Remove the key from starting switch (2).
3-44
OPERATION OPERATION
CHECK AFTER STOPPING ENGINE

1. Walk around the machine and check the work equipment, paintwork, and undercarriage, and check also for
leakage of oil or water.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard.
4. Remove any mud stuck to the undercarriage.
TRAVELING POSTURE FOR MACHINE
WARNING
● For general travel, always lock the front frame and rear frame with the articulate lock pin.
● Before moving any work equipment control lever, check the distance between the blade and tires.
NOTICE
Be sure to maintain a clearance between the blade and
inside tire.
If the machine is articulated with the blade at an angle, the
step may be bent by the blade.
1. For general travel, raise the blade fully as shown in the

diagram on the right, and set so that the blade does not
extend outside the machine.
3-45
OPERATION OPERATION
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR),

STOPPING
WARNING
● When moving off, check that the area around the machine is safe, and sound the horn before moving.
Clear all personnel from the machine and the area.
Use extreme care when reversing the machine. Note there is a blind spot behind the machine.
● Do not operate the machine when air pressure is abnormal.
● Before starting operations, check that the seat belt is properly installed.
NOTICE
When starting travel, check the following items.
● Check that the parking brake lamp is turned off.
● Check that the parking brake warning buzzer is turned off.
● When the braking force is lowered because of rainwater, washing water, etc., apply the brake lightly
several times to dry up the lining with frictional heat.
PREPARATIONS FOR MOVING OFF

1. Set the blade to the travel posture.
2. Set safety lock lever (2) of gearshift lever (1) to the FREE
position.
3-46
OPERATION OPERATION
3. Depress inching pedal (3), then set gearshift lever (1) to

1st, 2nd, or 3rd speed.
Do not start the machine off in 4th speed or above.
4. Return parking brake lever (4) to the FREE position. At

the same time, be sure to check that parking brake lamp
(5) goes out.
5. Let inching pedal (3) back and depress accelerator pedal

(6) to move the machine off.
3-47
OPERATION OPERATION
SHIFTING GEAR ON MACHINE
WARNING
Avoid sudden shifting of gear when traveling at high
speed. When shifting gear, use the brake to reduce speed
before shifting gear.
NOTICE
When shifting gear, always shift one gear at a time.
When shifting gear, do as follows.
Increase speed
Let back accelerator pedal (1) and shift gearshift lever (2) up to
the next speed range.
Reducing speed
Release accelerator pedal (1) to reduce speed, then shift gear-
shift lever (2) down one range.
3-48
OPERATION OPERATION
SHIFTING BETWEEN FORWARD AND REVERSE
WARNING
● When shifting between forward and reverse, always
check that it is safe to travel in the new direction.
Use extreme care when reversing the machine. Note
there is an blind spot behind the machine.
● Do not shift between forward and reverse when travel-

ing at high speed.
When shifting between forward and reverse, always stop the

machine first.
1. Depress brake pedal (1) to reduce speed, then depress

inching pedal (2) to stop the machine.
2. Shift gearshift lever (3) to F or R and set in 1st or 2nd

speed.
3. Let inching pedal (2) back while depressing accelerator

pedal (4) to start the machine off.
3-49
OPERATION OPERATION
STOPPING MACHINE
WARNING
Do not stop the machine suddenly except in emergencies.
Give yourself ample room when stopping.
1. Release accelerator pedal (1).
2. Depress brake pedal (2) to reduce speed, then just

before the machine stops, depress inching pedal (3) and
stop the machine.
3. Set gearshift lever (4) to the N position, then set the

3-50
OPERATION OPERATION
4. Pull parking brake lever (5) to set the parking brake to the
LOCK position. At the same time, the parking brake pilot
lamp will light up.
3-51
OPERATION OPERATION
TURNING MACHINE
WARNING
● It is dangerous to turn the machine suddenly at high
speed or to turn the machine on steep slopes.
● If the engine stops when the machine is traveling, the

steering will become heavy, so never stop the engine.
This is particularly dangerous on slopes, so never
allow the engine to stop while traveling on slopes
under any circumstance.
If the engine stops, immediately apply the brake and
stop the machine in a safe place.
To turn the machine when traveling, turn steering wheel (1) in the direction of the turn.
LEANING OPERATION
Operate leaning control lever (2) to change the angle of the
front tires as follows.
Pull BACK to lean to RIGHT.

Push FORWARD to lean to LEFT.
When traveling forward and turning the machine, the radius of

the turn becomes smaller if the tires are leaned in the direction
of the turn.
When traveling in reverse and turning the machine, the radius

of the turn becomes smaller if the tires are leaned in the oppo-
site direction to the turn.
3-52
OPERATION OPERATION
ARTICULATING OPERATION
WARNING
Do not remove the lock pin for general travel.
NOTICE
When turning with the machine articulated, pay particular
attention to the clearance between the blade end and the
wheel.
To carry out articulation operations, remove the lock pin on the

left side of the chassis.
The machine can be articulated up to a maximum of 26º to the

left or right, and the turning radius becomes 7.5 m (24 ft 7 in).
1. Stop the machine, remove pin (1), and insert it in the stor-
age position.
2. Operate articulate control lever (2) as follows.

Pull BACK to articulate to LEFT.
Push FORWARD to articulate to RIGHT.
3-53
OPERATION OPERATION
3. When not operating the articulation, set the front frame

and rear frame straight, align the pin holes, and fix the
front and rear frames in the original position with pin (1).
3-54
OPERATION OPERATION
OPERATING WORK EQUIPMENT
(1) Left blade control lever (4) Blade rotation control lever
(2) Right blade control lever (5) Power tilt control lever
(3) Blade side shift control lever (6) Drawbar side shift control lever
BLADE OPERATION
BLADE LIFT OPERATION

Operate left blade control lever (1) as follows.
Pull BACK to RAISE left end of blade

Push FORWARD to LOWER left end of blade
3-55
OPERATION OPERATION
Operate right blade control lever (2) as follows.
Pull BACK to RAISE right end of blade

Push FORWARD to LOWER right end of blade
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
3-56
OPERATION OPERATION
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
CHANGING BLADE CUTTING ANGLE

Operate power tilt control lever (5) as follows.
Pull BACK to make cutting angle SMALLER

Push FORWARD to make cutting angle LARGER
3-57
OPERATION OPERATION
Use a larger cutting angle when cutting hard soil and a smaller
cutting angle when cutting soft soil.
The distance between the cutting surface and the blade edge
can be changed, so it is possible to carry out fine adjustment of
the height of the cutting surface.
OPERATING DRAWBAR SIDE SHIFT

Operate drawbar side-shift control lever (6) as follows.
Pull BACK to shift drawbar to RIGHT

Push FORWARD to shift drawbar to LEFT
3-58
OPERATION OPERATION
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER
LEVELING GROUND TO RIGHT

1. Operate the drawbar side shift and move the circle
approx. 200 mm (7.9 in) to the left.
2. Set the blade so that the earth is discharged outside the

rear left wheel.
3. Operate the blade lift cylinder so that the blade is at the

desired digging depth, then set it horizontal.
4. Lean the front wheels to the left.
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.
5. Rotate so that the blade is at the optimum position for the soil. (Be careful not to let the rear left wheel run
over the windrow discharged from the blade.)
3-59
OPERATION OPERATION
6. Operate the power tilt so that the top of the blade is

slightly in front of the cutting edge, then start operation.
7. Discharge the soil to the side to prevent any excessive

load from bearing on the machine.
8. Spread fine crushed loose soil over the ground surface until it is level.
REMARK
● Generally speaking, 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.
● If the tires start to spin, turn the blade to a greater angle to reduce the digging width, thereby reducing the load
on the machine.
● In leveling operations, discharge the soil outside the rear wheels. This makes it easier to steer with the rear
wheels.
LEVELING GROUND TO LEFT

1. Operate the drawbar side shift and move the circle
approx. 200 mm (7.9 in) to the right.
2. Set the blade so that the earth is discharged outside the

rear right wheel.
3-60
OPERATION OPERATION
3. Operate the blade lift cylinder so that the blade is at the

desired digging depth, then set it horizontal.
4. Lean the front wheels to the right.
5. Carry out the operation in the same way as when leveling

to the right.
DIGGING RIGHT V-DITCHES
NOTICE
Set the frame straight. If the machine is articulated, the side of the tire will be pushed against the slope
face, and this will cause damage to the side face of the tires. In addition, mud will be pushed in between
the tire and rim, and this will cause problems such as leakage of air.
1. Set the right edge of the blade in line with the outside of
the front right wheel.

slightly in front of the cutting edge.
3-61
OPERATION OPERATION
3. Operate the left blade lift cylinder and raise the left edge
of the blade. (The right end of the blade determines the
depth of the ditch. The left end of the blade determines
the shape of the ditch.)
4. Rotate the blade so that the soil is discharged inside the

rear left wheel, then set the blade at an angle.
5. Operate the right blade lift cylinder and set the right end
of the blade to a digging depth of 50 - 100 mm (2.0 - 3.9
in).
6. Lean the front wheels to the left.
7. Operate the blade lift cylinder to the right to set the right
edge of the blade to the desired digging depth.
8. Align the front right wheel with the bottom of the ditch and
dig a ditch of the desired depth.
● First, dig to depth of 30 - 50 mm (1.2 - 2.0 in) to deter-

mine the line of the ditch.
● The chassis is in an unstable posture when digging
ditches, so align the front and rear wheels with the bot-
tom of the ditch when carrying out such operations.
3-62
OPERATION OPERATION
DIGGING LEFT V-DITCHES
NOTICE
Set the frame straight. If the machine is articulated, the side of the tire will be pushed against the slope
face, and this will cause damage to the side face of the tires. In addition, mud will be pushed in between
the tire and rim, and this will cause problems such as leakage of air.
1. Set the left edge of the blade in line with the outside of
the front left wheel.

slightly in front of the cutting edge.
3. Operate the right blade lift cylinder and raise the right
edge of the blade. (The left end of the blade determines
the depth of the ditch. The right end of the blade deter-
mines the shape of the ditch.)
4. Rotate the blade so that the soil is discharged inside the

rear right wheel, then set the blade at an angle.
3-63
OPERATION OPERATION
5. Operate the left blade lift cylinder and set the right end of
the blade to a digging depth of 50 - 100 mm (2.0 - 3.9 in).
6. Lean the front wheels to the right.
7. Operate the blade lift cylinder to the left to set the left end
of the blade to the desired digging depth.
8. Align the front right wheel with the bottom of the ditch and
dig a ditch of the desired depth.
● First, dig to depth of 30 - 50 mm (1.2 - 2.0 in) to deter-

mine the line of the ditch.
● The chassis is in an unstable posture when digging
ditches, so align the front and rear wheels with the bot-
tom of the ditch when carrying out the operation.
3-64
OPERATION OPERATION
RIGHT DITCH FINISHING

1. Set the right side of the blade behind the front right
wheel.
2. Operate the right blade lift cylinder and set the blade to
the depth of the ditch.
3. Be careful not to let the rear left wheel run over the win-
dow discharged from the blade.
Operate the blade lift cylinder and blade rotation to set
the blade in position.
4. Lean the front wheels slightly to the left.
5. To push out the soil to the top of the slope face and the
road shoulder, a separate pass is needed. Spread the
soil, then carry out final finishing with the grader.
3-65
OPERATION OPERATION
LEFT DITCH FINISHING

1. Set the left side of the blade behind the front left wheel.
2. Operate the left blade lift cylinder and set the blade to the
depth of the ditch.
3. Be careful not to let the rear right wheel run over the
windrow discharged from the blade.
Operate the blade lift cylinder and blade rotation to set
the blade in position.
4. Lean the front wheels slightly to the right.
5. To push out the soil to the top of the slope face and the
road shoulder, a separate pass is needed. Spread the
soil, then carry out final finishing with the grader.
3-66
OPERATION OPERATION
FINISHING RIGHT ROAD SHOULDER

1. Set so that the right end of the blade is in line with the
outside of the right tire. Set the blade so that the soil is
discharged between the two wheels. (The soil can be
moved more smoothly if the blade is at a small propulsion
angle.)
2. Align the center of the machine with the line of the soil
discharged when digging the ditch.
3. Operate the left and right blade lift cylinders to keep the
blade horizontal and at the desired digging depth.
4. Lean the front wheels slightly to the left.
3-67
OPERATION OPERATION
FINISHING LEFT ROAD SHOULDER

1. Operate the drawbar shift cylinder to set the circle to the
left end.
2. Set so that the left end of the blade is in line with the out-
side of the left tire. Set the blade so that the soil is dis-
charged between the two wheels. (The soil can be
moved more smoothly if the blade is at a small propulsion
angle.)
3. Align the center of the machine with the line of the soil
discharged when digging the ditch.
4. Operate the left and right blade lift cylinders to keep the
blade horizontal and at the desired digging depth.
5. Lean the front wheels slightly to the right.
3-68
OPERATION OPERATION
CONSTRUCTING ROAD - METHOD OF MAKING V-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.
When carrying out Steps 4 and 7, articulate the frame.
1. Line of ditch: Light-duty digging
● Determine the line of the ditch along the measured

points.
Depth: 30 - 50 mm (1.2 - 2.0 in)

Travel speed: 0.5 km/h (0.3 MPH)
2. Second digging pass: Heavy-duty digging
3. Third digging pass: Heavy-duty digging
4. Finishing road shoulder
3-69
OPERATION OPERATION
5. Leveling center
6. Fourth digging pass: Heavy-duty digging
8. Spreading to center
9. Slope face and bank
3-70
OPERATION OPERATION
10. Finishing bottom of ditch
11. Ditch digging pass (finishing and shaping inside of the

slope face)
12. Finishing slope face
14. Leveling and finishing
3-71
OPERATION OPERATION
FLAT-BOTTOMED DITCH
When there is no V-ditch, make a V-ditch at the depth of the
flat-bottomed ditch.
The slope face of the road shoulder must be flatter than nor-
mal.
1. Operate the power tilt and angle the blade to the front.
2. Operate the drawbar shift cylinder and set the circle fully
to the left of the machine.
3. Place the front right tire in the bottom of the V-ditch.
4. 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-bot-
tomed ditch.
5. Operate the right blade lift cylinder to lower the right end
of the blade, and set it to the digging depth.
6. Operate the left blade lift cylinder to raise the right end of
the blade, and set it to the desired angle for the slope
face of the road shoulder.
3-72
OPERATION OPERATION
7. Lean the front wheels to the left. Dig the No. 2 V-ditch to
the same depth or slightly deeper than the No. 1 ditch.
8. Dig the flat bottom. Set the right blade lift cylinder to the
desired depth.
9. Operate the left blade lift cylinder as required.
10. Set the front right tire at the bottom of the first V-ditch and
start the operation.
11. Set the right edge of the blade at the bottom of the slope.
12. Lower the right blade lift cylinder so that the tip of the
blade is the set precision for the ditch.
13. Lower the left lift cylinder to the desired digging depth.
Lean the front wheels to the left.
14. 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.
3-73
OPERATION OPERATION
CONSTRUCTING ROAD - 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.
1. Make the slope face on the inside flat.
2. Dig the width and depth of the bottom of the ditch with the
left ditching method.
3. Finish the road shoulder.
4. Spread the soil to the center.
3-74
OPERATION OPERATION
5. Finish the slope face on the bank.
6. Make the bottom of the ditch flat.
7. Finish the ditch.
8. Finish the slope face on the inside.
9. Finish the road shoulder.
3-75
OPERATION OPERATION
10. Carry out 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.
1. Articulate the machine so that the front wheels and blade

remain in the ditch. Steer with the front wheels.
2. 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.
LEVELING SLOPE FACE
WARNING
● When operating on slopes where the machine may slip to the side, make sure that you understand the
operation of the machine completely.
● Do not articulate the machine fully on steep slopes.
● On steep slopes, lower the engine speed and operate in 1st gear.
● When operating on slopes, use the accelerator to control the machine speed.
3-76
OPERATION OPERATION
BANK CUTTING METHOD - RIGHT SIDE
WARNING
Lower the blade to the ground before removing the bank control lock pin.
1. The roadbed where the foundation is to be dug must be uniform.
2. 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.
3. Set to the bank cut posture. For details, see "BANK

