Professional Documents
Culture Documents
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.
NOTICE
Komatsu has Operation & Maintenance Manuals
written in some other languages. If a foreign language
manual is necessary, contact your local distributor for
availability.
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FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand them fully.
Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it
periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
Some of Komatsu machines have the software based on the Open Source Software (OSS).
By the license of the OSS, Komatsu publishes the license information of the software to be used in the website
that follows.
https://www.komatsu.jp/en/ProductInfo/opensoft/
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SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
WARNING
To avoid hitting unlocked operation levers, lower equipment to ground and move SAFETY LOCK LEVER to LOCK position before
starting up from operator's seat.
Sudden and unwanted machine movement can cause serious injury or death.
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
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Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when performing
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.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: (1))
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INTENDED USE
This Komatsu machine is designed to be used mainly for the following work:
Smoothing
Repair and maintenance of gravel roads
Ditch digging
Cutting slope faces
Excavating operations
Mixed operations
Spreading operations
Front wheel offset operations
See the section "WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER (PAGE 3-80)" for further
details.
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.
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1-6
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Distributor name
Address
Service Personnel
Phone/Fax
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CONTENTS FOREWORD
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 3
INTENDED USE 1- 5
DIRECTIONS OF MACHINE 1- 5
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 6
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 6
ENGINE SERIAL NO. PLATE POSITION 1- 6
SERVICE METER POSITION 1- 7
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 7
SAFETY 2- 1
SAFETY INFORMATION 2- 2
SAFETY LABELS 2- 5
POSITION FOR ATTACHING SAFETY LABELS 2- 6
SAFETY LABELS 2- 7
GENERAL PRECAUTIONS 2- 13
PRECAUTIONS DURING OPERATION 2- 21
STARTING ENGINE 2- 21
OPERATION 2- 23
TRANSPORTATION 2- 27
BATTERY 2- 28
TOWING 2- 31
PRECAUTIONS FOR MAINTENANCE 2- 32
PRECAUTIONS WITH TIRES 2- 38
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 6
MONITOR PANEL 3- 6
METERS AND LAMPS 3- 19
SWITCHES 3- 20
CONTROL LEVERS, PEDALS 3- 29
DUST INDICATOR 3- 38
ARTICULATE LOCK PIN 3- 38
FUSE BOX 3- 39
HANDLING BATTERY DISCONNECT SWITCH 3- 41
OPERATOR'S CAB LIFT MECHANISM 3- 42
BACKUP ALARM 3- 42
TOOL BAG 3- 43
STORAGE BOX 3- 43
QUICK-FILL FUEL FILLER 3- 43
OPERATION 3- 44
CHECK BEFORE STARTING ENGINE 3- 44
STARTING ENGINE 3- 60
OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 63
STOPPING ENGINE 3- 65
CHECK AFTER STOPPING ENGINE 3- 65
TRAVELING POSTURE FOR MACHINE 3- 66
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FOREWORD CONTENTS
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CONTENTS FOREWORD
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SAFETY INFORMATION
SAFETY LABELS 2- 5
POSITION FOR ATTACHING SAFETY LABELS 2- 6
SAFETY LABELS 2- 7
GENERAL PRECAUTIONS 2- 13
SAFETY RULES 2- 13
IF PROBLEMS ARE FOUND 2- 13
CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 13
FIRE EXTINGUISHER AND FIRST AID KIT 2- 13
SAFETY FEATURES 2- 13
KEEP MACHINE CLEAN 2- 14
INSIDE OPERATOR'S COMPARTMENT 2- 14
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 14
HANDRAILS AND STEPS 2- 15
MOUNTING AND DISMOUNTIN 2- 15
DO NOT GET CAUGHT IN ARTICULATED PORTION 2- 16
PREVENTION OF BURNS 2- 16
FIRE PREVENTION 2- 17
ACTION IF FIRE OCCURS 2- 18
WINDOW WASHER LIQUID 2- 18
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 18
PRECAUTIONS FOR ATTACHMENTS 2- 18
UNAUTHORIZED MODIFICATION 2- 18
SAFETY AT WORKSITE 2- 19
WORKING ON LOOSE GROUND 2- 19
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 19
ENSURE GOOD VISIBILITY 2- 20
VENTILATION FOR ENCLOSED AREAS 2- 20
CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 20
EMERGENCY ESCAPE FROM OPERATOR'S CAB 2- 20
ASBESTOS DUST HAZARD PREVENTION 2- 20
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SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of 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 labels to
peel off.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
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SAFETY LABELS
(1) Caution before operating machine (09651-A0641)
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2-9
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GENERAL PRECAUTIONS
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions in this manual when operating or performing maintenance on
the machine.
If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate
or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.
When working with another operator or with the person on the worksite traffic duty, discuss the content of the
operation beforehand and use the determined signals when performing the operation.
SAFETY FEATURES
Be sure that all guards, covers and mirrors are in their proper position. Have guards and covers repaired
immediately if they are damaged.
Understand the method of use of safety features and use them properly.
Never remove any safety features. Always keep them in good operating condition.
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2 - 14
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PREVENTION OF BURNS
Hot coolant
To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap by
hand before starting the operation. Even when the coolant has
cooled down, loosen the cap slowly to relieve the pressure
inside the radiator before removing the cap.
Hot oil
To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to a temperature where it
is possible to touch the cap or plug by hand before starting the
operation. Even when the oil has cooled down, loosen the cap
or plug slowly to relieve the internal pressure before removing
the cap or plug.
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FIRE PREVENTION
Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to flammable substances
such as fuel, oil, coolant or window washer fluid. There is danger
that they may catch fire. To prevent fire, always observe the
following:
Do not smoke or use any open flame near fuel or other
flammable substances.
Stop the engine before adding fuel.
Do not leave the machine when adding fuel or oil.
Tighten all fuel and oil caps securely.
Be careful not to spill fuel on overheated surfaces or on parts
of the electrical system.
After adding fuel or oil, wipe up any spilled fuel or oil.
Put greasy rags and other combustible materials into a safe
container to maintain safety at the workplace.
When washing parts with oil, use a non-flammable oil. Do not
use diesel oil or gasoline. There is danger that they may
catch fire.
Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
Determine well-ventilated areas for storing oil and fuel. Keep
the oil and fuel in the determined place and do not allow
unauthorized persons to enter.
When performing grinding or welding work on the machine,
move any flammable materials to a safe place before
starting.
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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 or death, accidents, product failures or other property damages
resulting from modifications made without authorization from Komatsu.
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SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do
not operate 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 identify their
locations. Be careful not to sever or damage any of these lines.
Take action to prevent unauthorized people from approaching
the jobsite.
When working on public roads, position flagmen and erect
barriers to ensure the safety of passing traffic and pedestrians.
When traveling or operating in shallow water or on soft ground,
check the shape and condition of the bedrock, and the depth
and speed of flow of the water before starting operations.
In order that travel operations can be carried out safely, always
keep the roads on the jobsite properly maintained.
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If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should
not leave the operator's compartment until it has been confirmed that the electricity has been shut off.
Also, do not let anyone near the machine.
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OPERATION
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Avoid traveling over obstacles when possible. If the machine has to travel over an obstacle, keep the work
equipment close to the ground and travel at low speed. Never travel over obstacles which make the machine tilt
strongly to one side.
When traveling or performing operations, always keep a safe distance from people, structures, or other machines
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, 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 anything.
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 a large destructive
force, and this may cause serious injury or death.
If you are going to drive the machine continuously, consult your Komatsu distributor.
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PROHIBITED OPERATIONS
When operating at the bottom of a cliff, there is danger that the soil may collapse or that rocks may fall. Never
operate in such places.
The edge of cliffs or road shoulders may easily collapse, and there is danger of falling. Do not go close to such
places.
Avoid sudden starts, sudden stops, and sudden steering.
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PARKING MACHINE
Park the machine on firm, level ground.
Select a place where there is no hazard of landslides, falling
rocks, or flooding.
Lower the work equipment completely to the ground.
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TRANSPORTATION
The machine can be divided into parts for transportation, so when transportating the machine, consult your Komatsu
distributor to have the work performed.
SHIPPING
When shipping the machine on a trailer, do as follows.
The weight, transportation height, and overall length of the machine differ according to the work equipment, so
be sure to confirm the dimensions.
When passing over bridges or structures on private land, check first that the structure is strong enough to support
the weight of the machine. When traveling on public roads, check first with the relevant authorities and follow their
instructions.
Lock the frame with the articulate lock pin to prevent the machine from articulating.
For details of the shipping procedure, see "TRANSPORTATION (PAGE 3-121)" in the OPERATION section.
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BATTERY
As there is a hazard that sparks will be generated, always observe the followings.
Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other
metal objects lying around near the battery.
Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals securely.
Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take
it to a well-ventilated place, and remove the battery caps before charging it.
Tighten the battery caps securely.
Install the battery securely to the determined place.
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DANGER OF SPARKS
As there is a hazard that sparks will be generated, always observe the followings.
Do not let tools or other metal objects make any contact between the battery terminals. Do not leave tools or other
metal objects lying around near the battery.
Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, and connect the ground last. Tighten the battery terminals securely.
Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take
it to a well-ventilated place, and remove the battery caps before charging it.
Tighten the battery caps securely.
Install the battery securely to the determined place.
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TOWING
WHEN TOWING
Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection
or inspection of the wire rope.
For towing, see "TOWING THE MACHINE (PAGE 3-127)".
Always wear leather gloves when handling wire rope.
During the towing operation, never stand between the towing
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 danger that the rope may
break during the towing operation.
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2 - 32
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After stopping the engine, operate the left and right blade lift
cylinder control levers fully to the RAISE and LOWER positions
2 or 3 times to release the pressure remaining in the hydraulic
circuit, then set gearshift lever (1) to the P (Parking) position.
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Never drop or insert tools or other objects into the fan or fan belt.
Parts may break or be sent flying.
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 or
death.
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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 property
damage. For this reason, always observe the following
precautions.
Do not disassemble the accumulator.
Do not bring it near open 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
Do not allow any unauthorized personnel into the area when servicing the machine. If necessary, employ a guard.
ATTACHMENTS
Appoint a leader before starting removal or installation
operations for attachments.
Place attachments that have been removed from the machine in
a stable condition so that they do not fall. And take steps to
prevent unauthorized persons 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.
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REPAIR WELDING
Welding operations must always be performed by a qualified welder and in a place equipped with proper equipment.
There is a hazard of gas, fire, or electrocution when performing welding, so never allow any unqualified personnel
to perform welding.
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WASTE MATERIALS
To prevent pollution, pay careful attention to the method of disposing of waste materials.
Always put oil drained from your machine in containers. Never
drain oil directly onto the ground or dump into the sewage
system, rivers, the sea, or lakes.
Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
COMPRESSED AIR
When performing cleaning with compressed air, there is a hazard of serious personal injury or death caused by
flying particles.
When using compressed air to clean elements or the radiator, always wear protective eyeglasses, dust mask,
gloves, and other protective equipment.
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3-1
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GENERAL VIEW
GENERAL VIEW OF MACHINE
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3-3
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(1) Engine coolant temperature gauge (14) Radiator coolant level monitor
(2) Speedometer (15) Engine preheating monitor
(3) Turn signal pilot lamp (16) Engine oil pressure monitor
(4) Transmission caution lamp (17) Hydraulic oil level monitor
(5) High beam pilot lamp (18) Coolant temperature monitor
(6) Fuel gauge (19) Brake air pressure monitor
(7) Differential control indicator (20) Radiator coolant level monitor
(8) Blade float (21) Emergency steering
(9) Accumulator indicator (22) Final drive oil temperature monitor
(10) Parking brake (23) Hydraulic oil level monitor
(11) Central caution lamp (24) Charge monitor
(12) Hydraulic oil level monitor (25) Service meter
(13) Engine oil level monitor
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3-5
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EXPLANATION OF COMPONENTS
The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.
MONITOR PANEL
Turn the starting switch to the ON position before starting the engine. All the monitors, gauges, and warning lamps
light up for approx. 3 seconds and the alarm buzzer sounds for approx. 2 seconds.
When this happens, the speedometer displays 188.
If the monitor does not light up, there is probably a failure or disconnection, so ask your Komatsu distributor to
carry out inspection.
When checking the monitor, wait for at least 30 seconds after stopping the engine.
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NOTICE
Do not rely on the "CHECK MONITOR GROUP (Check items before starting)" only for the check before starting.
Always make the check by referring to "MAINTENANCE" or "CHECK BEFORE STARTING (PAGE 3-47)".
Park the machine on level ground and check the monitor lamps.
Confirm that these monitor lamps light for approximately 3 seconds after turning the starting switch to ON. If any monitor lamp
does not light, ask your Komatsu distributor to inspect that monitor lamp.
This shows basic ones of those items to be checked before starting the engine.
If a problem is found, the monitor of the problem comes on.
Wehn the engine is started, these monitor lamps will go off even if there are abnormalities.
(1) Hydraulic oil level monitor (3) Radiator coolant level monitor
(2) Engine oil level monitor
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3-8
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NOTICE
Park the machine on level ground and check the monitor lamps.
Confirm that these monitor lamps light for approximately 3 seconds after turning the starting switch to ON while the engine is
at rest. If any monitor lamp does not light, ask your Komatsu distributor to inspect that monitor lamp.
This item must be observed carefully when the engine is running. If any abnormality occurs, take the necessary
action as soon as possible.
If any abnormality occurs, the monitor for the location of the abnormality flashes, and at the same time, the central
warning lamp flashes.
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CHARGE MONITOR
This monitor (1) indicates an abnormality in the charging system
while the engine is running.
If the lamp flashes during operation, stop the engine and check the
V-belt tension. If any abnormality is found, see "OTHER
TROUBLE (PAGE 3-134)".
REMARK
The monitor lamps and central warning lamp may flash when the
engine is started, but if they go out when the engine speed is
increased, there is no abnormality.
EMERGENCY STEERING
(if equipped)
This monitor (4) lights up when the emergency steering is
actuated.
When this happens, the alarm buzzer sounds continuously.
The emergency steering uses an electric motor pump to provide
hydraulic power to the steering system. This prevents any sudden
increase in the operating effort of the steering wheel if the engine
stops or there is a failure in the hydraulic pump when the machine
is traveling.
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2. After stopping the machine, turn the main switch OFF, stop the emergency steering, then contact your Komatsu
distributor for inspection.
NOTICE
To protect the electric motor pump for the emergency steering, do not run it for more than 30 seconds.
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NOTICE
Park the machine on level ground and check the monitor lamps.
