O&M GD825A-2 12503-UP TEN00334-00

TEN00334-00

MOTOR GRADER

GD825A -2 SERIAL NUMBERS

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.

12503

and up

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FOREWORD

FOREWORD

FOREWORD This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.

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

Storage location for the Operation and Maintenance Manual: Pocket on right side inside cab

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FOREWORD

SAFETY INFORMATION

SAFETY INFORMATION To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the machine to give explanations of situations involving potential hazards and of the methods of avoiding such 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. Example of safety message using signal word

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.

Other signal words 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. This word is used for information that is useful to know.

1-3

. SAFETY INFORMATION

FOREWORD

Safety labels Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying out operation or maintenance of the machine that may involve hazard. This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures. Example of safety label using words

Safety labels using pictogram Safety pictograms use a picture to express a level of hazardous condition equivalent to the signal word. These safety pictograms use pictures in order to let the operator or maintenance worker understand the level and type of hazardous condition at all times. Safety pictograms show the type of hazardous condition at the top or left side, and the method of avoiding the hazardous condition at the bottom or right side. In addition, the type of hazardous condition is displayed inside a triangle and the method of avoiding the hazardous condition is shown inside a circle.

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 J (1))

1-4

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FOREWORD

INTENDED USE

INTENDED USE This Komatsu machine is designed to be used mainly for the following work: Smoothing Repair and maintenance of gravel roads 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 3-79)" 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.

1-5

. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

FOREWORD

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items.

PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE This is on the left side of the front frame. The design of the nameplate differs according to the territory.

ENGINE SERIAL NO. PLATE POSITION This is on the left side of engine cylinder block as seen from the fan.

1-6

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FOREWORD

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

SERVICE METER POSITION On top of the machine monitor

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Product identification number (PIN) Distributor name Address

Service Personnel Phone/Fax

1-7

. CONTENTS

FOREWORD

CONTENTS FOREWORD FOREWORD SAFETY INFORMATION INTENDED USE DIRECTIONS OF MACHINE LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ENGINE SERIAL NO. PLATE POSITION SERVICE METER POSITION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SAFETY SAFETY INFORMATION SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS PRECAUTIONS DURING OPERATION STARTING ENGINE OPERATION TRANSPORTATION BATTERY TOWING PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WITH TIRES OPERATION GENERAL VIEW GENERAL VIEW OF MACHINE GENERAL VIEW OF CONTROLS AND GAUGES EXPLANATION OF COMPONENTS MONITOR PANEL METERS AND LAMPS SWITCHES CONTROL LEVERS, PEDALS DUST INDICATOR ARTICULATE LOCK PIN FUSE BOX OPERATOR'S CAB LIFT MECHANISM BACKUP ALARM FRONT GLASS TOOL BAG STORAGE BOX QUICK-FILL FUEL FILLER OPERATION CHECK BEFORE STARTING ENGINE STARTING ENGINE OPERATIONS, CHECKS AFTER STARTING ENGINE STOPPING ENGINE CHECK AFTER STOPPING ENGINE TRAVELING POSTURE FOR MACHINE

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1 2 3 5 5 6 6 6 7 7 1 2 4 5 6 12 20 20 22 26 27 29 30 36 1 2 2 3 6 6 19 20 29 38 38 39 41 41 42 43 43 43 44 44 59 62 64 64 65

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FOREWORD

MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING TURNING MACHINE OPERATING WORK EQUIPMENT WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER PRECAUTIONS WHEN OPERATION ADJUSTING WORK EQUIPMENT POSTURE PARKING MACHINE CHECKS AFTER COMPLETION OF OPERATION LOCKING HANDLING THE TIRES HANDLING BLADE ACCUMULATOR HANDLING BLADE FLOAT TRANSPORTATION LOADING, UNLOADING WORK PRECAUTIONS FOR LOADING COLD WEATHER OPERATION PRECAUTIONS FOR LOW TEMPERATURE CAUTIONS AFTER COMPLETION OF WORK AFTER COLD WEATHER LONG-TERM STORAGE BEFORE STORAGE DURING STORAGE AFTER STORAGE TROUBLESHOOTING AFTER RUNNING OUT OF FUEL WHEN LEANING PIPING IS DAMAGED TOWING THE MACHINE IF BATTERY IS DISCHARGED OTHER TROUBLE TRANSMISSION CONTROLLER MAINTENANCE GUIDES TO MAINTENANCE OUTLINES OF SERVICE HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC RELATING TO ELECTRIC SYSTEM WEAR PARTS WEAR PARTS LIST USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS TORQUE LIST PERIODIC REPLACEMENT OF CRITICAL PARTS CRITICAL PARTS MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART SERVICE PROCEDURE INITIAL 250 HOURS SERVICE (only after the first 250 hours) WHEN REQUIRED CHECK BEFORE STARTING EVERY 50 HOURS SERVICE EVERY 250 HOURS SERVICE

CONTENTS

3- 66 3- 72 3- 74 3- 79 3-107 3-111 3-112 3-114 3-114 3-115 3-116 3-118 3-120 3-120 3-121 3-122 3-122 3-123 3-123 3-124 3-124 3-124 3-124 3-125 3-125 3-125 3-126 3-129 3-132 3-137 4- 1 4- 2 4- 4 4- 4 4- 6 4- 7 4- 7 4- 8 4- 12 4- 12 4- 13 4- 13 4- 14 4- 14 4- 16 4- 16 4- 17 4- 27 4- 28 4- 29

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. CONTENTS

EVERY 500 HOURS SERVICE EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE EVERY 4000 HOURS SERVICE SPECIFICATIONS SPECIFICATIONS ATTACHMENTS, OPTIONS HANDLING EMERGENCY STEERING DEVICE CHECKING AIR CONDITIONER LOCATIONS AND FUNCTIONS OF CONTROL PANEL METHOD OF OPERATION PRECAUTIONS WHEN USING HANDLING AIR-SUSPENSION SEAT ADJUST OPERATOR'S SEAT INDEX

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FOREWORD

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42 50 59 63 1 2 1 2 2 3 3 5 5 6 6 1

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2-1

. SAFETY INFORMATION

SAFETY

SAFETY INFORMATION SAFETY LABELS POSITIONS OF SAFETY PICTOGRAMS SAFETY LABELS

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4 5 6

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

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12 12 12 12 12 12 13 13 13 14 14 15 15 16 16 17 17 17 17 18 18 18 19 19 19 19 19

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SAFETY

SAFETY INFORMATION

PRECAUTIONS DURING OPERATION STARTING ENGINE CHECKS BEFORE STARTING ENGINE, ADJUST PRECAUTIONS WHEN STARTING PRECAUTIONS IN COLD AREAS OPERATION CHECKS BEFORE STARTING OPERATION PRECAUTIONS BEFORE MOVING OFF PRECAUTIONS WHEN TRAVELING PRECAUTIONS WHEN TRAVELING ON SLOPES PRECAUTIONS WHEN OPERATIONS ON SLOPES PROHIBITED OPERATIONS PRECAUTIONS WHEN OPERATING OPERATE CAREFULLY ON SNOW PARKING MACHINE TRANSPORTATION LOADING AND UNLOADING SHIPPING BATTERY BATTERY HAZARD PREVENTION STARTING WITH BOOSTER CABLES TOWING WHEN TOWING

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20 20 20 20 21 22 22 22 23 24 24 24 24 25 25 26 26 26 27 27 28 29 29

PRECAUTIONS FOR MAINTENANCE WARNING TAG KEEP WORK PLACE CLEAN AND TIDY APPOINT LEADER WHEN WORKING WITH OTHERS STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING PROPER TOOLS ACCUMULATOR PERSONNEL ATTACHMENTS WORK UNDER THE MACHINE NOISE PRECAUTIONS WHEN USING HAMMER REPAIR WELDING REMOVING BATTERY TERMINAL PROHIBITED TO DISASSEMBLE BANK CONTROL LOCK PIN PRECAUTIONS WITH HIGH-PRESSURE OIL HANDLING HIGH-PRESSURE HOSES WASTE MATERIALS MAINTENANCE OF AIR CONDITIONER COMPRESSED AIR PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS

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30 30 30 30 31 32 32 33 33 33 33 33 34 34 34 34 34 35 35 35 35 35

PRECAUTIONS WITH TIRES HANDLING TIRES PRECAUTIONS WHEN STORING TIRE

2- 36 2- 36 2- 36

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. SAFETY LABELS

SAFETY

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. There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same way. 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.

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SAFETY

SAFETY LABELS

POSITION FOR ATTACHING SAFETY LABELS

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. SAFETY LABELS

SAFETY LABELS (1) Caution before starting (09651-03001)

(2) Caution when coolant is at high temperature (09668-03001)

(3) Caution when oil is at high temperature (09653-03001)

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SAFETY

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SAFETY

SAFETY LABELS

(4) Caution when handling battery cable (09808-03000)

(5) Caution when traveling in reverse (09802-43000)

(6) Warning of compressed spring (09820-03000)

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. SAFETY LABELS

(7) Warning for handling accumulator (235-53-31130)

(8) Articulate lock (09161-33000)

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SAFETY

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SAFETY

SAFETY LABELS

(9) Cab lift mechanism (09821-03000)

(10) Do not enter (09162-33000)

(11) Caution when handling battery (235-53-31210)

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. SAFETY LABELS

(12) Caution when handling battery (235-53-31220)

(13) Warning when removing bank-control lock pin (09819-03000)

(14) "Do not modify ROPS" sign (09620-A2000)

(15) Prohibition of operation with engine cover open (09667-03001)

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SAFETY

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SAFETY

SAFETY LABELS

(16) "Do not come near machine" sign (09812-13000)

(17) Warning for handling accumulator (09659-33000)

(18) Warning for battery (This plate is stick on the machine by the battery maker)

(19) Jump start prohibited (09842-A0481)

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. GENERAL PRECAUTIONS

SAFETY

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 carrying out the operation. IF PROBLEMS ARE FOUND If you find any problems in the machine during operation or maintenance (noise, vibration, smell, incorrect gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in charge and have the necessary action taken. Do not operate the machine until the problem has been corrected. CLOTHING AND PERSONAL PROTECTIVE ITEMS Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other protruding parts. If you have long hair and it hangs out from your hard hat, there is a hazard that it may get caught up in the machine, so tie your hair up and be careful not to let it get caught. Always wear a hard hat and safety shoes. If the nature of the work requires it, wear safety glasses, mask, gloves, ear plugs, and safety belt when operating or maintaining the machine. Check that all protective equipment functions properly before using it.

FIRE EXTINGUISHER AND FIRST AID KIT Always follow the precautions below to prepare for action if any injury or fire should occur. Be sure that fire extinguishers have been provided and read the labels to ensure that you know how to use them in emergencies. Carry out periodic inspection and maintenance to ensure that the fire extinguisher can always be used. Provide a first aid kit in the storage point. Carry out periodic checks and add to the contents if necessary.

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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SAFETY

GENERAL PRECAUTIONS

KEEP MACHINE CLEAN If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not use water or steam to wash the electrical system (sensors, connectors). If inspection and maintenance is carried out when the machine is still dirty with mud or oil, there is a hazard that you will slip and fall, or that dirt or mud will get into your eyes. Always keep the machine clean.

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

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SAFETY

HANDRAILS AND STEPS To prevent personal injury caused by slipping or falling off the machine, always do as follows. Use the handrails and steps marked by arrows in the diagram on the right when getting on or off the machine.

To ensure safety, always face the machine and maintain three-point contact (both feet and one hand, or both hands and one foot) with the handrails and steps to ensure that you support yourself. Do not grip the control levers when getting on or off the machine. Never climb on the engine hood or covers where there are no non-slip pads. Before getting on or off the machine, check the handrails and steps, and if there is any oil, grease, or mud on them, wipe it off immediately. In addition, repair any damage and tighten any loose bolts. Do not get on or off the machine while holding tools in your hand. MOUNTING AND DISMOUNTING Never jump on or off the machine. Never get on or off a moving machine. If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try to stop it.

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SAFETY

GENERAL PRECAUTIONS

DO NOT GET CAUGHT IN ARTICULATED PORTION The clearance in the area around the work equipment changes according to the movement of the link. If you get caught, it will lead to serious injury. Do not allow anyone near any of the rotating or telescoping parts.

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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SAFETY

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

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SAFETY

GENERAL PRECAUTIONS

WINDOW WASHER LIQUID Use an ethyl alcohol base washer liquid. Methyl alcohol base washer liquid may irritate your eyes, so do not use it. PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) Install ROPS when working in places where there is danger of falling rocks, such as in mines and quarries, or in places where there is danger of rolling over. If ROPS is installed, do not remove it when operating the machine. ROPS is installed to protect the operator when machine rolls over. When machine rolls over, ROPS supports its weight and absorbs its impact energy. If ROPS is modified, its strength may be reduced. When modifying, consult your Komatsu distributor. If ROPS is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always Komatsu contact your distributor for advice of the method of repair. Even if ROPS is installed, always fasten your seat belt properly when operating the machine. If you do not use your fasten your seat belt properly, it cannot display its effect.

PRECAUTIONS FOR ATTACHMENTS When installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore contact your Komatsu distributor for advice. Any injuries, accidents, product failures or other property damages resulting from the use of unauthorized attachments or parts will not be the responsibility of Komatsu. When installing and using optional attachments, read the instruction manual for the attachment, and the general information related to attachments in this manual. UNAUTHORIZED MODIFICATION Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor. Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu.

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SAFETY

GENERAL PRECAUTIONS

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. WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after earthquakes is weak in these areas. When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling. DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always do as follows. Before starting work near electric cables, inform the local power company of the work to be performed, and ask them to take the necessary action.

Even going close to high-voltage cables can cause electric shock, which may cause serious burns or even death. Always maintain a safe distance (see the table on the right) between the machine and the electric cable. Check with the local power company about safe operating procedure before starting operations. To prepare for any possible emergencies, wear rubber shoes and gloves. Lay a rubber sheet on top of the seat, and be careful not to touch the chassis with any exposed part of your body. Use a signalman to give warning if the machine approaches too close to the electric cables. When carrying out operations near high voltage cables, do not let anyone near the machine.

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Voltage of Cables

Safety Distance

100 V - 200 V

Over 2 m (7 ft)

6,600 V

Over 2 m (7 ft)

22,000 V

Over 3 m (10 ft)

66,000 V

Over 4 m (14 ft)

154,000 V

Over 5 m (17 ft)

187,000 V

Over 6 m (20 ft)

275,000 V

Over 7 m (23 ft)

500,000 V

Over 11 m (36 ft)

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SAFETY

GENERAL PRECAUTIONS

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. ENSURE GOOD VISIBILITY Check for any persons or obstacles in the area around the machine and check the conditions of the jobsite to ensure that operations and travel can be carried out safely. Always do as follows. Position a signalman if there are areas at the rear of the machine where the visibility is not good. When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up additional lighting in the work area if necessary. Stop operations if the visibility is poor, such as in mist, snow, rain, or dust. VENTILATION FOR ENCLOSED AREAS The engine exhaust gas contains substances that may damage your health or even cause death. Start or operate the engine in a place where there is good ventilation. If the engine or machine must be operated inside a building or under ground, where the ventilation is poor, take steps to ensure that the engine exhaust gas is removed and that ample fresh air is brought in.

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

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. PRECAUTIONS DURING OPERATION

SAFETY

PRECAUTIONS DURING OPERATION STARTING ENGINE If there is a warning tag hanging from gear shift lever, do not start the engine or touch the levers.