CUTTING POSTURE (RIGHT SIDE) (PAGE 3-85)".
4. Angle the blade at 3/4 to the front from the high bank
position to set to the low bank posture.
5. Extend the left blade lift cylinder, 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.
6. The rear right wheel must be in the V at the base of the

slope face.
7. Extend the right blade lift cylinder and set the angle to the desired bank slope face.
8. Gradually progress with the cutting.
REMARK
The wheels should normally be almost perpendicular.
3-77
OPERATION OPERATION
9. If the digging is comparatively heavy duty, angle the

wheels towards the slope face.
10. If the digging is comparatively light duty, angle the wheels

away from the slope face.
Discharge the soil from the slope face to the outside of
the rear wheels.
REMARK
The procedure in the diagram is for the right side. For the left
side, set the blade in the opposite position.
SHOULDER REACH METHOD - RIGHT SIDE

Set to the shoulder reach posture and carry out operations.
For details, see "SHOULDER REACH POSTURE (RIGHT SIDE) (PAGE 3-87)".
3-78
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. It is dangerous to do
this, as the engine cannot be used to brake the machine. Always place the transmission in the appro-
priate speed range before starting to travel down a hill.
● To prevent overrun, always shift down one gear at time. Allowing the engine to overrun may cause
damage to the engine or transmission.
TRAVELING DOWNHILL
When traveling downhill, use the same speed range as when traveling uphill, and make full use of the braking
force of the engine. If the machine travel speed is still too fast, use the foot brake.
IF ENGINE STOPS
CAUTION
If the engine stops, 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, even when the pedal is depressed with the same
force.
If the engine stops on a slope, immediately depress the brake pedal fully to stop the machine, then move the gear
shift lever to the N position and start the engine again.
PRECAUTIONS WHEN USING ARTICULATED STEERING

When the articulation is used to steer the machine, the machine will turn sharply, so at high speed there is a dan-
ger that it will turn over. For this reason, only use the articulation at speeds of less than 10 km/h (6.2 MPH).
PRECAUTIONS WHEN TRAVELING ON ROADS

When traveling on roads (high speed travel), stop after traveling 80 km or 2 hours (whichever comes first), and rest
for 30 minutes. For the next cycle, rest for one hour, and for the cycle after that, rest for 30 minutes. Repeat this
double cycle until you reach the destination.
3-79
OPERATION OPERATION
CAUTIONS IN OPERATION OF WORK EQUIPMENT

When operating the work equipment control lever, always pay careful attention to the movement of the work equip-
ment and do not move it more than necessary as the work equipment or the hydraulic cylinder may hit and dam-
age other parts.
When the work equipment is operated, special attention should be given to avoiding contact between the following
parts.
● Front wheel and blade
● Blade and step
● Rear wheel and blade
● Blade and frame
3-80
OPERATION OPERATION
● Drawbar stopper and lifter portion

When operating the drawbar side shift with the blade
raised to the maximum height (This portion is designed so
that it mounts the stopper at the drawbar end.)
3-81
OPERATION OPERATION
ADJUSTING WORK EQUIPMENT POSTURE
BLADE PROTRUSION
The degree of protrusion is controlled by the control lever during operation. If further protrusion is needed, stop the
grader for a while and change the installing position of the blade horizontal shifting cylinder piston rod, as follows.
1. Lower the blade to the ground.
2. Loosen the bolt holding the blade to the bracket at the tip of the cylinder rod, then remove the bolt and lock
washer.
3. Pull in the cylinder rod.
4. Align the bolt hole in the bracket with a hole in another place on the blade.
5. Install the lock washer and bolt, then tighten the bolt.
● Protrusion to right Position (1)

● Protrusion to left Position (2)
BLADE PROPULSION ANGLE

The angle between the blade and the center line of the
machine body is called the blade propulsion angle.
Set the blade propulsion angle to about 60º for general cutting
work, but set it narrower in the following cases.
● When the cutting resistance is high.
● When the soil is hard.
● When the soil accumulated in front of the blade dose not

flow smoothly.
3-82
OPERATION OPERATION
ADJUSTING BLADE CUTTING ANGLE

Generally, the operating efficiency is better if the blade cutting
angle is large when cutting hard soil and small when cutting
soft soil.
The blade cutting angle is installed to the power tilt blade, and it
can be freely changed within the range below.
Cutting angle
Minimum: 28.5º
Maximum: 86.5º
It is possible to set to the optimum blade cutting angle to match

the type of soil simply by operating one lever.
It is possible to keep the cutting edge sharp for operations, so

this blade can display its power when removing frozen ice dur-
ing snow-clearing operations.
3-83
OPERATION OPERATION
It is possible to change the distance between the cutting edge

and cutting surface, so fine adjustment can be made in the
height of the cutting surface and cutting edge.
When scooping up soil or snow with the low bank posture, the optimum blade cutting angle is selected, so work
can be carried out efficiently.
SAFETY DEVICE OF BLADE

A shear pin is fitted to the circle to prevent accidents when an
abnormal impact load is applied to the end of the blade during
work. If this shear pin is broke during work, replace it according
to the following procedure.
Remove bolt (2), then remove the lock plate. Pull out shear pin
(1) and fit a new one.
3-84
OPERATION OPERATION
BANK CUTTING POSTURE (RIGHT SIDE)
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.
NOTICE
● When shifting to the bank cut posture, be careful not to let the blade hit any other part of the machine.
● If the bank pin passes over the hole in the lifter guide, do not rotate the lifter any further.
There is danger that the frame and bank pin case will come into contact and that the bank pin case will
be broken.
1. Extend the blade and drawbar fully to the right, rotate the
circle and set the end of the blade at the side of the front
right wheel, then lower the blade so that it is lightly in con-
tact with the ground.
2. Move the bank switch from the LOCK position to the

RETRACT position, then remove the lock pin from the
lifter.
If pin (1) is blocked by lifter (2) and cannot be removed,
operate the blade lift cylinder to remove it.
3-85
OPERATION OPERATION
3. Extend the right blade lift cylinder, retract the left blade lift
cylinder, and rotate lifter (2) counterclockwise. When
lifter (2) has rotated, move the bank switch pin from the
RETRACT position to the INDEX position, then rotate
lifter (2) gradually until pin (1) enters hole (3) in the lifter
guide.
4. When pin (1) enters hole (3) in the lifter guide, move the
bank switch from the INDEX position to the LOCK posi-
tion.
5. Retract the right lift cylinder and extend the left lift cylin-
der repeatedly, then raise the blade and rotate it to the
right side of the machine to set the blade to the bank cut
position.
When setting to the bank cut posture on the left side, use
the same procedure as above, but in the opposite direc-
tion.
REMARK
The banking performance can be improved by changing the
mounting position of the piston rod of the blade side shift cylin-
der to the left for right side banking and to the right for left side
banking.
3-86
OPERATION OPERATION
SHOULDER REACH POSTURE (RIGHT SIDE)
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.
NOTICE
● When shifting to the shoulder reach posture, be careful not to let the blade hit any other part of the
machine.
● If the bank pin passes over the hole in the lifter guide, do not rotate the lifter any further.
There is danger that the frame and bank pin case will come into contact and that the bank pin case will
be broken.
1. Put the blade lightly in contact with the ground (just

touching).
2. Move the bank switch from the LOCK position to the

RETRACT position, then remove the lock pin from the
lifter.
If pin (1) is blocked by lifter (2) and cannot be removed,
operate the blade lift cylinder to remove it.
3. Extend the right blade lift cylinder, retract the left blade lift
cylinder, and rotate lifter (2) counterclockwise. When
lifter (2) has rotated, move the bank switch pin from the
RETRACT position to the INDEX position, then rotate
lifter (2) gradually until pin (1) enters hole (3) in the lifter
guide.
3-87
OPERATION OPERATION
4. When pin (1) enters hole (3) in the lifter guide, move the
bank switch from the INDEX position to the LOCK posi-
tion.
5. Shift the blade to the side as shown in the diagram.

● Shift the blade fully to the right.
● Shift the drawbar fully to the right.
6. Rotate the circle and set to the desired position.
When setting to the shoulder reach posture on the left side, use
the same procedure as above, but in the opposite direction.
REMARK
If it is desired to make the shoulder reach posture even larger,
change the mounting position of the piston rod of the blade
side shift cylinder.
For details, see "BLADE PROPULSION ANGLE (PAGE 3-82)".
3-88
OPERATION OPERATION
PARKING MACHINE
WARNING
● Avoid stopping suddenly; give yourself ample room
when stopping.
● Do not park the machine on slopes.

If the machine has to be parked on a slope, set it at
right angles to the slope, put blocks under the tires,
and dig the blade into the ground surface to prevent
the machine from moving.
● If the control levers are not locked and they are

touched by accident when starting the engine, the
work equipment may move unexpectedly, and this
may lead to a serious accident.
When standing up from the operator's seat, always set
the safety lock lever to the LOCK position.
1. Release accelerator pedal (1).
2. Depress brake pedal (2) to reduce speed, then just

before the machine stops, depress inching pedal (3) and
stop the machine.
3-89
OPERATION OPERATION
3. Set gearshift lever (4) to the N position, then set the

4. Pull parking brake lever (5) to set the parking brake to the
LOCK position. At the same time, the parking brake pilot
lamp will light up.
5. Operate the work equipment control lever and lower the

blade to the ground.
If the optional scarifier is installed, lower the scarifier to
the ground also.
3-90
OPERATION OPERATION
CHECKS AFTER COMPLETION OF OPERATION

Check the engine water temperature, engine oil pressure, and
fuel level on the main panel.
If the engine has overheated, do not stop the engine suddenly.

Run the engine at a mid-range speed and allow it to cool down
before stopping it.
LOCKING (if equipped with cab)

Always lock the following parts.
(1) Lock door (right) with lever inside cab

(2) Lock door (left) from outside of cab with key
REMARK
Use the special key to lock the left cab door.
HANDLING THE TIRES
PRECAUTIONS WHEN HANDLING TIRES

To ensure safety, it is necessary to replace tires if they have the following defects.
● Tires with cuts, broken or excessively deformed bead wire.
● Excessively worn tires in which the carcass ply (excluding breaker) is exposed along 1/4 the circumference.
● Tires whose carcass is damaged more than 1/3 the tire width.
● Tires with ply separation.
● Tires with radial cracks which reach the carcass.
● Aged, deformed or abnormally damaged tires.
When replacing the tires, please contact your Komatsu distributor or the tire maker.
3-91
TRANSPORTATION OPERATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to ensure safety.
LOADING, UNLOADING WORK
WARNING
● Make sure the ramp has sufficient width, length and thickness to enable the machine to be safely
loaded and unloaded.
● When loading and unloading the machine, park the trailer on a flat firm roadbed. Keep a fairly long
distance between the road shoulder and the machine.
● Remove the mud from the undercarriage to prevent the machine from slipping to the side on slopes.
Be sure the ramp surface is clean and free of grease, oil, ice and loose materials.
● Never change the direction of travel when on the ramps. If it is necessary to change direction, drive
off the ramps and correct the direction, then drive on to the ramps again.
When loading or unloading, always use ramps or a platform and carry out the operations as follows.
1. Apply the brakes on the trailer securely and insert blocks

under the tires to ensure that the trailer does not move.
Then fix the ramps in line with the centers of the trailer
and the machine.
Be sure that the two sides are at the same height as one
another.
Make the angle of the ramps a maximum of 15º.
Set the distance between the ramps to match the center
of the tires.
2. Set the machine in line with the ramps, then drive the
machine slowly to load or unload it.
3. Load the machine correctly in the specified position on the trailer.
PRECAUTIONS FOR LOADING

After loading to the specified position, secure the machine as follows.
1. Lower the work equipment carefully.
2. Set the gear shift lever at the N position, then set the safety lock knob to the LOCK position. Pull the parking
brake lever to apply the parking brake.
3. Turn the starting switch to the OFF position, and stop the engine, then remove the key.
4. Lock the front frame and rear frame with the articulate lock pin.
5. When transporting the machine, place wooden blocks underneath the front and rear tires to prevent the
machine from moving about.
Also, hold it down with chain or rope.
3-92
OPERATION COLD WEATHER OPERATION
COLD WEATHER OPERATION
PRECAUTIONS FOR LOW TEMPERATURE

When the temperature becomes low, it is difficult to start the engine, and the coolant may freeze, so do as follows.
FUEL AND LUBRICANTS

Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see "USE OF
FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-8)".
COOLANT
WARNING
Keep antifreeze fluid away from open flames. Never smoke when using antifreeze.
NOTICE
Never use methanol, ethanol or propanol based antifreeze.
Where no permanent antifreeze is available, an ethylene glycol antifreeze without corrosion inhibitor may be used
only for the cold season. In this case, clean the cooling system twice a year (in spring and autumn). When refilling
the cooling system, add antifreeze in autumn, but do not add any in spring.
Absolutely avoid using any water leak preventing agent irrespective of whether it is used independently or mixed
with an antifreeze.
Do not mix one antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM
(PAGE 4-18)".
Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the stan-
dard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If it is
doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for infor-
mation.
Standard requirements for permanent antifreeze.
● SAE ............................................................................................................................................................J1034
● FEDERAL STANDARD........................................................................................................................ O-A-548D
3-93
COLD WEATHER OPERATION OPERATION
BATTERY
WARNING
● To avoid gas explosions, do not bring fire or sparks near the battery.
● Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts
of water, and consult a doctor.
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low,
the battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%, and insulate it
against cold temperature so that the machine can be started easily the next morning.
Measure the specific gravity and calculate the rate of charge from the following conversion table.
Temp. of fluid
20ºC 0ºC -10ºC -20ºC
Rate of charge
100% 1.28 1.29 1.30 1.31
90% 1.26 1.27 1.28 1.29
80% 1.24 1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26
When adding distilled water, wait until the next morning and add distilled water before starting work. This is to pre-
vent the electrolyte from freezing during the night.
3-94
OPERATION COLD WEATHER OPERATION
CAUTIONS AFTER COMPLETION OF WORK