Confirm that these monitor lamps light for approximately 3 seconds after turning the starting switch to ON while the engine is
at rest. If any monitor lamp does not light, ask your Komatsu distributor to inspect that monitor lamp.
This item must be observed carefully when the engine is running. If any abnormality occurs, take the necessary
action as soon as possible.
If any abnormality occurs, the alarm buzzer sounds intermittently, the monitor for the location of the abnormality
flashes, and at the same time, the central caution lamp flashes.
(1) Final drive oil temperature monitor (4) Coolant temperature monitor
(2) Final drive oil temperature monitor (5) Brake air pressure monitor
(3) Hydraulic oil level
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REMARK
This monitor lamp flashes and the alarm buzzer sounds when the
starting switch is turned to ON immediately after the engine is
started or immediately before the engine is stopped. It does not
indicate an abnormality.
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METER GROUP
PILOT DISPLAY
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ACCUMULATOR INDICATOR
This monitor (2) lights up when the accumulator switch is turned
ON.
BLADE FLOAT
This monitor (3) lights up when the blade float switch is set to the
ON position.
PARKING BRAKE
This monitor (4) lights up to inform the operator that the parking
brake has been applied.
During operation: Lights up
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METERS
CAUTION
If the alarm buzzer sounds, the central warning lamp lights up, or the
engine water temperature monitor flashes, stop the machine, run the
engine at low idling, and wait for the green range to light up.
FUEL GAUGE
This meter (7) indicates the amount of fuel in the fuel tank.
If there is enough fuel in the tank while the engine is running, the
green range (A) lights.
If the red range (B) lights, there is less than 70 liters (18.49 US gal)
of fuel in the tank.
When the red range lights, add fuel.
REMARK
If there is a disconnection in the turn signal lamp, the flashing
interval becomes shorter.
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SPEEDOMETER
This monitor (10) indicates the travel speed of the machine.
SERVICE METER
This meter (11) shows the total operation hours of the machine.
The service meter advances while the engine is running - even if
the machine is not traveling.
While the engine is running, green pilot lamp on the service meter
flashes to show the service meter advances.
The service meter progresses by 1 when the engine is operated for
one hour, regardless of the engine speed.
When the machine is in the following condition, it flashes, and the alarm buzzer sounds intermittently at the same
time.
Abnormality has occurred in "EMERGENCY CAUTION DISPLAY PORTION (PAGE 3-12)".
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(1) Air pressure gauge (2) Lift arm lock pilot lamp
NOTICE
If the warning buzzer frequently sounds, the piping joints may be loose, so check for the cause.
This meter (1) indicates the air pressure inside the air tank.
It should indicate the green range during normal operations.
If it drops to the red range during operations, the warning buzzer
will sound, the central warning lamp will flash, and the brake air
pressure monitor will also flash.
If this happens, stop the machine, increase the engine speed and
wait for the indicator to return to the green range.
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SWITCHES
3 - 20
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STARTING SWITCH
This switch (1) is used to start or stop the engine.
OFF position
The key can be inserted or with drawn. The switches for the electric
system are all turned off and the engine is stopped.
ON
Electricity flows to the charging circuit and lamp circuit.
START
This is the position for starting the engine. Keep the key at this position while cranking the engine. When the engine
starts, release the key immediately.
The key returns automatically to the ON position.
BANK SWITCH
WARNING
Lower the blade completely to the ground before removing the pin.
This switch (2) is used to pull out the lock pin and set the blade in
the bank-cut position.
(a) RETRACT: You can pull out the pin securing the lifter guide
and frame.
(b) LOCK: The pin is locked.
(c) INDEX: Select this position to adjust the lifter guide and frame.
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3 - 22
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3 - 23
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CAUTION
The emergency steering motor must not be operated continuously for more than 30 seconds.
Use this switch (11) to actuate the electric motor for the emergency
steering.
(1) AUTO position: If the hydraulic pressure in the steering circuit
goes below 0.69 MPa {7 kg/cm2, 99.4 PSI}, the
electric motor is automatically actuated to
rotate the hydraulic pump.
(2) MANU position: Use this position to check the actuation.
This actuates the electric motor regardless of
the hydraulic pressure and rotates the
hydraulic pump.
When the machine is stopped or is traveling at a speed of less than 1 km/h (0.6 MPH), the emergency steering is
not actuated automatically.
If it is necessary to release the parking brake, use the procedure given in "HANDLING EMERGENCY STEERING
DEVICE (PAGE 6-2)".
3 - 24
.
CAUTION
Do not operate the differential lockup switch while the machine is turning.
Do not use the differential lockup function while the machine is traveling at high speed.
Do not operate the differential lockup switch while one side of tire is skidding.
In this case, lower the engine speed, check that no tire is skidding, and then perform the differential lockup operation.
If there is a possibility of tire skidding, turn ON the differential lockup function before a tire begins to skid.
This switch (12) is used when the wheel on one side is in mud and
starts to slip.
ON position: The differential is locked and the indicator lamp lights
up.
OFF position: The differential operates and the indicator lamp
goes off.
REMARK
Keep the differential unlocked (Set the differential lock switch in the OFF position) during normal travel. If the
differential is locked during normal travel, the tires are worn.
3 - 25
.
ACCUMULATOR SWITCH
This switch (13) is used when actuating the accumulator.
ON position: The accumulator is actuated, and the absorber pilot
lamp lights up at the same time.
OFF position: The accumulator is canceled.
WARNING
Lower the blade completely to the ground before removing the pin.
For details of handling the blade float, see "HANDLING BLADE FLOAT (PAGE 3-119)".
3 - 26
.
DIMMER SWITCH
This switch (15) the head lamp between high beam and low beam.
Position (1): High beam
Position (2): Low beam
HORN BUTTON
When the button (17) in the center of the steering wheel is pressed,
the horn will sound.
3 - 27
.
WARNING
Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine
operators.
3 - 28
.
(1) Left blade lift cylinder control lever (9) Option lever
(2) Ripper lift cylinder control lever (if equipped) (10) Right blade lift cylinder control lever
(3) Blade side shift control lever (11) Fuel control lever
(4) Power tilt control lever (12) Gearshift lever
(5) Blade rotation control lever (13) Inching pedal
(6) Drawbar side shift control lever (14) Brake pedal
(7) Articulate control lever (15) Accelerator pedal
(8) Leaning control lever (16) Decelerator pedal
3 - 29
.
3 - 30
.
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.
3 - 31
.
NOTICE
To prevent damage to the tires, be careful not to let the blade hit the tires when rotating the blade.
3 - 32
.
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.
3 - 33
.
OPTION LEVER
This lever (9) is used to operate any optional equipment or
attachment.
3 - 34
.
REMARK
The fuel control lever is used only during operations with the
work equipment. For general travel, use the accelerator pedal.
The fuel control lever is set to a maximum speed of 1500 rpm.
This is to prevent any sudden rise in the engine speed if the
engine is started with the lever pulled fully and to ensure safety
if the lever is pulled during operations.
3 - 35
.
WARNING
When parking the machine, always set the gearshift lever to the P position to apply the parking brake.
This lever (12) is used to shift the travel speed range and to apply or release the parking brake.
There are 8 speeds in FORWARD and REVERSE, and the gear can be shifted simply by moving the gearshift lever
to the desired position.
A shift lock mechanism is installed to prevent the lever from entering the P (parking) position during normal
operations. When shifting from P to N or from N to P, operate lever button (1) as follows: Push -> shift -> release
-> shift.
REMARK
The engine will not start if the speed lever is not at the P (parking) position.
INCHING PEDAL
NOTICE
Do not use continuously for more than 10 seconds.
This pedal (13) connects and disconnects the motive force from
the engine and is used when stopping or starting the machine, or
when switching between FORWARD and REVERSE.
When the pedal is depressed, the motive force is cut off.
In 1st, 2nd, and 3rd speeds, fine control of the machine is possible
using this pedal.
3 - 36
.
BRAKE PEDAL
WARNING
Do not place your foot on this pedal unnecessarily.
ACCELERATOR PEDAL
This pedal (15) is used to control the engine speed and output.
This is interconnected with the fuel control lever, and can be
operated freely between the speed set by the fuel control lever and
the full speed position.
DECELERATOR PEDAL
This pedal (16) is used to reduce the engine speed.
It is possible to adjust the speed freely between the speed set by
the fuel control lever and the low idling speed.
3 - 37
.
DUST INDICATOR
Dust indicator is a device to check the clogging state of the air
cleaner element.
The degree of clogging is shown in 5 stages.
Clean the element when the yellow display board which shows the
degree of clogging reaches the red line.
Push the reset button after you finish cleaning, then the yellow
display board goes back to the original position.
This pin is used to lock the front frame and rear frame to prevent the
machine from bending during normal travel or when servicing or
transporting the machine.
3 - 38
.
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.
Open cover and replace the fuse.
Replace the fuse with another of the same capacity.
Fuse
No. Circuit name
capacity
1 10A Bank, Differential, Accumulator
2 20A Cab mount working lamp
3 15A Front working lamp
4 20A Rear working lamp, Air conditioner
Horn, Turn signal lamp,
5 10A
Transmission control
6 10A Air pressure gauge
7 10A Brake lamp, Air dryer
8 20A Emergency steering
9 10A Auto drain
10 10A Cab (wiper, washer)
11 10A Cab (wiper)
12 15A Head lamp
13 10A Monitor
Transmission control,
14 10A
Parking blake
15 20A Air conditioner, Heater
3 - 39
.
Fuse
No. Circuit name
capacity
1 10A Hazard flasher
2 5A Car radio
3 20A A/C condenser
4 10A (Spare)
5 -
6 -
3 - 40
.
NOTICE
When the battery disconnect switch is turned OFF, the memory and
chronometric functions in the radio are reset.
EXPLANATION OF COMPONENTS
(B): ON position
Electricity flows from the battery to the circuits.
Always set to this position before operating the machine.
HANDLING
WARNING
Do not turn the battery disconnect switch OFF when the engine is running or immediately after the engine is stopped. There is
danger that this may cause serious damage to the electrical system.
In the following cases, set the battery disconnect switch to the OFF position.
When machine is put into long-term storage (1 month or more)
When electrical system is to be repaired
When carrying out electric welding
When inspecting or handling battery
When replacing fuse or slow blow fuse
3 - 41
.
BACKUP ALARM
The backup alarm sounds immediately when the gear shift lever is placed in reverse.
If it does not sound, please contact your Komatsu distributor.
3 - 42
.
TOOL BAG
CAUTION
Do not leave the tool bag on the floor by your feet.
It will get in the way during operations.
REMARK
A tool box for holding the tool supplied with the machine is also
available as an option. This tool box can be installed to the
drawbar.
The tool box already installed to the drawbar contains the tools
used when lifting the cab.
STORAGE BOX
There is a box for storing small articles at the top left of the cab.
3 - 43
.
OPERATION OPERATION
OPERATION
CHECK BEFORE STARTING ENGINE
WALK-AROUND CHECK
Before starting the engine, walk around the machine and look at the underside of chassis for anything unusual like
loose bolts and nuts, leakage of fuel, oil and coolant. Also check the condition of the work equipment and the
hydraulic system.
Also check for loose wiring, play, and collection of dust at places that reach high temperature.
WARNING
Remove any combustible materials from around the battery, engine, muffler, turbocharger, or other high temperature engine
parts.
Leakage of fuel or oil will cause the machine to catch fire. Check carefully, be sure to repair any problem, or contact your Komatsu
distributor.
Perform the following inspections and cleaning every day before starting engine for the day's work.
1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses
Check for cracks, excessive wear, play in work equipment, cylinders, linkage, and hoses. If any problem is
found, repair it.
2. Remove dirt and debris from around the engine, battery, and radiator.
Check for dirt accumulated around the engine and radiator. Also check for flammable material (dry leaves, twigs,
etc.) around the battery, engine muffler, turbocharger, or other high temperature engine parts. If any dirt or
flammable materials are found, remove them.
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 problem is found, repair the place where the oil is leaking.
6. Check for damaged or worn tires, wheels, and wheel hub bolts and nuts, check for loose wheel hub bolts and
nuts.
Check for cracks or peeling of the tires and for cracks or wear to the wheels (side rim, rim base, lock ring).
Tighten any loose wheel hub bolts or nuts. If any abnormality is found, repair or replace the part.
If any valve caps are missing, install new caps.
3 - 44
.
OPERATION OPERATION
12. Check for damage to the seat belt and mounting clamps.
WARNING
Even if there are no signs of damage, replace belts in accordance with the following schedule:
5 years after the date of seat belt manufacture, or every 3 years after the start of actual usage, whichever date comes first.
REMARK
The date of seat belt manufacture attached to the seat belt is the start of the 5-year period. It is not the start of the
3-year period of actual usage.
REMARK
The date of manufacture of the seat belt is marked on the belt at the
place indicated by the arrow in the figure on the right.
Check that there are no loose bolts on the equipment mounting the
seat belt to the machine, and tighten if necessary.
Tightening torque: 24.5 ± 4.9 Nm {2.5 ± 0.5 kgm, 18.1 ± 3.6 lbft}
3 - 45
.
OPERATION OPERATION
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 grooves of less than 15% of that of a new tire
Tires with extreme uneven wear or with stepped-type wear
Damage:
Tires with damage that has reached the cords, 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
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 - 46
.
OPERATION OPERATION
WARNING
Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check
the sub-tank.
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 check the coolant level in this condition, there is a hazard of burns. Wait for the temperature to go
down, then turn the cap slowly to release the pressure and remove it carefully.
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.
1. Check that the coolant is between the FULL and LOW marks
on sub-tank (1). If the water level is low, add water to the FULL
level through the water filler port in sub-tank (1).
2. After adding water, tighten the cap securely.
3. If the sub-tank becomes empty, coolant leakage is presumed.
After checking, repair any abnormality immediately. If no
abnormality is found, check if the radiator main tank is full. If it
is low, add coolant of the same density in radiator according to
the coolant density table in "CLEAN INSIDE OF COOLING
SYSTEM (PAGE 4-23)", then add coolant to the sub-tank.
REMARK
In summer, the coolant may overflow from the sub-tank drain hose.
This is no problem. It occurs because too much coolant has been
added.
3 - 47
.
OPERATION OPERATION
WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring open
flame near fuel because it is highly flammable and dangerous.
NOTICE
If breather hole (1) in the cap becomes clogged, the pressure inside the
tank will go down and the fuel may not flow, so clean the breather hole from
time to time.
2. After completing work, fill the fuel tank through fuel filler port
(F).
3. After adding fuel, tighten the cap securely.
Fuel capacity: 500 liters (132.1 US gal)
REMARK
The fuel will not be drained if it is not above the installation position
of drain valve (1) on the tank.