CHECKS BEFORE STARTING ENGINE, ADJUST Carry out the following checks before starting the engine at the beginning of the day's work. Remove all dirt from the surface of the window glass to ensure a good view. Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and check that they light up correctly. Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check for damage to the electric wiring. Check that there is no mud or dust accumulated around the movable parts of the accelerator pedal or brake pedal, and check that the pedals work properly. Adjust the operator's seat to a position where it is easy to carry out operations, and check that there is no damage or wear to the seat belt or mounting clamps. Check the operation of the instruments and gauges, check the angle of the mirror, and check that the control levers are all at the Neutral position. Before starting the engine, check that the gearshift lever is at the P (Parking) position. Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. Refer to "WALK-AROUND CHECK (PAGE 3-44)". Check that there are no persons or obstacles above, below, or in the area around the machine. PRECAUTIONS WHEN STARTING Start and operate the machine only while seated. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. When starting the engine, sound the horn as a warning. Do not allow anyone apart from the operator to ride on the machine. For machines equipped with a back-up alarm, check that the alarm works properly.

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SAFETY

PRECAUTIONS DURING OPERATION

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

2 - 21


SAFETY

OPERATION CHECKS BEFORE STARTING OPERATION When carrying out the checks, move the machine to a wide area where there are no obstructions, and operate slowly. Do not allow anyone near the machine. Always fasten your seat belt. Check the operation of travel, steering and brake systems, and work equipment control system. Check for any problem in the sound of the machine, vibration, heat, smell, or gauges; check also that there is no leakage of oil or fuel. If any problem is found, carry out repairs immediately.

When carrying out operations that require the machine to be articulated, insert the articulation lock pin in the stowing position. Before traveling on a road, check that the articulation lock pin is at the LOCK position.

PRECAUTIONS BEFORE MOVING OFF Before travelling, check again that there is no one in the surrounding area, and that there are no obstacles. Before travelling, sound the horn to warn people in the area. Always operate the machine only when seated. Do not allow anyone apart from the operator to ride on the machine. Check that the backup alarm (alarm buzzer when machine travels in reverse) works properly. Fix the operator's compartment doors and windows in the closed position securely. If there is an area to the rear of the machine which cannot be seen, position a signal person. Take special care not to hit other machines or people when turning or swinging the machine. Always be sure to carry out the above precautions even when the machine is equipped with mirrors.

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SAFETY


PRECAUTIONS WHEN TRAVELING Never turn the key in the starting switch to the OFF position. It is dangerous if the engine stops when the machine is traveling, because the steering becomes heavy. If the engine stops, depress the brake pedal immediately to stop the machine. When traveling on rough ground, travel at low speed and do not operate the steering suddenly. There is danger that the machine may turn over. The work equipment may hit the ground surface and cause the machine to lose its balance, or may damage the machine or structures in the area. Operate carefully when the wheels are leaning. It is prohibited to travel on roads with the wheels leaning.

Travel at a maximum speed of 10 km/h (6.2 MPH) when using the articulation. If the articulation is used when traveling at a speed of over 10 km/h (6.2 MPH), there is danger that the machine may overturn. Never use the articulation at speeds of over 10 km/h (6.2 MPH).

Avoid traveling over obstacles 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 carrying out 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 body 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 an extremely large destructive force, and this may cause serious injury. When traveling continuously, travel for 2 hours or 80 km, then rest for 30 minutes. Next, travel for 2 hours, then rest for 1 hour, or contact your Komatsu distributor. If you are going to travel continuously, please consult your Komatsu distributor.

2 - 23


SAFETY

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

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SAFETY


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

When leaving the machine, set gearshift lever (1) to the P (Parking) position, then stop the engine. Always close the operator's cab door, and use the key to lock all the equipment in order to prevent any unauthorized person from moving the machine. Always remove the key, take it with you, and leave it in the specified place.

If it is necessary to park the machine on a slope, set blocks under the wheels to prevent the machine from moving.

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SAFETY

TRANSPORTATION The machine can be divided into parts for transportation, so when transportating the machine, please contact your Komatsu distributor to have the work carried out. LOADING AND UNLOADING When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary. Always do as follows. Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge of the road or cliff. Always use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough to provide a safe loading slope. Take suitable steps to prevent the ramps from moving out of position or coming off. Be sure the ramp surface is clean and free of grease, oil, ice and loose materials. Remove dirt from machine-tracks. On a rainy day, in particular, be extremely careful since the ramp surface is slippery. Run the engine at low speed and travel slowly. Never correct your steering on the ramps. If necessary, drive off the ramps, correct the direction, then enter the ramps again. When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and grade. For machines equipped with a cab, always lock the door after boarding the machine. If this is not done, the door may suddenly open during transportation. Refer to "TRANSPORTATION (PAGE 3-120)". 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 3-120)" in the OPERATION section.

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SAFETY


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

If you spill acid on your clothes or skin, immediately flush the area with large amount of water. If acid gets into your eyes, flush them immediately with large amount of water and seek medical attention. Before working with batteries, turn the starting switch to the OFF position.

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

2 - 27


SAFETY

STARTING WITH BOOSTER CABLES If any mistake is made in the method of connecting the booster cables, it may cause the battery to explode, so always do as follows. When starting with a booster cable, carry out the starting operation with two workers (one worker sitting in the operator's seat and the other working with the battery). When starting from another machine, do not allow the two machines to touch. When connecting the booster cables, turn the starting switch OFF position for both the normal machine and problem machine. There is a hazard that the machine will move when the power is connected. Be sure to connect the positive (+) cable first when installing the booster cables. Disconnect the negative (-) cable (ground side) first when removing them. When removing the booster cables, be careful not to let the booster cable clips touch each other or to let the clips touch the machine. Always wear safety glasses and rubber gloves when starting the engine with booster cables. When connecting a normal machine to a problem machine with booster cables, always use a normal machine with the same battery voltage as the problem machine. For details of the starting procedure when using booster cables, see "STARTING ENGINE WITH BOOSTER CABLE (PAGE 3-130)" in the OPERATION section.

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SAFETY


TOWING WHEN TOWING Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection or inspection of the wire rope. For towing, see "TOWING THE MACHINE (PAGE 3-126)". 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.

2 - 29

. PRECAUTIONS FOR MAINTENANCE

SAFETY

PRECAUTIONS FOR MAINTENANCE WARNING TAG Attach the DO NOT OPERATE warning tag to gear shift lever in the operator's cab during the inspection and maintenance. Attach additional warning tags around the machine if necessary. Warning tag Part No. 09963-03001 Keep the warning tag in the tool box when it is not used. If the tool box is unavailable, keep it in the case for operation manual. If others start the engine, or touch or operate the work equipment control lever while you are performing service or maintenance, you could suffer serious injury or property damage.

KEEP WORK PLACE CLEAN AND TIDY Do not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances that will cause you to slip. Always keep the work place clean the tidy to enable you to carry out operations safely. If the work place is not kept clean and tidy, there is the danger that you will trip, slip, or fall over and injure yourself. APPOINT LEADER WHEN WORKING WITH OTHERS When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his instructions during the operation. When working with others, misunderstandings between workers can lead to serious accidents.

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SAFETY

PRECAUTIONS FOR MAINTENANCE

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Stop 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 and stop the engine.

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.

Put blocks under the front and rear of the tires.

Insert the articulation lock pin in the LOCK position to prevent the machine from articulating.

2 - 31


SAFETY

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least two workers and do as follows. One worker must always sit in the operator's seat and be ready to stop the engine at any time. All workers must maintain contact with the other workers. Place speed lever (1) at the P (parking) position to prevent the machine from moving. When carrying out operations near the fan, fan belt, or other rotating parts, there is a hazard of being caught in the parts, so be careful not to come close. Do not touch any control levers. If any control lever must be operated, give a signal to the other workers to warn them to move to a safe place.

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.

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SAFETY


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 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.

WORK UNDER THE MACHINE If it is necessary to go under the work equipment or the machine to carry out service and maintenance, support the work equipment and machine securely with blocks and stands strong enough to support the weight of the work equipment and machine.

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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SAFETY

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

REPAIR WELDING Welding operations must always be carried out by a qualified welder and in a place equipped with proper equipment. There is a hazard of gas, fire, or electrocution when carrying out welding, so never allow any unqualified personnel to carry out welding. REMOVING BATTERY TERMINAL When repairing the electrical system or when carrying out electrical welding, remove the negative (-) terminal of the battery to prevent the flow of current. PROHIBITED TO DISASSEMBLE BANK CONTROL LOCK PIN If the bank control pin assembly is disassembled, there is danger that the spring will fly out and cause serious injury. Never disassemble the bank control pin assembly. PRECAUTIONS WITH HIGH-PRESSURE OIL The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious personal injury, so always do as follows. When carrying out inspection and maintenance of the pressure, release the pressure before starting. For details, see "STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE (PAGE 2-31)". Do not carry out inspection or replacement work with the circuit under pressure. If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping and hoses and for swelling in the hoses. When carry out inspection, wear safety glasses and leather gloves. There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly. If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.

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SAFETY


HANDLING HIGH-PRESSURE HOSES If oil or fuel leaks from high-pressure hoses, there is danger that it may cause fire or defective operation, which may lead to serious injury or fire. If there are any loose hoses or piping, or any leakage of oil or fuel from the hose or piping mount, stop operation and tighten to the specified torque. If any hoses or pipes are damaged or deformed, please contact your Komatsu distributor. Replace the hose if any of the following problems are found. Damaged or leaking hydraulic fitting. Frayed or cut covering or exposed reinforcement wire layer. Covering swollen in places. Twisted or crushed movable portion. Foreign material embedded in covering. WASTE MATERIALS To prevent pollution, pay careful attention to the method of disposing of waste materials. Always put oil drained from your machine in containers. Never drain oil directly onto the ground or dump into the sewage system, rivers, the sea, or lakes. Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, and batteries.

MAINTENANCE OF AIR CONDITIONER If air conditioner refrigerant gets into your eyes, it may cause blindness; if it touches your skin, it may cause frostbite. Never touch refrigerant. COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles. When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves, and other protective equipment. PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS In order for the machine to be operated safety for a long time, it is necessary to add oil and to carry out service and maintenance at periodic intervals. In order to further increase safety, components with a strong relationship to safety, such as hoses and seat belts, must be replaced at periodic intervals. Replacement of safety critical parts: See "PERIODIC REPLACEMENT OF CRITICAL PARTS (PAGE 4-13)". The material of these components naturally changes over time, and repeated use causes deterioration, wear, and fatigue. As a result, there is a hazard that these components may fail and cause serious injury or death. It is difficult to judge the remaining life of these components from external inspection or the feeling when operating, so always replace them at the specified interval. Replace or repair safety-critical parts if any defect is found, even when they have not reached the specified replacement time.

2 - 35

. PRECAUTIONS WITH TIRES

SAFETY

PRECAUTIONS WITH TIRES HANDLING TIRES If tires or rims are handled mistakenly, there is danger that the tire may explode or be damaged, or that the rim may fly off and cause serious personal injury or death. To maintain safety, always do as follows. Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special technology, so always ask your Komatsu distributor to carry out these operations. Always use the tires specified by Komatsu and maintain the specified inflation pressure. Suitable tire inflation pressure: see "CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM (PAGE 4-26)" When pumping up the tires, check that no other person is standing near the tire, and install an air chuck with a clip that can be secured to the air valve. To prevent the tire inflation pressure from becoming too high, measure the pressure from time to time with an air gauge while pumping up the tire. If the tire pressure goes down abnormally or the rim parts do not fit the tire, there is a problem with the tire or rim parts. Always contact your Komatsu distributor for repairs. If the rim parts are not fitted properly when the tire is being pumped up, there is danger that the rim parts may fly off, so set up a protective fence around the tire, and do not stand directly in front of the rim. Stand beside the tread when pumping up the tire. Do not adjust the tire inflation pressure immediately after traveling at high speed or carrying out operations under heavy load. Never carry out welding or light a fire near the tire. PRECAUTIONS WHEN STORING TIRE Tires for construction equipment are extremely heavy, it may lead to serious personal injury or death. As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter. If the tires must be stored outside, always erect a fence and put up "No Entry" signs. Stand the tire on level ground, and block it securely so that it cannot roll or fall over if any person should touch it. Do not lay the tire on its side. This will deform the tire and cause it to deteriorate. If the tire should fall over, do not attempt to stop it. Get out of the way quickly.

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3-1

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OPERATION

GENERAL VIEW

GENERAL VIEW GENERAL VIEW OF MACHINE

(1) (2) (3) (4) (5)

3-2

Blade lift cylinder Drawber shift cylinder Cab Ripper Rear wheel

(6) (7) (8) (9)

Articulate cylinder Blade Front wheel Head lamp

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OPERATION

GENERAL VIEW

GENERAL VIEW OF CONTROLS AND GAUGES

(1) (2) (3) (4) (5) (6)

Inching pedal Work equipment control lever Horn button Steering wheel Turn signal lever Yellow rotating lamp switch (if equipped)

(7) (8) (9) (10) (11)

Brake pedal Gearshift lever Fuel control lever Accelerator pedal Decelerator pedal

3-3

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OPERATION

GENERAL VIEW

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15)

3-4

Central caution lamp Front lamp switch Dimmer switch Transmission caution lamp Turn signal pilot lamp High beam pilot lamp Speedometer Accumlater and brade float switch Service meter Differential lock switch Differential control indicator Accumulator indicator Blade float Parking brake Engine preheating monitor

(16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29)

Radiator coolant level monitor Engine oil level monitor Hydraulic oil level monitor Fuel gauge Engine coolant temperature gauge Final drive oil temperature monitor Engine oil pressure monitor Hydraulic oil level Coolant temperature monitor Air pressure monitor Radiator coolant level monitor Charge monitor Hydraulic oil temperature monitor Emergency steering

.

OPERATION

(1) (2) (3) (4) (5) (6) (7) (8)

Starting switch Hazard lamp switch (if equipped) Front wiper switch (top) Front wiper switch (bottom) Air pressure gauge Rear wiper switch (if equipped) Door wiper switch (if equipped) Emergency steering switch (if equipped)

GENERAL VIEW

(9) (10) (11) (12) (13) (14)

Lift arm lock pilot lamp Bank switch Working lamp switch (cab) Working lamp switch (rear) Front working lamp switch (at rear of blade) Front working lamp switch (in front of blade)

3-5

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OPERATION

EXPLANATION OF COMPONENTS

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

A: B: C:

Check monitor group Caution display portion Emergency caution display portion

D: E:

Meter group Central caution lamp

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.

3-6

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OPERATION


CHECK MONITOR GROUP 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 about 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 there is any abnormality, the appropriate monitor lamp will flash. Wehn the engine is started, these monitor lamps will go off even if there are abnormalities.

(1) (2)

Hydraulic oil level monitor Engine oil level monitor

(3)

Radiator coolant level monitor

HYDRAULIC OIL LEVEL MONITOR This monitor (1) indicates a low hydraulic oil level. If the monitor lamp flashes, check the oil level and add oil as required.

3-7

. EXPLANATION OF COMPONENTS

ENGINE OIL LEVEL MONITOR This monitor (2) indicates a low oil level in the engine oil pan. If the monitor lamp flashes, check the oil level in the engine oil pan and add oil as required.

RADIATOR COOLANT LEVEL MONITOR This monitor (3) indicates a low radiator coolant level. If the monitor lamp flashes, check the coolant level and add water as required.

3-8

OPERATION

.

OPERATION


CAUTION DISPLAY PORTION

CAUTION If these monitor lamps flash, inspect and repair the appropriate place as soon as possible.

NOTICE Park the machine on level ground and check the monitor lamps. Confirm that these monitor lamps light for about 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.

(1) (2) (3)

Charge monitor Radiator coolant level monitor Hydraulic oil temperature monitor

(4) (5)

Emergency steering (if equipped) Transmission caution lamp

3-9


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 3-132)". 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. RADIATOR COOLANT LEVEL MONITOR This monitor (2) indicates a low radiator coolant level. If the monitor lamp flashes, stop the engine, check the coolant level, and add water as required.