To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on
the following morning, always observe the following precautions.
● Mud and water on the machine body should be completely removed. This is to prevent damage to the seal
caused by mud or dirt getting inside the seal with drops of water.
● Park the machine on concrete or hard ground. If this is impossible, park the machine on wooden boards.
● Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
● As the battery capacity drops markedly in low temperatures, cover the battery or remove it from the machine,
keep it in a warm place, and install it again the next morning.
AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as follows.
● Replace the fuel and oil for all parts with oil of the viscosity specified.
For details, see "USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE (PAGE 4-8)".
● If for any reason permanent antifreeze cannot be used, and an ethyl glycol base antifreeze (winter, one sea-
son type) is used instead, or if no antifreeze is used, drain the cooling system completely, then clean out the
inside of the cooling system thoroughly, and fill with fresh water.
3-95
LONG-TERM STORAGE OPERATION
LONG-TERM STORAGE
BEFORE STORAGE
When putting the machine in storage for more than one month, do as follows.
● After every part is washed and dried, house the machine in a dry building. Never leave it outdoors.
In case it is indispensable to leave it outdoors, park the machine on the flat ground and cover it with canvas
etc.
● Completely fill the fuel tank, lubricate and change the oil before storage.
● Apply a thin coat of grease to metal surface of the hydraulic piston rods and the idler adjusting rods.
● Disconnect the negative terminals of the battery and cover it, or remove it from the machine and store it sepa-
rately.
● If the ambient temperature is expected to drop below 0ºC, always add antifreeze to the cooling water.
Komatsu genuine Super Coolant (AF-ACL) is added to the cooling water, so there is no need to change the
density for temperatures down to -10ºC.
If the temperature goes below -10ºC, adjust the density. For details, see "CLEAN INSIDE OF COOLING SYS-
TEM (PAGE 4-18)".
● Place gear shift levers at the neutral position, operate the safety lock knob to the LOCK position. Pull the park-
ing brake lever to apply the parking brake.
● Fit a block under the center of the front wheel and the tandem case, jack up the tires from the ground, then put
a block under the blade and lower it on top of the block.
DURING STORAGE
WARNING
If it is unavoidably necessary to carry out the rust-preventive operation while the machine is indoors,
open the doors and windows to improve ventilation and prevent gas poisoning.
● Operate the engine and move the machine for a short distance once a month so that a new film of oil will be
coated over movable parts and component surfaces. At the same time, also charge the battery.
● Before operating the work equipment, wipe off the grease on the hydraulic piston rod.
AFTER STORAGE
NOTICE
If the machine is stored without carrying out the monthly rust prevention operation, request your Komatsu
distributor for service.
Carry out the following procedure when taking the machine out of long-term storage.
● Wipe off the grease from the hydraulic cylinder rods.
● Add oil and grease to all places.
3-96
OPERATION TROUBLESHOOTING
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL

When starting after running out of fuel, fill with fuel, then bleed the air from the fuel system before starting.
PROCEDURE FOR BLEEDING AIR

1. Loosen air bleed plug (2).
2. Loosen the knob of feed pump (3), then pump it up and

down until no more bubbles come out with the fuel from
air bleed plug (2).
3. Tighten air bleed plug (2).
4. Push in the knob of feed pump (3) and tighten it.
3-97
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, dangerously unstable steering and excessively worn tires will
result. Repair the faulty leaning pipe quickly.
If the leaning piping is broken, call your Komatsu distributor for repair.
METHOD OF USING LEANING STOPPER

Secure leaning rod (2) to the front axle with bolt (1) (any avail-
able bolt).
3-98
TOWING THE MACHINE
WARNING
● If the machine is towed in the wrong way, it may lead to personal injury or death.
● If there is a failure in the air circuit, the brakes cannot be used, so be extremely careful when towing.
NOTICE
● Towing is for moving the machine to a place where inspection and maintenance can be carried out,
and not for moving it long distances.
The machine must not be towed for long distances.
● For details of the procedure for towing a machine when it has broken down, please contact your
Komatsu distributor.
WHEN ENGINE CAN BE USED

● Always keep the engine running when towing the machine, so that the steering and braking can be used.
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 (5.0
MPH) or less.
● If the distance is more than the above mentioned, or if more than one day has elapsed since the engine trou-
ble, be sure to use a trailer for transportation.
NOTICE
If the machine is towed without the engine running, no lubrication oil will be supplied to the transmission.
The gears and bearings are rotated, so this may cause them to be damaged.
Tow the machine properly according to the instructions given below.
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. It must be moved a maximum of 600 m (1968 ft) and at a maximum speed of 8 km/h (5.0 MPH). This pro-
cedure is only for emergency purposes. If the machine must be moved a long distance, use a transporter.
To protect the operator if the towing rope or bar should break, install a protector plate to the machine being towed.
If it is impossible to use the steering or brakes on the machine being towed, do not have anyone sitting in the oper-
ator’s seat.
Before towing, check that the tow rope or bar are in good condition, and that they have ample strength for the tow-
ing operation. If the machine being towed may get stuck in mud or may have to be towed uphill, the tow rope or bar
must be of a strength of at least 1.5 times greater than the weight of the machine being towed.
Keep the angle of the towing line to the minimum. Operate the machine so that the angle does not become greater
than 30º from the straight line.
If the machine is moved suddenly, the tow rope or bar will be subjected to an excessive load, and it may break.
Start the machine gradually and travel at a constant speed.
Normally, use a towing machine of about the same capacity as the machine being towed. The towing machine
must have ample brake capacity, weight, and rimpull. Check that both machines can be controlled on slopes and
on the tow road.
3-99
When moving a failed machine on a downhill slope, a larger towing machine must be used to ensure ample control
and braking power. Another method is to use a second towing machine at the rear of the failed machine. In this
way, it is possible to prevent the failed machine from going out of control and turning over.
It is impossible to determine the drawbar pull needed for various conditions. The minimum drawbar pull may be
sufficient on horizontal, flat ground, but the maximum drawbar pull is needed on slopes or on rough roads.
When towing a failed machine, please contact your Komatsu distributor.
3-100
IF BATTERY IS DISCHARGED
WARNING
● It is dangerous to charge the battery when it is still
installed on the machine. Always remove the battery
from the machine before charging.
● When checking or handling the battery, stop the

engine and turn the starting key to the OFF position
before starting.
● The battery generates hydrogen gas, so there is dan-

ger of explosion. Do not bring lighted cigarettes near
the battery, or do anything that will cause sparks.
● Battery electrolyte is dilute sulphuric acid, and it will

attack your clothes and skin. If it gets on your clothes
or on your skin, wash it immediately off with large
amounts of water.
If it gets in your eyes, wash it out with fresh water, and
consult a doctor.
● When handling battery, always wear protective gog-

gles and rubber gloves.
● When removing the battery, first disconnect the cable

from the ground (normally, from the negative (-) termi-
nal). When installing, install the positive (+) terminal
first.
If a tool touches the cable connecting the positive ter-
minal and the chassis, there is danger that it will
cause sparks.
● If the terminals are loose, there is danger that the

defective contact may generate sparks that will cause
an explosion.
When installing the terminals, install them tightly.
● When removing or installing, check which is the posi-

tive (+) terminal and negative (-) terminal.
● Green rust around the terminals is a cause of self- dis-

charge of the battery. Polish the terminals with sand-
paper. After removing the rust, coat the terminals
thinly with grease before installing.
REMOVAL AND INSTALLATION OF BATTERY

When starting the engine with a booster cable, do as follows:
● When removing battery, first disconnect the cable from the ground (normally, from the negative (-) terminal). If
a tool touches a cable connecting the positive terminal and the chassis, there is danger of sparks being emit-
ted.
● When installing battery, the ground cable should be connected to the ground terminal as the last step.
3-101
PRECAUTIONS WHEN CHARGING BATTERY

When charging the battery, if the battery is not handled cor-
rectly, there is danger that the battery may explode. Always
follow the instructions in "IF BATTERY IS DISCHARGED
(PAGE 3-101)" and the instruction manual accompanying the
charger, and do as follows.
● Set the voltage of the charger to match the voltage of the

battery to be charged. If the voltage is not selected cor-
rectly, the charger may overheat and cause an explosion.
● Connect the positive (+) charger clip of the charger to the

positive (+) terminal of the battery, then connect the nega-
tive (-) charger clip of the charger to the negative (-) termi-
nal of the battery. Be sure to fix the clips securely.
● Set the charging current to a maximum of 1/10 of the value of the rated battery capacity; when carrying out
rapid charging, set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire
and explode.
● If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is danger that this will ignite the battery electrolyte and cause the battery to explode.
● Do not use or charge the battery when the battery electrolyte level is below the lower level line. This will cause
an explosion. Always check the battery electrolyte level periodically and add distilled water to the upper level
line.
3-102
STARTING ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows.
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE
WARNING
● When connecting the cables, never connect the posi-
tive (+) and negative (-) terminals.
● When starting the engine with a booster cable, always ~

wear safety glasses and gloves.
~
● Be careful not to let the normal machine and problem
machine contact each other. This prevents sparks
from generating near the battery which could ignite
the hydrogen gas given off by the battery and cause
an explosion.
● Make sure that there is no mistake in the booster

cable connection. The final connection is to the
engine block of the problem machine, but sparks will
be generated when this is done, so connect to a place
as far as possible from the battery. (However, avoid
connecting the cable to the work equipment, as con-
duction is poor.)
● Use care when removing the booster cables. Do not

allow the booster cables clips to contact each other or
the machine.
NOTICE
● The size of the booster cable and clip should be suitable for the battery size.
● The battery on the normal machine must be the same capacity as that on the problem machine.
● Check the cables and clips for damage or corrosion.
● Make sure that the cables and clips are firmly connected.
● Check that the safety lock levers and parking brake levers on both machines are at the LOCK position.
● Check that all levers are at neutral.
3-103
CONNECTING THE BOOSTER CABLES

Make sure that the starting switches of the normal machine and
problem machine are both at the OFF position.
Connect the booster cable as follows, in the order of the num-
bers marked in the diagram.
1. Connect one clip of booster cable (A) to the positive (+)

terminal of the problem machine.
2. Connect the other clip of booster cable (A) to the positive

(+) terminal of the normal machine.
3. Connect one clip of booster cable (B) to the negative (-)

terminal of the normal machine.
4. Connect the other clip of booster cable (B) to the engine block of the problem machine.
STARTING THE ENGINE
WARNING
Check that the safety lock levers on both the normal machine and problem machine are at the LOCK posi-
tion. Check also that all levers are at neutral.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start the engine of the normal machine and run it at high idling speed.
3. Turn the starting switch of the problem machine to the START position and start the engine. If the engine
does not start, wait for at least 2 minutes before trying again.
DISCONNECTING THE BOOSTER CABLES

After the engine has started, disconnect the booster cables in
the reverse of the order in which they were connected.
1. Remove one clip of booster cable (B) from the engine

block of the problem machine.
2. Remove the other clip of booster cable (B) from the nega-
tive (-) terminal of the normal machine.
3. Remove one clip of booster cable (A) from the positive

(+) terminal of the normal machine.
4. Remove the other clip of booster cable (A) from the posi-
tive (+) terminal of the problem machine.
3-104
OTHER TROUBLE
ELECTRICAL SYSTEM
● ( ): Always contact your Komatsu distributor when dealing with these items.
● In cases of abnormalities or causes which are not listed below, please contact your Komatsu distributor for
repairs.
Problem Main causes Remedy
Lamp does not glow brightly even ● Defective wiring ( ● Check, repair loose terminals,
when the engine runs at high disconnection)
speed
Lamp flickers while engine is run- ● Defective adjustment of fan belt ● Check fan belt wear, replace.
ning tension For details, see EVERY 250
HOURS SERVICE.
Charge lamp do not go out even ● Defective lamp ( ● Replace)

when engine is running ● Defective alternator ( ● Replace)
● Defective wiring ( ● Check, repair)
Abnormal noise is generated from ● Defective alternator ( ● Replace)

alternator
Starting motor does not turn when ● Defective wiring ( ● Check, repair)
starting switch is turned to ON ● Insufficient battery charge ● Charge
Pinion of starting motor keeps ● Insufficient battery charge ● Charge

going in and out
Starting motor turns engine slug- ● Insufficient battery charge ● Charge

gishly ● Defective starting motor ( ● Replace)
Starting motor disengages before ● Defective wiring ( ● Check, repair)

engine starts ● Insufficient battery charge ● Charge
Heater signal does not glow red ● Defective wiring ( ● Check, repair)
● Defective heater relay ( ● Replace)
● Defective heater signal ( ● Replace)
Charge lamp does not light up ● Defective lamp ( ● Replace)

while engine is stopped (with start- ● Defective wiring ( ● Check, repair)
ing switch at ON position)
Outside of electrical intake air ● Defective wiring ( ● Check, repair)

heater is not warm when touched ● Disconnection in electrical intake ( ● Replace)
by hand air heater
● Defective operation of heater ( ● Replace heater relay switch)
relay switch intake air heater
3-105
CHASSIS
repairs.
Lack of drawbar pull (lack of ● Lack of engine horsepower ● See ENGINE

speed) ● Low transmission oil pressure ( ● Check, adjust)
● Parking brake still applied ● Release parking brake lever
Machine does not move when ● Lack of oil in transmission case ● Add oil to specified level. For
gearshift lever is operated details, see EVERY 250
HOURS SERVICE.
● Oil pressure in transmission (● Check, service)
does not rise
More noise than usual is generated ● Lack of oil in transmission case, ● Add oil to specified level. For
from power train tandem case details, see EVERY 250
HOURS SERVICE.
Abnormal wear of front tires ● Incorrect adjustment of toe-in ● Adjust. For details, see
EVERY 1000 HOURS SER-
VICE.
Heat generated from front wheel ● Loose bearing preload adjust- ( ● Check, adjust [adjust bearing
hub ment nut for front wheel preload])
● Lack of grease ● Supply grease
Front wheels wobble when travel- ● Incorrect adjustment of toe-in, ● Adjust. For details, see
ing loose tie rod EVERY 1000 HOURS SER-
VICE.
● Inflation pressure of left and ● Inflate tires to same air pres-
right tires not same sure
● Wheel not properly installed ● Install again. For details, see
HANDLING TIRES.
● Loose front wheel bearing (● Adjust)
mounting nut
Steering wheel is heavy ● Defective Orbit-roll ( ● Adjust)