3 - 48
.
OPERATION OPERATION
WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until they
have cooled down before starting the work.
1. Open the side cover on the right side at the rear of the chassis.
2. Remove dipstick (G), and wipe the oil off with a cloth.
3. Fully insert dipstick (G) into dipstick pipe, then remove it.
4. The oil level should be between H and L marks on dipstick (G).
If the oil level is below L mark, add oil through oil filler port (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 operated,
wait for at least 15 minutes after stopping the engine before
checking. If the machine is at an angle, make it horizontal before
checking.
When adding oil, remove the dipstick from the guide to release the
air inside the crankcase.
3 - 49
.
OPERATION OPERATION
3 - 50
.
OPERATION OPERATION
WARNING
If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause and immediately
perform repairs, or contact your Komatsu distributor for repairs.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash
the battery cap to clean the breather hole.
Check that there is no damage to the fuses; that fuses of the specified capacity are used; that there is no open circuit
or trace of short-circuiting in the electric wiring and no damage to the covering. Check also that there is no loosened
terminals. If any, tighten them.
Moreover, pay particular attention to the electric wiring when checking the battery, engine starting motor and
alternator.
Be sure to check that there is no inflammable material accumulated around the battery. If any is found, remove
immediately.
Please contact your Komatsu distributor for investigation and correction of the cause.
CHECK THAT ALL PROBLEMS FROM PREVIOUS DAY HAVE BEEN REPAIRED
CHECK THAT WINDSHIELD WIPER, WINDOW WASHER, AND DEFROSTER WORK PROPERLY, CHECK WASHER
FLUID LEVEL
3 - 51
.
OPERATION OPERATION
3 - 52
.
OPERATION OPERATION
ADJUSTMENTS
WARNING
Park the machine in a safe place and stop the engine when performing 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 down with the operator's back against the backrest.
WARNING
Do not adjust the instrument panel when traveling.
3 - 53
.
OPERATION OPERATION
WARNING
Do not adjust the instrument panel when traveling.
Turn steering wheel tilt lever (1) to the left to release the lock, then
tilt the steering wheel and gauge panel to the desired position, and
lock in position with the lever.
Amount of adjustment: 20 degrees (stepless)
ADJUSTING MIRROR
Sit in the operator's seat and adjust the mirrors so that you can see
the side and rear of the machine.
3 - 54
.
OPERATION OPERATION
REMARK
The date of seat belt manufacture attached to the seat belt is the start of the 5-year period. It is not the start of the
3-year period of actual usage.
3 - 55
.
OPERATION OPERATION
3 - 56
.
OPERATION OPERATION
2. Lower the blade and ripper to the ground, and check that work equipment control levers (2) are at the HOLD
position.
3 - 57
.
OPERATION OPERATION
3. Insert the key in starting switch (3), turn the key to the ON
position and check that all monitor lamps and warning lamps
light up for 3 seconds, and that the alarm buzzer sounds for 2
seconds.
1) The buzzer will sound for approx. 2 seconds, and the
following monitors and gauges will light up for approx. 3
seconds.
Central caution lamp
Parking brake pilot lamp
Blade float pilot lamp
Accumulator pilot lamp
Differential control indicator pilot lamp
Engine coolant temperature gauge
Fuel gauge
Hydraulic oil level monitor
Engine oil level monitor
Radiator coolant level monitor
Engine preheating monitor pilot lamp
Final drive oil temperature monitor
Engine oil pressure monitor
Coolant temperature monitor
Brake air pressure monitor
Charge monitor
Hydraulic oil temperature monitor
Emergency steering
2) After approx. 3 seconds, the following gauges will remain on and the other monitors will go out.
Engine coolant temperature gauge
Fuel gauge
Engine oil pressure monitor
Charge monitor
When the engine starts, the engine oil pressure and battery charge lamps go out.
3 - 58
.
OPERATION OPERATION
5. Press horn switch (5) to confirm that the horn will sound.
6. Operate each lamp switch (6) to check that the lamps light up.
7. Operate each wiper switch (7) and check that the wiper and
washer equipment works properly.
3 - 59
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OPERATION OPERATION
STARTING ENGINE
NORMAL STARTING
WARNING
Sit down in the operator's seat before starting the engine.
Do not attempt to start the engine by short-circuiting the engine starting
circuit. Such an act may cause serious injury, death or fire.
Check that there are no persons or obstacles in the surrounding area,
then sound the horn and start the engine.
Exhaust gas is toxic. When starting the engine in confined spaces, be
particularly careful to ensure 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 fuel control lever and the accelerator pedal depressed to the FULL OPEN position.
2. Turn the key in starting switch (2) to the START position. The
engine will start.
3. When the engine starts, release the key in starting switch (2).
The key will return automatically to ON position.
3 - 60
.
OPERATION OPERATION
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 fuel control lever and the accelerator
pedal depressed to the FULL OPEN position.
3 - 61
.
OPERATION OPERATION
REMARK
If the preheating time is too short or too long, the engine will be
difficult to start, so always keep to the correct preheating time.
3. When preheating monitor (3) goes off, turn key (2) to the
START position to start the engine.
4. When the engine starts, release the key in starting switch (2).
The key will automatically return to the ON position.
3 - 62
.
OPERATION OPERATION
NOTICE
Before operating the machine for the first time, check that there is coolant in the radiator. If the machine has been delivered
without coolant in the radiator, run water through the system to flush the system thoroughly, then fill the radiator with coolant.
3 - 63
.
OPERATION OPERATION
NORMAL OPERATION
After the engine starts, do not start operating the machine
immediately. First, perform the following operations and checks.
NOTICE
Do not accelerate the engine suddenly until the warming-up operation has
been completed.
Do not run the engine at low idle or high idle continuously for more than 20
minutes.
If it is necessary to continue to run the engine at idle, apply a load from time
to time or run the engine at a mid-range speed.
1. Pull fuel control lever (1), and run the engine at a mid- range
speed for approx. 5 minutes to carry out warming-up.
3 - 64
.
OPERATION OPERATION
STOPPING ENGINE
NOTICE
If the engine is stopped abruptly, service life of component parts of the
engine may be considerably reduced. Do not stop the engine abruptly
except in an emergency. If the engine has overheated, do not try to stop it
abruptly but run it at medium speed to allow it to cool down gradually, and
then stop it.
1. Place fuel control lever (1) in the low idle position and run the
engine at low idle speed for approximately 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 - 65
.
OPERATION OPERATION
NOTICE
Be careful of the clearance between the blade and front wheels.
If the blade is at a propulsion angle and the machine is articulated, the blade may bend the steps.
If the shank at the center of the ripper body is inserted from above when the ripper is in the central position, it will interfere with
the cylinder, so move the ripper away from the center position when installing the shank.
1. During general travel operations, raise the front and rear ends
of the blade equally and set so that the blade does not extend
outside the machine, as shown in the diagram on the right.
3 - 66
.
OPERATION OPERATION
3 - 67
.
OPERATION OPERATION
NOTICE
Do not try to start the machine with the transmission in 4th or above.
3 - 68
.
OPERATION OPERATION
NOTICE
When shifting gear, always shift one gear at a time.
INCREASE SPEED
Let back accelerator pedal (1) and shift gearshift lever (2) up to the
next speed range.
REDUCING SPEED
Release accelerator pedal (1) to reduce speed, then shift gearshift
lever (2) down one range.
NOTICE
If the transmission is shifted down suddenly when traveling at high speed, there is danger that the engine or transmission may
be damaged. Use the following table as a guideline for suitable speeds when shifting down.
3 - 69
.
OPERATION OPERATION
3 - 70
.
OPERATION OPERATION
STOPPING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
CAUTION
If the fuel control lever is pulled when depressing the brake pedal, there is
danger that the stopping distance will increase. In addition, a large heat
load is generated in the brake clutch, and this will lead to deformation or
damage of the clutch.
3 - 71
.
OPERATION OPERATION
4. Check that parking brake pilot lamp (5) on the machine monitor
is lighted up.
3 - 72
.
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 opposite
direction to the turn.
3 - 73
.
OPERATION OPERATION
ARTICULATING OPERATION
WARNING
Do not remove the lock pin for general travel.
NOTICE
To prevent damage to the tires, be careful not to let the blade hit the tires when articulating the machine.
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 25° to the left
or right, and the turning radius becomes 7.9 m (25 ft 11 in).
1. Stop the machine, remove pin (1), and insert it in the storage
position.
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 - 74
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OPERATION OPERATION
(1) Left blade control lever (5) Power tilt control lever
(2) Right blade control lever (6) Drawbar side-shift control lever
(3) Blade side-shift control lever (7) Ripper control lever
(4) Blade rotation control lever
BLADE OPERATION
3 - 75
.
OPERATION OPERATION
3 - 76
.
OPERATION OPERATION
3 - 77
.
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.
3 - 78
.
OPERATION OPERATION
OPERATING RIPPER
(if equipped)
Operate ripper control lever (7) as follows.
Pull BACK to RAISE ripper
Push FORWARD to LOWER ripper
3 - 79
.
OPERATION OPERATION
2. Set the blade so that the earth is discharged outside the rear
left wheel.
3. Operate blade lift cylinder (2) so that the top of blade (1) is at
the desired digging position.
If only the blade cylinder is extended or retracted, the blade will
move slightly to the left or right. If necessary, adjust with
drawbar shift cylinder (3).
3 - 80
.
OPERATION OPERATION
When the drawbar shift cylinder is not extended and only the lift
cylinder is extended.
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 (A)
discharged from the blade.
6. Operate the power tilt so that the top of the blade (1) 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.
3 - 81
.
OPERATION OPERATION
2. Set the blade so that the earth is discharged outside the rear
right wheel.
3. Operate the blade lift cylinder so that the blade is at the desired
digging depth, then set it horizontal.
3 - 82
.
OPERATION OPERATION
NOTICE
Set the frame straight. If the machine is articulated, the side of the tire will be pushed against the opposite slope face (back slope),
and this will cause damage to the side face of the tire. In addition, mud will be pushed in between the tire and rim, and this will
cause problems such as leakage of air and flat tires.
1. Align the right edge of the blade with the outside edge of the
front right tire.
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. Angle the blade so that a windrow is formed at the center of the
chassis.
5. Operate the right blade lift cylinder and dig the right edge of the
blade 50 to 100 mm (2.0 to 3.9 in) into the ground.
3 - 83
.
OPERATION OPERATION
8. Set the machine with both the front and rear tires on the bottom
of the groove formed in the 1st digging pass, then continue the
digging operation until the ditch is the desired depth.
(Heavy-duty digging)
Lean the front wheels so that they are perpendicular.
9. Before the rear wheels start to run over the windrow, move it
from the load shoulder and spread it.
3 - 84
.
OPERATION OPERATION
NOTICE
Set the frame straight. If the machine is articulated, the side of the tire will be pushed against the opposite slope face (back slope),
and this will cause damage to the side face of the tire. In addition, mud will be pushed in between the tire and rim, and this will
cause problems such as leakage of air and flat tires.
1. Align the left edge of the blade with the outside edge of the front
left tire.
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 determines the shape of the
ditch.)
4. Angle the blade so that a windrow is formed at the center of the
chassis.
5. Operate the left blade lift cylinder and dig the left edge of the
blade 50 to 100 mm (2.0 to 3.9 in) into the ground.
3 - 85
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OPERATION OPERATION
8. Set the machine with both the front and rear tires on the bottom
of the groove formed in the 1st digging pass, then continue the
digging operation until the ditch is the desired depth.
(Heavy-duty digging)
Lean the front wheels so that they are perpendicular.
9. Before the rear wheels start to run over the windrow, move it
from the load shoulder and spread it.
3 - 86
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OPERATION OPERATION
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 windrow (A)
formed by the blade.
4. Operate the blade lift cylinder and blade rotation to set so that
the windrow is pushed to the outside of the rear left wheel.
5. Lean the front wheels slightly to the left.
6. 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 - 87
.
OPERATION OPERATION
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 - 88
.
OPERATION OPERATION
2. Move the right edge of the blade to the outside of the front right
wheel and adjust (reduce) the propulsion angle so that the
windrow comes between the rear wheels (chassis).
3 - 89
.
OPERATION OPERATION
4. Spread the windrow from the road shoulder to the center of the
road.
Make the propulsion angle as large as possible to push the
windrow to one side.
Set the digging angle to the maximum.
Be careful not to let the rear wheels run over the windrow.
For the finishing operation, travel at a speed of 2 to 6 km/h
(1.2 to 3.7 MPH).
3 - 90
.
OPERATION OPERATION
2. Move the left edge of the blade to the outside of the front left
wheel and adjust (reduce) the propulsion angle so that the
windrow comes between the rear wheels (chassis).
3 - 91
.
OPERATION OPERATION
4. Spread the windrow from the road shoulder to the center of the
road.
Make the propulsion angle as large as possible to push the
windrow to one side.
Set the digging angle to the maximum.
Be careful not to let the rear wheels run over the windrow.
For the finishing operation, travel at a speed of 2 to 6 km/h
(1.2 to 3.7 MPH).
3 - 92
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OPERATION OPERATION
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 to 50 mm (1.2 to 2.0 in)
Travel speed: 0.5 km/h (0.3 MPH)
3 - 93
.
OPERATION OPERATION
5. Leveling center
3 - 94
.
OPERATION OPERATION
8. Spreading to center
11. Ditch digging pass (finishing and shaping inside of the slope
face)
3 - 95
.
OPERATION OPERATION
3 - 96
.
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 normal.
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.
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.
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.
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OPERATION OPERATION
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.
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OPERATION OPERATION
2. Dig the width and depth of the bottom of the ditch with the left
ditching method.
3 - 99
.
OPERATION OPERATION
3 - 100
.
OPERATION OPERATION
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.
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OPERATION OPERATION
The procedure given indicates the procedure for the right side. For the left side, operate the blade in the opposite
way.
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. Operate the blade shift cylinder and shift the blade to the right.
4. Operate the drawbar shift cylinder and shift the drawbar to the
right.
5. Rotate the circle and set the end of the blade at the side of the
front right wheel.
6. In the position in Step 5, lower the blade so that it is lightly in
contact with (touching) the ground.
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OPERATION OPERATION
8. Extend the right blade lift cylinder, retract the left blade lift
cylinder and drawbar shift cylinder, and rotate the lifter guide
counterclockwise enough for the bank control lock pin to come
out of the lock hole.
9. When the lifter has rotated, move the bank switch from the
RETRACT position to the INDEX position.
10. Operate the lifter to the specified position (counter mark), then
insert the bank control lock pin.