HYDRAULIC OIL TEMPERATURE MONITOR This monitor (3) flashes if the hydraulic oil temperature goes above 108°C (226.4 °F). If it flashes, stop the engine and ask your Komatsu distributor to carry out an inspection.

3 - 10

OPERATION

.

OPERATION


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.

Action when emergency steering is actuated 1. If the emergency steering is actuated, move the machine quickly to a safe place and stop the machine. 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. TRANSMISSION CAUTION LAMP This monitor (5) flashes when there is any abnormal operation or abnormality in the control system, such as trying to start the machine with the transmission in 4th or above, or trying to shift down forcibly. The alarm buzzer also sounds continuously according to the seriousness of the abnormality. A controller is used to carry out control to prevent damage or breakage of the transmission caused by mistaken operation. If the conditions are fulfilled, the warning lamp lights up and the buzzer sounds. However, try to avoid operations that will cause the warning lamp to flash. In addition, if there is any abnormality in the control system, stop the engine, and ask your Komatsu distributor to carry out repairs.

3 - 11

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OPERATION


EMERGENCY CAUTION DISPLAY PORTION

CAUTION If these monitor lamps flash, inspect and repair the appropriate place as soon as possible.

NOTICE Park the machine on level ground and check the monitor lamps. Confirm that these monitor lamps light for about 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) (2) (3)

3 - 12

Final drive oil temperature monitor Engine oil pressure monitor Hydraulic oil level monitor

(4) (5)

Coolant temperature monitor Air pressure monitor

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OPERATION


FINAL DRIVE OIL TEMPERATURE MONITOR This monitor (1) flashes if the oil temperature in the final drive becomes abnormally high. If it flashes, stop the machine, turn the differential lock switch to the OFF position, and wait for the monitor to go out.

ENGINE OIL PRESSURE MONITOR This monitor (2) warns the operator that the engine lubricating oil pressure has dropped. If it flashes, stop the engine and look for the cause. 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.

HYDRAULIC OIL LEVEL MONITOR This monitor (3) flashes if the level of the oil in the hydraulic tank is too low. If it flashes, stop the engine and check the oil level in the oil tank, then add oil.

COOLANT TEMPERATURE MONITOR This monitor (4) indicates a rise in the coolant temperature. When the monitor lamp flashes, stop the machine, run the engine with no load at midrange speed until the green range of the engine water temperature gauge lights.

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AIR PRESSURE MONITOR This monitor (5) indicates a drop in the air pressure in the air tank. If the lamp flashes, stop the machine, increase the engine speed and wait until the lamp goes out.

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OPERATION

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OPERATION


METER GROUP

PILOT DISPLAY (1) Differential control indicator (2) Accumulator indicator (3) Blade float (4) Parking brake (5) Engine preheating monitor

METERS (6) Engine coolant temperature gauge (7) Fuel gauge (8) Turn signal pilot lamp (9) High beam pilot lamp (10) Speedometer (11) Service meter

PILOT DISPLAY DIFFERENTIAL CONTROL INDICATOR This monitor (1) lights up when the differential lock is ON. Even when the differential lock switch is at the ON position, if the gear shift lever is at position 5 or above, the differential lock is canceled and this lamp goes out. To engage the differential lock again, shift the gear shift lever down to position 4 or below. The differential lock is then actuated and the lamp lights up again.

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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

ENGINE PREHEATING MONITOR This monitor (5) shows the preheating time when starting the engine in temperatures of below 5°C (41°F). When the starting switch is turned to the HEAT position, it lights up for approx. 36 seconds. After that, it flashes for approx. 16 seconds, and then goes out. When it goes out, it indicates that the preheating is completed.

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OPERATION

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OPERATION


METERS ENGINE COOLANT TEMPERATURE GAUGE

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.

This meter (6) shows the temperature of the coolant water. The green range should be lighted up during normal operations. If the top level lights up, the alarm buzzer will sound, the central warning lamp will light up, and the engine water temperature monitor will flash. 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 lights. If the red range lights, there is less than 70 liters (18.49 US gal) of fuel in the tank. When the red range lights, add fuel.

TURN SIGNAL PILOT LAMP This pilot lamp (8) flashes at the same time as the turn signal lamp flashes. REMARK If there is a disconnection in the turn signal lamp, the flashing interval becomes shorter.

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OPERATION

HIGH BEAM PILOT LAMP This monitor (9) lights up when the head lamp is at high beam.

SPEEDOMETER This monitor (10) indicates the travel speed of the machine. REMARK A speedmeter for MPH is also available.

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.

CENTRAL CAUTION LAMP If the machine is in the following condition, this lamp will flash. Abnormality has occurred in "CAUTION DISPLAY PORTION (PAGE 3-9)". 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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OPERATION


METERS AND LAMPS

(1)

Air pressure gauge

(2)

Lift arm lock pilot lamp

AIR PRESSURE GAUGE 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 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.

LIFT ARM LOCK PILOT LAMP This lamp (2) indicates the condition of the lift arm lock pin. It is turned OFF while the lift arm lock pin is locked.

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OPERATION


SWITCHES

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

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Starting switch Bank switch Front working lamp switch (in front of blade) Front working lamp switch (at rear of blade) Working lamp switch (rear) Working lamp switch (cab) (if equipped) Front wiper switch (top) Front wiper switch (bottom) Rear wiper switch (if equipped) Door wiper switch (if equipped) Emergency steering switch (if equipped)

(12) (13) (13) (14) (15) (16) (17) (18) (19) (20)

Differential lock switch Accumulator switch Accumulator and blade float switch (if equipped) Front lamp switch Dimmer switch Turn signal lever Horn button Room lamp switch Hazard lamp switch Yellow rotating lamp switch (if equipped)

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OPERATION


STARTING SWITCH This switch (1) is used to start or stop the engine. OFF position The key can be inserted or with drawn. The switches for the electric system are all turned off and the engine is stopped. ON Electricity flows to the charging circuit and lamp circuit.

START This is the position for starting the engine. Keep the key at this position while cranking the engine. When the engine starts, release the key immediately. The key returns automatically to the ON position. HEAT (preheating) position Use this position when starting in cold weather (ambient temperature below 5°C (41 °F)). When the key is held at the HEAT position, the electrical heater will be heated and the preheating monitor will light up. When the preheating monitor goes out after flashing, release the key immediately. When the key is released, it returns to the OFF position, so turn it immediately to the START 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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FRONT WORKING LAMP SWITCH (IN FRONT OF BLADE) This switch (3) is used to turn the working lamp in front of the blade ON and OFF. When the switch is pressed, the lamps will light up and the lamp inside the switch will also light up. Press the switch again to turn the lamps off.

FRONT WORKING LAMP SWITCH (AT REAR OF BLADE) This switch (4) is used to turn the working lamp at the rear of the blade ON and OFF. When the switch is pressed, the lamps will light up and the lamp inside the switch will also light up. Press the switch again to turn the lamps off.

WORKING LAMP SWITCH (REAR) This is the switch (5) for the rear working lamp. When the switch is pressed, the lamps will light up and the lamp inside the switch will also light up. Press the switch again to turn the lamps off.

WORKING LAMP SWITCH (CAB) (If equipped) This switch (6) is for the cab working lamp. When the switch is pressed, the lamps will light up and the lamp inside the switch will also light up. Press the switch again to turn the lamps off.

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OPERATION

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OPERATION


FRONT WIPER SWITCH (TOP) This switch (7) actuates the wiper at the top of the front glass. Position (1): Washer fluid is sprayed out. If the switch is released, it returns to the OFF position and washer fluid is stopped. OFF position: Wiper stops. Position (2): Wiper is operated Position (3): Wiper is operated and washer fluid is sprayed out. If the switch is released, it returns to position (2) and washer fluid is stopped.

FRONT WIPER SWITCH (BOTTOM) This switch (8) actuates the wiper at the bottom of the front glass. Position (1): Washer fluid is sprayed out. If the switch is released, it returns to the OFF position and washer fluid is stopped. OFF position: Wiper stops. Position (2): Wiper is operated Position (3): Wiper is operated and washer fluid is sprayed out. If the switch is released, it returns to position (2) and washer fluid is stopped.

REAR WIPER SWITCH (If equipped) This switch (9) actuates the wiper for the door glass. OFF position: Wiper stops Position (1): Wiper is operated

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OPERATION


DOOR WIPER SWITCH (If equipped) This switch (10) actuates the wiper for the door glass. OFF position: Wiper stops Position (1): Wiper is operated

EMERGENCY STEERING SWITCH (If equipped)

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)".

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OPERATION


DIFFERENTIAL LOCK SWITCH 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. Keep the differential locked during normal operations. Even while the differential lock switch is in the ON position, if the gear shift lever is set in the 5th or higher position, the differential is unlocked and it operates. If the gear shift lever is set in the 4th or lower position, the differential is locked again. 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.

ACCUMULATOR AND BLADE FLOAT SWITCH (If equipped) 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. For details of handling the accumulator, see "HANDLING BLADE ACCUMULATOR (PAGE 3-116)".

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BLADE FLOAT SWITCH

WARNING Lower the blade completely to the ground before removing the pin.

This switch (13) is used when actuating the blade float. ON position: The blade moves freely under external force, regardless of the position of the blade control lever. OFF position: The blade is moved by operating the blade control lever. For details of handling the blade float, see "HANDLING BLADE FLOAT (PAGE 3-118)".

FRONT LAMP SWITCH This switch (14) lights up the front lamp, rear lamp, and panel lamp. Position (1): Rear lamp and panel lamp light up Position (2): Front lamp, rear lamp, and panel lamp light up

DIMMER SWITCH This switch (15) the head lamp between high beam and low beam. Position (1): High beam Position (2): Low beam

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OPERATION

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OPERATION


TURN SIGNAL LEVER This lever (16) operates the turn signal lamps. (1) LEFT TURN: Push lever up. (2) RIGHT TURN: Push lever down. If the lever is operated, the turn signal pilot lamp flashes. When the steering wheel is returned to the straight travel position, the lever does not return to the neutral position. Return the lever by hand.

HORN BUTTON When the button (17) in the center of the steering wheel is pressed, the horn will sound.

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

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OPERATION


HAZARD LAMP SWITCH (If equipped)

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

Use this switch (19) only in emergencies, such as when the machine has to be stopped on the road because of a failure. When the switch is pressed, all the turn signal indicator lamps will flash; when the switch is pressed again, the lamps will go out.

YELLOW ROTATING LAMP SWITCH (If equipped) Use this switch (20) to light up and rotate the yellow rotating lamp. (a) ON position: The lamp lights up and rotates. (b) OFF position: The lamp goes off and stops rotating.

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OPERATION


CONTROL LEVERS, PEDALS

(1) (2) (3) (4) (5) (6) (7) (8)

Left blade lift cylinder control lever Ripper lift cylinder control lever (if equipped) Blade side shift control lever Power tilt control lever Blade rotation control lever Drawbar side shift control lever Articulate control lever Leaning control lever

(9) (10) (11) (12) (13) (14) (15) (16)

Option lever Right blade lift cylinder control lever Fuel control lever Gearshift lever Inching pedal Brake pedal Accelerator pedal Decelerator pedal

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LEFT BLADE LIFT CYLINDER CONTROL LEVER This lever (1) operates the left blade lift cylinder. (1) LOWER: The left side of the blade goes down. (2) HOLD: The blade stops and is held in the same position. (3) RAISE: The left side of the blade goes up.

RIPPER LIFT CYLINDER CONTROL LEVER (If equipped) This lever (2) operates the ripper. (1) LOWER: The ripper goes down. (2) HOLD: The ripper stops and is held in the same position. (3) RAISE: The ripper goes up.

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OPERATION

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OPERATION


BLADE SIDE SHIFT CONTROL LEVER This lever (3) shifts the blade to the side. (1) LEFT SHIFT: The blade is shifted to the left position. (2) HOLD: The blade stops and is held in the same position. (3) RIGHT SHIFT: The blade is shifted to the right.

POWER TILT CONTROL LEVER This lever (4) changes the cutting angle of the blade. (1) Max. cutting angle: This makes the blade cutting angle bigger. This is effective when operating on hard ground. Max. cutting angle: 115° (2) HOLD : The blade stops and is held in the same position. (3) Min. cutting angle: This makes the blade cutting angle smaller. This is effective when operating on soft ground. Min. cutting angle: 58° 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.

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BLADE ROTATION CONTROL LEVER NOTICE To prevent damage to the tires, be careful not to let the blade hit the tires when rotating the blade. This lever (5) rotates the blade. (1) LEFT ROTATION: The blade is rotated to the left. (2) HOLD: The blade stops and is held in the same position. (3) RIGHT ROTATION: The blade is rotated to the right.

DRAWBAR SIDE SHIFT CONTROL LEVER This lever (6) shifts the drawbar to the side. (1) LEFT SHIFT: The drawbar is shifted to the left. (2) HOLD: The drawbar stops and is held in the same position. (3) RIGHT SHIFT: The drawbar is shifted to the right.

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OPERATION

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OPERATION


ARTICULATE CONTROL LEVER

WARNING Operate this lever only when traveling at a speed of below 10 km/h (6.2 MPH). If the articulation is operated at a speed of over 10 km/h (6.2 MPH), there is danger that the machine may overturn.

NOTICE To prevent damage to the tires, be careful not to let the blade hit the tires when articulating the machine. This lever (7) is used to operate the articulation. (1) Left articulation: The machine is articulated to the left. (2) HOLD: The articulated condition is maintained. (3) Right articulation: The machine is articulated to the right. Max. articulating angle: 25° to left or right. Min. turning radius (when also using leaning): 7.9 m (25 ft 11 in) when turning to left or right.

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LEANING CONTROL LEVER This lever (8) is used to operate the leaning. (1) LEFT TURN: The tires lean to the left. (2) HOLD: The leaning is kept in the same condition. (3) RIGHT TURN: The tires lean to the right. If the leaning is used, it is possible to turn the machine to the left or right without operating the steering wheel. During blade operations, force is generated by the digging resistance to turn the machine to one side, but by using a suitable leaning angle, this force can be canceled out and the machine can continue to travel in a straight line. If the leaning is operated in the same direction as steering, the turning radius can be made smaller. (Turn the steering to the left (right) and lean the front wheels to the left (right).)

OPTION LEVER This lever (9) is used to operate any optional equipment or attachment.

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OPERATION

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OPERATION


RIGHT BLADE LIFT CYLINDER CONTROL LEVER This lever (10) operates the right blade lift cylinder. (1) LOWER: The right side of the blade goes down. (2) HOLD: The blade stops and is held in the same position. (3) RAISE: The right side of the blade goes up.

FUEL CONTROL LEVER This lever (11) is used to control the engine speed and output. (1) Low idling position: Push the lever forward fully. (2) High idling position: Pull the lever fully back from the low idling position. 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.

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OPERATION


GEARSHIFT LEVER

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. P position: Parking brake applied. The parking brake is applied. When the gearshift lever is set to the P position, the parking brake is applied and the parking brake indicator lamp on the machine monitor lights up. When applying or releasing the parking brake, press lever button (1) and operate the gearshift lever. N position: Neutral Position 1: 1st Position 2: 2nd Position 3: 3rd Position 4: 4th Position 5: 5th Position 6: 6th Position 7: 7th Position 8: 8th Groove on F side: FORWARD Groove on R side: REVERSE 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.

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OPERATION


BRAKE PEDAL

WARNING Do not place your foot on this pedal unnecessarily.

This pedal (14) applies the wheel brakes.

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.

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OPERATION


DUST INDICATOR This device indicates clogging of the air cleaner element. When red piston (1) appears in the transparent part of this indicator, the element is clogged. Immediately clean the element. After cleaning, push indicator button (2) to return the red piston to the original position.