Even when brake pedal is ● Worn lining ( ● Inspect, repair)
depressed, braking effect is poor ● Air leakage in brake piping ( ● Inspect, repair)
● Seized lining ( ● Finish surface of lining with
sandpaper)
● Defective piston seal ( ● Replace)
Poor braking effect of parking ● Defective adjustment of brake ( ● Adjust)

brake shoe
● Oil on lining surface ( ● Finish surface of lining with
sandpaper)
● Seized lining ( ● Finish surface of lining with
sandpaper)
● Sand, water, mud inside brake ( ● Disassemble, clean)
3-106
CHASSIS continued
Blade moves up and down exces- ● Play in lift cylinder ball joint ● Adjust shim. For details, see
sively during operation EVERY 250 HOURS SER-
VICE.
● Excessive clearance between ● Adjust shim at circle guide con-
sliding surface of circle and nector. For details, see
drawbar EVERY 500 HOURS SER-
VICE.
● Worn blade rail side bushing ● Worn side bushing
● Excessive clearance of circle in ● Correct blade rail
radial direction
Rotation of blade during operation ● Excessive clearance in circle in ● Adjust position of guide con-
is excessive radial direction nector. For details, see
EVERY 500 HOURS SER-
VICE.
Work equipment does not move ● Lack of oil ● Add oil to specified level. For
properly when work equipment details, see EVERY 250
control lever is operated HOURS SERVICE.
Heat generated from parking brake ● Lining in contact with drum ● Adjust clearance
drum
3-107
ENGINE
repairs.
After warming-up operation, ● Oil level in engine oil pan is low ● Add oil to specified level. For
engine oil pressure gauge does not (sucking in air) details, see CHECK BEFORE
work even when engine speed is STARTING.
raised ● Clogged oil filter element ● Replace element. For details,
see EVERY 250 HOURS SER-
VICE.
● Leakage of oil due to damage, (● Check, repair)
defective tightening of oil pipe,
pipe joint
● Defective gauge ( ● Replace)
● Defective oil pressure switch ( ● Replace)
Steam spurts out from top of radia- ● Coolant level is low ● Check, add water. For details,
tor (pressure valve) see WHEN REQUIRED.
Water temperature gauge is in red ● Loose fan belt ● Adjust tension. For details, see
range EVERY 250 HOURS SER-
VICE.
● Dirt or scale accumulated in ● Change cooling water, clean
cooling system cooling system. For details,
see WHEN REQUIRED.
● Radiator fins clogged or bent ● Clean or repair. For details,
see EVERY 500 HOURS SER-
VICE.
● Defective thermostat (● Replace thermostat)
● Loose radiator filler cap (high ● Tighten cap or replace packing
altitude operations)
● Defective monitor ( ● Replace)
Water temperature gauge does not ● Defective thermostat ( ● Replace thermostat)

work ● Defective water temperature ( ● Replace water temperature
gauge gauge)
Engine does not start when start- ● Lack of fuel ● Add fuel. For details, see
ing motor is turned CHECK BEFORE STARTING.
● Air in fuel system ● Repair place where air is
sucked in
● Defective fuel injection pump or (● Replace pump or nozzle)
nozzle
● Starting motor cranks engine ● See ELECTRICAL SYSTEM
sluggishly
● Preheating monitor does not ● See ELECTRICAL SYSTEM
light up
● Defective compression
● Defective valve clearance ( ● Adjust clearance)
● Defective stop motor ( ● Replace)
3-108
ENGINE continued
Exhaust gas is white or blue ● Too much oil in oil pan ● Reduce oil to specified level.
For details, see CHECK
BEFORE STARTING.
● Lack of fuel ● Add fuel. For details, see
CHECK BEFORE STARTING.
● Improper fuel ● Change to specified fuel
Exhaust gas sometimes turns ● Clogged air cleaner element ● Clean or replace. For details,
black see WHEN REQUIRED.
● Defective nozzle (● Replace nozzle)
● Defective compression (● See "Defective compression"
above)
● Defective turbocharger (● Clean or replace turbocharger)
Combustion noise occasionally ● Defective nozzle ( ● Replace nozzle)

makes breathing sound ● Defective fuel injection pump ( ● Replace pump)
Abnormal noise generated (fuel ● Low-grade fuel being used ● Change to specified fuel
system or mechanical system) ● Overheating ● See "Engine water tempera-
ture gauge is in red range top".
● Damage inside muffler ● Replace muffler
● Excessive valve clearance (● Adjust clearance)
3-109
MEMO
3-110
MAINTENANCE
41
WARNING
4-1
GUIDES TO MAINTENANCE MAINTENANCE
GUIDES TO MAINTENANCE
Do not carry out any inspection and maintenance operation that is not given in this manual.
Perform maintenance work on hard, flat ground.
Check service meter:

Check the service meter reading every day to see if the time has come for any necessary maintenance to be car-
ried out.
Komatsu genuine replacement parts:

Use Komatsu genuine parts specified in the parts list as replacement parts.
Komatsu genuine oils:

Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient tem-
perature.
Always use clean washer fluid:

Use automobile window washer fluid and be careful not to let any dirt get into it.
Clean oil and grease:

Use clean oil and grease. Also, keep containers of the oil and grease clean. Keep foreign materials away from oil
and grease.
Keeping the machine clean:

Always keep the machine clean. This makes it easier to find parts causing problems. In particular, keep grease fit-
tings, breathers and oil lever gauges clean and prevent dirt and dust from getting in them.
Be careful of hot water and oil:

Draining hot oils and coolants and removing their filters immediately after the engine stops is hazardous.
Allow the engine to cool.
If the oil has to be drained when it is cold, warm up the oil to a suitable temperature (approx. 20 - 40ºC) before
draining it.
Checking foreign material in drained oil:

After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign material. If large
quantities of metallic particles or foreign materials are found, contact your Komatsu distributor.
Fuel strainer:
If your machine is equipped with a fuel strainer, do not remove it while fueling.
Oil change:
Check or change oils in a place where there is no dust, and keep dirt and dust away from oils.
Warning tag:
Attach the warning tag to the starting switch or other appropriate control lever to prevent anyone from starting the
engine.
Obey precautions:
During the operation, always obey the precautions on the safety label stuck to the machine.
4-2
MAINTENANCE GUIDES TO MAINTENANCE
Welding instructions:
● Turn off the engine starting switch.
● Do not apply more than 200 V continuously.
● Connect grounding cable within 1 m from the area to be welded.
● Avoid seals or bearings from being between the area to be welded and the position of grounding point.
Fire prevention:
Use nonflammable cleaner or light oil for cleaning parts. Keep flame or cigarette light away from light oil.
Clamp faces:
When O-rings or gaskets are removed, clean the clamp faces and replace the O-rings and gaskets with new ones.
Be sure to fit O-rings and gaskets when assembling.
Objects in your pockets:

Keep your pockets free of loose objects which can fall out and drop into the machinery; especially when you work
on the machinery while bending over it.
Checking undercarriage:
When working in rocky areas, check for damage to the undercarriage and for looseness, cracks, wear and dam-
age in bolts and nuts.
Cleaning machine:
● Do not direct any steam jet directly at any mechatronics parts or connectors.
● Do not direct a high-pressure jet directly at the radiator.
● Do not splash water over the electrical equipment.
Pre-and post-work checks:

Before starting work in mud, rain, snow or at the seashore, check plugs and valves for tightness. Wash the
machine immediately after the work to protect components from rusting.
Lubricate components more frequently than usual. Be sure to lubricate work equipment pins daily if they are sub-
merged in water.
Dusty worksites:
When working at dusty worksites, do as follows:
● Check the air cleaner for clogging more frequently. Clean the air cleaner at shorter intervals than specified.
● Clean the radiator core frequently to avoid clogging.
● Clean and replace the fuel filter frequently.
● Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
Avoid mixing oils:

Never mix oils of different brands. If you have only oil which is a different brand from the one that is used in the
machine, do not add it but replace all the oil.
Electrical interference:
If there is any external electrical interference, the controller on the machine monitor may work incorrectly, so con-
sult your Komatsu distributor before installing any radio equipment on the machine.
4-3
OUTLINES OF SERVICE MAINTENANCE
OUTLINES OF SERVICE
OUTLINE OF OIL, FUEL, COOLANT
OIL
● Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pres-
sure), and it deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Man-
ual. Even if the oil is not dirty, always replace the oil after the specified interval.
● Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities
(water, metal particles, dirt, etc.) from getting in.
The majority of problems with machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
● Never mix oils of different grades or brands.
● Always add the specified amount of oil.

Having too much oil or too little oil are both causes of problems.
● If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases,
● When changing the oil, always replace the related filters at the same time.
● We recommend you to have an analysis made of the oil periodically to check the condition of the machine.
For those who wish to use this service, please contact your Komatsu distributor.
FUEL
● The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.
● Be extremely careful not to let impurities get in when storing or adding fuel.
● Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15ºC),
so it is necessary to change to a fuel that matches the temperature.
● To prevent the moisture in the air forming water inside the fuel tank, always fill the fuel tank after completing
the day’s work.
● Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water
from the fuel tank.
● If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
4-4
MAINTENANCE OUTLINES OF SERVICE
COOLANT
● River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the
engine and radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.
● When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.
● Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped.
This anti-freeze is effective in preventing corrosion of the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is even
in hot areas.
● Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.
● The proportion of anti-freeze to water differs according to the ambient temperature. For details of the mixing
proportions, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-18)".
● If the engine overheats, wait for the engine to cool before adding coolant.
● If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air in
the coolant.
GREASE
● Grease is used to prevent twisting and noise at the joints.
● The nipples not included in the maintenance section are nipples for overhaul, so they do not need grease. If
any part becomes stiff after being used for a long time, add grease.
● Always wipe off all of the old grease that is pushed out when greasing. 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.
STORING OIL AND FUEL

● Keep indoors to prevent any water, dirt, or other impurities from getting in.
● When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at
the side. (To prevent moisture from being sucked in)
If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect
them.
● To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use
the oldest oil or fuel first).
4-5
OUTLINES OF SERVICE MAINTENANCE
FILTERS
● Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working in severe conditions, it is necessary to consider replacing the filters at shorter inter-
vals according to the oil and fuel (sulfur content) being used.
● Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
● When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are found,
● Do not open packs of spare filters until just before they are to be used.
● Always use genuine Komatsu filters.
RELATING TO ELECTRIC SYSTEM

● If the wiring gets wet or the insulation is damaged, the electric system leaks and this could result in hazardous
malfunction of the machine.
● Services relating to the electric system are (1) check of fan belt tension, (2) check of damage or wear in the
fan belt and (3) check of battery fluid level.
● Never remove or disassemble any electric components installed in the machine.
● Never install any electric components other than these specified by Komatsu.
● Be careful to keep the electric system free of water when washing the machine or when it rains.
● When working on the seashore, carefully clean the electric system to prevent corrosion.
● Never connect any optional power source to the fuse, starting switch, battery relay, etc.
4-6
MAINTENANCE WEAR PARTS LIST
WEAR PARTS LIST

Wear parts such as the filter element, cutting edge, etc. are to be replaced at the time of periodic maintenance or
before their abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
For part change, Komatsu genuine parts of excellent quality should be used.
The parts in parentheses are to be replaced at the same time.
Item Part No. Part Name Q’ty Replacement interval
Engine oil filter 600-211-1230 Cartridge 1 Every 250 hours
Fuel filter 600-311-8291 Cartridge 1 Every 500 hours

Transmission oil filter 281-16-11290 Element 1
Every 500 hours
(07000-12125) (O-ring) (1)
Hydraulic oil filter 07063-01100 Element 1

Every 1000 hours
(07000-12135) (O-ring) (1)
Corrosion resister 600-411-1150 Cartridge 1 Every 1000 hours
6125-81-7032 Element ass’y 1

Air cleaner -
600-181-4300 Outer element ass’y 1
Blade 234-70-12710 Edge 2

234-70-32230 End bit 2
234-70-32240 End bit 2
(234-70-32250) (Bolt) (26)
(234-70-32260) (Bolt) (2) -
(234-70-32270) (Bolt) (10)
(234-70-32280) (Bolt) (2)
(234-70-32290) (Washer) (40)
(01643-32060) (Nut) (40)
Electrical heater 600-815-3811 Gasket 2 -
4-7
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE
USE OF FUEL, COOLANT AND LUBRICANTS

ACCORDING TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

AMBIENT TEMPERATURE
KIND OF CAPACITY
RESERVOIR
FLUID Specified Refill
SAE 30 CD, CE
SAE 10WCD, CE
30 liters 24 liters
Engine oil pan 7.92 US gal 6.34 US gal
SAE 10W-30CD, CE, CF-4

Engine oil
SAE 15W-40CD, CE, CF-4
Transmission case SAE 30 CD 48 liters 24 liters

12.67 US gal 6.34 US gal
Tandem drive case 105 liters 105 liters

SAE 10WCD
(each) 27.72 US gal 27.72 US gal
SAE 140 36 liters 33 liters

Final drive case 9.51 US gal 8.72 US gal
Gear oil SAE 90

Circle reverse gear 12 liters 12 liters
case SAE 80 3.17 US gal 3.17 US gal
120 liters 60 liters

Hydraulic system Engine oil SAE 10WCD 31.68 US gal 15.84 US gal
ASTM D975 No.2

Fuel tank Diesel fuel 400 liters -
105.6 US gal
Grease fitting Grease NLGI No.2 - -
55 liters
Cooing system Water Add antifreeze 14.52 US gal -
✽ASTM D975 No. 1
4-8
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
REMARK
● When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours
described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
Change interval of oil in

Fuel sulphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval

Above 1.0% 1/4 of regular interval
● When starting the engine in an atmospheric temperature of lower than 0ºC, be sure to use engine oil of
SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up to 10ºC more or
less in the day time.
● Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to
half.
● There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add
single grade oil that matches the temperature in the table.
● We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine
and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
4-9
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE MAINTENANCE
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT(Winter, one
EO15-40CD season type)
Diesel sigma S
super dieselmulti-
2 AGIP Rotra MP GR MU/EP -
grade
*Sigma turbo
Multi-purpose gear PYKON premium

3 AMOCO *Amoco 300 -
oil grease
Litholine HEP 2
4 ARCO *Arcofleet S3 pius Arco HD gear oil -
Arco EP moly D
Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP
*RPM delo 400 Universal thuban Marfak all purpose 2

6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -
Universal gear
9 CONOCO *Fleet motor oil Super-sta grease -
lubricant
Multiperformance 3C Tranself EP
10 ELF - Glacelf
Performance 3C Tranself EP type 2
Essolube D3
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
Delvac 1300 Mobilux EP2