11. When the lifter guide is at the specified position, move the bank
switch from the INDEX position to the LOCK position.
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OPERATION OPERATION
12. Retract the right lift cylinder and extend the left lift cylinder to
set the blade to the bank slope position.
13. Rotate the circle to the right.
14. Rotate the circle and extend or retract the left and right blade
lift cylinders to set to the bank slope face posture.
15. Angle the blade at 3/4 to the front from the high bank position
to set to the low bank posture.
16. 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.
17. The rear right wheel must be in the V at the base of the slope
face.
18. Extend the right blade lift cylinder and set the angle to the
desired bank slope face.
19. Gradually progress with the cutting.
REMARK
The wheels should normally be almost perpendicular.
3 - 104
.
OPERATION OPERATION
3 - 105
.
OPERATION OPERATION
3. Extend the right blade lift cylinder, retract the left blade lift
cylinder, and rotate the lifter guide to the left.
4. When the lifter has rotated, move the bank switch from the
RETRACT position to the INDEX position.
3 - 106
.
OPERATION OPERATION
6. When the lifter guide is at the specified position, move the bank
switch from the INDEX position to the LOCK position.
8. Lower the blade to the desired depth, then set the blade at an angle to discharge the soil to the side.
3 - 107
.
OPERATION OPERATION
TRAVELING DOWNHILL
When traveling downhill, select the same gear range as when traveling uphill, and make full use of the engine to
reduce the travel speed.
IF ENGINE STOPS
CAUTION
When the engine stops, the steering booster does not work and the steering wheel becomes heavy. This condition is dangerous.
Also, when the air pressure of air tank decreases, the brake efficiency decreases. Be careful.
If the engine stops on a slope, immediately depress the brake pedal fully to stop the machine, set the gearshift lever
to the P (Parking) position, then start the engine again.
3 - 108
.
OPERATION OPERATION
Use the following table as a guideline for the suitable travel speed in each speed range.
3 - 109
.
OPERATION OPERATION
NOTICE
If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the parking brake checked
for any abnormality.
3 - 110
.
OPERATION OPERATION
Keep the ripper at a depth where there is no tire slip and where the
engine horsepower can be used to its full.
NOTICE
To prevent damage, raise the ripper from the ground before turning the machine.
3 - 111
.
OPERATION OPERATION
3 - 112
.
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 gearshift
lever to the P (Parking) position.
3 - 113
.
OPERATION OPERATION
4. Check that parking brake pilot lamp (5) on the machine monitor
is lighted up.
5. Operate the work equipment control lever and lower the blade
and ripper to the ground.
3 - 114
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OPERATION OPERATION
LOCKING
Always lock the following parts.
(1) Fuel filler cap
(2) Engine side cover
(3) Cab door
(4) Hydraulic oil filler cap
(5) Radiator water filler cap
REMARK
The starting switch key is also used for these locks.
3 - 115
.
OPERATION OPERATION
3 - 116
.
OPERATION OPERATION
OPERATION
WARNING
The accumulator is charged with high-pressure nitrogen gas, so it is
extremely dangerous if handled incorrectly. Always obey the following
rules strictly.
Never make a hole in the accumulator or bring it does to any flame or
fire.
Do not weld any boss to the accumulator.
When discarding the accumulator, the gas must be released, so contact
your Komatsu distributor.
In the figure on the right, the left side shows the switches for the
machine equipped with an accumulator and blade float, and
the right side shows the switches for the machine equipped
with an accumulator.
3. Turn off accumulator switch 2, then start the engine.
In the figure on the right, the left side shows the switches for the
machine equipped with an accumulator and blade float, and
the right side shows the switches for the machine equipped
with an accumulator.
4. Next, extend the right and left blade lift cylinders approximately
50 mm (2.0 in).
At this time, holding pressure is produced at the bottom of the
blade lift cylinders.
3 - 117
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OPERATION OPERATION
In the figure on the right, the left side shows the switches for the
machine equipped with an accumulator and blade float, and
the right side shows the switches for the machine equipped
with an accumulator.
REMARK
At this time, a pressure is maintained at the bottom of the blade lift cylinders, that is, a pressure acts on the blade.
When the machine is operated under this condition.
The blade can follow a difference in ground level of approximately 150 mm (5.9 in), which is the standard
operation when an accumulator is in use.
In actual operation, the blade lift cylinder levers will move properly so that the blade can follow the required
difference in ground level with the proper pressing force.
Once the accumulator is set and the machine is started, the blade lift levers do not need to be operated. When
stopping the work for a time, the accumulator can be reset to the same condition as before stopping the work by
turning off the switch, lifting the blade, lowering it to the ground again, and turning on the switch again.
EASE OF WORK
No need to operate blade
This work does not require a lot of skill.
IMPROVED WORKABILITY
Good pushing of blade
Good avoidance by blade
3 - 118
.
OPERATION OPERATION
OPERATION
WARNING
If the blade float switch is turned ON when the blade is raised, the pressure
will be released from the left cylinder and the blade will fall suddenly. Never
allow anyone near the machine when turning the blade float switch ON.
4. If the blade lift control lever is returned to the HOLD position when the blade is raised or lowered, the pressure
in the lift cylinder will be released and the blade will suddenly drop to the ground.
REMARK
When the starting switch is ON (current flowing through the circuit), it is possible to switch the float condition at any
time by operating the blade float switch ON/OFF.
3 - 119
.
OPERATION OPERATION
EASE OF OPERATION
No need to operate blade
No need to employ experienced operator (relief of condition)
SAFETY, PROTECTION
Shocks are reduced.
The machine is protected from buried objects. (The machine runs over projecting objects.)
The work equipment is protected (the impact load is reduced).
3 - 120
.
OPERATION TRANSPORTATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
When loading or unloading, always use ramps or a platform and perform the operations as follows.
1. Insert the shank as shown in the diagram on the right.
2. 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 15 deg.
Set the distance between the ramps to match the center of the
tires.
3. Set the machine in line with the ramps, then drive the machine
slowly to load or unload it.
4. Load the machine correctly in the specified position on the
trailer.
3 - 121
.
TRANSPORTATION OPERATION
3 - 122
.
COOLANT
WARNING
Coolant is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash it
off with large amounts of fresh water and see a doctor at once.
When changing the coolant or when handling the cooling water containing coolant that has been drained during repair of
radiator, contact your Komatsu distributor or request a specialist company to perform the operation. Coolant is toxic. Do not
let it flow into drainage ditches or spray it onto the ground surface.
NOTICE
Use Komatsu genuine SUPERCOOLANT (AF-NAC) for the coolant. As a basic rule, we do not recommend the use of any coolant
other than SUPERCOOLANT (AF-NAC).
For details of the density of coolant and the interval for changing the coolant, see "CLEAN INSIDE OF COOLING
SYSTEM (PAGE 4-23)".
3 - 123
.
BATTERY
WARNING
The battery generates flammable gas. Do not bring open flame near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
Battery electrolyte dissolves paint. If it gets on the bodywork, wash it off immediately with water.
If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is danger
that the battery may explode.
Battery electrolyte is toxic. Do not let it flow into drainage ditches or spray it on to the ground surface.
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%. Insulate it against cold
temperature to ensure the machine can be started easily the next morning.
Measure the specific gravity and calculate the rate of charge from the following conversion table.
Electrolyte
Temperature 20°C 0°C -10°C -20°C
Charging (68°F) (32°F) (14°F) (-4°F)
Rate (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the
electrolyte from freezing.
3 - 124
.
LONG-TERM STORAGE
BEFORE STORAGE
When putting the machine in storage for a long time, do as follows.
After every part is washed and dried, 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.
Coat the exposed portion of the hydraulic cylinder piston rod with grease.
Disconnect the negative terminals of the battery and cover it or remove it from the machine and store it separately.
If the ambient temperature is expected to drop below 0ºC (32°F), 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 (14°F).
If the temperature goes below -10ºC (14°F), adjust the density. For details, see "CLEAN INSIDE OF COOLING
SYSTEM (PAGE 4-23)".
Place gear shift levers at the P (parking) position.
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.
To prevent rust, fill with coolant to give a density of at least 30% for the engine coolant.
DURING STORAGE
WARNING
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors and windows to improve
ventilation and prevent gas poisoning.
During storage, operate and move the machine for a short distance once a month so that a new film of oil will coat
moving parts. At the same time, also charge the battery.
When operating the work equipment, wipe off all the grease from the hydraulic cylinder rods.
If the machine is equipped with an air conditioner, operate the air conditioner for 3 to 5 minutes once a month to
lubricate all parts of the air conditioner compressor. Always run the engine at Low idle (MIN) when doing this.
In addition, check the refrigerant level twice a year.
AFTER STORAGE
NOTICE
If the machine has been stored without performing the monthly rust-prevention operation, consult your Komatsu distributor
before using it.
When using the machine after long-term storage, do as follows before using it.
Wipe off the grease from the hydraulic cylinder rods.
Add oil and grease to all places.
When the machine is stored for a long period, moisture in the air will mix with the oil. Check the oil before and after
starting the engine. If there is water in the oil, change all the oil.
3 - 125
.
TROUBLESHOOTING OPERATION
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
When starting after running out of fuel, fill with fuel and bleed the air from the fuel system before starting.
Always watch the fuel level and be careful not to run out of fuel.
If the engine has stopped because of lack of fuel, it is necessary to use the priming pump to bleed the air completely
from the fuel circuit.
If the leaning piping is broken, call your Komatsu distributor for repair.
3 - 126
.
OPERATION TROUBLESHOOTING
NOTICE
Towing is to be used only for moving the machine to a safe place where it is possible to carry out inspection and maintenance.
Do not use towing to move a machine for a long distance.
Please consult your Komatsu distributor for details of the method of towing a machine that has broken down.
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.
3 - 127
.
TROUBLESHOOTING OPERATION
WARNING
When releasing the parking brake, stop the machine on level ground and check that the surrounding area is safe. If it is
necessary to release the brake on a slope in an emergency, block the tires before starting the operation.
If the parking brake is released, the brake cannot be used, so check the safety carefully when moving the machine.
If the pressure in the air tank drops below 0.24 MPa {2.4 kg/cm2,
34.1 PSI}, the parking brake is applied automatically. Therefore,
when towing the machine, release the parking brake as follows.
Turn bolt (1) and the parking brake will be released.
NOTICE
After releasing the parking brake and moving the machine, it is necessary to adjust the parking brake again. Please contact your
Komatsu distributor to have the parking brake adjusted.
WARNING
When the engine is stopped, it is impossible to steer the machine, and this may lead to personal injury. If the engine should stop
during operations, immediately apply the service brake and stop the machine.
3 - 128
.
OPERATION TROUBLESHOOTING
WARNING
Never operate the electrical motor for the emergency steering for more than 30 seconds.
If the machine battery cells are not functioning, the emergency steering cannot display its capacity.
This mechanism works to prevent steering failure caused by a breakdown of the engine or hydraulic pump while the
machine is being operated.
If the oil pressure in the steering hydraulic circuit drops below 0.69 MPa {7 kg/cm2, 99.4 PSI}, the hydraulic switch
is turned on, and the electrical motor is actuated to turn the hydraulic pump and enable steering to be carried out.
If the machine is traveling at a speed of less than 1 km/h (0.6 MPH), or if the machine is stopped, the emergency
steering device automatically stops.
If it is necessary to release the parking brake, use the procedure given in "HANDLING EMERGENCY STEERING
DEVICE (PAGE 6-2)".
3 - 129
.
TROUBLESHOOTING OPERATION
IF BATTERY IS DISCHARGED
WARNING
It is dangerous to charge a battery installed on a machine. Make sure
that it is removed before charging.
When checking or handling the battery, stop the engine and turn the
starting switch key to OFF position.
The battery generates hydrogen gas, so there is a hazard of explosion.
Do not bring lighted cigarettes near the battery, or do nothing that will
cause sparks.
Battery electrolyte is dilute sulfuric acid, and it will attack your clothes
and skin. If it gets on your clothes or on your skin, immediately wash it
off with a large amount of water. If it gets in your eyes, wash it out with
fresh water and consult a doctor.
When handling batteries, always wear protective eyeglasses and rubber
gloves.
When removing the battery, first disconnect the cable from the ground
(normally the negative (-) terminal). When installing, install the positive
(+) terminal first.
If a tool touches the positive (+) terminal and the chassis, there is
danger that it will cause a spark, so be extremely careful.
If the terminals are loose, there is danger that the defective contact may
generate sparks that will cause an explosion.
When installing the terminal, securely install it.
When removing or installing the terminals, check which is the positive
(+) terminal and which is the negative (-) terminal.
3 - 130
.
OPERATION TROUBLESHOOTING
Set the voltage of the charger to match the voltage of the battery
to be charged. If the correct voltage is not selected, 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 negative (-)
charger clip of the charger to the negative (-) terminal of the
battery. Be sure to attach the clips securely.
Set the charging current to 1/10 of the value of the rated battery capacity; when performing 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 a danger that this will ignite the battery electrolyte and cause the battery to explode.
Do not use or charge the battery if the battery electrolyte level is below LOWER LEVEL line. This may cause an
explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to
UPPER LEVEL line.
3 - 131
.
TROUBLESHOOTING OPERATION
WARNING
When connecting the cables, never contact the positive (+) and negative
(-) terminals.
When starting the engine with a booster cable, wear protective
eyeglasses and rubber 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.
Make sure that there is no mistake in the booster cable connections.
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.
When disconnecting the booster cable, take care not to bring the clips
in contact with each other or with the machine.
NOTICE
The size of the booster cable and clip should be suitable for the battery size.
The battery of the normal machine must be the same capacity as that of the engine to be started.
Check the cables and clips for damage or corrosion.
Make sure that the cables and clips are firmly connected.
Check that the work equipment lock levers and parking brake levers of both machines are in LOCK position.
Check that each lever is in NEUTRAL position.
3 - 132
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OPERATION TROUBLESHOOTING
CAUTION
Check that the gearshift levers on both the normal machine and problem machine are at the P (Parking) position. Check also that
all levers are at neutral.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at High idle (MAX).
3. Turn the starting switch of the failed machine to START position and start the engine.
If the engine doesn't start at first, try again after 2 minutes or so.
3 - 133
.
TROUBLESHOOTING OPERATION
OTHER TROUBLE
ELECTRICAL SYSTEM
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
3 - 134
.