ARTICULATE LOCK PIN

WARNING When servicing or transporting the machine always use this lock pin. For normal travel, always use the lock pin.

This pin is used to lock the front frame and rear frame to prevent the machine from bending during normal travel or when servicing or transporting the machine.

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OPERATION


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 CAPACITY AND NAME OF CIRCUIT Fuse box (1) No.

Fuse capacity

1

10A

Bank, Differential, Accumulator

2

20A

Cab mount working lamp

3

15A

Front working lamp

4

20A

Rear working lamp, Air conditioner

5

10A

Horn, Turn signal lamp, 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

14

10A

Transmission control, Parking blake

15

20A

Air conditioner, Heater

Circuit name

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OPERATION


Fuse box (2) No.

Fuse capacity

1

10A

2

5A

3

20A

A/C condenser

4

10A

(Spare)

5

-

6

-

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Circuit name Hazard flasher Car radio

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OPERATION


OPERATOR'S CAB LIFT MECHANISM

WARNING If the operator's cab is not raised in the correct way, the cab may fall and cause serious injury or even death. Please contact your Komatsu distributor first before using he lift mechanism. Be sure to follow all instructions regarding the method of operation and safety precautions when lifting the cab. Do not use the lift mechanism without receiving guidance from your Komatsu distributor. Komatsu and Komatsu distributors cannot bear any responsibility of any injury or damage is caused due to incorrect use of the lift mechanism.

By using the lift mechanism, it is possible to raise and hold the operator's cab in position without using a crane.

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.

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FRONT GLASS It is possible to open the front glass to the front.

WHEN OPENING 1. Remove lock (1) at the bottom left and right sides of the front glass. 2. Push the bottom of the front glass out and open it to the desired position.

3. Turn left and right lock knobs (2) in the direction of the arrow to fix the glass in position.

WHEN CLOSING 1. Turn left and right lock knobs (2) in the direction of the arrow to release the glass. 2. Pull the bottom of the front glass to close it.

3. Lock the front glass in position with lock (1) at the bottom left and right sides of the front glass.

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OPERATION

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OPERATION


TOOL BAG

CAUTION Do not leave the tool bag on the floor by your feet. It will get in the way during operations.

A bag is provided to hold the tools supplied with the machine. When not using the tools, put them in the tool bag and put the tool bag behind the operator's seat. 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 right of the cab.

QUICK-FILL FUEL FILLER A commercially available mount and relief valve can be installed for use when filling quickly with fuel from a fuel tanker. For details of the method of installing and handling, please see the instruction manual provided with the quick tanker fill device.

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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 flammable 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 wotk 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. 3. Check for coolant and oil leakage around the engine Check for oil leakage from the engine and coolant leaks from the cooling system. If any problem is found, repair it. 4. Check for oil leakage of oil from transmission case, final drive case, tandem drive case, hydraulic tank, circle reverse gear case, hose, joints. Check that there is no oil leakage. If any problem is found, repair the place where the oil is leaking. 5. Check for leakage of air from brake line Check that there is no leakage of air. If any abnormality is found, repair the place where the air is leaking. 6. Check for damage, wear to tires, wheels, check for loose mounting bolts Check that there is no peeling of the tires or cracking of the wheels (side ring, rim base, lock ring). Tighten any loose wheel nuts. If any problem is found, repair or replace. If the valve cap is lost, install a substitute part. 7. Check for problems in handrails, steps, loose bolts. If any problem is found, repair it. Tighten any loose bolts.

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OPERATION

OPERATION

8. Check for problem in gauges, monitor. Check for problem in the gauges and monitor in the operator's cab. If any problem is found, replace the parts. Clean off any dirt from the surface. 9. Check for damaged mirror, reflector, loose mounting bolts Check that there is no damage to the mirror or reflectors, and replace if there is any problem. Tighten any loose bolts. Clean all dirt from the surface of the mirror and reflector. 10. Is door lock normal? Check that there is no damage to the cab door lock. Repair or replace if any problem is found. 11. Clean cab window To ensure a good view during operations, always keep the cab windows clean. 12. Check for damage to the seat belt and mounting clamps.

WARNING Even if there appears to be no abnormality with the seat belt, replace it once every three years.

REMARK The date of manufacture of the seat belt is marked on the belt at the place indicated by the arrow in the diagram 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) If the belt is damaged or fluff is starting to form, or if there is any damage or deformation of the seat belt holders, replace the seat belt.

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OPERATION

OPERATION

13. Inspect tires.

WARNING If worn or damaged tires are used, they may burst and cause serious injury or death. To ensure safety, do not use the following tires. Wear: Tires with a tread 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

14. Inspect rims.

WARNING Check the rims (wheels) and rings for deformation, corrosion and cracks. In particular, check the side rings, lock rings and rim flanges thoroughly.

15. Check for loose ROPS mounting bolts. Check if any bolt is loose or damaged. If it is loose, tighten it (torque: 1520 to 1910 Nm (155 to 195 kgm , 1121.1 to 1410.4 lbft). If it is broke then replace it with Komatsu genuine bolt.

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OPERATION

OPERATION

CHECK BEFORE STARTING Always carry out the item in this section before starting the engine each day.

CHECK COOLANT LEVEL, ADD WATER

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 is empty, check for leakage of water and confirm that the radiator main tank is full, then add water to the radiator 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.

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OPERATION

OPERATION

CHECK FUEL LEVEL, ADD FUEL

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 flames 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.

1. Turn the engine starting switch to the ON position and check the fuel level with fuel level gauge (G). After checking, turn the switch back to the OFF position.

2. After completing work, fill the fuel tank through fuel filler port (F). 3. After adding fuel, tighten the cap securely. Fuel capacity: 500 liters (132.1 US gal)

DRAIN WATER AND SEDIMENT IN FUEL TANK Loosen fuel tank drain valve (1) and drain the sediment and water, accumulated at the bottom, together with fuel. REMARK The fuel will not be drained if it is not above the installation position of drain valve (1) on the tank.

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OPERATION

OPERATION

CHECK ENGINE OIL PAN LEVEL, ADD OIL

WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation.

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 filler pipe, then remove it. 4. The oil level should be between the H and L marks on dipstick (G). If the oil level is below the L mark, add 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.

CHECK DUST INDICATOR 1. Check that the red piston has not appeared in the transparent portion of dust indicator (1). 2. If the red piston has appeared, clean or replace the elementimmediately. For details of the method of cleaning the element, see "CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT (PAGE 4-19)". 3. After checking, cleaning, and replacing, press the knob of dust indicator (1) to return the red piston to its original position.

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OPERATION

OPERATION

CHECK AND ADJUST STEERING WHEEL Start the engine and check the steering wheel play. Standard: 10 to 12 mm (0.4 to 0.5 in) maximum If the steering wheel play is out of the standard range or the steering wheel waves normally or is abnormally heavy, ask your Komatsu distributor for repairs.

CHECK ELECTRIC WIRING

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 disconnection 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 BRAKING EFFECT Drive the machine forward and check the effect of the brakes. If there is any problem in the actuation of the brakes, please contact your Komatsu distributor to have the brakes adjusted.

CHECK PARKING BRAKE EFFECT 1. Set the machine on a dry downhill slope, set the gearshift lever to the P (Parking) position, and check if the parking brake can hold the machine in position. 2. If any problem is found, please contact your Komatsu distributor.

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OPERATION

OPERATION

CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE CHECK THAT ALL PROBLEMS FROM PREVIOUS DAY HAVE BEEN REPAIRED CHECK THAT WINDSHIELD WIPER, WINDOW WASHER, AND DEFROSTER WORK PROPERLY, CHECK WASHER FLUID LEVEL DRAIN WATER, SEDIMENT FROM WATER SEPARATOR The water separator separates water mixed in the fuel. If float (2) is at or above red line (1) , drain the water according to the following procedure. 1. Loosen drain plug (3) and drain the accumulated water until the float reaches the bottom. 2. Tighten drain plug (3). 3. If the air is sucked into fuel line when draining and water, be sure to bleed air in the same manner as for the fuel filter. See "EVERY 500 HOURS SERVICE (PAGE 4-42)".

CHECK INFLATION PRESSURE OF TIRES Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work. Check for damage or wear to the tires and the rims. Check for loose wheel hub nuts (bolts). The proper inflation pressure is shown below.

Tire size

Inflation pressure MPa (kgf/cm2, PSI)

23.5-25-12PR

0.25 (2.6, 36.9)

IS THE RISE IN THE AIR PRESSURE NORMAL? When the pressure in the air tank is 0, it should be possible to charge with air so that the indicator on the air pressure gauge enters the green range by running the engine at low idling for approx. 3 minutes and at full throttle for 1.5 minutes or less.

REMOVAL OF ARTICULATE LOCK PIN

WARNING For general travel, maintenance, and transportation, always keep the articulate lock pin installed.

If the articulation is to be used during travel operations, remove the articulate lock pin and keep it in the place shown by the arrow.

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OPERATION

OPERATION

ADJUSTMENTS ADJUST OPERATOR'S SEAT

WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. 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.

(A) Adjustment of seat height Turn lever (1) to raise or lower the seat as follows. Turn to RIGHT to LOWER seat Turn to LEFT to RAISE seat (B) Fore-and-aft adjustment of seat Move lever (2) to the left, set the seat in the desired position, then release the lever. (C) Adjust reclining angle Pull lever (3) up, set the backrest to the desired position, the release the lever. Range of adjustment: 87° (17 stages)

ADJUSTING POSITION OF STEERING CONSOLE, WORK EQUIPMENT CONTROL LEVERS

WARNING Do not adjust the instrument panel when traveling.

When steering console tilt pedal (1) is depressed, the steering console will move towards you. Adjust to a position that matches your physique and the operating posture. Amount of adjustment: 5 stages

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OPERATION

OPERATION

ADJUSTING ANGLE OF INSTRUMENT PANEL

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° (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.

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OPERATION

OPERATION

USING SEAT BELT

WARNING Before fastening the seat belt, check that there is no problem in the securing brackets or belt. If there is any wear or damage, replace. Even if there appears to be no problem in the seat belt, replace the seat belt once every 3 years. The date of manufacture is woven on the reverse side of the belt. Adjust and fasten the seat belt before operating the machine. Always use the seat belt when operating the machine. Do not use the seat belt with either half of the belt twisted.

FASTEN THE BELT AND REMOVE IT 1. Sit in the seat. Adjust the seat so that the brake pedal can be depressed all the way with the operator's back against the backrest. 2. Sit in the seat. Hold buckle (1) with your left hand and tongue (2) with your right hand, and put tongue (2) into buckle (1). Pull the belt to check that the belt has locked. 3. When removing the belt, raise the tip of buckle lever (1) to release it. Fasten the belt along your body without kinking it. Adjust the lengths of the belt on both the buckle and the tongue sides so that the buckle is located at the front, mid-point of your body.

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OPERATION

OPERATION

ADJUST THE BELT LENGTH TO SHORTEN THE BELT Pull the free end of the belt on either the buckle body or tongue side.

TO LENGTHEN THE BELT Pull the belt while holding it at a right angle to the buckle or tongue.

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OPERATION

OPERATION

OPERATIONS, CHECKS BEFORE STARTING ENGINE

WARNING When starting the engine, check that the gearshift lever is properly at the P (Parking) position. If the control levers are touched by accident when the engine is started, the work equipment may move suddenly and cause a serious accident. When standing up from the operator's seat, always set the gearshift lever to the P (Parking) position, regardless of whether the engine is running or stopped.

1. Check that gearshift lever (1) is at the P (Parking) position. When starting the engine, if gearshift lever (1) is not at the P (Parking) position, the engine will not start.

2. Lower the blade and ripper to the ground, and check that work equipment control levers (2) are at the HOLD position.

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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 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.

4. Check if parking brake pilot lamp (4) on the machine monitor is lighted up. If it is not lighted up, check if the gearshift lever is at the P position. When starting the engine, if the parking brake is not applied, the engine will not start.

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. 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.

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OPERATION

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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 bodily injury 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. 1. Set fuel control lever (1) to the low idling position.

2. Turn the key in starting switch (2) to the START position. The engine will start.

3. When the engine starts, release the key in starting switch (2). The key will return automatically to the ON position.

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OPERATION

OPERATION

STARTING IN COLD WEATHER

WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine. Never use starting aid fluids as they may cause explosions. 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. When starting in low temperatures, do as follows. 1. Set fuel control lever (1) to the low idling position.

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OPERATION

OPERATION

2. Hold starting key (2) at the HEAT position until preheating monitor (3) flashes. 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.

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OPERATION

OPERATION

OPERATIONS, CHECKS AFTER STARTING ENGINE

WARNING Emergency stop If the operation is abnormal or any other trouble occurs, turn the key in the starting switch to the OFF position. If the work equipment is operated without warming up the machine sufficiently, the response of the work equipment to the movement of the control lever will be slow. The work equipment may not move as the operator desires. Follow all warm-up procedures. Particularly in cold areas, make sure to warm up the machine properly.

BREAKING IN THE MACHINE

CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter). During break-in operations, follow the precautions described in this manual.

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. Idle the engine for 5 minutes after starting it up. Avoid operation with heavy loads or at high speeds. Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and sudden changes in direction.

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OPERATION

OPERATION

NORMAL OPERATION After the engine starts, do not start operating the machine immediately. First, carry out 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.

2. After the warm-up run is completed, check gauges and caution lamps for proper operation. If any abnormality is found, repair it. Continue to run the engine at light load until engine coolant temperature gauge indicator (2) falls within the green range. 3. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 4. Watch air pressure gauge (3) and check that the air pressure rises normally. If the air pressure rises slowly, check the following. When the pressure inside the air tank is 0, the time taken to fill with air to a point where the indicator of the air pressure gauge enters the green range is as follows. Engine low idling: Approx. 3 min. Engine high idling: Max. 1.5 min. If the rise in pressure is too slow, contact your Komatsu distributor for inspection and repair.

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. 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 about 5 minutes to allow it to gradually cool down.

2. Turn the key in starting switch (2) to the OFF position and stop the engine. 3. Remove the key from starting switch (2).

CHECK AFTER STOPPING ENGINE 1. Walk around the machine and check the work equipment, machine exterior, and undercarriage, also check for any leakage of oil or coolant. If any problems are found, repair them. 2. Fill the fuel tank. 3. Check the engine compartment for paper and debris. Clean out any paper and debris to avoid a fire hazard. 4. Remove any mud affixed to the undercarriage. 5. Depress the brake pedal several times to drain the water from the drain valve.

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OPERATION

OPERATION

TRAVELING POSTURE FOR MACHINE

WARNING For general travel, always lock the front frame and rear frame with the articulate lock pin. Before moving any work equipment control lever, check the distance between the blade and tires.

NOTICE Be 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.

2. Insert the shank as shown in the diagram on the right.

3. Raise the ripper.

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OPERATION

OPERATION

MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING

WARNING When moving off, check that the area around the machine is safe, and sound the horn before moving. Clear all personnel from the machine and the area. Use extreme care when reversing the machine. Note there is a blind spot behind the machine. Do not operate the machine when air pressure is abnormal. Before starting operations, check that the seat belt is properly installed.

PREPARATIONS FOR MOVING OFF 1. Check that central caution lamp (1) is not lighted up.

2. Set the blade to the travel posture. 3. Depress inching pedal (2).

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OPERATION

OPERATION

4. Operate gear shift lever (3) to the F (FORWARD) or R (REVERSE) position, and set it at 1st speed or 2nd or 3rd speed. NOTICE Do not try to start the machine with the transmission in 4th or above.

5. Depress accelerator pedal (4) while releasing inching pedal (2), and move the machine off.

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OPERATION

OPERATION

SHIFTING GEAR ON MACHINE

WARNING Avoid sudden shifting of gear when traveling at high speed. When shifting gear, use the brake to reduce speed before shifting gear.