Mobilube GX
13 MOBIL *Delvac super Mobilgrease 77 -
Mobilube HD
10W-30, 15W-40 Mobilgrease special
Multi-purpose white
*Superme duty fleet Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease
4-10
MAINTENANCE USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
FINA potonic N
15 PETROFINA FINA kappa TD FINA marson EPL2 FINA tamidor
FINA potonic NE
Spirax EP
16 SHELL Rimura X Albania EP grease -
Spirax heavy duty
Sunoco ultra pres- Sunoco antifreeze

Sunoco GL5
17 SUN - tige 2EP and summer cool-
gear oil
Sun prestige 742 ant
*Ursa super plus Multifak EP2 Coda 2055 startex

18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze
*Rubia X
TM
20 UNION *Guardol MP gear lube LS Unoba EP -
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B - Antifreeze
MDC Multigear C
4-11
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS MAINTENANCE
STANDARD TIGHTENING TORQUES FOR BOLTS

AND NUTS
TORQUE LIST
CAUTION
If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to
the tightened parts, and this will cause failure of the machine or problems with operation.
Always pay careful attention when tightening parts.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
The tightening torque is determined by the width across the flats of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that
was replaced.
Tightening torque
Width
Thread across Target value Service limit
diameter flat
a(mm) b(mm) N•m kgf•m lbft N•m kgf•m lbft
6 10 13.2 1.35 9.8 11.8 - 14.7 1.2 - 1.5 8.7 - 10.8
8 13 31 3.2 23.1 27 - 34 2.8 - 3.5 20.3 - 25.3
10 17 66 6.7 48.5 59 - 74 6.0 - 7.5 43.4 - 54.2
12 19 11 11.5 83.2 98 - 123 10.0 - 12.5 72.3 - 90.4
14 22 177 18 130.2 157 - 196 16.0 - 20.0 115.7 - 144.7
16 24 279 28.5 206.1 245 - 309 25.0 - 31.5 180.8 - 227.8
18 27 382 39 282.1 343 - 425 35.0 - 43.5 253.2 - 314.6
20 30 549 56 405.0 490 - 608 50.0 - 62.0 361.7 - 448.4
22 32 745 76 549.7 662 - 829 67.5 - 84.5 488.2 - 611.2
24 36 927 94.5 683.5 824 - 1030 84.0 - 105.0 607.6 - 759.5
27 41 1320 135.0 976.5 1180 - 1470 120.0 - 150.0 868.0 - 1085.0
30 46 1720 175.0 1265.8 1520 - 1910 155.0 - 195.0 1121.1 - 1410.4
33 50 2210 225.0 1627.4 1960 - 2450 200.0 - 250.0 1446.6 - 1808.3
36 55 2750 280.0 2025.2 2450 - 3040 250.0 - 310.0 1808.3 - 2242.2
39 60 3280 335.0 2423.1 2890 - 3630 295.0 - 370.0 2133.7 - 2676.2
Apply the following table for Hydraulic Hose.
Tightening torque
Width
Thread across Target value Service limit
diameter flat
a(mm) b(mm) N•m kgf•m lbft N•m kgf•m lbft
10 14 14.7 1.5 10.8 12.7 - 16.7 1.3 - 1.7 9.4 - 12.3
14 19 29.4 3.0 21.7 27.5 - 39.2 2.8 - 4.0 20.3 - 28.9
18 24 78.5 8.0 57.3 58.8 - 98.1 6.0 - 10.0 43.4 - 72.3
22 27 117.7 12.0 86.8 88.3 - 137.3 9.0 - 14.0 65.1 - 101.3
24 32 147.1 15.0 108.5 117.7 - 176.5 12.0 - 18.0 86.8 - 130.2
30 36 215.7 22.0 159.1 176.5 - 245.2 18.0 - 25.0 130.2 - 180.8
33 41 255.0 26.0 188.1 215.7 - 284.4 22.0 - 29.0 159.1 - 209.8
4-12
MAINTENANCE PERIODIC REPLACEMENT OF CRITICAL PARTS
PERIODIC REPLACEMENT OF CRITICAL PARTS

To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out
periodic maintenance. In addition, to further improve safety, the user should also carry out periodic replacement of
the parts given in the table. These parts are particularly closely connected to safety and fire prevention.
With these parts, the material changes as time passed, or they easily wear or deteriorate. However, it is difficult to
judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed
time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function
completely.
However, if these parts show any abnormality before the replacement interval has passed, they should be repaired
or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same as the
hoses.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.
Ask your Komatsu distributor to replace the critical parts.
CRITICAL PARTS
No. Safety critical parts for periodic replacement Q’ty Replacement interval
1 Fuel hose (fuel tank - fuel injection pump) 2
2 Fuel hose (fuel injection pump - fuel filter) 2
3 Fuel spill hose (fuel tank return) 2
4 Fuel return hose (fuel injection pump - adapter) 1
5 Fuel return hose (adapter - fuel tank) 1
6 Turbo lubrication hose 1
7 Dust seal for steering cylinder 2

Every 2 years or
8 O-ring for steering cylinder 2 every 4000 hours,
whichever comes
9 Rod packing for steering cylinder 4 sooner.
10 Steering circuit rubber hose (steering pump - steering valve) 2
11 Steering circuit rubber hose (steering valve - steering cylinder) 7

12 Steering circuit rubber hose (steering valve - hydraulic tank) 7
13 O-ring for steering valve 1
Leaning circuit rubber hose

14 4
(right side of work equipment control valve - leaning cylinder)
15 Brake circuit rubber hose 1
16 Seat belt 1 Every 3 years
4-13
MAINTENANCE SCHEDULE CHART MAINTENANCE
MAINTENANCE SCHEDULE CHART
MAINTENANCE SCHEDULE CHART
INITIAL 250 HOURS SERVICE (only after the first 250 hours)
REPLACE FUEL FILTER CARTRIDGE .............................................................................................................. 4-17
CHANGE OIL IN TRANSMISSION CASE .......................................................................................................... 4-17
CHANGE OIL IN FINAL DRIVE CASE ............................................................................................................... 4-17
CHANGE OIL IN CIRCLE REVERSE GEAR CASE ........................................................................................... 4-17
CHANGE OIL IN HYDRAULIC TANK, REPLACE FILTER ELEMENT ............................................................... 4-17
CHANGE OIL IN TANDEM DRIVE CASE........................................................................................................... 4-17
CHECK ENGINE VALVE CLEARANCE, ADJUST.............................................................................................. 4-17
WHEN REQUIRED
CLEAN INSIDE OF COOLING SYSTEM ............................................................................................................ 4-18
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ............................................................................ 4-21
CHECK ELECTRICAL INTAKE AIR HEATER .................................................................................................... 4-23
REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT ........................................................ 4-23
CHECK INCHING PEDAL................................................................................................................................... 4-23
CHECK DISC BRAKE ......................................................................................................................................... 4-24
SELECTION AND INSPECTION OF TIRES....................................................................................................... 4-26

See "CHECK BEFORE STARTING" in the OPERATION section.
EVERY 50 HOURS SERVICE

LUBRICATING .................................................................................................................................................... 4-29
4-14
MAINTENANCE MAINTENANCE SCHEDULE CHART

LUBRICATING .................................................................................................................................................... 4-30
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ........................................ 4-33
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL ................................................................................ 4-35
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...................................................................................... 4-36
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL................................................................................. 4-37
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL ................................................................. 4-37
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ....................................................................................... 4-38
CHECK LEVEL OF BATTERY ELECTROLYTE ................................................................................................. 4-39
CHECK BALL JOINT CLEARANCE, ADJUST ................................................................................................... 4-39
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT ............................................................................ 4-40
CHECK PARKING BRAKE LEVER STROKE, ADJUST..................................................................................... 4-41
CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION AND WEAR.............................. 4-42
CHECK FAN BELT TENSION, ADJUST............................................................................................................. 4-42

REPLACE FUEL FILTER CARTRIDGE.............................................................................................................. 4-43
REPLACE TRANSMISSION OIL FILTER ELEMENT ......................................................................................... 4-44
CLEAN, CHECK RADIATOR FINS ..................................................................................................................... 4-44
CHECK CIRCLE GUIDE CLEARANCE, ADJUST .............................................................................................. 4-45

GREASE DRIVE SHAFT .................................................................................................................................... 4-47
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER ......................................................................... 4-48
CHANGE OIL IN FINAL DRIVE CASE ............................................................................................................... 4-49
CHANGE OIL IN CIRCLE REVERSE GEAR CASE ........................................................................................... 4-50
CHANGE OIL IN HYDRAULIC TANK, REPLACE FILTER ELEMENT AND CLEAN STRAINER....................... 4-51
CHECK LOOSENESS IN DRAWBAR FRONT BALL JOINT .............................................................................. 4-52
CHECK TOE-IN, ADJUST .................................................................................................................................. 4-53
REPLACE CORROSION RESISTOR CARTRIDGE........................................................................................... 4-54
CHECK FRONT WHEEL BEARING PLAY, ADJUST.......................................................................................... 4-54
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER............................................................................... 4-54
CHECK PLAY OF TURBOCHARGER ROTOR .................................................................................................. 4-54
4-15
MAINTENANCE SCHEDULE CHART MAINTENANCE

CHANGE OIL IN FRONT WHEEL BEARING ..................................................................................................... 4-55
CHANGE OIL IN TANDEM DRIVE CASE........................................................................................................... 4-55
CHECK ALTERNATOR, STARTING MOTOR ..................................................................................................... 4-55
CHECK ENGINE VALVE CLEARANCE, ADJUST.............................................................................................. 4-55
CHECK VIBRATION DAMPER ........................................................................................................................... 4-55
CLEAN, CHECK TURBOCHARGER .................................................................................................................. 4-56
CLEAN ENGINE BREATHER ELEMENT ........................................................................................................... 4-56

CHECK WATER PUMP....................................................................................................................................... 4-57
4-16
MAINTENANCE SERVICE PROCEDURE
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE

Carry out the following maintenance 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 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 500 HOURS, 1000 HOURS AND
2000 HOURS SERVICE.
4-17
SERVICE PROCEDURE MAINTENANCE
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 safety lock lever to the LOCK position.
● For details of starting the engine, see "CHECK BEFORE STARTING ENGINE (PAGE 3-24)" and
"STARTING ENGINE (PAGE 3-38)" 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.
● Stop the machine on level ground when cleaning or changing the coolant.
● Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the
table below.
Cleaning inside of cooling system

Kind of coolant Replacing corrosion resistor
and changing coolant
Permanent type antifreeze (All Every year (autumn)or every 2000

season type) hours, whichever comes first
Every 1000 hours and when
Non-permanent type anti- Every 6 months (spring, autumn)
cleaning the inside of the cooling
freeze containing ethylene gly- (Drain antifreeze in spring, add
system and when changine cool-
col (winter, one season type) antifreeze in autumn)
ant.
Every 6 months or every 1000
When not using antifreeze
hours, whichever comes first
● Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene
glycol.
● 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 before to estimate a temperature about 10ºC lower when deciding the mixing rate.
4-18
Mixing rate of water and antifreeze
Min. °C -10 -15 -20 -25 -30

atmospheric
temperature °F 14 5 -4 -13 -22
Amount of liters 17 20 23 25 27.5

antifreeze US gal 4.49 5.28 6.07 6.60 7.26
Amount of liters 38 35 32 30 27.5

water US gal 10.03 9.24 8.45 7.92 7.26
WARNING
Coolant is flammable, so keep it away from flames.
Antifreeze is toxic. When removing the drain plug, be careful not to get any water containing antifreeze on
yourself. If it should gets into your eyes, wash your eyes with large quantities of fresh water and see a
doctor at once.
Use tap water for the coolant. If the only available water is river water or well water, contact your Komatsu distribu-
tor for advice.
We recommend use of an antifreeze density gauge to control the mixing proportions.
Prepare the following:

Container to mix coolant: Min. 55 liters (14.52 US gal) capacity
1. Stop the engine and turn corrosion valves (1) to the OFF
position to close it.
2. Turn radiator cap (2) slowly to remove it.
4-19
3. Set a container in position to catch the coolant, then open

drain valve (3) at the bottom of the radiator and drain plug
(4) on the oil cooler and drain the coolant.
4. After draining the coolant, close drain valve (3) and drain
plug (4), and fill with tap water.
When the radiator is full, start the engine, run at low
idling, and operate for approx. 10 minutes to raise the
water temperature to at leaset 90ºC (194ºF).
5. Stop the engine, open drain valve (3) and drain plug (4),
and drain the water.
6. After draining the water, use a cleaning agent to carry out

cleaning.
Follow the instructions on the cleaning agent container
when carrying out the cleaning operation.
7. Close drain valve (3) and drain plug (4).
8. 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 4-54)".
9. Pour in the antifreeze and water through the water filler up to the bottom of the water filler port.
10. To remove the air in the coolant, run the engine for 5 minutes at low idling, then run for a further 5 minutes at
high idling. (When doing this, leave the water filler cap off.)
11. Stop the engine, wait for approx. 3 minutes, then add tap water until the water level is near the water filler
port, and tighten the cap. Check the coolant level and add water if necessary.
4-20
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
WARNING
● Never clean or replace the air cleaner element with the engine running.
● When using pressure air to clean the element wear safety glasses or goggles to protect the eyes.
NOTICE
Do not clean the air cleaner element before red piston in dust indicator appears.
If the element is cleaned frequently before the red piston appears, the air cleaner will not be able to dis-
play its performance fully, and the cleaning efficiency will also go down.
In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner element.
CHECKING
Whenever the red piston in dust indicator (1) appears, clean
the air cleaner element.
CLEANING OR REPLACING OUTER ELEMENT

1. Loosen wing bolt (2), clamp (3) and cover (4), then
remove outer element (3).
2. Clean the air cleaner body interior and the cover.
3. Direct dry compressed air (less than 0.69 MPa (7 kgf/

cm2, 99.4 PSI)) to the element from inside along its folds,
then direct it from outside along its folds and again from
inside.
(1) Remove one seal from the outer element. The num-
ber of times the outer element has been cleaned can
be seen by the number of removed seals.
(2) Replace the outer element which has been cleaned
6 times repeatedly or used throughout a year.
Replace the inner element at the same time.
(3) Replace the element when the air cleaner clogged warning lamp lights up soon after installing the
cleaned element even though it has not been cleaned 6 times.
(4) Check inner element mounting nuts for looseness and, if necessary, retighten.
4-21
(5) Replace seal washer (5) or wing nut (6) with new
parts if they are broken.
(6) Remove evacuator valve and clean with compressed
air. After cleaning, reset the evacuator valve.
NOTICE
If small holes or thinner parts are found on the element
when it is checked with an electric bulb after cleaning and
drying, replace the element.
Do not use an element whose folds or gasket or seal are
damaged.
When cleaning the element, do not hit it or beat it against
something.
4. Set the cleaned element.
5. Push dust indicator (1) reset button to return the red pis-
ton to the original position.
REPLACING INNER ELEMENT