OPERATION TROUBLESHOOTING
CHASSIS
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
More noise than usual is generated Lack of oil in transmission case, Add oil to specified level
from power train tandem case For details, see EVERY 250
HOURS SERVICE
Final drive oil temperature lamp on Lack of oil in final drive case Add oil to specified level
machine monitor flashes For details, see EVERY 250
HOURS SERVICE
Differential has been operated for Stop using differential until oil
a long time temperature goes down
Abnormal wear of front tires Incorrect adjustment of toe-in Adjust. For details, see
EVERY 1000 HOURS
SERVICE
Lack of inflation pressure Check, adjust
Heat generated from front wheel Loose bearing preload ( Check, adjust [adjust bearing
hub adjustment nut for front wheel preload])
Lack of grease Supply grease
Front wheels wobble when traveling Incorrect adjustment of toe-in, Adjust. For details, see
loose tie rod EVERY 1000 HOURS
SERVICE
Inflation pressure of left and right Inflate tires to same air
tires not same pressure
Wheel not properly installed Install again. For details,
see HANDLING TIRES
Steering wheel is heavy Defective Orbit-roll ( Adjust)
3 - 135
.
TROUBLESHOOTING OPERATION
3 - 136
.
OPERATION TROUBLESHOOTING
ENGINE
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, ask your Komatsu distributor for repairs.
3 - 137
.
TROUBLESHOOTING OPERATION
3 - 138
.
OPERATION TROUBLESHOOTING
TRANSMISSION CONTROLLER
If there is a failure in the transmission system, check the failure code on the transmission controller and ask your
Komatsu distributor to carry out repairs.
Transmission control (1) is installed inside the engine hood at the rear of the cab. Open panel (2) and check the
failure code on the controller.
3 - 139
.
TROUBLESHOOTING OPERATION
3 - 140
.
OPERATION TROUBLESHOOTING
CAUTION SYSTEM
If any of the mistaken operations in the table below are carried out,
caution lamp (1) or the alarm buzzer are actuated to give a
warning.
Abnormal Caution
operation Content of abnormal operation Record
code Lamp Buzzer
When shifting down, or when changing direction between F and R, and shifting
N -> F (R) when machine is still traveling, shift-down command is issued
10 according to travel speed
Caution is issued until it reaches speed range selected by lever position (from 1
sec after lever operation)
When shifting N -> F (R) when machine is traveling at more than 4 km/h (2.5
11
MPH) -
Caution issued (for 5 sec after lever operation)
When transmission is shifted to F4 (R4) or above when engine speed is more
12
than 350 rpm and travel speed is less than 2 km/h (1.2 MPH)
Caution issued
Plate calculated temperature
Inching time (sec) Clutch Category
( °C (°F))
1 200 - 230 (392 - 446)
2 230 - 260 (446 - 500)
F
3 260 - 290 (500 - 554)
4 290 (554) or above
13 0 - 10 - -
1 200 - 230 (392 - 446)
2 230 - 260 (446 - 500)
R
3 260 - 290 (500 - 554)
4 290 (554) or above
0 200 (392) or below
1 200 - 230 (392 - 446)
F 2 230 - 260 (446 - 500)
3 260 - 290 (500 - 554)
4 290 (554) or above
14 10 - 30
0 200 (392) or below
1 200 - 230 (392 - 446)
R 2 230 - 260 (446 - 500)
3 260 - 290 (500 - 554)
4 290 (554) or above
3 - 141
.
TROUBLESHOOTING OPERATION
Abnormal Caution
operation Content of abnormal operation Record
code Lamp Buzzer
0 200 (392) or below
1 200 - 230 (392 - 446)
F 2 230 - 260 (446 - 500)
3 260 - 290 (500 - 554)
4 290 (554) or above
15 30 or above
0 200 (392) or below
1 200 - 230 (392 - 446)
R 2 230 - 260 (446 - 500)
3 260 - 290 (500 - 554)
4 290 (554) or above
Caution issued when engine is running at high speed
Caution lamp lights up when engine is operated continuously for 5 sec. at
16 2525 rpm or more
Alarm buzzer sounds when engine is operated continuously for 10 sec. at
2525 rpm or more
Acceleration when inching pedal is depressed (exceeding hydraulic control
range)
17
Caution lamp if more than max speed for speed range selected by lever position
At above danger speed, shift up and caution buzzer
Time that lubricating oil temperature is above 120 °C (248 °F)
18
Caution issued after more than 30 seconds
Time that lever position is at N and travel speed is more than 4 km/h (2.5 MPH)
19 and engine speed is more than 1400 rpm - -
Recorded as abnormal operation after more than 10 seconds
Lever position at F (R) and inching pedal depressed (exceeding hydraulic
control range)
1A Time that travel speed is more than 4 km/h (2.5 MPH) and engine speed is - -
more than 1400 rpm
Recorded as abnormal operation after more than 10 seconds
3 - 142
.
4-1
.
GUIDES TO MAINTENANCE
Do not perform any inspection and maintenance operation that is not found in this manual.
Welding instructions:
Turn off the engine starting switch.
Do not apply more than 200 V continuously.
Connect grounding cable within 1 m (3 ft 3 in) of the area to be welded. If grounding cable is connected near
instruments, connectors, etc., the instruments may malfunction.
If a seal or bearing happens to come between the part being welded and grounding point, change the grounding
point to avoid such parts.
Do not use the area around the work equipment pins or the hydraulic cylinders as the grounding point.
4-2
.
Dusty worksites:
When working at dusty worksites, do as follows:
Inspect the air cleaner clogging monitor frequently to see if the dust indicator is clogged.
Clean the air cleaner element at a shorter interval than specified.
Clean the radiator core frequently to avoid clogging.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting
into the oil.
4-3
.
OUTLINES OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
OIL
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual.
Even if the oil is not dirty, always change the oil after the specified interval.
Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from getting in.
The majority of problems with the 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 capacity 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,
consult your Komatsu distributor.
When changing the oil, always replace the related filters at the same time.
We recommend you have an analysis made of the oil periodically to check the condition of the machine. For
those who wish to use this service, consult 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 Operation and Maintenance Manual.
Fuel congeals at certain temperature (particularly at temperature below -15°C (5°F). Therefore, select fuel
according to the using temperature.
To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank
after completing the day's work.
Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from
the fuel tank.
If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.
4-4
.
BIO-FUEL
The biofuel is a fuel that is formed in a transesterification reaction of vegetable oil, animal fat, and edible oil.
The ASTM D975 diesel fuel can contain 5 % or less of biofuel.
Use the biofuel conforming to ASTM D7467 if its mixing ratio is between 6% to 20%.
The EN590 diesel fuel can contain 7 % or less of biofuel.
When you use 100% biofuel for mixing, it needs to conform to ASTM D6751 or EN14214.
In the United States, purchase the biofuel from the dealer certified by BQ-9000.
In the EU, purchase the biofuel from the member companies of European Biodiesel Board (EBB).
In other countries or regions, purchase the biofuel from the dealer that guarantees the same quality as BQ-9000 or
EBB.
NOTICE
When you use biofuel other than the preceding diesel fuel and its mixing ratio is up to 20 %, obey the precautions that follow.
It is necessary to consult with the local regulatory authorities of engine exhaust gas regulation whether the biofuel can be used
or not.
The fuel can possibly leak because of the deterioration of rubber material of the fuel hose.
Replace it with the fuel hose applicable for biofuel. Consult your Komatsu distributor for replacement of the fuel hose.
Biofuel cannot be stored for a long time because it is easy to deteriorate and change in quality.
Use the fuel in the storage tank or the fuel tank of the machine within 6 months.
If the deteriorated and altered biofuel is used, it can cause bad effects on the engine parts.
When you store the machine which uses the diesel fuel mixed with the biofuel for more than 3 months, do the procedure that
follows.
o Replace it with pure diesel fuel or the new diesel fuel mixed with the biofuel at the lowest possible mixing ratio.
o After you change the fuel, run the engine for a minimum of 30 minutes before you store the machine.
Because the biofuel dissolves the materials stuck to the fuel tank and fuel line, the fuel filter can be clogged with them.
When you change the diesel fuel to the biofuel, replace the fuel main filter cartridge and fuel prefilter cartridge with new ones.
When you replace the fuel main filter cartridge and fuel prefilter cartridge, make the replacement interval half the normal time
until the second replacement after you change the diesel fuel to the biofuel.
Because the biofuel absorbs moisture easily, it can possibly cause a growth of microorganism.
When the microorganism grows in the biofuel, it can cause corrosion of the fuel system and the clogging of the fuel filter.
Drain the water from the fuel tank before you start the operation.
When you complete the operation, fill the fuel tank to reduce the air layer.
If the biofuel is used in the conditions of the specific operation, the fuel can possibly get mixed into the engine oil.
The fuel level in the engine oil must not exceed 5 %. Deteriorated engine oil can cause adverse effects on the engine parts such
as a reduction of lubricating function. It is recommended to take a sample of the oil on a periodic basis.
The characteristics of the biofuel change when outside air temperature is low. The fuel filter can be clogged and the fuel inside
the fuel tank can be solidified. Store the biofuel in the warm building or in the storage tank.
The energy density of the biofuel becomes lower by 7 to 10% with that of the diesel fuel. Fuel consumption and
output can possibly be lowered when the mixing ratio is high.
4-5
.
PARAFFIN-BASED FUEL
The paraffin-based fuel is generated by natural gas, coal, vegetable oil, and animal and plant fat, and its main
constituent is paraffin.
The paraffin-based fuel has almost the same characteristics as the diesel fuel.
Vegetable oil and fat-derived fuel are called renewable diesel (RD) and hydrogenated vegetable oil (HVO).
The fuel synthesized from natural gas is called gas-to-liquid (GTL).
NOTICE
Use the paraffin-based fuel which agrees with EN15940:2016 and ASTM D975.
As long as the fuel agrees with EN15940:2016 and ASTM D975, its mixing ratio can be up to 100 %.
The energy density of the paraffin-based fuel becomes lower up to 10% with that of the diesel fuel. Thus, fuel
consumption and output can possibly be lowered.
GREASE
Grease is used to prevent seizure and noises at the joints.
Grease fittings not listed in the inspection and maintenance section are grease fittings that are used at the time
of overhaul, so there is no need to grease these points.
When using the machine after it has been in storage for a long time, carry out greasing if there is any stiffness or
screeching.
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.
4-6
.
Others
Measurements are made of items such as the ratio of water, coolant, and fuel in the oil, and dynamic viscosity,
if necessary, to enable a highly precise diagnosis of the machine and the components' condition.
OIL SAMPLING
Sampling interval
500 hours
Precautions when sampling
Make sure that the oil is well mixed before sampling.
Perform sampling at regular fixed intervals.
Do not perform sampling on rainy or windy days when water or dust can get into the oil.
For further details of KOWA, contact your Komatsu distributor.
4-7
.
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, replace the filters at shorter intervals according to the oil and fuel
(sulfur content) being used.
Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
When replacing oil filters, check if any metal particles are attached to the old filter. If any metal particles are found,
consult your Komatsu distributor.
Do not open packs of spare filters until just before they are to be used.
Always use Komatsu genuine filters.
4-8
.
4-9
.
WEAR PARTS
Wear parts such as the filter element, air cleaner element, edge, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits. The wear parts should be replaced correctly in order to ensure more
economic use of the machine. When replacing parts, always use Komatsu genuine parts.
As a result of our continuous efforts to improve product quality, the part number may change, so inform your
Komatsu distributor of the machine serial number and check for the latest part number when ordering parts.
4 - 10
.
4 - 11
.
NOTICE
When you use biofuel other than the preceding diesel fuel and its mixing ratio is up to 20 %, obey the precautions that follow.
It is necessary to consult with the local regulatory authorities of engine exhaust gas regulation whether the biofuel can be used
or not.
The fuel can possibly leak because of the deterioration of rubber material of the fuel hose.
Replace it with the fuel hose applicable for biofuel. Consult your Komatsu distributor for replacement of the fuel hose.
Biofuel cannot be stored for a long time because it is easy to deteriorate and change in quality.
Use the fuel in the storage tank or the fuel tank of the machine within 6 months.
If the deteriorated and altered biofuel is used, it can cause bad effects on the engine parts.
When you store the machine which uses the diesel fuel mixed with the biofuel for more than 3 months, do the procedure that
follows.
o Replace it with pure diesel fuel or the new diesel fuel mixed with the biofuel at the lowest possible mixing ratio.
o After you change the fuel, run the engine for a minimum of 30 minutes before you store the machine.
Because the biofuel dissolves the materials stuck to the fuel tank and fuel line, the fuel filter can be clogged with them.
When you change the diesel fuel to the biofuel, replace the fuel main filter cartridge and fuel prefilter cartridge with new ones.
When you replace the fuel main filter cartridge and fuel prefilter cartridge, make the replacement interval half the normal time
until the second replacement after you change the diesel fuel to the biofuel.
Because the biofuel absorbs moisture easily, it can possibly cause a growth of microorganism.
When the microorganism grows in the biofuel, it can cause corrosion of the fuel system and the clogging of the fuel filter.
Drain the water from the fuel tank before you start the operation.
When you complete the operation, fill the fuel tank to reduce the air layer.
If the biofuel is used in the conditions of the specific operation, the fuel can possibly get mixed into the engine oil.
The fuel level in the engine oil must not exceed 5 %. Deteriorated engine oil can cause adverse effects on the engine parts such
as a reduction of lubricating function. It is recommended to take a sample of the oil on a periodic basis.
The characteristics of the biofuel change when outside air temperature is low. The fuel filter can be clogged and the fuel inside
the fuel tank can be solidified. Store the biofuel in the warm building or in the storage tank.
NOTICE
Use the paraffin-based fuel which agrees with EN15940:2016 and ASTM D975.
As long as the fuel agrees with EN15940:2016 and ASTM D975, its mixing ratio can be up to 100 %.
4 - 12
.
REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulfur content is above 0.5%.
When starting the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine oil
of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C (50°
F) more or less during the day.
Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to add
single grade oil that matches the temperature range in the table.
We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and
hydraulic work equipment applications.
Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as
preventing freezing.
Even in the areas where freezing is not an issue, the use of antifreeze COOLANT is essential.
Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has excellent
anticorrosion, antifreeze and cooling properties and can be used continuously for two years or 4000 hours.
SUPERCOOLANT (AF-NAC) is strongly recommended wherever available.
For details of the density of the COOLANT, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-23)".
COOLANT is supplied already diluted. In this case, add the pre-diluted fluid to keep the tank full. (Never dilute
the COOLANT with ordinary water.)
To maintain the anticorrosion properties of COOLANT, always keep the density of COOLANT between 30% and
68%.
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.
4 - 13
.
4 - 14
.