NOTICE When shifting gear, always shift one gear at a time. When shifting gear, do as follows.

INCREASE SPEED Let back accelerator pedal (1) and shift gearshift lever (2) up to the next speed range.

REDUCING SPEED Release accelerator pedal (1) to reduce speed, then shift 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.

Gearshift lever

Suitable speed for shifting down km/h (MPH)

8th -> 7th

35.0 (21.7)

7th -> 6th

25.0 (15.5)

6th -> 5th

18.5 (11.5)

5th -> 4th

12.0 (7.5)

4th -> 3rd

9.0 (5.6)

3rd -> 2nd

7.0 (4.3)

2nd -> 1st

4.0 (2.5)

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OPERATION

OPERATION

SHIFTING BETWEEN FORWARD AND REVERSE

WARNING When shifting between forward and reverse, always check that it is safe to travel in the new direction. Use extreme care when reversing the machine. Note there is an blind spot behind the machine. Do not shift between forward and reverse when traveling at high speed.

When shifting between forward and reverse, always stop the machine first. 1. Depress brake pedal (1) to reduce speed, then depress inching pedal (2) to stop the machine.

2. Shift gearshift lever (3) to F (FORWARD) or R (REVERSE) and set in 1st or 2nd speed.

3. Let inching pedal (2) back while depressing accelerator pedal (4) to start the machine off.

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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.

1. Release accelerator pedal (1).

2. Depress brake pedal (2). Before the machine comes to a stop, depress inching pedal (3).

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OPERATION

OPERATION

3. Set gear shift lever (4) at the P position.

4. Check that parking brake pilot lamp (5) on the machine monitor is lighted up.

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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.

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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.

2. Operate articulate control lever as follows. Pull BACK to articulate to RIGHT. Push FORWARD to articulate to LEFT.

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).

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OPERATION

OPERATION

OPERATING WORK EQUIPMENT

(1) (2) (3) (4)

Left blade control lever Right blade control lever Blade side-shift control lever Blade rotation control lever

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

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(5) (6) (7)

Power tilt control lever Drawbar side-shift control lever Ripper control lever

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OPERATION

OPERATION

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

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

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. OPERATION

OPERATING BLADE ROTATION Operate blade rotation control lever (4) as follows. Pull BACK to rotate blade to RIGHT Push FORWARD to rotate blade to LEFT

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OPERATION

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OPERATION

OPERATION

CHANGING BLADE CUTTING ANGLE Operate power tilt control lever (5) as follows. Pull BACK to make cutting angle SMALLER Push FORWARD to make cutting angle LARGER

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

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. OPERATION

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

OPERATING RIPPER (If equipped) Operate ripper control lever (7) as follows. Pull BACK to RAISE ripper Push FORWARD to LOWER ripper

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OPERATION

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OPERATION

OPERATION

WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER LEVELING GROUND TO RIGHT 1. Operate the drawbar side shift and move the circle approx. 200 mm (7.9 in) to the left.

2. Set the blade so that the earth is discharged outside the rear left wheel.

3. Operate 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).

Example of lift cylinder and drawbar shift cylinder extended a suitable amount and lowered directly.

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. OPERATION

OPERATION

When the drawbar shift cylinder is not extended and only the lift cylinder is extended.

4. Lean the front wheels to the left. REMARK Leaning the wheels to the left prevents the machine from being pushed to the right by the load acting on the left side of the machine.

5. Rotate so that the blade is at the optimum position for the soil. Be careful not to let the rear left wheel run over the windrow (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.

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OPERATION

OPERATION

LEVELING GROUND TO LEFT 1. Operate the drawbar side shift and move the circle approx. 200 mm (7.9 in) to the right.

2. Set the blade so that the earth is discharged outside the rear right wheel.

3. Operate the blade lift cylinder so that the blade is at the desired digging depth, then set it horizontal.

4. Lean the front wheels to the right. 5. Carry out the operation in the same way as when leveling to the right.

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. OPERATION

OPERATION

DIGGING RIGHT V-DITCHES 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.

2. Set the cutting angle at approx. 40°. Operate the power tilt so that the top of the blade is slightly in front of the cutting edge.

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.

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OPERATION

OPERATION

6. Lean the front wheels to the left. 7. Start the digging operation. The first digging pass acts as a guide for the 2nd and later passes. (Cutting the guide groove.)

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.

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. OPERATION

OPERATION

DIGGING LEFT V-DITCHES NOTICE Set the frame straight. If the machine is articulated, the side of the tire will be pushed against the 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.

2. Set the cutting angle at approx. 40°. Operate the power tilt so that the top of the blade is slightly in front of the cutting edge.

3. Operate the right blade lift cylinder and raise the right edge of the blade. (The left end of the blade determines the depth of the ditch. The right end of the blade 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.

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OPERATION

OPERATION

6. Lean the front wheels to the right. 7. Start the digging operation. The first digging pass acts as a guide for the 2nd and later passes. (Cutting the guide groove.)

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.

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. OPERATION

RIGHT DITCH FINISHING 1. Set the right side of the blade behind the front right wheel.

2. Operate the right blade lift cylinder and set the blade to the depth of the ditch.

3. Be careful not to let the rear left wheel run over 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.

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OPERATION

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OPERATION

OPERATION

LEFT DITCH FINISHING 1. Set the left side of the blade behind the front left wheel.

2. Operate the left blade lift cylinder and set the blade to the depth of the ditch.

3. Be careful not to let the rear right wheel run over the windrow discharged from the blade. Operate the blade lift cylinder and blade rotation to set the blade in position. 4. Lean the front wheels slightly to the right. 5. To push out the soil to the top of the slope face and the road shoulder, a separate pass is needed. Spread the soil, then carry out final finishing with the grader.

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. OPERATION

FINISHING RIGHT ROAD SHOULDER 1. Move the drawbar to the right.

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. Adjust the blade height to move the windrow to the center of the road. Set the position of the machine as follows. 1) If the road shoulder is hard, travel with the wheels on either side of the windrow at the road edge to process it. (Spreading posture) 2) If the road shoulder is soft, use the extreme side reach posture to process it. (Shoulder reach posture) Be careful not to let the rear wheels run over the windrow.

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OPERATION

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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).

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FINISHING LEFT ROAD SHOULDER 1. Move the drawbar to the left.

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. Adjust the blade height to move the windrow to the center of the road. Set the position of the machine as follows. 1) If the road shoulder is hard, travel with the wheels on either side of the windrow at the road edge to process it. (Spreading posture) 2) If the road shoulder is soft, use the extreme side reach posture to process it. (Shoulder reach posture) Be careful not to let the rear wheels run over the windrow.

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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).

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OPERATION

CONSTRUCTING ROAD - METHOD OF MAKING V-DITCH Set the blade to the ditch-digging posture, and carry out digging to a maximum digging depth of approx. 10 cm (3.9 in) to make a line along the stakes erected as the planned line for the ditch (marking cut). Set the front and rear wheels in the groove made by the marking cut, open the blade slightly, and dig the blade deep to cut along the line of stakes. When doing this, set the blade so that the windrow is formed between the rear wheels. Normally, a ditch is dug on both sides, so do a U-turn and continue to carry out the operation driving forward. When making comparatively short ditches on one side only, operations are carried out in reverse, but carry out the main digging traveling forward at least one time to form the basic shape of the ditch before traveling in reverse. Move the windrow formed on the road shoulder and spread it from the road shoulder to the center of the road. If the road shoulder is comparatively hard, travel with the wheels on either side of the windrow at the road shoulder to process it. If the road shoulder is soft, use the shoulder reach posture to process it. To cut the outside slope of the ditch to the determined grade, use the bank-cut posture. Align the blade with the grade of the slope and set so that the rear end of the blade is at the bottom of the ditch slope.

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)

2. Second digging pass: Heavy-duty digging

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OPERATION

OPERATION

3. Third digging pass: Heavy-duty digging

4. Finishing road shoulder

5. Leveling center

6. Fourth digging pass: Heavy-duty digging


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8. Spreading to center

9. Slope face and bank Use the bank cutting posture.

10. Finishing bottom of ditch

11. Ditch digging pass (finishing and shaping inside of the slope face)

12. Finishing slope face

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OPERATION

OPERATION


14. Leveling and finishing

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. 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.

3. Place the front right tire in the bottom of the V-ditch. 4. Set the blade so that the right edge of the blade comes to the inside of the front right tire at the width of the flat-bottomed ditch.

5. Operate the right blade lift cylinder to lower the right end of the blade, and set it to the digging depth. 6. Operate the left blade lift cylinder to raise the right end of the blade, and set it to the desired angle for the slope face of the road shoulder.

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

CONSTRUCTING ROAD - METHOD FOR MAKING FLAT-BOTTOMED DITCH The procedure shown in the diagrams is for one side of the road. Repeat the same operation on the opposite side of the road. 1. Make the slope face on the inside flat.

2. Dig the width and depth of the bottom of the ditch with the left ditching method.

3. Finish the road shoulder.

4. Spread the soil to the center.

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OPERATION

5. Finish the slope face on the bank.

6. Make the bottom of the ditch flat.

7. Finish the ditch.

8. Finish the slope face on the inside.

9. Finishing slope face

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OPERATION

10. Leveling and finishing

FINISHING WITH GRADER FOR DITCHES WHERE WET ROAD SHOULDER IS LOOSE This method is used when avoiding hanging trees or protruding rocks which are obstacles when cleaning old ditches. 1. Articulate the machine so that the front wheels and blade remain in the ditch. Steer with the front wheels. 2. Keep the rear wheels on the road shoulder and be careful that the wheels do not slip on the soft weak soil of the ditch.

LEVELING SLOPE FACE

WARNING When operating on slopes where the machine may slip to the side, make sure that you understand the operation of the machine completely. Do not articulate the machine fully on steep slopes. On steep slopes, lower the engine speed and operate in 1st gear. When operating on slopes, use the accelerator to control the machine speed.

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OPERATION

BANK CUTTING METHOD - RIGHT SIDE

WARNING Lower the blade to the ground before removing the bank control lock pin.

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.

7. Move the bank switch from the LOCK position to the RETRACT position, then remove the lock pin from the lifter.

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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.

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20. If the digging is comparatively heavy duty, angle the wheels towards the slope face.

21. If the digging is comparatively light duty, angle the wheels away from the slope face. Discharge the soil from the slope face to the outside of the rear wheels.

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OPERATION

OPERATION

EXTREME SIDE REACH

WARNING Lower the blade to the ground before removing the bank control lock pin.

1. Lower the blade so that it is lightly in contact with the ground. 2. Move the bank switch from the LOCK position to the RETRACT position, then remove the lock pin from the lifter.

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.

5. Operate the lifter to the specified position (counter mark), then insert the bank control lock pin.

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OPERATION

6. When the lifter guide is at the specified position, move the bank switch from the INDEX position to the LOCK position.

7. Shift the blade to the side as shown in the diagram. Shift the blade fully to the right. Shift the drawbar fully to the right. Set the blade propulsion angle to approx. 60°

8. Lower the blade to the desired depth, then set the blade at an angle to discharge the soil to the side.

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OPERATION

PRECAUTIONS WHEN OPERATION PRECAUTIONS WHEN TRAVELING UPHILL OR DOWNHILL

WARNING Do not shift gear or place the transmission in neutral when going downhill. The braking effect of the engine cannot be used, so this is dangerous. Always keep the gear shift lever in a travel position when going downhill. Failure to do this may result in engine overrun and damage to the engine or transmission. To prevent engine overrun, always shift down one gear at a time.

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 If the engine stops, the brake booster will not work, so the operating effort of the pedal will become heavier and the effect of the brake will become lower even when the pedal is depressed with the same force.

If the engine stops on a slope, immediately depress the brake pedal fully to stop the machine, set the gearshift lever to the P (Parking) position, then start the engine again.

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OPERATION

PRECAUTIONS WHEN USING INCHING PEDAL Do not use the inching operation for long periods. If the inching operation is carried out continuously (for more than 10 seconds), there is danger of abnormal wear and damage to the transmission clutch. If the inching operation is used frequently when traveling downhill, the engine will run at low speed. This will cause lack of lubricating oil, which will have an adverse effect on the transmission.

PRECAUTIONS WHEN OPERATING TRANSMISSION Pay careful attention to the following points to protect the engine and transmission.

PRECAUTIONS WHEN MOVING MACHINE OFF Check that the central warning lamp on the instrument panel is not flashing. Depress the inching pedal, place the gearshift lever at 1, 2, or 3 in F or R, then release the inching pedal slowly to move the machine off. Moving the machine off suddenly will cause damage to the transmission. If the machine is started in 4th, there is danger that the transmission clutch will seize.

PRECAUTIONS WHEN SHIFTING GEAR There is danger of damage to the engine or transmission if the engine overruns. Always do as follows. Do not shift down suddenly when traveling at high speed. When shifting down, release the accelerator pedal and depress the brake pedal to reduce speed, then shift down one speed at a time. When shifting up, release the accelerator pedal slightly and shift up one speed at a time. When traveling at low speed (2 km/h (1.2 MPH) or below), do not shift to 4th speed or above. When changing direction between forward and reverse, stop the machine first. Trying to change direction where the machine is still moving will cause damage to the transmission. Use the following table as a guideline for the suitable travel speed in each speed range. Gearshift lever

Suitable speed for shifting down km/h (MPH)

8th -> 7th

35.0 (21.7)

7th -> 6th

25.0 (15.5)

6th -> 5th

18.5 (11.5)

5th -> 4th

12.0 (7.5)

4th -> 3rd

9.0 (5.6)

3rd -> 2nd

7.0 (4.3)

2nd -> 1st

4.0 (2.5)

PRECAUTIONS WHEN TRAVELING DOWNHILL If the inching pedal is operated when traveling downhill, the flow of lubricating oil in the engine and transmission will drop, and this will lead to internal wear. To prevent this, the caution lamp on the instrument panel or the alarm buzzer may be actuated. If the caution lamp or alarm buzzer are actuated, release the inching pedal immediately. If the transmission is shifted down when traveling downhill, the engine and transmission may overrun, and this will cause damage to the engine and transmission. To prevent this, the caution lamp on the instrument panel or the alarm buzzer may be actuated. If the caution lamp or alarm buzzer are actuated, depress the brake immediately. It is extremely dangerous to set the gearshift lever to the N position when traveling downhill, because the engine cannot be used as a brake. In addition, if the machine travels with the gearshift lever at the N position, the flow of lubricating oil in the transmission will drop, and this will lead to internal wear.

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OPERATION

OPERATION

PERMITTED WATER DEPTH When crossing rivers, do not operate the machine in places where the water is above the permissible depth (up to the bottom face of the tandem case). Raise the work equipment (blade, ripper) to the maximum height. After crossing the river, check the effect of the brakes, and if necessary clean or dry them. Wash the work equipment carefully and carry out greasing thoroughly for greasing points that went under water.

WHEN BRAKES DO NOT WORK If the machine does not stop even when the brake pedal is depressed, set the gearshift lever to the P (Parking) position to apply the parking brake and stop the machine. 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.

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

PRECAUTIONS WHEN TRAVELING ON ROADS When moving the machine to another place and traveling at high speed, stop the machine and rest for 30 minutes after traveling 80 km or 2 hours (whichever comes sooner). For the following cycle, rest for one hour, and for the cycle after that, rest for 30 minutes. Repeat this and be sure not to exceed the conditions.

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

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OPERATION

PRECAUTIONS WHEN OPERATING RIPPER

CAUTION When using the ripper, set the frame straight.

For heavy-duty conditions, use 1 to 3 shanks.