1. First remove the cover and the outer element, and then remove the inner element.
2. To prevent dust from getting in, use a clean cloth or tape to cover the air connector (outlet side).
3. Clean the air cleaner body interior, then remove the cover installed in Step 2.
4. Fit a new inner element to the connector and tighten it with nuts. Do not clean and reinstall the inner element.
NOTICE
Do not clean the inner element and use it again.
When replacing the outer element, replace the inner element with a new part at the same time.
5. Install the outer element and the cover.
6. After replacing the element, return the red piston in the dust indicator to its original position.
REMARK
When installing both the inner element and outer element, move the element lightly to bring the seal rubber at the
tip of the element into tight contact with the inside of the body while tightening the nut.
4-22
CHECK ELECTRICAL INTAKE AIR HEATER

Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air
heater repaired or checked for dirt or disconnections.
REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT
WARNING
Do not raise the blade unnecessarily high. Be sure not to
put any part of your body underneath the blade when
blocking it.
Replace the cutting edge before it wears to the end face of the
blade. Always replace the cutting edge and side edge when the
distance from the blade holder is less than 10 mm (0.4 in). If
the mounting surface is worn, correct the mounting surface
before replacing the cutting edge or side edge.
1. Lift the blade to a suitable height and put a block underneath the blade rail to prevent it from falling.
2. Remove nuts (1), then remove end bit (2) and the cutting edge (3).
3. Clean the mounting face for cutting edge and end bit.
4. Install a new cutting edge to the blade.
5. If the cutting edge (bottom) of the end bit is worn, reverse the end bit and interchange the left and right sides,
or replace, then install.
Tightening torque of mounting nut :260 ± 34.3 N•m (26.5 ± 3.5 kgf•m, 191.7 ± 25.3 lbft)
6. After several hours of running, retighten the nuts.
CHECK INCHING PEDAL

If any of the following problems have occurred, please contact your Komatsu distributor for inspection and adjust-
ment.
● If the machine does not stop even when the inching pedal is depressed.
● If the machine does not move or lacks power even when the inching pedal is released.
4-23
CHECK DISC BRAKE
WARNING
A small amount of oil will come out from the inspection plug hole, so do not look through the plug hole
when the brake is applied.
PERIODICAL REPLACEMENT OF DISC BRAKE

Inspection: Every 12 months
Disassembly: Every 24 months
As a basic rule, the guideline for disassembly is every 24 months or 2000 hours.
When judging the timing for disassembly or maintenance, use 24 months or 2000 hours, whichever comes sooner.
METHOD OF INSPECTING PISTON SEAL FUNCTION

1. Remove drain plug (3) from the cage, and measure the
amount of oil that leaks out from the piston chamber.
2. Depress the brake pedal and keep the brake applied.
3. If the amount of oil leaking is more than 20 cc, disassem-

ble and replace the seal.
4-24
METHOD OF CHECKING BRAKE DISC WEAR

1. Remove inspection plug (1) from the cage.
2. Depress the brake pedal and keep the brake applied.
3. Inspect the clearance between the end of the inspection

hole and separator plate (2) as shown in the diagram.
4. If there is no clearance, the disc has reached the wear

limit, so replace it.
4-25
SELECTION AND INSPECTION OF TIRES
WARNING
If a tire or a rim is handled wrongly, the tire may burst or
may be damaged and the rim may be broken and scat-
tered, and that can cause serious injury and death.
● Since maintenance, disassembly, repair and assembly

of the tires and rims require special equipment and
skill, be sure to ask a tire repair shop to carry out the
work.
● Do not heat or weld the rim to which the tire is

installed. Do not make a fire near the tire.
SELECTION OF TIRES
WARNING
Select the tires according to the conditions of use and attachments on the machine. Use only specified
tires and inflate them to the specified pressure.
Select the tires according to the conditions of use and attachments of the machine. Use the following table. Since
the indicated speed varies with the tire size, consult your Komatsu distributor when using optional tires.
Maximum load Tire size Remarks
Front wheel 3670 kg (8092 lb) 16.00-24-12PR Type 2 for construction

Rear wheel 3670 kg (8092 lb) 16.00-24-12PR equipment
4-26
CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM
WARNING
● When inflating a tire, check that no one will enter the
working area and use an air chuck which has a clip
and which can be fixed to the air valve.
While inflating the tire, check the inflation pressure
occasionally so that it will not rise too high.
If the rim is not fitted normally, it may be broken and
scattered while the tire is inflated. To ensure safety,
place a guard around the tire and do not work in front
of the rim but work on the tread side of the tire.
● Abnormal drop of inflation pressure and abnormal fit-

ting of the rim indicate a trouble in the tire or rim. In
this case, be sure to ask a tire repair shop to carry out
repairs.
● Be sure to observe the specified inflation pressure.
● Do not adjust the inflation pressure of the tires just

after high-speed travel or heavy-duty work.
Check
Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.
Inflation of tires
Adjust the inflation pressure properly.
When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not
work in front of the rim but work on the tread side of the tire.
The proper inflation pressure is shown below.
Tire size Inflation pressure
Front 16.00-24-12PR 0.22 MPa (2.2 kgf/cm2, 31.24 PSI)
Rear 16.00-24-12PR 0.22 MPa (2.2 kgf/cm2, 31.24 PSI)
NOTICE
The optimum inflation pressure differs according to the type of work. For details, see "HANDLING THE
TIRES (PAGE 3-91)".
4-27

For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-26)" in the OPERATION section.
● Check coolant level, add water
● Check fuel level, add fuel
● Drain water, sediment from fuel tank
● Drain water from air tank
● Check oil level in engine oil pan, add oil
● Check dust indicator
● Check and adjust steering wheel
● Check electric wiring
● Check braking effect
● Check stroke of parking brake lever
● Check that rise in air pressure is correct
● Check flashing of lamps, check for dirt and damage
● Check that all abnormalities from previous day have been repaired
● Check that windshield wiper, window washer, and defroster work properly, check washer fluid level
● Check inflation pressure of tires
4-28
LUBRICATING
WARNING
● Apply the parking brake, and secure the front and rear frame with the articulate lock pin.
● Set the work equipment in a stable condition, and stop the engine.
1. Apply grease to the grease fittings shown by arrows.
Circle pinion gear

Apply grease all around the circle part.
Blade guide rail

Apply grease all over the guide rail.
4-29

Maintenance for the 50 hours service should be carried out at the same time.
LUBRICATING
WARNING
1. Using a grease pump, pump in grease through the grease fittings shown by arrows.
2. After greasing, wipe off any old grease that was pushed out.
(1) Leaning cylinder pin (1 point)
(2) Tie rod (4 points)
(3) Steering linkage (9 points)
4-30
(4) Drawbar ball joint (1 point)
(5) Blade lift cylinder yoke (6 points)
(6) Blade lift cylinder ball joint (2 points)
(7) Drawbar side shift rod ball joint (2 points)
(8) Articulate cylinder pin (4 points)
4-31
(9) Articulate lock pin (1 point)

Apply grease
(10) Articulate center pin (2 points)
(11) Bank control guide (3 points)
(12) Bank control lock pin

Apply grease
4-32
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CAR-
TRIDGE
WARNING
The oil is at high temperature after the engine has been operated, so never change the oil immediately
after finishing operations. Wait for the oil to cool down before changing it.
Prepare the followings.
● Container to catch drained oil: Min 24 liters capacity
● Refill capacity: 24 liters (6.34 US gal)
● Filter wrench
1. Open oil filler (F).
2. Set a container to catch the oil directly under drain plug

(P).
3. Loosen drain plug (P), and drain the oil.
4. Check the drained oil, and if there are excessive metal

particles or foreign material, please contact your
Komatsu distributor.
5. Install drain plug (P).
6. Using a filter wrench, turn filter cartridge (1) counterclock-

wise to remove it.
In particular, if this operation is carried out immediately
after stopping the engine, a large amount of oil will come
out, so wait for 10 minutes before starting the operation.
7. Clean the filter holder, coat the packing surface of a new

filter cartridge with engine oil (or coat it thinly with
grease), then install it to the filter holder.
8. When installing, tighten until the packing surface contacts

the seal surface of the filter holder, then tighten it up fur-
ther 1/2 of a turn.
4-33
9. After replacing the filter cartridge, add engine oil through

oil filler (F) until the oil level is between the H and L marks
on the dipstick (G).
10. Run the engine at idling for a short time, then stop the
engine, and check that the oil level is between the H and
L marks on the dipstick. For details, see "CHECK OIL
LEVEL IN ENGINE OIL PAN, ADD OIL (PAGE 3-28)".
4-34
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL
WARNING
● The oil if at high temperature immediately after the machine has been operated. Wait for the oil to cool
down before starting the operation.
● Inspection is carried out with the engine idling, so always do as follows.
❍ Before inspecting, place the shift lock lever at the LOCK position and set all levers at the neutral
position to ensure that the machine does not move.
❍ After starting the engine, run until the oil level is stable, then wait for a further 5 minutes.
1. With the engine idling, remove dipstick (G) and leave for
at least 5 minutes.
2. Wipe dipstick (G) with a cloth.
again.
4. Check that the oil level is between the H and L marks on

dipstick (G).
oil filler (F).
6. If the oil level is correct, insert dipstick (G) in the oil filler
tube.
4-35
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
WARNING
The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool
1. Stop the engine, and leave it for 5 minutes.
2. Open left side cover and lower plate.
3. Remove dipstick (G) and wipe the oil off with a cloth.
again.
5. Check that the oil level is between the H and L marks on

dipstick (G).
oil filler (F).
6. If the oil level is above the H mark, drain the excess

engine oil from drain plug (P), and check the oil level
again.
pipe.
4-36
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL
WARNING
2. Remove dipstick (G), and wipe the oil off with a cloth.
again.
4. The oil level should be between the H and L marks on

dipstick (G). If the oil level below the L mark, add engine
oil through oil filler (F).
pipe.
6. If the oil level is above the H mark, drain the excess engine oil from drain plug (P), and check the oil level
again.
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL
WARNING
down before starting operation.
2. Remove plug (F) from oil filler port, and check if oil level
is enough by level gauge in the standard tools.
3. If the oil level is not up to the top surface of the gear, add
engine oil through the oil filler port.
4. If the oil level is correct, install oil filler plug (F).
REMARK
There may be wear particles in the oil, but there is no problem
using the oil as it is.
4-37
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
WARNING
When removing the oil filler cap, oil may spurt out, so stop the engine and wait for the oil temperature to
go down, then turn the cap slowly to release the internal pressure before removing the cap.
NOTICE
Do not add oil if the level is above the H line. This will damage the hydraulic equipment and cause the oil
to spurt out.
1. Set the machine in position as follows to check the oil level.

● Return the leaning of the front tires to the upright position and face the wheels straight to the front.
● Set the front frame and rear frame facing straight (articulated angle = 0º). Install the articulate lock pin.
● Return the blade sideshift to the center of the machine, set the blade at right angles to the chassis and
lower it lightly to the ground.
2. Stop the engine, wait for 5 minutes, then check that the
oil level is between the H and L marks on sight gauge
(G).
3. If the oil level is below the L mark, add engine oil through
oil filler (F).
4-38
CHECK LEVEL OF BATTERY ELECTROLYTE

Carry out this check before operating the machine.
WARNING
● To avoid gas explosions, do not bring fire or sparks near the battery.
● Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amounts
of water, and consult a doctor.
NOTICE
When adding distilled water in cold weather, add it before
starting operations in the morning to prevent the electro-
lyte from freezing.
1. Remove cap (1), and check that the electrolyte is up to

the UPPER LEVEL line. If the level is low, add distilled
water.
Do not add water above the UPPER LEVEL line. This
may cause leakage of the electrolyte, which may cause
fire.
If the battery electrolyte is spilled, have dilute sulphuric
acid added.
2. When adding distilled water to any cell at cap (1), add distilled water also to the other cells.
3. Clean the air hole in the battery cap, then tighten the cap securely.
CHECK BALL JOINT CLEARANCE, ADJUST

There are ball joints, so inspect and adjust all of these places.
● Prepare a thickness gauge
1. Remove all the shims from the ball joint.
2. Tighten the caps with bolts (1) to make the same clear-
ance on the left and right.
3. Measure the clearance with a thickness gauge, then

insert one shim more than this dimension, and tighten the
cap.
Thickness of one shim : 0.2 mm(0.008 in),
0.5 mm(0.020 in)
4-39
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT
NOTICE
Loose wheel hub nuts (1) and hub bolts will result in short-
ened life of tires or other troubles.
1. Carefully check for loose nuts.