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT(Winter, one
EO15-40CD season type)
Diesel sigma S
super dieselmulti-
2 AGIP Rotra MP GR MU/EP -
grade
*Sigma turbo
Multi-purpose gear PYKON premium
3 AMOCO *Amoco 300 -
oil grease
Litholine HEP 2
4 ARCO *Arcofleet S3 pius Arco HD gear oil -
Arco EP moly D
Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP
*RPM delo 400 Universal thuban Marfak all purpose 2
6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -
Universal gear
9 CONOCO *Fleet motor oil Super-sta grease -
lubricant
Multiperformance 3C Tranself EP
10 ELF - Glacelf
Performance 3C Tranself EP type 2
Essolube D3
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
Delvac 1300 Mobilux EP2
Mobilube GX
13 MOBIL *Delvac super Mobilgease 77 -
Mobilube HD
10W-30, 15W-40 Mobilgrease special
4 - 15
.
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
Multi-purpose white
*Superme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease
PETROFIN FINA potonic N
15 FINA kappa TD FINA marson EPL2 FINA tamidor
E FINA potonic NE
Spirax EP
16 SHELL Rimura X Albania EP grease -
Spirax heavy duty
Sunoco ultra pres- Sunoco antifreeze
Sunoco GL5
17 SUN - tige 2EP and summer
gear oil
Sun prestige 742 coolant
*Ursa super plus Multifak EP2 Coda 2055 startex
18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze
*Rubia X
TM
20 UNION *Guardol MP gear lube LS Unoba EP -
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B - Antifreeze
MDC Multigear C
4 - 16
.
Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below.
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.
4 - 17
.
Inspection /Replacement
No. Target parts Q'ty
interval
1 Fuel hose (fuel tank - fuel injection pump) 1 Every 2 years or every
2 Fuel hose (fuel injection pump - fuel filter) 2 4000 hours, whichever
3 Fuel return hose (fuel injection pump - fuel tank) 1 comes sooner.
4 - 18
.
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
REPLACE FUEL FILTER CARTRIDGE 4- 55
CHECK CIRCLE GUIDE CLEARANCE, ADJUST 4- 57
CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR 4- 64
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER 4- 68
CHANGE OIL IN FINAL DRIVE CASE, CLEAN STRAINER 4- 69
REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK 4- 71
CHANGE OIL IN HYDRAULIC TANK 4- 72
CHANGE OIL IN CIRCLE REVERSE GEAR CASE 4- 76
CHANGE OIL IN TANDEM DRIVE CASE 4- 77
CHECK AND ADJUST ENGINE VALVE CLEARANCE 4- 79
WHEN REQUIRED
CLEAN INSIDE OF COOLING SYSTEM 4- 23
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 4- 26
CHECK ELECTRICAL INTAKE AIR HEATER 4- 33
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES 4- 33
CLEAN HYDRAULIC TANK BREATHER 4- 34
REPLACING RIPPER POINT 4- 35
CHECK INCHING PEDAL 4- 35
CLEAN ELEMENT OF AIR CONDITIONER FRESH AIR FILTER 4- 35
CLEAN ELEMENT OF AIR CONDITIONER RECIRCULATION AIR FILTER 4- 36
CHECK QUANTITY OF REFRIGERANT 4- 37
SELECTION AND INSPECTION OF TIRES 4- 38
INSPECTING CORROSION, WEAR OF WHEEL RIM, LOCK RING, SIDE RING 4- 39
4 - 19
.
4 - 20
.
4 - 21
.
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
Perform the following maintenance only after the first 250 hours of operation on new machines.
REPLACE FUEL FILTER CARTRIDGE
CHECK CIRCLE GUIDE CLEARANCE, ADJUST
CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER
CHANGE OIL IN FINAL DRIVE CASE
REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK
CHANGE OIL IN HYDRAULIC TANK
CHANGE OIL IN CIRCLE REVERSE GEAR CASE
CHANGE OIL IN TANDEM DRIVE CASE
CHECK AND ADJUST ENGINE VALVE CLEARANCE
For details of the method of replacing or maintaining, see EVERY 500 HOURS, EVERY 1000 HOURS and EVERY
2000 HOURS SERVICE.
4 - 22
.
WHEN REQUIRED
Stop the machine on level ground when cleaning or changing the coolant.
Clean the inside of the cooling system, change the coolant according to the table below.
*1: When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor.
When no corrosion resistor is used, use the special cover (600-411-9000). Please consult your Komatsu
distributor about the method of installing.
When using corrosion resistor, use Komatsu genuine corrosion resistor. If you use another corrosion resistor,
it may cause serious problems such as corrosion of the engine and parts of the cooling system that use light
metals such as aluminum.
Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as
preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu
machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has excellent
anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. As a basic
rule, we do not recommend the use of any coolant other than SUPERCOOLANT (AF-NAC). If you use another
coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system.
To maintain the anticorrosion properties of coolant, always keep the density of coolant between 30% and 64%.
When selecting coolant, investigate the lowest temperature in the past and decide the density for the coolant from
the coolant density table below. When actually deciding the density for the coolant, set it approximately 10°C {18°
F} below lowest temperature. The density must be over 30% at least. If the density of obtained coolant is higher than
the necessary density for lowest temperature, dilute it with adequate distilled water, and then fill it into the tank.
If there is any unclear point, contact your Komatsu distributor.
4 - 23
.
WARNING
Coolant is toxic. Be careful not to get coolant on you when opening the drain valve.
If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.
Ask a specialist company or contact your Komatsu distributor for performing the change of coolant or disposal of the cooling
water containing coolant that has been drained during repair of radiator. Coolant is toxic. Do not let it flow into drainage ditches
or spray it onto the ground surface.
COOLANT is already diluted with distilled water, so it is not flammable. (For details of the distilled water, see
"COOLANT AND WATER FOR DILUTION (PAGE 4-6)"). Check the density with a COOLANT tester.
1. Stop the engine and turn radiator cap (1) slowly to remove it.
2. Tighten corrosion resistor cartridge (2) of valve (3).
4 - 24
.
12. Stop the engine, wait for approximately 3 minutes, add coolant up to the mouth of the filler port, and tighten the
radiator cap (1).
13. Drain the water from sub tank (6), wash the inside of the sub
tank, then add cooling water to a point midway between the
FULL and LOW marks.
4 - 25
.
NOTICE
If dirt goes into the engine, it can damage the engine. Be sure to stop the engine before you check, clean, and do the
maintenance of the air cleaner. Do not check, clean, and do the maintenance of the air cleaner in strong winds, or in a dusty
area.
Also, dirt stuck to the element can fall inside the inner element during cleaning more frequently.
Replace the outer element if it has been cleaned 6 times repeatedly or used throughout 1 year. Replace the inner element at the
same time.
After the outer element has been cleaned six times or the air cleaner element is used for one year, replace the outer
element, inner element, and O-ring. For the replacement procedure, see "REPLACING ELEMENT (PAGE 4-31)".
If the dust indicator indicates 5.0 kPa just after the element is cleaned, replace the element even if the outer element
has not been cleaned six times or the air cleaner element has not been used for one year.
CHECKING
NOTICE
Do not remove the inner element. If it is removed, dirt will go in and can cause an engine failure.
Do not clean and use the inner element again. When you replace the outer element, replace the inner element with a new one
at the same time.
When cleaning the element, do not hit it or beat it against something.
Do not use an element whose pleats or gasket or seal are damaged.
1. Stop the engine.
2. Open engine side cover (1).
4 - 26
.
WARNING
Dirt will fly if compressed air is used for cleaning. If dirt gets into your eyes it may cause blindness, and if you breathe in the
dust it may damage your lungs. To prevent these problems, always wear protective eyeglasses, dust mask, and other
protective equipment.
When pulling out the air cleaner element, make sure that you are standing on a firm place. If your footing is not secure when
you perform the operation, there is danger of falling and suffering injury.
NOTICE
When cleaning the element, clean only the outer element. Do not clean the inner element. There is danger that dirt and dust may
get inside the engine when the outer element is being cleaned, and this will damage the engine.
3. Remove 6 hooks (4) of dust cup (3), then remove the dust cup.
4. Hold outer element (5) with your both hands and pull it out while
shaking it vertically and horizontally.
5. While holding inner element (6) to prevent it from coming out,
clean the inside of the air cleaner body with dry cloths.
6. Clean dirt stuck to the dust cup (3) with a dry cloth or the
compressed air.
4 - 27
.
NOTICE
If a damaged element is used, dust will pass the air cleaner filter and be sucked into the engine. Do not use any cleaning
method that will damage the element. If the element is damaged, replace it with a new element.
Never tap or hit the element against any other object when cleaning it.
Do not use an element with damaged pleats or a damaged gasket or seal.
Do not clean the element until the dust indicator shows red.
If the element is cleaned frequently before the dust indicator shows red, the air cleaner cannot show its normal performance
and the cleaning effect decreases.
Also, dirt stuck to the element can fall inside the inner element during cleaning more frequently.
7. Blow dry compressed air (less than 0.2 MPa (2.1 kgf/cm2, 30.0
PSI)) from inside of outer element (5) along its folds.
Next, blow the compressed air from outside along the folds,
and the blow from inside again.
4 - 28
.
11. Hitch hooks (4) of dust cup (3) to the projections of the air
cleaner body to lock.
NOTICE
Do not use the element with damaged pleats or a damaged gasket or seal.
If the element and O-ring are cleaned and used again after they are used for more than one year, itwill cause problems. Do not
use them again.
Wrap an unused element and keep it in a dry place.
12. Check that there is no dirt or oil stuck to the seal portion of the new element or cleaned element. Wipe off any
dirt or oil.
NOTICE
The air cleaner element must be installed in the correct direction.
Turn the bottoms of the air cleaner element (face where no hole is
drilled) (B) and (C) to the dust cup (3) side, and install it.
If it is not installed in correct direction, it can cause breakage of the air
cleaner element or serious damage to the engine.
When you insert the element into the body, if the rubber at the end is
bulged or the outer element (5) is not pushed in straight, and the dust
cup (3) is installed by force with the hook (4), there is a danger that the
hook and air cleaner body will be damaged. Be careful when you install
it.
13. Press the head of dust indicator (2) to reset the indication of
clogging.
4 - 29
.
4 - 30
.
REPLACING ELEMENT
WARNING
When pulling out the air cleaner element, make sure that you are standing on a firm place. If your footing is not secure when you
perform the operation, there is danger of falling and suffering injury.
3. Remove 6 hooks (4) of dust cup (3), then remove the dust cup.
4. Hold outer element (5) with your both hands and pull it out while
shaking it vertically and horizontally.
5. While holding inner element (6) to prevent it from coming out,
clean the inside of the air cleaner body with dry cloths.
6. Clean dirt stuck to the dust cup (3) with a dry cloth or the
compressed air.
4 - 31
.
10. Hitch hooks (4) of dust cup (3) to the projections of the air
cleaner body to lock.
11. Press the head of dust indicator (2) to reset the indication of
clogging.
4 - 32
.
NOTICE
The inner element must not be used again even after its cleaning.
When replacing the outer element, replace the inner element at the same time.
If the outer element and cover are installed while the inner element is not installed correctly, the outer element can be damaged.
Do not use improper parts. The seal parts do not have sufficient precision, and it will cause entry of dirt, and thus damage to
the engine.
Replace the cutting edge before it wears to the end face of the blade.
If the mounting surface is worn, correct it before turning or replacing the end bits.
1. Lift the blade to a suitable height and put a block underneath the blade rail to prevent it from falling.
2. Remove bolts and nuts (1), then remove the cutting edge (2).
3. Clean the mounting face for the cutting edge (2).
4. Turn cutting edge (2) and install to the blade. When turning the
edge, turn the left and right edges and interchange them.
When both sides are worn, replace with new parts. If the wear
has extended to the mounting surface, repair the mounting
surface before turning the cutting edge.
5. Tighten bolts and nuts (1) uniformly so that there is no clearance between the blade and cutting edge.
Tightening torque for mounting run: 392 to 530 Nm {40 to 54 kgm , 289.3 to 390.6 lbft}
6. After several hours of running, retighten the nuts.
4 - 33
.
4. Install the element with the surface put the mark shown in (7)
upward.
5. Install cover (5) and nut (4).
Tightening torque: 10 to 14 Nm {1.0 to 1.4 kgm, 7.23 to 10.1
lbft}
NOTICE
If the tightening torque is too large, the screws can be damaged.
6. Then close cover (2).
4 - 34
.
1. Raise the ripper to suitable height, and put a block under the beam to prevent the ripper from coming down.
2. Using a hammer and bar, remove the pin, then remove the point.
3. Install a new point, and insert the pin.
Dimension of point
New part: 377 mm (14.9 in)
Limit of use: 170 mm (6.7 in)
If the air conditioner is being used, clean the air filter element.
Stop the air conditioner before cleaning the element.
1. Loosen bolt (1), then remove cover (2).
2. Loosen bolt (3), then remove plate (4).
3. Loosen bolt (5), then take out element (7) and clean it.
4. Blow dry compressed air (less than 0.2 MPa {2.1 kgf/cm2, 30.0
PSI}) from the inside of the element along its pleats. Then blow
the compressed air from the outside along the pleats, and
again from the inside.
4 - 35
.
NOTICE
When bracket (4) is removed using bolt (3), the balance of unit (5) will be
lost. Be careful not to let unit (5) fall off or cause damage to the wiring.
4 - 36
.
If the cooling effect is poor, the refrigerant (gas) level may be low.
If this happens, check the sight glass in the receiver drier.
REMARK
Run the engine at idle, and if bubbles appear in the sight glass
when the air conditioner is set to cooling, the refrigerant level is low,
so please contact your Komatsu distributor to have it refilled.
4 - 37
.
SELECTION OF TIRES
WARNING
Select the tires according to the conditions of use and the weight of the 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 the weight of the attachments of the machine. Use the
following table.
Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when
using optional tires.
4 - 38
.
WARNING
When inflating a tire, check that no one will enter the working area. 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 fitting of the rim
indicate 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.
CHECKING
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.
NOTICE
The optimum inflation pressure differs according to the type of work. For details, see "HANDLING THE TIRES (PAGE 3-116)".
4 - 39
.
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.
4 - 40
.
LUBRICATING
WARNING
Set the gearshift lever to the P (Parking) position, and secure the front and rear frame with the articulate lock pin.
Set the work equipment in a stable condition, and stop the engine.
4 - 41
.
LUBRICATING
WARNING
Set the gearshift lever to the P (Parking) position, and secure the front and rear frame with the articulate lock pin.
Set the work equipment in a stable condition, and stop the engine.
CAUTION
Do not insert your finger into any of the holes at the 17 greasing points.
1. By 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 - 42
.