For general soil condition, use 3 to 5 shanks. Keep the ripper at a depth where there is no tire slip and where the engine horsepower can be used to its full. Travel in a straight line at approx. 2 to 4 km/h (1.2 to 2.5 MPH), and gradually insert the points into the ground. On slopes, carry out ripping downhill to use the weight of the machine. NOTICE To prevent damage, raise the ripper from the ground before turning the machine. Carry out cross ripping only when there is a special purpose. When breaking up a paved surface, raise the ripper after digging up the ground under the surface.

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OPERATION

OPERATION

ADJUSTING WORK EQUIPMENT POSTURE Move the work equipment to the most suitable position for each operation and carry out operations efficiently.

BLADE PROTRUSION The degree of protrusion is controlled by the control lever during operation. If further protrusion is needed, stop the grader for a while and change the installing position of the blade horizontal shifting cylinder piston rod, as follows. 1. Lower the blade to the ground. 2. Loosen the bolt holding the blade to the bracket at the tip of the cylinder rod, then remove the bolt and lock washer. 3. Pull in the cylinder rod. 4. Align the bolt hole in the bracket with a hole in another place on the blade. 5. Install the lock washer and bolt, then tighten the bolt. Protrusion to right: Position (1)

BLADE PROPULSION ANGLE The angle between the blade and the center line of the machine body is called the blade propulsion angle. Set the blade propulsion angle to about 60° for general cutting work, but set it narrower in the following situations. When the cutting resistance is high. When the soil is hard. When the soil accumulated in front of the blade dose not flow smoothly.

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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.

1. Release accelerator pedal (1).

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OPERATION

2. Depress brake pedal (2). Before the machine comes to a stop, depress inching pedal (3).

3. Set gear shift lever (4) at the P position.

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.

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CHECKS AFTER COMPLETION OF OPERATION Use the machine monitor to check the engine water temperature, engine oil pressure, and fuel level. If the engine has overheated, do not stop the engine suddenly. Run it at a mid-range speed to cool it gradually before stopping.

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.

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OPERATION

OPERATION

HANDLING THE TIRES PRECAUTIONS WHEN HANDLING TIRES

WARNING To ensure safety, the defective tires given below must be replaced with new tires. Tires where the bead wire has been cut, broken, or greatly deformed Excessively worn tires where more than 1/4 of the circumference of the carcass ply (excluding the breaker) is exposed Tires where damage to the carcass exceeds 1/3 of the tire width Tires where ply separation has occurred Tires where radial cracks extend to the carcass Tires where there is abnormal deterioration, deformation, and damage, and the tire cannot withstand use.

Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care.

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OPERATION

HANDLING BLADE ACCUMULATOR (If equipped)

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.

1. Lower the blade to the ground and stop the engine. 2. Turn starting switch (1) to the ON position to supply power to the electric circuits, then turn on accumulator switch (2). Next, move the right and left blade lift levers forward and backward to release the residual pressure in the accumulator and the hydraulic circuits. 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 about 50 mm (2.0 in). At this time, holding pressure is produced at the bottom of the blade lift cylinders.

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OPERATION

5. Turn on the accumulator switch to operate the accumulator. The oil in the bottom of the right and left blade lift cylinders will flow into the accumulator, both blade lift cylinders will retract, and the front wheels will lower to the ground. 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 about 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.

FEATURES OF THE BLADE ACCUMULATOR The blade accumulator has the following characteristics. EASE OF WORK No need to operate blade This work does not require a lot of skill. SAFETY AND 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). IMPROVED STEERING PERFORMANCE Steering performance on curves is improved. Side slips on curves are reduced. Steering performance with the leaning system is improved. Reduction in side slippage when using leaning No pulling of front wheels (floating, safety of front wheels) IMPROVED WORKABILITY Good pushing of blade Good avoidance by blade

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OPERATION

OPERATION

HANDLING BLADE FLOAT (If equipped)

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.

1. Lower the blade to the ground and stop the engine.

2. Turn starting switch (1) ON (electric current flows through the circuit), then set the blade lift control lever to the HOLD position and turn blade float switch (2) ON. In this condition, the pressure is released from the head and bottom ends of the blade lift cylinder, so the blade is placed in the float condition.

3. If the blade lift cylinder control lever is operated to the RAISE position when blade float switch (2) is ON, the blade will rise, and if it is operated to the LOWER position, the blade will go down.

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.

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OPERATION

OPERATION

FEATURES OF BLADE FLOAT The blade float has the following characteristics. 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). IMPROVEMENT IN EASE OF STEERING Steering performance on curves is improved. Side slips on curves are reduced. Steering performance with the leaning system is improved. Reduction in side slippage when using leaning No pulling of front wheels (floating, safety of front wheels) IMPROVEMENT IN EASE OPERATION Good pushing of blade Good avoidance by blade Priority system for lever control

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TRANSPORTATION

TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety.

LOADING, UNLOADING WORK

WARNING When loading or unloading the machine, run the engine at low speed, travel at low speed, and operate slowly. When loading or unloading the machine, stop the trailer on firm level ground. In addition, keep well away from the road shoulder. Use ramps of ample width, length, thickness, and strength, and install them securely at an angle of less than 15°. When using an embankment, compact the fill soil thoroughly and make sure that the slope face does not collapse. Remove the mud stuck to the undercarriage to prevent the machine from slipping to the side on the ramps. In addition, remove any water, snow, ice, grease, or oil from the ramps. Never change direction on the ramps. There is danger that the machine may tip over. If it is necessary to change direction, return to the ground surface or the trailer platform, correct the direction, and start again. The position of the center of gravity of the machine will change suddenly at the connection of the ramp and trailer, and there is danger of the machine losing its balance. Always drive slowly over this point.

When loading or unloading, always use ramps or a platform and carry out 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 15º. 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.

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OPERATION

TRANSPORTATION

PRECAUTIONS FOR LOADING After placing the machine on the specified position of the trailer, secure it according to the following procedure. 1. Lower the work equipment slowly. 2. Set the gear shift lever at the P (parking) position. 3. Turn the starting switch to the OFF position, and stop the engine, then remove the key. 4. Lock the front frame and rear frame with the articulate lock pin. 5. When transporting the machine, place wooden blocks underneath the front and rear tires to prevent the machine from moving about. Also, hold it down with chain or rope.

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OPERATION

COLD WEATHER OPERATION

COLD WEATHER OPERATION PRECAUTIONS FOR LOW TEMPERATURE If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.

FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity, see "USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-8)".

COOLANT

WARNING Antifreeze 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 coolant containing antifreeze that has been drained when repairing the radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Antifreeze is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface. Antifreeze is flammable. Do not bring any flame close. Do not smoke when handling antifreeze.

NOTICE Never use methanol, ethanol or propanol based antifreeze. Avoid using any leak-preventing agent, regardless if it is sold separately or in antifreeze. Do not mix one brand of antifreeze with a different brand. For details of the antifreeze mixture when changing the coolant, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-17)". Use a Permanent Antifreeze (ethylene glycol mixed with corrosion inhibitor, antifoam agent, etc.) meeting the standard requirements as shown below. With permanent antifreeze, no change of coolant is required for a year. If it is doubtful that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for information. Standard requirements for permanent antifreeze SAE J1034 FEDERAL STANDARD O-A-548D REMARK In areas where permanent antifreeze is not available, it is possible to use antifreeze whose main component is ethylene glycol and does not contain any corrosion inhibitor. (Such antifreeze can be used for the winter season only.) However, in such a case, the coolant must be changed twice a year (spring and autumn), so use permanent antifreeze when possible.

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OPERATION

COLD WEATHER OPERATION

BATTERY

WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with 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 (68°F)

0°C (32°F)

-10°C (14°F)

-20°C (-4°F)

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

Charging Rate (%)

When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from freezing.

CAUTIONS AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, observe the following precautions. Remove all the mud and water from the machine. Be particularly careful to remove mud and drops of water from the surface of the hydraulic cylinder rod. This will prevent the mud from getting inside the seal and causing damage to the seal. Park the machine on hard, dry ground. If this is impossible, park the machine on wooden boards. The boards help protect the tracks from being frozen in soil and the machine can start next morning. Open the drain valve and drain any water collected in the fuel system to prevent it from freezing. As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine, store the battery in a warm place, and install it the next morning.

AFTER COLD WEATHER When the season changes and the weather becomes warmer, do as follows. Replace the fuel and oil for all parts with oil of the viscosity specified. For details, see "USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE (PAGE 4-8)".

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OPERATION

LONG-TERM STORAGE

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 4-17)". 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.

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 when doing this. In addition, check the refrigerant level twice a year.

AFTER STORAGE NOTICE If the machine has been stored without carrying out 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.

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OPERATION

TROUBLESHOOTING

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.

PROCEDURE FOR BLEEDING AIR 1. Loosen air bleed plug (1). 2. Loosen the knob of feed pump (2) and move it up and down to let the fuel flow out of air bleed plug (1) until bubbles do not comes out any more. 3. Tighten air bleed plug (1). 4. Push in the knob of feed pump (2) and tighten it.

WHEN LEANING PIPING IS DAMAGED

WARNING If the machine is driven with the leaning cylinder piston rod fluctuating or the front wheels leaning on one side because of damaged leaning piping, dangerously unstable steering and excessively worn tires will result. Repair the faulty leaning pipe quickly.

If the leaning piping is broken, call your Komatsu distributor for repair.

METHOD OF USING LEANING STOPPER Fix the leaning rod (2) to the front axle using the bolts (1) provided in the tool box.

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OPERATION

TROUBLESHOOTING

TOWING THE MACHINE

WARNING The brakes will not work if there is a failure in the air system, so be extremely careful. If a mistaken method is used when towing, there is danger of causing death or serious injury. Before releasing the brakes, always put blocks under the tires. When towing, always use a wire rope of ample strength for the load being towed. Avoid applying a sudden load to the wire rope.

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.

WHEN ENGINE CAN BE USED Always keep the engine running when towing the machine, so that the steering and braking can be used.

WHEN ENGINE CANNOT BE USED When towing a disabled machine the distance should be within 600 m (1968 ft) at a speed of 8 km/h (5.0 MPH) or less. If the distance is more than the above mentioned, or if more than one day has elapsed since the engine trouble, be sure to use a trailer for transportation. NOTICE If the machine is towed without the engine running, no lubrication oil will be supplied to the transmission. The gears and bearings are rotated, so this may cause them to be damaged. Tow the machine properly according to the instructions given below. The explanation given here is only to be used for a machine that has failed and is to be moved to a safe place for repairs. It must be moved a maximum of 600 m (1968 ft) and at a maximum speed of 8 km/h (5.0 MPH). This procedure is only for emergency purposes. If the machine must be moved a long distance, use a transporter. To protect the operator if the towrope or bar should break, install a protector plate to the machine being towed. If it is impossible to use the steering or brakes on the machine being towed, then do not have anyone sitting in the operator's seat. Before towing, check that the tow rope or bar are in good condition, and that they have ample strength for the towing operation. If the machine being towed may get stuck in mud or may have to be towed uphill, the tow rope or bar must be of a strength of at least 1.5 times greater than the weight of the machine being towed. Keep the angle of the towing line to the minimum. Operate the machine so that the angle does not become greater than 30° from the straight line. If the machine is moved suddenly, the towrope or bar will be subjected to an excessive load, and it may break. Start the machine gradually and travel at a constant speed. Normally, use a towing machine of about the same capacity as the machine being towed. The towing machine must have ample brake capacity, weight, and rimpull. Check that both machines can be controlled on slopes and on the tow road. When moving a failed machine on a downhill slope, a larger towing machine must be used to ensure ample control and braking power. Another method is to use a second towing machine at the rear of the failed machine. In this way, it is possible to prevent the failed machine from going out of control and turning over. It is impossible to determine the drawbar pull needed for various conditions. The minimum drawbar pull may be sufficient on horizontal, flat ground, but the maximum drawbar pull is needed on slopes or on rough roads.

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OPERATION

TROUBLESHOOTING

When towing a failed machine, please contact your Komatsu distributor.

METHOD OF RELEASING PARKING BRAKE

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.

TOWING MACHINE WITHOUT EMERGENCY STEERING

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.

The standard steering works only when the engine is running.

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OPERATION

TROUBLESHOOTING

TOWING MACHINES WITH EMERGENCY STEERING

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)".

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OPERATION

TROUBLESHOOTING

IF BATTERY IS DISCHARGED

WARNING It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates hydrogen gas, so there is a hazard of explosion. Do not bring lighted cigarettes near the battery, or do anything 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 safety glasses 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 removing or installing the terminals, check which is the positive (+) terminal and which is the negative (-) terminal.

REMOVAL AND INSTALLATION OF BATTERY Before removing the battery, remove the ground cable (normally connected to the negative (-) terminal). If any tool touches between the positive terminal and the chassis, there is a hazard of sparks being generated. When installing the battery, connect the ground cable last.

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OPERATION

TROUBLESHOOTING

PRECAUTIONS WHEN CHARGING BATTERY When the charging the battery, if the battery is mistakenly handled, there is danger of explosion. Follow the precautions in "IF BATTERY IS DISCHARGED (PAGE 3-129)" and the instructions given in the charger manual, and always do as follows. 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 carrying out rapid charging, set it to less than the rated battery capacity. If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery to catch fire and explode. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is 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 the LOWER LEVEL line. This may cause an explosion. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level to the UPPER LEVEL line.

STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows.

PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE

WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, wear safety glasses 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 body.

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 the LOCK position. Check that each lever is in the NEUTRAL position.

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OPERATION

TROUBLESHOOTING

CONNECTING THE BOOSTER CABLES Keep the starting switch of the normal machine and problem machine in the OFF position. Connect the booster cable as follows, in the order of the numbers marked in the diagram. 1. Connect one clip of booster cable (A) to the positive (+) terminal of the problem machine. 2. Connect the other clip of booster cable (A) to the positive (+) terminal of the normal machine. 3. Connect one clip of booster cable (B) to the negative (-) terminal of the normal machine. 4. Connect the other clip of booster cable (B) to the engine block of the problem machine.

STARTING THE ENGINE

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 speed. 3. Turn the starting switch of the problem machine to the START position and start the engine. If the engine doesn't start at first, try again after 2 minutes or so.

DISCONNECTING THE BOOSTER CABLES After the engine has started, disconnect the booster cables in the reverse of the order in which they were connected. 1. Remove one clip of booster cable (B) from the engine block of the problem machine. 2. Remove the other clip of booster cable (B) from the negative (-) terminal of the normal machine. 3. Remove one clip of booster cable (A) from the positive (+) terminal of the normal machine. 4. Remove the other clip of booster cable (A) from the positive (+) terminal of the problem machine.

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OPERATION

TROUBLESHOOTING

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, contact your Komatsu distributor for repairs.

Problem

Main causes

Lamp does not glow brightly even when the engine runs at high speed

Defective wiring

Lamp flickers while engine is running

Defective adjustment of fan belt tension

Charge lamp do not go out even when engine is running

Remedy (

Check, repair loose terminals, disconnection) Check fan belt wear, replace For details, see EVERY 250 HOURS SERVICE

Defective lamp Defective alternator Defective wiring

( ( (

Replace) Replace) Check, repair)

Abnormal noise is generated from alternator

Defective alternator

(

Replace)

Starting motor does not turn when starting switch is turned to ON

Defective wiring Insufficient battery charge Defective starting motor

Check, repair) Charge ( Replace)

Pinion of starting motor keeps going in and out

Insufficient battery charge

Starting motor turns engine sluggishly

Insufficient battery charge Defective starting motor

Starting motor disengages before engine starts

Defective wiring Insufficient battery charge

(

Check, repair) Charge

Preheating monitor does not goes out

Defective wiring Defective heater relay Defective monitor

( ( (

Check, repair) Replace) Replace)

Charge lamp does not light up while engine is stopped (with starting switch at ON position)

Defective monitor Defective wiring

( (

Replace) Check, repair)

Outside of electrical intake air heater is not warm when touched by hand

( Defective wiring Disconnection in electrical intake ( air heater ( Defective operation of heater relay switch intake air heater

Check, repair) Replace)

3 - 132

(

Charge

(

Charge Replace)

Replace heater relay switch)

.