When checking for loose nuts, always turn the nut in the
tightening direction to check.
Tightening torque: 490 ± 49 N•m (50 ± 5 kgf•m, 361.7 ±

36.2 lbft)
2. If a hub bolt is broken, replace all the hub bolts.
4-40
CHECK PARKING BRAKE LEVER STROKE, ADJUST
CHECKING
NOTICE
When the performance test of the parking brake is performed, a large force is applied to the drive system
and an excessive load is applied to the transmission. Accordingly, do not perform this test unnecessarily.
When the parking brake lever is pulled by 2 - 3 clicks, if the

machine is stopped securely, the lever stroke is normal. If the
lever can be pulled to the 6 click before the brake takes effect,
adjust it according to the following procedure.
ADJUSTING
1. Move the vehicle so that adjustment hole (1) of the brake
drum will be about 15 mm (0.6 in) right to the bottom cen-
ter. As the machine moves about 29 cm (11.4 in), the
brake drum revolves by one turn.
2. Insert a screwdriver in the adjustment hole and turn the

adjusting screw in the direction to expand the shoe (lower
the grip of the screwdriver) to fit the shoe to the drum,
then return by 8 clicks (the shoe clearance becomes 0.23
mm (0.009 in)).
3. Adjust the yoke and nut at both ends of the cable for the
proper stroke of the lever (3 - 4 clicks).
4. After adjustment, drive about 500m (1640 ft), then check the temperature of the drum to see if it is lower than
that of the adjacent drive shaft. A higher temperature indicates that the brake is dragging.
REMARK
● Since the parking brake is independent and used only for parking the vehicle, generally, it is only slightly worn.
However, the parking brake will be worn when the vehicle travels without releasing it.
If the parking brake is worn in this manner, its performance is lowered. Accordingly, remove the burnt layer
from the brake lining.
● If oil or grease sticks to the surface of the brake lining, wipe it off, then finish with sandpaper.
● When checking the effect of the parking brake, pull the parking brake lever, run the engine at full speed in F3,
then slowly release the inching pedal and check that the engine stops when the power is transmitted.
When this happens, the machine may move slightly, but this does not indicate any abnormality.
4-41
CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION
AND WEAR
If the wheel rim, lock ring and side ring are heavily corroded, ask the tire manufacturer or your Komatsu distributor
for inspection.
CHECK FAN BELT TENSION, ADJUST

TESTING
The deflection should be approx. 10 mm (0.4 in) when the fan
belt is pushed at a point midway between the alternator pulley
and fan pulley with a force of approx. 59N (6 kgf).
ADJUSTING
1. Loosen nuts (1) and (2), and alternator fulcrum nut (3),
then move alternator (4) to adjust the belt tension.
2. Check each pulley for damage, wear of the V-groove,

and wear of the V-belt. Be particularly careful to check
that the V-belt does not contact the bottom of the V-
groove.
3. If the belt has elongated and there is no more allowance

for adjustment, or if the belt is cut or cracked, replace the
belt.
4. When adjusting the V-belt, tighten nut (1) or (2) (the nut in the opposite direction from the direction to move
the alternator), then move the alternator.
When the position is fixed, tighten the other nut and the fulcrum nut (3) to hold alternator (4) in position.
5. If the V-belt has been replaced, adjust again after operating for 1 hour.
4-42

Maintenance for every 50 and 250 hours service should be carried out at the same time.
REPLACE FUEL FILTER CARTRIDGE
WARNING
● Engine is at high temperature immediately after the machine has been operated. Wait for engine to
cool down before replacing the filter.
● Do not bring fire or sparks near the fuel.
Prepare a filter wrench and a container to catch the fuel.
1. Set the container under the filter cartridge to catch the fuel.
2. Using a filter wrench, turn filter cartridge (1) counterclock-

wise to remove it.
3. Clean the filter holder, fill a new filter cartridge with clean
fuel, coat the packing surface with engine oil, then install
it to the filter holder.
4. When installing, tighten until the packing surface contacts

the seal surface of the filter holder, then tighten it 1/2 of a
turn.
If the filter cartridge is tightened too far, the packing will
be damaged and this will lead to leakage of fuel. If the fil-
ter cartridge is too loose, fuel will also leak from the pack-
ing, so always tighten to the correct amount.
5. After replacing filter cartridge (1), loosen air bleed plug

(2).
6. Loosen feed pump knob (3) and move the pump knob up
and down to draw off fuel until air ceases to come out of
air bleed plug (2).
7. Tighten up air bleed plug (2).

8. Push in the knob of feed pump (3) and tighten it.
9. After replacing the filter cartridge, start the engine, and

check that there is no leakage of fuel from the filter seal.
If there is any leakage of fuel, check the tightening of the
filter cartridge. If there is still leakage, repeat Steps 1 and
2 to remove the filter cartridge, then check the packing
surface for damage or foreign material.
If there is any damage or foreign material in the packing,
replace with a new cartridge and repeat Steps 3 to 8.
4-43
REPLACE TRANSMISSION OIL FILTER ELEMENT
WARNING
The oil is at high temperature after the engine is stopped. Wait for the temperature to go down before
starting the operation.
1. Remove bolts (1) (4 on outside), then remove case (2).
2. Take out the element, clean the inside of the case and the
removed parts, then install a new element.
CLEAN, CHECK RADIATOR FINS
WARNING
If compressed air, steam, or water hit your body directly, there is danger of injury. Always wear protective
glasses, mask, and safety shoes.
When cleaning, use a maximum pressure of less than 0.2 MPa (2.0 kgf/cm2, 28.4 PSI).
Clean the radiator fins if any mud or dirt is stuck to the radiator.
1. Remove bolts (1) to remove panel (2).
2. Clean the radiator fins clogged with mud, dust and leaves
with compressed air. Steam or water may be used
instead of compressed air.
3. Check the rubber hoses. If they are cracked or brittle,

replace them. At this time, check the hose clamps for
looseness.
4-44
CHECK CIRCLE GUIDE CLEARANCE, ADJUST
WARNING
● Before carrying out maintenance, check the clearance between the tip of the teeth (or root of the
teeth) of the circle gear and the root of the teeth (or tip of the teeth) of the pinion gear of the circle
rotator. If there is no clearance, replace the guide and carry out adjustment.
● When raising the blade, do not raise it higher than necessary.
NOTICE
If the condition is as shown below, replace the circle
guide.
● When there is no clearance (R) between the circle and
circle guide.
● When there is no clearance between the tip of the teeth
(or root of the teeth) of the circle gear and the root of
the teeth (or tip of the teeth) of the pinion gear of the
circle rotator.
Prepare the following:

● Feeler gauge
● Shims (thickness: 1 mm (0.039 in), 0.5 mm (0.020 in); 2

types)
TESTING
1. Raise the blade and use a feeler gauge to measure the
clearance (P) between the top surface of the circle and
the bottom surface of the drawbar as shown in the dia-
gram. The standard clearance is 1.5 ± 0.5 mm (0.059 ±
0.020 in).
2. Raise the blade and use a feeler gauge to measure clear-

ance (Q) F (front), (Q) C (center), and (Q) R (rear)
between the circle and circle guide as shown in the dia-
gram. Standard clearances (Q) F, (Q) C, and (Q) R are as
follows.
(Q) F = 0 mm, (Q) C = 0.7 mm (0.028 in), (Q) R = 1.5 mm
(0.059 in), or (Q) F = (Q) R = 1 mm (0.039 in)
4-45
ADJUSTING
1. Raise the blade, remove bolts (1), (5), and (9) for clear-
ance (P), remove circle guides (2), (6), and (10), then
adjust the shim thickness. (Shim thickness: 1 mm (0.039
in), 0.5 mm(0.020 in); 2 types)
2. Loosen bolt (1), then loosen locknut (4) and screw in bolt
(3) to push open circle guide (2) and make (Q) F = 0.
(When doing this, push open the left and right bolts uni-
formly.)
3. When (Q) F = 0, tighten locknut (4), then tighten bolt (1).
4. Loosen bolt (5), then loosen locknut (8) and screw in bolt
(7) to push open circle guide (6) and make (Q) C = 0.
(When doing this, push open the left and right bolts uni-
formly.)
5. When (Q) C = 0, turn back bolt (7) 1/4 turns, tighten lock-
nut (8), return circle guide (10) until it contacts bolt (7),
then tighten bolt (5).
6. Loosen bolt (9), then loosen locknut (12) and screw in

bolt (11) to push open circle guide (10) and make (Q) R =
0. (When doing this, push open the left and right bolts
uniformly.)
7. When (Q) R = 0, turn back bolt (11) half a turn, tighten

locknut (12), return circle guide (10) until it contacts bolt
(11), then tighten bolt (9).
8. The clearance between the tip of the teeth of the circle

gear and the root of the teeth of the pinion gear of the
rotator should be 1.5 - 3.0 mm (0.059 - 0.118 in).
4-46

Maintenance for every 50, 250 and 500 hours service should be carried out at the same time.
GREASE DRIVE SHAFT
WARNING
1. Using a grease pump, pump in grease through the

grease fittings shown by arrows.
2. After greasing, wipe off any old grease that was pushed
out.
4-47
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER
WARNING
Prepare the following.
● Container to catch drained oil: Min 24 liters (6.34 US gal) capacity
1. Remove the under cover and set a container under the transmission case to catch the oil.
2. To prevent getting oil on yourself, loosen drain plug (P)

and drain the oil.
To prevent the oil from spurting out, loosen drain plug (P),
then gradually remove it.
3. After draining the oil, wrap drain plug (P) with sealing
tape and install.
Tightening torque: 127 - 177 N•m

(13 - 18 kgf•m, 94 - 130.2 lbft)
4. After removing bolts (1), remove tube (2), bolt (4) and
cover (3), then take out the strainer, and wash it.
5. Remove all the dirt stuck to the strainer, then wash it in

clean diesel oil or flushing oil. If the strainer is damaged,
replace it with a new part.
6. After washing the strainer, install it, then install cover (3)
with bolt (4), tube (2) with bolts (1).
7. Refill the specified quantity of engine oil through oil filler

(F).
For details of the oil to use, see "USE OF FUEL, COOLANT

AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE (PAGE 4-8)".
8. After refilling, check that the oil is at the specified level.

For details, see "CHECK OIL LEVEL IN TRANSMISSION
CASE, ADD OIL (PAGE 4-35)".
9. Check that there is no leakage of oil from the transmis-

sion case or oil filter.
4-48
CHANGE OIL IN FINAL DRIVE CASE
WARNING
● Container to catch drained oil: Min. 33 liters (8.72 US gal) capacity
1. Set a container under the final drive case to catch the oil.
2. To prevent getting oil on yourself, loosen drain plug (P)

and drain the oil.
3. After draining the oil, tighten drain plug (P).
Tightening torque: 68.6 ± 9.81 N•m (7 ± 1 kgf•m, 50.6 ±

7.2 lbft)
4. Refill the specified quantity of engine oil through oil filler

(F).
5. After refilling, check that the oil is at the specified level.

For details, see "CHECK OIL LEVEL IN FINAL DRIVE
6. Check for oil leakage from the final drive case.
4-49
CHANGE OIL IN CIRCLE REVERSE GEAR CASE
WARNING

● Container to catch drained oil:Min. 12 liters (3.17 US gal)
capacity
1. Set the container under drain plug (P) to catch the oil.
2. Remove drain plug (P) and drain the oil.
3. After draining the oil, clean drain plug (P) and install it
again.
4. Remove oil filler plug (F) and add gear oil to the specified
level.
5. Check that the oil is at the specified level.

For details, see "CHECK OIL LEVEL IN CIRCLE
REVERSE GEAR CASE, ADD OIL (PAGE 4-37)".
6. Install oil filler plug (F).
4-50
CHANGE OIL IN HYDRAULIC TANK, REPLACE FILTER ELEMENT AND

CLEAN STRAINER
WARNING
down before changing the oil. When removing the oil filler cap, turn it slowly to release the internal pres-
sure, then remove it carefully.

● Container to catch drained oil: Min. 60 liters (15.84 US gal) capacity
1. Set the machine in position as follows to check the oil level.

● Return the leaning of the front tires to the upright position and face the wheels straight to the front.
● Set the front frame and rear frame facing straight (articulated angle = 0º).
● Return the drawbar sideshift and 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.
2. Loosen oil filler port (F) slowly to completely release the

air inside the hydraulic tank.
3. Set the container immediately under drain plug (P) to

catch the oil.
4. Remove drain plug (P) slowly to avoid getting oil on your-

self, and drain the oil.
5. After draining the oil, install drain plug (P).

To prevent environmental pollution in areas where people
or animals live, always do as follows.
6. Remove bolt (1), then remove cover (2), take out the ele-
ment, clean the inside of the filter case and the removed
parts, then install a new element.
7. Add the specified amount of engine oil through oil filler

(F).
8. After filling with oil, check that the oil is at the specified
level. For details, see "CHECK OIL LEVEL IN HYDRAU-
LIC TANK, ADD OIL (PAGE 4-38)".
9. Install oil filler (F).
4-51
CHECK LOOSENESS IN DRAWBAR FRONT BALL JOINT

Check ball joint connecting nuts (1) at the front of the drawbar
for loosening. If the connecting portion are loose, retighten
them.
4-52
CHECK TOE-IN, ADJUST
HOW TO MEASURE TOE-IN:

Check toe-in and adjust it so that no side slip is caused. When no side slip tester is available, use the following
procedure.
1. Park the grader on a level ground without steering and leaning the wheels.
Be sure to drive straight at least a few meters before parking.
2. Measure the height from the ground to the center of the

front wheel axle.
3. Mark the same dimension as measured in step 2 at about

the center position of the tire width.
Use the same procedure to mark both the left and right
tires.
4. Measure the distance between the two marks.

This distance is called "A".
5. Next, drive the machine forward slowly to move the

marks on the tire to the rear, 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.
Always travel forward when doing this.
6. Measure the distance between the two marks.

This distance is called "B".
7. When toe-in (B - A) is adjusted to -8.2 ± 1.5 mm (-0.323 ±

0.059 in) of standard range, side slip is decreased to
zero.
If any value other than the standard range is measured,
adjust toe-in using the following procedure.
4-53
HOW TO ADJUST TOE-IN:
NOTICE
When adjusting, make sure that the front axle is horizontal and that the front wheels are not leaning.
1. Loosen tightening nut (1), fit a wrench to corner (2) of the

tie rod, then turn the left and right tie rods as shown in the
diagram on the right to adjust as follows.
To INCREASE toe-in, turn in DIRECTION OF ARROW
To DECREASE toe-in, turn in OPPOSITE DIRECTION
Amount of extension for 1/3 turn of left or right tie rod in
direction of extension: 3.5 mm (0.138 in)
2. After adjusting, tighten tightening nut (1).
REPLACE CORROSION RESISTOR CARTRIDGE

1. Screw in valves (2) at the corrosion resistor.
2. Using the filter wrench provided, remove cartridge (1) by

turning it counterclockwise.
3. Coat the seal surface of the new cartridge with engine oil
and install it to the filter holder.
4. When installing, bring the gasket into contact with the

seal surface of the filter holder, then tighten approx. 2/3
turns.
5. After replacement, open the valve (2).
CHECK FRONT WHEEL BEARING PLAY, ADJUST

Please ask your Komatsu distributor to carry out this inspection and adjustment.
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER

Contact your Komatsu distributor to have the tightening portions checked.
CHECK PLAY OF TURBOCHARGER ROTOR

Contact your Komatsu distributor to have the play checked.
4-54

Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time.
CHANGE OIL IN FRONT WHEEL BEARING

Please ask your Komatsu distributor to carry out this inspection and adjustment.
CHANGE OIL IN TANDEM DRIVE CASE
WARNING

● Container to catch drained oil:Min. 210 liters (55.44 US gal) capacity
● Refill capacity: Each 105 liters (27.72 US gal)
1. Set the container under drain plug (P) to catch the oil.
2. Remove drain plug (P) and drain the oil.
3. After draining the oil, clean drain plug (P) and install it
again.
4. Supply engine oil through oil filler (F) up to the specified

level.
5. Check that the oil is at the specified level.

For details, see "CHECK OIL LEVEL IN TANDEM DRIVE
CHECK ALTERNATOR, STARTING MOTOR

The brush may be worn, or the bearing may have run out of grease, so contact your Komatsu distributor for
inspection or repair.
If the engine is started frequently, carry out inspection every 1000 hours.
CHECK ENGINE VALVE CLEARANCE, ADJUST

Contact your Komatsu distributor for inspection or adjustment.
CHECK VIBRATION DAMPER

Check that there are no cracks or peeling in the outside surface of the rubber.
If any cracks or peeling are found, contact your Komatsu distributor to have the parts replaced.
4-55
CLEAN, CHECK TURBOCHARGER

Please ask your Komatsu distributor to carry out this clean and adjustment.
CLEAN ENGINE BREATHER ELEMENT

1. Before removing the breather, wipe off all the dirt around
it.
2. Remove breather (1).
3. Remove any dirt stuck to the element inside, then wash

the element in clean diesel oil.
4. Install breather (1).