4 - 43
.
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
WARNING
Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury. Accordingly, wait until
they have cooled down before starting the work.
When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
1. Open the engine side cover on the right side of the machine.
2. Open oil filler (F).
3. Set a container to catch the oil immediately under the drain
plug (P) at the bottom of the machine.
4. Loosen drain plug (P), and drain the oil.
5. Check the drained oil, and if there are excessive metal
particles or foreign material, contact your Komatsu distributor.
6. Install drain plug (P).
7. Using a filter wrench, turn filter cartridge (1) counterclockwise
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.
8. Clean the filter holder, fill the new filter cartridge with oil, then coat the seal and thread of the filter cartridge with
oil (or coat thinly with grease) and install.
9. When installing, bring the seal surface into contact with the filter holder, then tighten a further 3/4 to 1 turns.
10. 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.
11. Run the engine at idling for a short time, then stop the engine
and check that the oil is between the marks on the level gauge.
For details, see "CHECK ENGINE OIL PAN LEVEL, ADD OIL
(PAGE 3-49)".
4 - 44
.
1. Stop the engine, remove dipstick (G), and leave for at least 5
minutes.
2. Wipe dipstick (G) with a cloth.
3. Fully insert dipstick (G) into dipstick pipe, then remove it.
4. Check that the oil level is between the H and L marks for STOP
on dipstick (G).
If the oil level is below the L mark, add engine oil through oil
filler (F).
NOTICE
The dipstick is marked on one side with the levels for STOP (engine stopped) and RUNNING (engine idling).
Always check the level using the STOP marks.
5. If the oil is above the top mark, drain the excess oil from drain plug (P), then check the oil level again.
6. If the oil level is correct, insert dipstick (G) in the oil filler guide, then install the oil filler cap.
4 - 45
.
4 - 46
.
REMARK
There may be wear particles in the oil, but there is no problem
using the oil as it is.
NOTICE
If the oil has been added to above H level, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from
the drain plug. If the oil is above H level, it will damage the hydraulic circuit or cause the oil to spurt out.
4 - 47
.
WARNING
Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. This will accelerate deterioration of the inside
of the battery and reduce the service life of the battery. In addition, it may cause an explosion.
The battery generates flammable gas and there is danger of explosion, do not bring open flame or sparks near the battery.
Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a
doctor.
When adding distilled water to the battery, do not allow the battery electrolyte to go above UPPER LEVEL line. If the electrolyte
level is too high, it may leak and cause damage to the paint surface or corrode other parts.
Do not use a direct air blow or dry cloth to clean the battery. A wet cloth will prevent fire or explosion from static electricity.
NOTICE
If there is a fear that the battery water may freeze after refilling with purified water (e.g. commercially available replenishment water
for a battery), do the replenishment before the day's work on the next day.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
4 - 48
.
REMARK
If distilled water is added to above U.L. line, use a syringe to lower
the level to U.L. line. Neutralize the removed fluid with baking soda
(sodium bicarbonate), then flush it away with a large amount of
water or consult your Komatsu distributor or battery maker.
Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.
REMARK
If water is added to above the bottom tip of the sleeve, use a pipette to remove electrolyte. Neutralize the removed
electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your
Komatsu distributor or your battery maker.
4 - 49
.
NOTICE
Loose wheel hub nuts (1) will result in shortened life of tires or other
troubles.
4 - 50
.
CHECKING
The belt should normally deflect by about 6 mm (0.315 in) when
pressed with the finger (with a force of approx. 59 N (6 kg)) at a
point midway between the fan pulley and tension pulley.
ADJUSTING
1. Loosen nut (1).
2. Use adjust bolt (2) to move tension pulley (3) so that the
deflection of the belt is approx. 6 mm (0.315 in) (at a pressure
of approx. 59 N (6 kg)).
3. Tighten nut (1) to fix tension pulley (3).
4. Check for damage to the pulleys, and wear of the V-groove and
V-belt. Be particularly careful to check that the V-belt is not in
contact with the bottom of the V-groove.
5. If the belt has elongated and there is no more allowance for
adjustment, or if the belt is cut or cracked, replace the belt.
6. When the new belt is set, readjust it after operation for an hour.
4 - 51
.
CHECKING
The belt tension should normally deflect by about 15 mm (0.6 in)
when pressed with the finger at a point midway between the
alternator pulley and the drive pulley (with a force of approx. 59 N
(6 kg)).
ADJUSTING
1. Loosen the nuts and bolts in the order (1) to (6), then move
alternator (8) to the side to adjust the belt tension. Adjust the
tension of the bolt with nut (7) as follows.
TIGHTEN nut to INCREASE tension
LOOSEN nut to DECREASE tension
2. After adjusting the belt tension, tighten the nuts and bolts in the
order (1) to (6). Finally, tighten nut (7).
3. Check each pulley for damage, wear of the V-groove, and wear
of the V-belt. In particular, be sure to check that the V-belt is not
touching the bottom the V-groove.
4. If the V-belt is so lengthened that it cannot be adjusted any
more or if it has any cuts or cracks, replace it.
4 - 52
.
CHECKING
The belt should normally defect by about 12 mm (0.5 in) when
pressed with the finger (with a force of approx. 59 N (6 kg)) at a
point midway between the compressor pulley and fan pulley.
ADJUSTING
1. Insert a bar between compressor (1) and the cylinder block,
and hold compressor (1) in position.
When holding compressor (1) in position, put a wooden block
between the bar and compressor (1) to prevent damage to the
compressor.
2. Loosen bolts and nuts (2), (3).
3. Use the bar to move compressor (1) so that the deflection of
the belt is approx. 12 mm (0.5 in) (at a pressure of approx. 59
N (6 kg)).
4. Tighten the bolts and nuts (2), (3) to fix compressor (1) in
position.
5. Check each pulley for damage, wear of the V-groove, and wear
of the V-belt. In particular, be sure to check that the V-belt is not
touching the bottom the V-groove.
6. If the V-belt is so lengthened that it cannot be adjusted any
more or if it has any cuts or cracks, replace it.
7. After the V-belt has been replaced, operate for 1 hour, then
adjust again.
4 - 53
.
1. Remove only one wheel at the front of the tandem on the left or
right side.
If the wheel is not worn much, it is not necessary to inspect the
three remaining wheels. If it is worn, inspect all the wheels.
REMARK
Before installing or removing tires, please contact your Komatsu
distributor.
4 - 54
.
1. Open the engine side cover on the right side of the chassis.
2. Set the container under the filter cartridge to catch the drained oil.
3. By using a filter wrench, turn filter cartridge (1)
counterclockwise to remove it.
4. 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.
5. When installing, tighten until the packing surface contacts the
seal surface of the filter holder, then tighten it up 1/2 to 3/4 of
a turn.
If the filter cartridge is tightened too far, the packing will be
damaged and this will lead to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing, so
always tighten to the correct amount.
6. After replacing filter cartridge (1), loosen air bleed plug (2).
7. Loosen feed pump (3) knob and move the pump knob up and down to draw off fuel until air ceases to come out
of air bleed plug (2).
8. Tighten up air bleed plug (2). 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
surface. If there is any leakage of fuel, check the tightening of the filter cartridge. If there is still leakage of fuel,
follow Step 2 and 3 to remove the filter cartridge, then check the packing surface for damage or foreign material.
If any damage or foreign material is found in the packing, replace the cartridge with a new part, then repeat Steps
4 to 9 to install the filter cartridge.
4 - 55
.
Clean the radiator fins if any mud or dirt is stuck to the radiator.
CAUTION
When cleaning the radiator fins, clean the air conditioner condenser fins at
the same time.
4 - 56
.
NOTICE
Before adjusting, check the thickness of the circle guide wear plate. If the thickness of the wear plate is 2 mm (0.079 in) and below,
replace it. For checking the thickness of the wear plate, see "Remarks", the last item of "ADJUSTING".
4 - 57
.
CHECKING
Checking top and bottom position
1. Measure clearance (P) with feeler gauge while keeping the
blade above the ground.
1.5 ± 0.5 mm (0.059 ± 0.02 in) is standard. (6 places)
4 - 58
.
NOTICE
The clearance between guide and circle is not even.
Measure the clearance at the narrowest position in each parts of F, C, and
R.
REMARK
There is larger clearance and smaller clearance depending on the
shape of guide. Adjust the clearance based on the smallest
clearance as a standard.
4 - 59
.
ADJUSTING
NOTICE
When tightening the locknut after adjusting the clearance between the circle guide and circle, hold the push bolt with a wrench
while tightening. If only the locknut is tightened, the push bolt will turn and the adjusted clearance will change.
2. Remove bolt (1), and remove circle guides (2), (3), and (4), and
adjust clearance (P) with number of shims (5).
(There are 2 types of the thickness of shims: 1 mm (0.039 in)
and 0.5 mm (0.02 in).)
REMARK
When not using guide pusher bolt (7), (11) to carry out the movement, use a lever block.
4 - 60
.
4. Lower the blade to the ground slightly, loosen bolt (1), and loosen lock nuts (6), (10), and (12). After loosening
push bolts (7), (11), and (13), open circle guide (2) with push bolt (11) so that F = 0.
(When doing this, open right and left bolts evenly.)
With F = 0 state, tighten lock nut (10), and tighten bolt (1).
5. Open circle guide (3) with push bolt (13) so that C = 0.
(When doing this, open right and left bolts evenly.)
With C = 0 state, loosen push bolt (13) once. After tightening push bolt (13) until it touches circle guide (3) with
your hands, loosen push bolt (13) by 1/4 turn to tighten lock nut (12), and move circle guide (3) until it touches
push bolt (13), and tighten bolt (1).
6. Open circle guide (4) with push bolt (7) so that R = 0.
(When doing this, open right and left bolts evenly.)
With R = 0 state, loosen push bolt (7) once. After tightening push bolt (7) until it touches circle guide (4) with your
hands, loosen push bolt (7) by 1/2 turn to tighten lock nut (6), and move circle guide (4) until it touches push bolt
(7), and tighten bolt (1).
7. After checking, F = 0, C = Max. 0.7 mm (0.028 in), R = Max. 1.5 mm (0.059 in), or F = C = R = Max. 1 mm (0.039
in), retighten bolt (1), lock nuts (6), (10), and (12).
8. Coat the sliding surface (P, F, C, R) of the circle guide with lubricant (LM-P).
9. Check that it rotates 90º to the left and right at high bank.
REMARK
If the following condition is reached, replace the wear plate of the
guide.
When dimension A of wear plate (14) or dimensions B or C of wear
plate (15) become 2 mm (0.079 in).
4 - 61
.
CHECKING
1. Place the gear shift lever in "P (Parking)" position, then confirm that slack adjuster move smoothly.
2. Check that the angle of the slack adjuster and push rod (2) of
brake chamber (1) is slightly more than 90 degrees.
4 - 62
.
ADJUSTING
Adjust the stroke by turning worm shaft (1) with a wrench. When
doing this, adjust 1 notch at a time so that ball (2) ships into the ball
stop position (hole (3) made to take the ball) of worm shaft (1).
4 - 63
.
CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR
WARNING
When jacking up the front tire, put blocks under the frame at the center of the front axle for safety.
CHECKING
1. Loosen bolt (1) and remove cover (2).
2. Push the blade against the ground to prevent the circle from
rotating, and jack up the front wheels or secure the end of the
blade.
3. Operate the blade rotation lever and check if the clutch slips.
4 - 64
.
ADJUSTING
IF CLUTCH SLIPS
1. Loosen bolts (3) and remove holder (4), then take out one 0.2 mm (0.008 in) shim (5).
2. Tighten holder (4) with mounting bolt (3).
3. Repeat the operation until there is no more slippage. For details, see the section on inspection.
4. If there is no more slippage, loosen bolt (3), remove holder (4),
add one 0.2 mm (0.008 in) shim (5) to match with the slip limit.
REMARK
If a shim is added, the pushing force of the belleville spring is
reduced, so it becomes easier for the clutch to slip.
If a shim is removed, the pushing force of the belleville spring is
increased, so it becomes more difficult for the clutch to slip.
4 - 65
.
4 - 66
.
1. Set the container to catch the oil under the filter case.
2. Remove drain plug (1) at the bottom of the filter case, drain the
oil, then tighten the plug again.
3. Hold case (2) and loosen center bolt (3), then remove case (2).
4. Remove the element and clean the inside of the case.
5. Replace the filter gasket and O-ring with new parts. Coat the
gasket and O-ring thinly with clean engine oil before installing.
6. Assemble the new element in the case, then install the case
with center bolt (3).
When installing center bolt (3), install so that chamfered portion
(4) of the washer comes on the same side as the hexagonal
head of the center bolt.
Be careful not to tighten center bolt (3) too much.
Tightening torque: 167 to 196 Nm (17 to 20 kgm , 123 to 144.7
lbft)
7. Run the engine for a short time at low idling, then stop the
engine and check that the oil is at the specified level. For
details, see "CHECK OIL LEVEL IN TRANSMISSION CASE,
ADD OIL (PAGE 4-45)".
4 - 67
.
4 - 68
.
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.
To prevent the oil from spurting out, loosen drain plug (P), then
gradually remove it.
3. After draining the oil, install drain plug (P).
Tightening torque: 58.8 to 78.4 Nm
{6 to 8 kgm, 43.4 to 57.9 lbft}
4. Remove 4 bolts (1), then remove cover (2) and take out
strainer (3).
5. Remove any dirt stuck to strainer (3), then wash it with flushing
oil. If the strainer is damaged, replace it with a new part.
6. After washing strainer (3), install it, then install cover (2) with bolts (1).
7. Pour in the specified capacity of oil from oil filler (F).
8. After refilling, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN FINAL DRIVE
CASE, ADD OIL (PAGE 4-46)".
9. Check for oil leakage from the final drive case.
4 - 69
.
4. Install the element with the surface put the mark shown in (7)
upward.
5. Install cover (5) and nut (4).
Tightening torque: 10 to 14 Nm {1.0 to 1.4 kgm, 7.23 to 10.1
lbft}
NOTICE
If the tightening torque is too large, the screws can be damaged.
6. Then close cover (2).
4 - 70
.
REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK
WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature
to go down before starting the work.
1. Remove bolt (1), then remove hose (2) from filter assembly (3).
2. Remove 4 bolts (4), then remove filter assembly (3) from the
hydraulic tank.
The other bolts are used to install the filter head and case, so
do not remove them.
4 - 71
.
7. Remove bolt (7) of the suction strainer, then remove cover (8).
8. Remove the strainer, wash the strainer and remove parts, then
install them to the hydraulic tank again.