OPERATION

TROUBLESHOOTING

CHASSIS ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.

Problem Even when engine is running, machine does not move

Main causes

( (

Wear, scuffing of transmission pump Leakage of oil from oil line Clogged transmission filter element

(

Defective operation of transmission, control valve Defective return of parking brake Even when engine is run at full throttle, machine moves slowly, lacks power

Remedy

Gearshift lever has not been shifted properly Gouging of lever linkage Transmission oil pressure does not rise Lack of oil in transmission case

Lack of oil in transmission

Clogged transmission oil filter cartridge Defective return of parking brake Improper adjustment of engine

Shift lever properly Check, repair) Check, adjust)

Add oil to specified level For details, see EVERY 250 HOURS SERVICE ( Check, replace) Check, repair) Clean, replace For details, see EVERY 1000 HOURS SERVICE ( Check, repair)

(

Check, repair)

Add oil to specified level For details, see EVERY 250 HOURS SERVICE Clean, replace For details, see EVERY 1000 HOURS SERVICE ( Check, repair) ( Check, repair)

More noise than usual is generated from power train

Lack of oil in transmission case, tandem case

Add oil to specified level For details, see EVERY 250 HOURS SERVICE

Final drive oil temperature lamp on machine monitor flashes

Lack of oil in final drive case

Add oil to specified level For details, see EVERY 250 HOURS SERVICE Stop using differential until oil temperature goes down

Differential has been operated for a long time Abnormal wear of front tires

Incorrect adjustment of toe-in

Adjust. For details, see EVERY 1000 HOURS SERVICE Check, adjust

Lack of inflation pressure Heat generated from front wheel hub Front wheels wobble when traveling

Loose bearing preload adjustment nut for front wheel Lack of grease Incorrect adjustment of toe-in, loose tie rod

(

Check, adjust [adjust bearing preload]) Supply grease Adjust. For details, see EVERY 1000 HOURS SERVICE Inflate tires to same air pressure Install again. For details, see HANDLING TIRES

(

Adjust)

Inflation pressure of left and right tires not same Wheel not properly installed Steering wheel is heavy

Defective Orbit-roll

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.

OPERATION

TROUBLESHOOTING

Problem Even when brake pedal is depressed, braking effect is poor

Poor braking effect of parking brake Blade moves up and down excessively during operation

Main causes Wear of disc Air leakage in brake piping Seizure of disc Defective piston seal Wear of brake pad Play in lift cylinder ball joint

Excessive clearance between sliding surface of circle and drawbar Worn blade rail guide bushing

Remedy ( ( ( ( (

Check, replace) Check, repair) Check, repair) Replace) Check, replace) Adjust shim. For details, see EVERY 250 HOURS SERVICE Adjust shim at circle guide connector. For details, see EVERY 500 HOURS SERVICE Replace guide bushing, shim Correct blade rail

Rotation of blade during operation is excessive

Excessive clearance in circle in radial direction

Adjust position of guide connector. For details, see EVERY 500 HOURS SERVICE

Work equipment does not move properly when work equipment control lever is operated

Lack of oil

Add oil to specified level For details, see EVERY 250 HOURS SERVICE

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.

OPERATION

TROUBLESHOOTING

ENGINE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.

Problem

Main causes

After warming-up operation, engine oil pressure monitor lights up even when engine speed is raised

Oil level in engine oil pan is low (sucking in air) Clogged oil filter element

Leakage of oil due to damage, defective tightening of oil pipe, pipe joint Defective monitor Defective oil pressure switch Diluted with fuel, water Defective pressure adjustment valve Steam spurts out from top of radiator (pressure valve)

Lack of coolant, leakage of coolant Loose fan belt

Dirt or scale accumulated in cooling system Engine water temperature gauge on machine monitor flashes in red range

Radiator fins clogged or bent

Defective thermostat Loose radiator filler cap (high altitude operations) Defective coolant temperature gauge Engine does not start when starting motor is turned

Lack of fuel Air in fuel system Defective fuel injection pump or nozzle Starting motor cranks engine sluggishly Preheating monitor does not light up Defective compression Defective valve clearance

Remedy Add oil to specified level For details, see CHECK BEFORE STARTING Replace cartridge For details, see EVERY 250 HOURS SERVICE ( Check, repair)

( ( ( (

Replace) Replace) Check, repair) Check valve, replace spring)

Check, add coolant, repair cooling system. For details, see WHEN REQUIRED Adjust tension For details, see EVERY 250 HOURS SERVICE Change coolant, clean cooling system For details, see WHEN REQUIRED Clean or repair For details, see EVERY 500 HOURS SERVICE ( Replace thermostat) Tighten cap or replace packing ( Replace) Add fuel. For details, see CHECK BEFORE STARTING ( Repair place where air is sucked in) ( Replace pump or nozzle) See ELECTRICAL SYSTEM See ELECTRICAL SYSTEM (

Adjust clearance)

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.

OPERATION

TROUBLESHOOTING

Problem Exhaust gas is white or blue

Main causes

Remedy

Too much oil in oil pan

Reduce oil to specified level For details, see CHECK BEFORE STARTING Add fuel. For details, see CHECK BEFORE STARTING Change to specified fuel

Lack of fuel

Improper fuel Exhaust gas sometimes turns black

Clogged air cleaner element

Defective turbocharger

Clean or replace. For details, see WHEN REQUIRED ( Replace nozzle) ( See "Defective compression" above) ( Wash or replace turbocharger)

Combustion noise occasionally makes breathing sound

Defective nozzle

(

Abnormal noise generated (fuel system or mechanical system)

Low-grade fuel being used Overheating

Change to specified fuel See "Engine coolant temperature gauge is in red range top" Replace muffler ( Adjust clearance)

Defective nozzle Defective compression

Damage inside muffler Excessive valve clearance

3 - 136

Replace nozzle)

.

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.

FAILURE CODE DISPLAY ON TRANSMISSION CONTROLLER When the starting switch is turned to the ON position, the transmission controller displays the failure codes as follows. 1. Display after starting switch is turned to ON position 1) To make it possible to check the LED, it displays "88" for 5 seconds. 2) To distinguish from the next display, ". " is displayed for 0.5 seconds. 3) CHECK SUM (controller version) is displayed for 3 seconds.

2. Displays past failure history Each failure code that occurred in the past is displayed in turn once.

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. TROUBLESHOOTING

1) To distinguish from the next display, ". " is displayed for 0.5 seconds. 2) The past failure codes are displayed for 3 seconds. If these failure codes are reset, they will not be displayed in future. Please ask your Komatsu distributor to carry out the resetting.

3. Displays existing failure history The failure codes for existing failures are displayed in turn once. If there is no existing failure, "00" is displayed for 3 seconds. 1) To distinguish from the next display, "E " is displayed for 0.5 seconds. 2) The existing failure codes are displayed for 3 seconds.

4. Displays number of recorded past abnormal operations 1) To distinguish from the next display, "- " is displayed for 0.5 seconds. 2) Displays abnormal operation codes for 3 seconds. 3) Displays the gear shifting pattern at the time of abnormal operation for 3 seconds. (If the code has no record for each transmission clutch, this is omitted.) 4) Displays number of abnormal operations for 3 seconds.

5. Display after completion of display in Step 4 1) If there is an existing failure, the display in Step 3 is repeated. If there is no existing failure, "0.0." Is displayed.

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OPERATION

.

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 operation code

Content of abnormal operation

10

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 according to travel speed Caution is issued until it reaches speed range selected by lever position (from 1 sec after lever operation)

11

12

Lamp Buzzer

When shifting N -> F (R) when machine is traveling at more than 4 km/h (2.5 MPH) Caution issued (for 5 sec after lever operation) When transmission is shifted to F4 (R4) or above when engine speed is more than 350 rpm and travel speed is less than 2 km/h (1.2 MPH) Caution issued Inching time (sec)

Clutch

F 13

0 - 10 R

F

14

Caution

Record

10 - 30

R

Category

{

{

{

{

{

-

{

{

{

{

-

-

{

{

{

Plate calculated temperature ( °C (°F))

1

200 - 230 (392 - 446)

2

230 - 260 (446 - 500)

3

260 - 290 (500 - 554)

4

290 (554) or above

1

200 - 230 (392 - 446)

2

230 - 260 (446 - 500)

3

260 - 290 (500 - 554)

4

290 (554) or above

0

200 (392) or below

1

200 - 230 (392 - 446)

2

230 - 260 (446 - 500)

3

260 - 290 (500 - 554)

4

290 (554) or above

0

200 (392) or below

1

200 - 230 (392 - 446)

2

230 - 260 (446 - 500)

3

260 - 290 (500 - 554)

4

290 (554) or above

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.

OPERATION

TROUBLESHOOTING

Abnormal operation code

Content of abnormal operation

Lamp Buzzer

F

0

200 (392) or below

1

200 - 230 (392 - 446)

2

230 - 260 (446 - 500)

3

260 - 290 (500 - 554)

4

290 (554) or above

0

200 (392) or below

1

200 - 230 (392 - 446)

2

230 - 260 (446 - 500)

3

260 - 290 (500 - 554)

4

290 (554) or above

{

{

{

16

Caution issued when engine is running at high speed Caution lamp lights up when engine is operated continuously for 5 sec. at 2525 rpm or more Alarm buzzer sounds when engine is operated continuously for 10 sec. at 2525 rpm or more

{

{

{

17

Acceleration when inching pedal is depressed (exceeding hydraulic control range) Caution lamp if more than max speed for speed range selected by lever position At above danger speed, shift up and caution buzzer

{

{

{

18

Time that lubricating oil temperature is above 120 °C (248 °F) Caution issued after more than 30 seconds

{

{

{

19

Time that lever position is at N and 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

{

-

-

1A

Lever position at F (R) and inching pedal depressed (exceeding hydraulic control range) 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

{

-

-

15

30 or above

R

3 - 140

Caution

Record

.

4-1

. GUIDES TO MAINTENANCE

MAINTENANCE

GUIDES TO MAINTENANCE Do not perform any inspection and maintenance operation that is not found in this manual. Check service meter: Check the service meter reading every day to see if the time has come for any necessary maintenance to be performed. Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: For lubrication of the machine, use the Komatsu genuine lubricants. Moreover use oil of the specified viscosity according to the ambient temperature. Always use clean washer fluid: Use automobile window washer fluid, and be careful not to let any dirt get into it. Clean oil and grease: Use clean oil and grease. Also, keep the containers of the oil and grease clean. Keep foreign materials away from oil and grease. Checking foreign material in drained oil: After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If large quantity of metal particles or foreign materials are found, always report to the person in charge, and carry out suitable action. Be careful of hot water and oil: If your machine is equipped with a fuel strainer, do not remove it while fueling. Welding instructions: Turn off the engine starting switch. Do not apply more than 200 V continuously. Connect grounding cable within 1 m (3.3 ft) 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. Objects in your pockets: When opening inspection windows or the oil filler port of the tank to carry out inspection, be careful not to drop nuts, bolts, or tools inside the machine. If such things are dropped inside the machine, it may cause damage and/or malfunction of the machine, and will lead to failure. If you drop anything inside the machine, always remove it immediately. Do not put unnecessary things in your pockets. Carry only things which are necessary for inspection.

4-2

.

MAINTENANCE

GUIDES TO MAINTENANCE

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. Avoid mixing oils: If a different brand or grade of oil has to be added, drain the old oil and replace all the oil with the new brand or grade of oil. Never mix different brand or grade of oil. Locking inspection covers: Lock inspection cover securely into position with the lock bar. If inspection or maintenance is performed with inspection cover not locked in position, there is a danger that it may be suddenly blow shut by the wind and cause injury to the worker. Bleeding air from hydraulic circuit: It is necessary to bleed the air from the circuit if the hydraulic equipment has been repaired, replaced, or the hydraulic piping has been removed. Precautions when installing hydraulic hoses: When removing parts at locations where there are O-rings or gasket seals, clean the mounting surface, and replace with new parts. When doing this, be careful not to forget to assemble the O-rings and gaskets. When installing the hoses, do not twist them or bend them sharply. If they are installed so, their service life will be shortened extremely and they may be damaged. Checks after inspection and maintenance: If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injury or property damage. Always do the following: Checks after operation (with engine stopped) Have any inspection and maintenance points been forgotten? Have all inspection and maintenance items been performed correctly? Have any tools or parts been dropped inside the machine? It is particularly dangerous if parts are dropped inside the machine and get caught in the lever linkage mechanism. Are there any leakage of coolant or oil? Have all nuts and bolts been tightened? Checks when operating engine For details of the checks when operating the engine, see "TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING (PAGE 2-32)" and pay careful attention to safety. Are the inspection and maintenance items working properly? Is there any leakage of oil when the engine speed is raised and load is applied to the oil pressure? Is there any leakage of oil or fuel when the engine speed is raised?

4-3

. OUTLINES OF SERVICE

MAINTENANCE

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 amount of oil. Having too much oil or too little oil are both causes of problems. If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases, please contact 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, please contact your Komatsu distributor.

FUEL The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly. Be extremely careful not to let impurities get in when storing or adding fuel. Always use the fuel specified in the Operation and Maintenance Manual. Fuel may congeal depending on the temperature when it is used (particularly in low temperature below -15°C (5 °F)). It is necessary to use the fuel that is suitable for the 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.

COOLANT River water contains large amount of calcium and other impurities, so if it is used, scale will stick to the engine and radiator, and this will cause defective heat exchange and overheating. Do not use water that is not suitable for drinking. When using antifreeze, always observe the precautions given in the Operation and Maintenance Manual. Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze is effective in preventing corrosion of the cooling system. For details of the anti-freeze, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-17)". Antifreeze is flammable, so be extremely careful not to expose it to flame or fire. The proportion of anti-freeze to water differs according to the ambient temperature. For details of the mixing proportions, see "CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-17)". If the engine overheats, wait for the engine to cool before adding coolant. If the coolant level is low, it will cause overheating, and will also cause problems with corrosion due to air entering the coolant.

4-4

.

MAINTENANCE

OUTLINES OF SERVICE

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.

CARRYING OUT KOWA (Komatsu Oil Wear Analysis) The Komatsu oil clinic samples the oil periodically and analyzes it. This is a preventive maintenance service, which provides early discovery of abnormal parts and wear of the drive parts of the machine. This then makes it possible to ensure prevention of failures and reduction in downtime. Komatsu's long years of experience and rich supply of accumulated data make it possible to accurately determine the condition of your machine. This enables us to locate the problems and to recommend suitable and timely repair methods. The oil clinic charges the customer only the actual costs, and provides an immediate report of the results of the analysis and recommendations for action to take, so we strongly recommend you to avail yourself of this service.

KOWA ANALYSIS ITEMS Measurement of density of metal wear particles This uses an ICP (Inductively Coupled Plasma) analyzer to measure the density of iron, copper, and other metal wear particles in the oil.

Measurement of quantity of particles This uses a PQI (Particle Quantifier Index) measurer to measure the quantity of iron particles of 5µm or more, enabling early detection of failures.

Others Measurements are made of items such as the ratio of water in the oil, density of the antifreeze coolant, ratio of fuel in the oil, and dynamic viscosity, enabling a highly precise diagnosis of the machine's health.

4-5

. OUTLINES OF SERVICE

MAINTENANCE

OIL SAMPLING Sampling interval 250 hours: Engine 500 hours: Other components 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, please contact your Komatsu distributor.