Replace the breather O-ring with a new part, coat it with
engine oil, then install.
4-56

Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be carried out at the same time.
CHECK WATER PUMP

Check that there is no play in the pulley or any grease leakage, water leakage, or clogging of the drain hole. If any
abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement.
4-57
MEMO
4-58
SPECIFICATIONS
51
5-1
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
Item Unit
Operating weight (including operator 75 kg (165 lb)) kg (lb) 17,620 (38,852)

Engine model - Komatsu S6D125 diesel engine
Flywheel horsepower kW(HP)/rpm 149(203)/2,000
A Overall length mm (ft in) 9,270 (30' 5")
B Overall height (to muffler) mm (ft in) 3,365 (11')
C Overall width mm (ft in) 2,800 (9' 2")
Min. ground clearance (to bottom surface of final drive case) mm (ft in) 410 (1' 4")
Min. turning radius (outermost part of chassis) mm (ft in) 7,500 (24' 7")
1st km/h (MPH) 3.9 (2.4)
2nd km/h (MPH) 5.2 (3.2)
3rd km/h (MPH) 7.6 (4.7)
4th km/h (MPH) 11.0 (6.8)
FORWARD
5th km/h (MPH) 15.2 (9.4)
6th km/h (MPH) 20.5 (12.7)
7th km/h (MPH) 30.0 (18.6)
8th km/h (MPH) 43.0 (26.7)
Travel speeds
1st km/h (MPH) 4.1 (2.5)
2nd km/h (MPH) 5.6 (3.5)
3rd km/h (MPH) 8.1 (5.0)
4th km/h (MPH) 11.7 (7.3)
REVERSE
5th km/h (MPH) 16.2 (10.1)
6th km/h (MPH) 21.8 (13.6)
7th km/h (MPH) 31.9 (19.8)
8th km/h (MPH) 45.9 (28.5)
5-2
OPTIONS, ATTACHMENTS
61
WARNING
6-1
HANDLING BLADE ACCUMULATOR OPTIONS, ATTACHMENTS
HANDLING BLADE ACCUMULATOR
FEATURES OF BLADE ACCUMULATOR
OPERATIONS MADE EASIER

● No need to operate blade
● No need to employ experienced operator (relief of condition)
SAFETY, PROTECTION
● Reduction in shock
● 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, safety of front wheels)
IMPROVEMENT IN EASE OF OPERATION

● Good pushing of blade
● Good avoidance by blade
6-2
OPTIONS, ATTACHMENTS HANDLING BLADE ACCUMULATOR
METHOD OF OPERATING BLADE ACCUMULATOR

1. Lower the blade to the ground and stop the engine.
2. Turn the starting switch to ON position (electricity flows in

the electrical circuit), then turn the accumulator switch
ON.
3. Maintain the condition in Step 2, operate the left and right

blade lift levers to the front and rear, and bleed the
remaining pressure inside the accumulator and hydraulic
circuit.
4. Turn the accumulator switch OFF, then start the engine.
5. Maintain the condition in Step 4, and extend the left and

right blade lift cylinders approx. 50 mm (2.0 in). (When
doing this, retaining pressure is generated at the bottom
of the blade lift cylinders.)
6. Turn the accumulator switch ON and start the accumulator. The oil at the bottom end of the left and right
blade lift cylinders will flow into the accumulator, the left and right blade cylinders will retract, and the front
wheels will come into contact with the ground.
REMARK
● In the condition Step 2, the pressure is maintained at the bottom end of the blade lift cylinder so the blade
pushes at a certain pressure.
If operations are carried out in the condition in Step 2, the blade will be able to follow a rise or fall of approx. 50
mm (2.0 in) in the ground surface, so uniform accumulator operations can be carried out.
● In actual fact, by operating the blade lift cylinder lever in a suitable way, work is carried out within a certain up-
down follow-up range with a small pushing pressure.
● Once the accumulator is set, there is no need to operate the blade lift cylinder when starting operations. If
the operation is stopped and the switch is turned OFF, raise the blade and put the blade in contact with the
ground again, then turn the switch ON to make it possible to set the accumulator to the same setting.
6-3
EXPLANATION OF NEGATIVE PARKING BRAKE OPTIONS, ATTACHMENTS
EXPLANATION OF NEGATIVE PARKING BRAKE

EXPLANATION OF STRUCTURE
1. A parking brake switch is installed instead of the manually operated parking brake lever.
2. When the engine is stopped, the parking brake is automatically applied.
3. When starting the engine, if the parking brake switch is not at the ON position, the engine will not start.
METHOD OF OPERATING PARKING BRAKE SWITCH

Each time the parking brake switch (1) is pressed, it will turn
ON or OFF.
ON: Parking brake is applied and parking lamp (2) lights up
OFF: Parking brake is released and parking lamp (2) goes out
REMARK
When starting the engine, press the parking brake switch (1) to
set it to the ON position. If the parking brake switch (1) is not
pressed, the engine will not start.
ACTION IF THERE IS A PROBLEM

If there is leakage of air from the air circuit and the internal pressure inside the air tank goes down (pressure inside
the air tank: Less than 0.26 MPa {2.7 kg/cm2}), the parking brake is automatically applied. When towing the
machine, do as follows to release the parking brake.
WARNING
Before releasing the parking brake, check that the machine is on level ground and that the surrounding
area is safe. If the parking brake has to be released on a slope in an emergency, put blocks under the
tires before releasing the brake.
Loosen nut (1), turn joint (2), and move lever (3) 14 - 18 mm
(0.55 - 0.71 in) in the direction of the arrow to release the park-
ing brake.
6-4
INDEX
INDEX
78
A G
ACTION IF THERE IS A PROBLEM ..................... 6-4 GENERAL PRECAUTIONS .................................. 2-7
ADJUSTING WORK EQUIPMENT POSTURE ... 3-82 GENERAL VIEW .................................................. 3-2
AFTER COLD WEATHER .................................. 3-95 GENERAL VIEW OF CONTROLS AND
AFTER RUNNING OUT OF FUEL ...................... 3-97 GAUGES .......................................................... 3-3
AFTER STARTING ENGINE .............................. 2-18 GENERAL VIEW OF MACHINE ........................... 3-2
AFTER STORAGE .............................................. 3-96 GUIDES TO MAINTENANCE ............................... 4-2
ARTICULATE LOCK PIN .................................... 3-22
H
B HANDLING BLADE ACCUMULATOR .................. 6-2
BATTERY ............................................................ 2-24 HANDLING THE TIRES ..................................... 3-91
BEFORE CARRYING OUT MAINTENANCE ...... 2-27
BEFORE STORAGE ........................................... 3-96
I
IF BATTERY IS DISCHARGED ........................ 3-101
C INITIAL 250 HOURS SERVICE .......................... 4-17
CAUTIONS AFTER COMPLETION OF WORK .. 3-95 INTENDED USE ................................................... 1-7
CHECK AFTER STOPPING ENGINE ................ 3-45 INTRODUCTION .................................................. 1-7
CHECK BEFORE STARTING ............................. 4-28
CHECK BEFORE STARTING ENGINE .............. 3-24
CHECKS AFTER COMPLETION OF L
OPERATION .................................................. 3-91 LOADING, UNLOADING WORK ........................ 3-92
COLD WEATHER OPERATION ......................... 3-93 LOCATION OF PLATES, TABLE TO ENTER
CONTROL LEVERS, PEDALS ........................... 3-14 SERIAL NO. AND DISTRIBUTOR ................... 1-8
CRITICAL PARTS ............................................... 4-13 LOCKING (if equipped with cab) ........................ 3-91
LONG-TERM STORAGE .................................... 3-96
D
DIRECTIONS OF MACHINE ................................ 1-7 M
DURING MAINTENANCE ................................... 2-29 MACHINE SERIAL NO. PLATE POSITION ......... 1-8
DURING STORAGE ........................................... 3-96 MAINTENANCE SCHEDULE CHART ................ 4-14
DUST INDICATOR .............................................. 3-22 METERS AND LAMPS ......................................... 3-5
METHOD OF OPERATING BLADE
ACCUMULATOR ............................................. 6-3
E METHOD OF OPERATING PARKING BRAKE
ENGINE SERIAL NO. PLATE POSITION ............. 1-8 SWITCH ........................................................... 6-4
EVERY 50 HOURS SERVICE ............................ 4-29 MOVING MACHINE OFF (FORWARD, REVERSE,
EVERY 250 HOURS SERVICE .......................... 4-30 SHIFTING GEAR), STOPPING ..................... 3-46
EVERY 500 HOURS SERVICE .......................... 4-43
EVERY 1000 HOURS SERVICE ........................ 4-47
EVERY 2000 HOURS SERVICE ........................ 4-55 O
EVERY 4000 HOURS SERVICE ........................ 4-57 OPERATING WORK EQUIPMENT .................... 3-55
EXPLANATION OF NEGATIVE PARKING OPERATION ....................................................... 3-24
BRAKE ............................................................. 6-4 OPERATIONS, CHECKS AFTER STARTING
EXPLANATION OF STRUCTURE ........................ 6-4 ENGINE ......................................................... 3-42
OUTLINE OF OIL, FUEL, COOLANT ................... 4-4
OUTLINES OF SERVICE ..................................... 4-4
F
FEATURES OF BLADE ACCUMULATOR ........... 6-2
FOREWORD ......................................................... 1-2 P
FUSE BOX .......................................................... 3-22 PARKING MACHINE .......................................... 3-89
PERIODIC REPLACEMENT OF CRITICAL
PARTS ........................................................... 4-13
7-1
INDEX
POSITION FOR ATTACHING SAFETY LABELS ..2-2

PRECAUTIONS DURING OPERATION .............2-16
PRECAUTIONS FOR LOADING ........................3-92
PRECAUTIONS FOR LOW TEMPERATURE ....3-93
PRECAUTIONS FOR MAINTENANCE ..............2-27
PRECAUTIONS WITH TIRES ............................2-34
PROPER SELECTION OF FUEL, COOLANT AND
LUBRICANTS ...................................................4-8
R
RELATING TO ELECTRIC SYSTEM ....................4-6
S
SAFETY INFORMATION ......................................1-5
SAFETY LABELS ...........................................2-2, 2-3
SERVICE METER POSITION ...............................1-9
SERVICE PROCEDURE ....................................4-17
SPECIFICATIONS ................................................5-2
STANDARD TIGHTENING TORQUES
FOR BOLTS AND NUTS ................................4-12
STARTING ENGINE ...........................................3-38
STOPPING ENGINE ...........................................3-44
SWITCHES ...........................................................3-9
T
TABLE TO ENTER SERIAL NO. AND
DISTRIBUTOR .................................................1-9
TORQUE LIST ....................................................4-12
TOWING .............................................................2-26
TOWING THE MACHINE ....................................3-99
TRANSPORTATION ..................................2-23, 3-92
TRAVELING POSTURE FOR MACHINE ...........3-45
TROUBLESHOOTING ........................................3-97
TURNING MACHINE ..........................................3-52
U
USE OF FUEL, COOLANT AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE .4-8
W
WEAR PARTS LIST ..............................................4-7
WHEN LEANING PIPING IS DAMAGED ............3-98
WHEN REQUIRED .............................................4-18
WORK WHICH CAN BE CARRIED OUT USING
A MOTOR GRADER ......................................3-59
7-2
7-3
GD705A-4 MOTOR GRADER
Form No. PEN00266-00
©2007
All Rights Reserved
Printed in Japan 09-07

GD705A-4 23001 and Up

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Copyright:

Available Formats

GD705A-4 23001 and Up

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Copyright:

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PEN00266-00

MOTOR GRADER GD705A -4

Place for keeping Operation and Maintenance Manual

Luggage box (1) inside cab

Example of safety message using signal word

Other signal words

This gives information that is useful to know.

Example of safety label using words

Safety labels using pictogram

Safety pictograms show the type of hazardous condition at the

● Repair and maintenance of gravel roads

● Cutting slope faces

● Front wheel offset operations

LOCATION OF PLATES, TABLE TO ENTER SERIAL

MACHINE SERIAL NO. PLATE POSITION

ENGINE SERIAL NO. PLATE POSITION

SERVICE METER POSITION

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.:

Engine serial No.:

Service personnel for your machine:

SAFETY INFORMATION...................................................................................................................................... 1-5

GENERAL PRECAUTIONS ................................................................................................................................. 2-7

PRECAUTIONS DURING OPERATION ............................................................................................................ 2-16

PRECAUTIONS FOR MAINTENANCE .............................................................................................................. 2-27

PRECAUTIONS WITH TIRES ............................................................................................................................ 2-34

EXPLANATION OF COMPONENTS.................................................................................................................... 3-5

DUST INDICATOR ................................................................................................................................... 3-22

COLD WEATHER OPERATION ........................................................................................................................ 3-93

LONG-TERM STORAGE.................................................................................................................................... 3-96

OUTLINES OF SERVICE ..................................................................................................................................... 4-4

WEAR PARTS LIST ............................................................................................................................................. 4-7

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....................... 4-8

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................... 4-12

PERIODIC REPLACEMENT OF CRITICAL PARTS ......................................................................................... 4-13

MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-14

SERVICE PROCEDURE .................................................................................................................................... 4-17

EXPLANATION OF NEGATIVE PARKING BRAKE............................................................................................ 6-4

POSITION FOR ATTACHING SAFETY LABELS

(5) Precautions when driving in reverse (6) Articulate lock (09161-E0641)

(7) Prohibited to enter (09162-E0641) (8) Precautions when handling battery

(13) Precautions when handling battery

IF ABNORMALITIES ARE FOUND

CLOTHING AND PERSONAL PROTECTIVE ITEMS

● Always wear a hard hat and safety shoes. If the nature of

FIRE EXTINGUISHER AND FIRST AID KIT

● Be sure that fire extinguishers have been provided and

● Carry out periodic inspection and maintenance to ensure

KEEP MACHINE CLEAN

● If inspection and maintenance is carried out when the

INSIDE OPERATOR’S COMPARTMENT

● Do not leave parts or tools lying around the operator’s compartment.

● Do not fix any suction pad to the window glass.

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT

● When leaving the machine, always lower the work equip-

HANDRAILS AND STEPS

● Use the handrails and steps marked by arrows in the dia-

● To ensure safety, always face the machine and maintain

● Do not grip the control levers when getting on or off the

● Never climb on the engine hood or covers where there are

● If there is any oil, grease, or mud on the handrails or steps,

● Do not get on or off the machine while holding tools in your

MOUNTING AND DISMOUNTING