9. Install cover (8) with bolt (7).
NOTICE
If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder
may cause damage to the piston packing.
10. Next, operate each cylinder 3 to 4 times to the end of its stroke.
4 - 72
.
4 - 73
.
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 one turn of left or right tie rod in
direction of extension: 9 mm (0.355 in)
2. After adjusting, tighten tightening nut (1).
4 - 74
.
1. Turn valve (1) at the top of the corrosion resistor to close it.
2. Set the container to catch the water under the cartridge.
3. By using a filter wrench, remove cartridge (2).
4. Clean the filter holder, coat the steel surface of the new filter
cartridge with clean engine oil, then install it.
5. When installing, tighten until the gasket contacts the seal surface of the filter holder, then tighten a further 2/3
turns.
If the filter cartridge is tightened too far, the gasket will be damaged and this will lead to leakage of water. If the
filter is too loose, water will also leak from the gap at the gasket, so always tighten the correct amount.
6. Turn valve (1) to open it.
7. After replacing the cartridge, start the engine and check that there is no leakage of water from the filter seal
surface. If there is any leakage of water, check the tightening of the filter cartridge.
NOTICE
Be careful not to get oil on the desiccant. This will reduce the ability of
the air dryer to absorb water.
After replacing, check the air pressure, then start the machine.
4 - 75
.
1. Set the front wheels in the normal position, then apply the P
(parking) position securely.
2. Remove plugs (1) from the left and right front axle housings,
drain the oil, then tighten the plugs again.
3. Remove plug (2) and add engine oil through the plug hole to
the specified level.
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. After adding the oil, check that the oil is at the specified level.
For details, see "CHECK OIL LEVEL IN CIRCLE REVERSE
GEAR CASE, ADD OIL (PAGE 4-47)"
6. Install oil filler plug (F).
4 - 76
.
1. Put an oil 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. Pour in the specified capacity of oil from oil filler (F).
5. After refilling the oil, check that the oil is at the specified level.
For details, see "CHECK OIL LEVEL IN TANDEM DRIVE
CASE, ADD OIL (PAGE 4-46)".
1. Before removing the breather, wipe off all the dirt around the
breather.
2. Remove breather (1).
3. Wash the whole breather (1) in diesel oil or flushing oil, then
blow it dry with compressed air.
4. Replace the breather O-ring with a new part, coat with engine
oil, and install it.
5. Install breather (1).
4 - 77
.
CLEAN BREATHER
Remove the breather, then wash it in clean diesel oil or flushing oil to rinse the dirt out from inside.
(1) Transmission case (1 place)
4 - 78
.
3. Use a cloth to wipe off all the grease stuck to hatched portion
(A) of the lever of potentiometer sensor (3), then coat thinly
with fresh grease (LM-G).
4. Install cover (2) with bolts (1).
4 - 79
.
4 - 80
.
5-1
.
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
GD825A-2
Item Unit
Operating weight
kg (lb) 29,700 (65,489)
(including operator 55 kg (121 lb))
Engine model - Komatsu S6D140E-2 diesel engine
Flywheel horsepower kW (HP)/rpm 209 (280)/2,100
A Overall length mm (ft in) 10,010 (32' 10")
B Overall height mm (ft in) 3,550 (11' 8")
C Overall width mm (ft in) 3,310 (10' 10")
Min. ground clearance
mm (ft in) 440 (1' 5")
(to bottom surface of final drive case)
Min. turning radius (outermost part of chassis) mm (ft in) 7,900 (25' 11")
1st km/h (MPH) 4.0 (2.5)
2nd km/h (MPH) 5.4 (3.4)
3rd km/h (MPH) 8.0 (5.0)
4th km/h (MPH) 11.5 (7.1)
Forward
5th km/h (MPH) 15.8 (9.8)
6th km/h (MPH) 21.4 (13.3)
7th km/h (MPH) 31.3 (19.5)
8th km/h (MPH) 44.9 (27.9)
Travel speeds
1st km/h (MPH) 4.3 (2.7)
2nd km/h (MPH) 5.8 (3.6)
3rd km/h (MPH) 8.5 (5.3)
4th km/h (MPH) 12.2 (7.6)
Reverse
5th km/h (MPH) 16.9 (10.5)
6th km/h (MPH) 22.8 (14.2)
7th km/h (MPH) 33.4 (20.8)
8th km/h (MPH) 47.9 (29.8)
5-2
.
SPECIFICATIONS SPECIFICATIONS
5-3
.
.
6-1
.
This system is installed to ensure that it is always possible to steer the machine. It is automatically actuated if there
is a failure in the engine or hydraulic pump during operations.
If the hydraulic pressure in the steering circuit goes below 0.69 MPa {7 kg/cm2, 99.4 PSI}, an electric motor is
actuated to provide oil pressure to the steering circuit and make it possible to steer the machine. If the travel speed
is less than 1 km/h (0.6 MPH) or the machine is stopped, the emergency steering system is not actuated.
CHECKING
NOTICE
There is danger of seizure if the electric motor is used continuously, so do not continue the checks in Steps 6 and 7 for more than
30 seconds.
8. Set the emergency steering switch to the AUTO position (1), and check that the monitor and warning lamp go
out and that the operation of the electric motor for the emergency steering stops.
NOTICE
If any abnormality occurs, turn the starting switch to the OFF position to stop the whole system.
6-2
.
AIR CONDITIONER
By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it
possible to provide a pleasant working environment even on dusty jobsites.
FAN SWITCH
This switch (1) can be used to adjust the air flow to 4 stages.
This switch also acts as the main switch for the air conditioner.
When the switch is pressed, the indicator lamp above the switch
lights up to indicate the air flow.
6-3
.
The color of the indicator lamp (A) changes while the switch is
being pressed.
When the temperature reaches the desired level, release the
switch to set the temperature.
The settings for each mode are retained in memory even when the starting switch is turned OFF.
However, in the followig cases, the settings must be made again.
When the machine has been out of use for more than 7 days
When the battery voltage is extremely low
When there has been abnormal interference from outside
When the fan switch is turned OFF (the setting is not kept in memory with only the air conditioner switch)
If the air conditioner is used at the FRESH position, the inside of the cab will be pressurized and this will prevent the
entry of dust.
The higher the position of the fan switch, the more effective the pressurizing becomes.
6-4
.
METHOD OF OPERATION
Switch Air conditioner Temperature control FRESH/RECIRC
Fan switch
Condition of use switch switch selector switch
High speed HI ON All green RECIRC
Cooling
Normal HI - LO ON More than half green FRESH
Dehumidification + heating HI - LO ON More than half red FRESH
High speed HI OFF All red RECIRC
Heating
Normal HI - LO OFF More than half red FRESH
Defroster HI ON More than half red FRESH
Ventilation or pressurization HI - LO OFF All green FRESH
When carrying out the defrosting, if the temperature control switch is set so that all lamps are red, this will improve
the performance for defrosting and demisting.
The standard cleaning cycle for the FRESH filter is 100 hours, but if it becomes clogged, it will become impossible
to pressurize the inside of the cab, and will also lead to failure. If the filter becomes clogged, carry out inspection
and cleaning immediately.
For details of the method of cleaning, see "CLEAN ELEMENT OF AIR CONDITIONER FRESH AIR FILTER
(PAGE 4-35)".
If large amounts of dust or dirt accumulate on the condenser, the cooling capacity will drop, so carry out inspection
and cleaning periodically.
NOTICE
If the ambient temperature is low and the compressor is run suddenly at high speed, it will cause failure of the compressor. In
addition, if the temperature inside the cab is less than 4°C (39.2°F) , the compressor will not rotate even if the cooler switch is
turned on; and if the temperature inside the cab goes below 3°C (37.4°F) when the air conditioner is running, the compressor will
stop.
6-5
.
6-6
.
NOTICE
When the seat is pushed forward, the available reclining angle becomes greater; when the seat is pushed back, the available
reclining angle becomes smaller. When moving the seat back, return the seat back to its original position before moving the seat.
Pull lever (2) up, set the seat back to a position where it is easy to
carry out operations, then release the lever.
When doing this, keep your back pressed against the seat back.
If your back is not against the seat back, the seat back may spring
back suddenly.
Rear tilt
Pull lever (3) up and adjust the angle of the rear of the seat.
To raise the rear of the seat, keep the lever pulled up and raise yourself slightly from the rear of the seat.
To lower the rear of the seat, keep the lever pulled up and apply your weight to the rear of the seat.
Amount of tilt: Up 13 deg., down 13 deg.
6-7
.
REMARK
If the seat back is tipped to the front without raising the armrest(4), the armrest will rise automatically.
REMARK
To adjust to the optimum setting, turn knob (6) so that the indicator in the transparent portion inside the knob
indicates the same as the operator's weight (kg).
6-8
.
INDEX
INDEX
<A> <H>
ADJUSTING WORK EQUIPMENT HANDLING AIR-SUSPENSION SEAT 6- 7
POSTURE 3-112 ADJUST OPERATOR'S SEAT 6- 7
AIR CONDITIONER 6- 3 HANDLING BATTERY DISCONNECT
LOCATIONS AND FUNCTIONS OF SWITCH 3- 41
CONTROL PANEL 6- 3 HANDLING BLADE ACCUMULATOR 3-117
METHOD OF OPERATION 6- 5 HANDLING BLADE FLOAT 3-119
PRECAUTIONS WHEN USING 6- 5 HANDLING EMERGENCY STEERING
ARTICULATE LOCK PIN 3- 38 DEVICE 6- 2
CHECKING 6- 2
<B> HANDLING OIL, FUEL, COOLANT, AND
BACKUP ALARM 3- 42 PERFORMING OIL CLINIC 4- 4
HANDLING THE TIRES 3-116
<C>
CHECK AFTER STOPPING ENGINE 3- 65 <I>
CHECK BEFORE STARTING ENGINE 3- 44 INTENDED USE 1- 5
CHECKS AFTER COMPLETION OF DIRECTIONS OF MACHINE 1- 5
OPERATION 3-115
COLD WEATHER OPERATION 3-123 <L>
AFTER COLD WEATHER 3-124 LOCATION OF PLATES, TABLE TO
CAUTIONS AFTER COMPLETION OF ENTER SERIAL NO. AND
WORK 3-124 DISTRIBUTOR 1- 6
PRECAUTIONS FOR LOW ENGINE SERIAL NO. PLATE
TEMPERATURE 3-123 POSITION 1- 6
CONTROL LEVERS, PEDALS 3- 29 PRODUCT IDENTIFICATION
NUMBER (PIN)/MACHINE SERIAL
<D> NO. PLATE 1- 6
DEFINED LIFE PARTS 4- 18 SERVICE METER POSITION 1- 7
DEFINED LIFE PARTS LIST 4- 18 TABLE TO ENTER SERIAL NO. AND
DUST INDICATOR 3- 38 DISTRIBUTOR 1- 7
LOCKING 3-115
<E> LONG-TERM STORAGE 3-125
EXPLANATION OF COMPONENTS 3- 6 AFTER STORAGE 3-125
BEFORE STORAGE 3-125
<F> DURING STORAGE 3-125
FOREWORD 1- 2
FUSE BOX 3- 39 <M>
MAINTENANCE SCHEDULE CHART 4- 19
<G> METERS AND LAMPS 3- 19
GENERAL PRECAUTIONS 2- 13 MONITOR PANEL 3- 6
GENERAL VIEW 3- 2 MOVING MACHINE OFF (FORWARD,
GENERAL VIEW OF CONTROLS AND REVERSE, SHIFTING GEAR),
GAUGES 3- 3 STOPPING 3- 67
GENERAL VIEW OF MACHINE 3- 2
GUIDES TO MAINTENANCE 4- 2
7-1
.
INDEX
<O> <T>
OPERATING WORK EQUIPMENT 3- 75 TOOL BAG 3- 43
OPERATION 3- 44 TORQUE LIST 4- 17
OPERATIONS, CHECKS AFTER TRANSPORTATION 3-121
STARTING ENGINE 3- 63 LOADING, UNLOADING WORK 3-121
OPERATOR'S CAB LIFT MECHANISM 3- 42 PRECAUTIONS FOR LOADING 3-122
OUTLINES OF SERVICE 4- 4 STEPS FOR TRANSPORTATION 3-121
TRAVELING POSTURE FOR MACHINE 3- 66
<P> TROUBLESHOOTING 3-126
PARKING MACHINE 3-113 AFTER RUNNING OUT OF FUEL 3-126
PRECAUTIONS DURING OPERATION 2- 21 IF BATTERY IS DISCHARGED 3-130
BATTERY 2- 28 OTHER TROUBLE 3-134
TOWING 2- 31 TOWING THE MACHINE 3-127
TRANSPORTATION 2- 27 TRANSMISSION CONTROLLER 3-139
PRECAUTIONS FOR MAINTENANCE 2- 32 WHEN LEANING PIPING IS
PRECAUTIONS WHEN OPERATION 3-108 DAMAGED 3-126
PRECAUTIONS WITH TIRES 2- 38 TURNING MACHINE 3- 73
<Q> <U>
QUICK-FILL FUEL FILLER 3- 43 USE OF FUEL, COOLANT AND
LUBRICANTS ACCORDING TO
<R> AMBIENT TEMPERATURE 4- 11
RELATING TO ELECTRIC SYSTEM 4- 9
<W>
<S> WEAR PARTS 4- 10
SAFETY INFORMATION 1- 3 WEAR PARTS LIST 4- 10
SAFETY INFORMATION 2- 2 WORK WHICH CAN BE CARRIED OUT
SAFETY LABELS 2- 5 USING A MOTOR GRADER 3- 80
POSITION FOR ATTACHING SAFETY
LABELS 2- 6
SAFETY LABELS 2- 7
SERVICE PROCEDURE 4- 22
CHECK BEFORE STARTING 4- 40
EVERY 1000 HOURS SERVICE 4- 66
EVERY 2000 HOURS SERVICE 4- 76
EVERY 250 HOURS SERVICE 4- 42
EVERY 4000 HOURS SERVICE 4- 80
EVERY 50 HOURS SERVICE 4- 41
EVERY 500 HOURS SERVICE 4- 55
INITIAL 250 HOURS SERVICE (ONLY
AFTER THE FIRST 250 HOURS) 4- 22
WHEN REQUIRED 4- 23
SPECIFICATIONS 5- 2
STANDARD TIGHTENING TORQUES
FOR BOLTS AND NUTS 4- 17
STARTING ENGINE 3- 60
STOPPING ENGINE 3- 65
STORAGE BOX 3- 43
SWITCHES 3- 20
7-2
.
.
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All Rights Reserved
Printed in Japan 01-2023