STORING OIL AND FUEL Keep indoors to prevent any water, dirt, or other impurities from getting in. When keeping drum cans for a long period, put the drum on its side so that the filler port of the drums is at the side to prevent moisture from being sucked in. If drums have to be stored outside, cover them with a waterproof sheet or take other measures to protect them. To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use the oldest oil or fuel first).

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, contact your Komatsu distributor. Do not open packs of spare filters until just before they are to be used. Always use Komatsu genuine filters.

RELATING TO ELECTRIC SYSTEM It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This will cause an electrical short circuit and may lead to malfunction of the machine. Do not wash the inside of the operator's cab with water. When washing the machine, be careful not to let water get into the electrical components. Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor. When working at the seashore, carefully clean the electric system to prevent corrosion. When installing an operator's cab cooler or any other electrical equipment, connect it to an independent power source connector. The cables to supply power to the optional equipment must never be connected to the fuse, starting switch, or battery relay.

4-6

.

MAINTENANCE

WEAR PARTS

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 changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book.

WEAR PARTS LIST The parts in parentheses are to be replaced at the same time.

Item

Part No.

Part Name

Q'ty

Replacement interval

Engine oil filter

600-211-1231

Cartridge

1

Every 250 hours

Fuel filter

600-311-7132

Cartridge

1

Every 500 hours

Corrosion resister

600-411-1151

Cartridge

1

Every 1000 hours

Transmission oil filter Hydraulic filter Strainer for emergency steering (if equipped)

424-16-11140 (424-16-11130) (424-16-11630) 234-60-31330 205-60-51450

235-832-2110 Strainer (235-832-2120) (O-ring) 6128-81-7043 600-181-4401

Air cleaner

Element (O-ring) (O-ring) Return filter element Suction strainer

Element ass'y Outer element ass'y

1 (1) (2) 1 1

Every 1000 hours Every 1000 hours

1 (1)

Every 1000 hours

1 1

-

235-70-12320 234-70-32230 (234-70-32260) (234-70-32270) (234-70-32290) (01643-32060) 235-70-12140 234-70-32230 234-70-32240 (234-70-32260) (234-70-32270) (234-70-32280) (234-70-32290) (01643-32060) (235-70-12330) 235-785-1310 (09244-02516)

Edge Side edge (Bolt) (Bolt) (Nut) (Washer) Edge Side edge End bit (Bolt) (Bolt) (Bolt) (Nut) (Washer) (Bolt) Point (Pin)

2 2 (8) (36) (44) (44) 2 2 2 (2) (34) (2) (44) (44) (6) 3 (3)

Circle guide

235-70-41190 235-70-11431

Wear plate Wear plate

6 6

-

Blade

235-70-42210

Rail guide

4

-

Air drier (desiccant)

235-44-11781

Service kit

1

Every year or every 1000 hours, whichever comes sooner

Straight edge

Blade

Curved edge

Ripper

-

-

-

4-7

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

MAINTENANCE

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE

4-8

.

MAINTENANCE

Reservoir

Engine oil pan

Transmission case

Final drive case

Liters

38

35

63

120

US gal

10.04

9.25

16.64

Liters

34

25

US gal

8.98

6.61

Capacity Specified

Refill


Tandem Blade drive case rotation gear (each) case

Hydraulic system

Front axle housing

Fuel tank

Cooling system

10

140

0.9

500

58

31.70

2.64

36.99

0.24

132.10

15.32

57

95

8

80

0.9

-

-

15.06

25.10

2.11

21.14

0.24

-

-

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. Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers API: American Petroleum Institute

Fuel sulfur content

Engine oil change interval

0.5 to 1.0%

1/2 of regular interval

Above 1.0%

1/4 of regular interval

4-9

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

No.

Supplier

Engine Oil [CD or CE] SAE10W, 30, 40 10W30, 15W40 (The 15W40 oil marked * is CE.)

Gear Oil [GL-4 or GL-5] SAE80, 90, 140

Grease [Lithium-Base] NLGI No.2

MAINTENANCE

Anti-freeze Coolant [Ethylene Glycol Base] Permanent Type

KOMATSU

EO10-CD EO30-CD EO10-30CD EO15-40CD

GO90 GO140

G2-LI G2-LI-S

2

AGIP

Diesel sigma S super dieselmultigrade *Sigma turbo

Rotra MP

GR MU/EP

-

3

AMOCO

*Amoco 300

Multi-purpose gear oil

PYKON premium grease

-

4

ARCO

*Arcofleet S3 pius

Arco HD gear oil

Litholine HEP 2 Arco EP moly D

-

5

BP

Vanellus C3

Gear oil EP Hypogear EP

Energrease LS-EP2

6

CALTEX

*RPM delo 400 RPM delo 450

Universal thuban Marfak all purpose 2 Universal thuban EP Ultra-duty grease 2

AF engine coolant

7

CASTROL

*Turbomax *RX super CRD

EP EPX Hypoy Hypoy B Hypoy C

MS3 Spheerol EPL2

Anti-freeze

8

CHEVRON *Delo 400

Universal gear

Ultra-duty grease 2

-

9

CONOCO

Universal gear lubricant

Super-sta grease

-

1

10 ELF

*Fleet motor oil Multiperformance 3C Performance 3C

-

AF-ACL AF-PTL AF-PT(Winter, one season type)

Antifreeze

Tranself EP Tranself EP type 2

Glacelf

Essolube D3 *Essolube XD-3 *Essolube XD-3 Extra *Esso heavy duty Exxon heavy duty

Gear oil GP Gear oil GX

Beacon EP2

All season coolant

12 GULF

Super duty motor oil *Super duty plus

Multi-purpose gear lubricant

Gulfcrown EP2 Gulfcrown EP special

Antifeeze and coolant

13 MOBIL

Delvac 1300 *Delvac super 10W-30, 15W-40

Mobilube GX Mobilube HD

Mobilux EP2 Mobilgease 77 Mobilgrease special

11

4 - 10

EXXON (ESSO)

-

.

MAINTENANCE

No.

Supplier


Engine Oil [CD or CE] SAE10W, 30, 40 10W30, 15W40 (The 15W40 oil marked * is CE.)

*Superme duty 14 PENNZOIL fleet motor oil 15

PETROFIN FINA kappa TD E

16 SHELL

Rimura X

17 SUN

-

Gear Oil [GL-4 or GL-5] SAE80, 90, 140

Grease [Lithium-Base] NLGI No.2

Anti-freeze Coolant [Ethylene Glycol Base] Permanent Type

Multi-purpose 4092 Multi-purpose 4140

Multi-purpose white grease 705 707L White-bearing grease

Anti-freeze and summer coolant

FINA potonic N FINA potonic NE

FINA marson EPL2

FINA tamidor

Spirax EP Spirax heavy duty

Albania EP grease

-

Sunoco GL5 gear oil

Sunoco ultra prestige 2EP Sun prestige 742

Sunoco antifreeze and summer coolant

18 TEXACO

*Ursa super plus Ursa premium

Multigear

Multifak EP2 Starplex 2

Coda 2055 startex antifreeze coolant

19 TOTAL

Rubia S *Rubia X

Total EP Total Transmission TM

Multis EP2

Antigal/antifreeze

20 UNION

*Guardol

MP gear lube LS

Unoba EP

21 VEEDOL

*Turbostar *Diesel star MDC

Multigear Multigear B Multigear C

-

Antifreeze

4 - 11

.

MAINTENANCE

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS TORQUE LIST

CAUTION If nuts, bolts, or other parts are not tightened to the specified torque, it will cause looseness or damage to the tightened parts, and this will cause failure of the machine or problems with operation. Always pay careful attention when tightening parts.

Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. 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.

Thread diameter of bolt (a)(mm)

Width across flats (b)(mm)

Nm

kgm

lbft

Nm

kgm

lbft

6 8 10 12 14

10 13 17 19 22

13.2 31 66 113 177

1.35 3.2 6.7 11.5 18

9.8 23.1 48.5 83.2 130.2

11.8-14.7 27-34 59-74 98-123 157-196

1.2-1.5 2.8-3.5 6.0-7.5 10.0-12.5 16.0-20.0

8.7-10.8 20.3-25.3 43.4-54.2 72.3-90.4 115.7-144.7

16 18 20 22 24

24 27 30 32 36

279 382 549 745 927

28.5 39 56 76 94.5

206.1 282.1 405.0 549.7 683.5

245-309 343-425 490-608 662-829 824-1030

25.0-31.5 35.0-43.5 50.0-62.0 67.5-84.5 84.0-105.0

180.8-227.8 253.2-314.6 361.7-448.4 488.2-611.2 607.6-759.5

27 30 33 36 39

41 46 50 55 60

1320 1720 2210 2750 3280

135.0 175.0 225.0 280.0 335.0

976.5 1265.8 1627.4 2025.2 2423.1

1180-1470 1520-1910 1960-2450 2450-3040 2890-3630

120.0-150.0 155.0-195.0 200.0-250.0 250.0-310.0 295.0-370.0

868.0-1085.0 1121.1-1410.4 1446.6-1808.3 1808.3-2242.2 2133.7-2676.2

Tightening torque Target value

Service limit

Apply the following table for Hydraulic Hose.

Thread diameter a (mm)

Width across flats b (mm)

Nm

kgm

lbft

Nm

kgm

lbft

10

14

14.7

1.5

10.8

12.7 - 16.7

1.3 - 1.7

9.4 - 12.3

14

19

29.4

3.0

21.7

27.5 - 39.2

2.8 - 4.0

20.3 - 28.9

18

24

78.5

8.0

57.9

58.8 - 98.1

6.0 - 10.0

43.4 - 72.3

88.3 - 137.3

Tightening torque Target value

Permissible range

22

27

117.7

12.0

86.6

9.0 - 14.0

65.1 - 101.3

24

32

147.1

15.0

108.5 117.7 - 176.5 12.0 - 18.0

86.8 - 130.2

30

36

215.7

22.0

159.1 176.5 - 245.2 18.0 - 25.0

130.2 - 180.8

33

41

255.0

26.0

188.1 215.7 - 284.4 22.0 - 29.0

159.1 - 209.8

4 - 12

.

MAINTENANCE

PERIODIC REPLACEMENT OF CRITICAL PARTS

PERIODIC REPLACEMENT OF CRITICAL PARTS To ensure safety at all times when operating or driving the machine, the user of the machine must always carry out periodic maintenance. In addition, to further improve safety, the parts in the safety-critical parts list on the next page must also be replaced at the specified interval. These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance. Hence, it is required to replace them with new ones regardless of their condition after a certain period of usage. This is important to ensure that these parts maintain their full performance at all times. Furthermore, should anything abnormal be found on any of these parts, replace it with a new one even if the periodic replacement time for the part has not yet arrived. If any of the hose clamps show deterioration like deformation or cracking, replace the clamps at the same time as the hoses. Also perform the following checks with hydraulic hoses which need to be replaced periodically. Tighten all loose clamps and replace defective hoses, as required. When replacing hoses, always replace O-rings, gaskets, and other such parts at the same time.

CRITICAL PARTS No.

Safety critical parts for periodic replacement

Q'ty

1

Fuel hose (fuel tank - fuel injection pump)

1

2

Fuel hose (fuel injection pump - fuel filter)

2

3

Fuel return hose (fuel injection pump - fuel tank)

1

4

Spill hose (between nozzles)

2

5

Fuel spill hose (nozzle - fuel tank)

1

6

Turbocharger lubricating hose

1

7

O-ring for brake disc piston

8

8

O-ring for steering valve

8

9

Steering circuit hose

16

10

Brake valve rubber parts

16

11

Rubber hose for leaning cylinder

2

12

Brake hose

13

13

O-ring for steering cylinder

7

14

Seat belt

1

Replacement interval

Every 2 years or every 4000 hours, whichever comes sooner

Every 3 years

4 - 13

. MAINTENANCE SCHEDULE CHART

MAINTENANCE

MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (only after the first 250 hours) REPLACE FUEL FILTER CARTRIDGE CHANGE OIL IN TRANSMISSION CASE CHANGE OIL IN FINAL DRIVE CASE CHANGE OIL IN CIRCLE REVERSE GEAR CASE CHANGE OIL IN HYDRAULIC TANK REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK CHANGE OIL IN TANDEM DRIVE CASE CHECK CIRCLE GUIDE CLEARANCE, ADJUST CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR CHECK ENGINE VALVE CLEARANCE, ADJUST

4444444444-

42 52 53 59 55 54 60 44 48 62

WHEN REQUIRED CLEAN INSIDE OF COOLING SYSTEM CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT CHECK ELECTRICAL INTAKE AIR HEATER REVERSE AND REPLACE THE END BITS AND CUTTING EDGES REPLACING RIPPER POINT CHECK INCHING PEDAL CLEAN ELEMENT OF AIR CONDITIONER FRESH AIR FILTER CLEAN ELEMENT OF AIR CONDITIONER RECIRCULATION AIR FILTER CHECK REFRIGERANT (GAS) LEVEL SELECTION AND INSPECTION OF TIRES INSPECTING CORROSION, WEAR OF WHEEL RIM, LOCK RING, SIDE RING

44444444444-

17 19 21 21 22 22 22 23 24 25 26

CHECK BEFORE STARTING EVERY 50 HOURS SERVICE LUBRICATING INSPECT WEAR OF BLADE GUIDE

4- 28 4- 28

EVERY 250 HOURS SERVICE LUBRICATING CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL CHECK LEVEL OF BATTERY ELECTROLYTE CHECK BALL JOINT CLEARANCE, ADJUST CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT CHECK FAN BELT TENSION, ADJUST CHECK ALTERNATOR BELT TENSION, ADJUST CHECK AIR CONDITIONER BELT TENSION, ADJUST CHECK, ADJUST FOOT BRAKE

44444444444444-

4 - 14

29 31 32 33 33 34 34 35 37 37 38 39 40 41

.

MAINTENANCE

MAINTENANCE SCHEDULE CHART

EVERY 500 HOURS SERVICE REPLACE FUEL FILTER CARTRIDGE CLEAN, CHECK RADIATOR FINS CHECK CIRCLE GUIDE CLEARANCE, ADJUST CHECK PARKING BRAKE LEVEL STROKE, ADJUST CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR

44444-

42 43 44 47 48

EVERY 1000 HOURS SERVICE GREASE DRIVE SHAFT GREASE FAN PULLEY AND TENSION PULLEY REPLACE TRANSMISSION OIL FILTER ELEMENT CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER CHANGE OIL IN FINAL DRIVE CASE, CLEAN STRAINER REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK CHANGE OIL IN HYDRAULIC TANK CHECK LOOSENESS IN DRAWBAR FRONT BALL JOINT AND BALL STUD CHECK TOE-IN, ADJUST CHECK FRONT WHEEL BEARING PLAY, ADJUST REPLACE CORROSION RESISTOR CARTRIDGE CHECK FOR LOOSE ROPS MOUNT BOLTS REPLACING AIR DRYER DESICCANT

4444444444444-

50 50 51 52 53 54 55 56 56 57 58 58 58

EVERY 2000 HOURS SERVICE CHANGE OIL IN FRONT WHEEL BEARING CHANGE OIL IN CIRCLE REVERSE GEAR CASE CHANGE OIL IN TANDEM DRIVE CASE CLEAN ENGINE BREATHER ELEMENT CLEAN BREATHER CLEAN AND INSPECT INCHING POTENTIOMETER SENSOR CHECK ALTERNATOR, STARTING MOTOR CHECK ENGINE VALVE CLEARANCE, ADJUST CHECK ALL TIGHTENING PARTS OF TURBOCHARGER CHECK PLAY OF TURBOCHARGER ROTOR CLEAN, CHECK TURBOCHARGER

44444444444-

59 59 60 60 61 62 62 62 62 62 62

EVERY 4000 HOURS SERVICE CHECK WATER PUMP CHECK VIBRATION DAMPER CHECK FAN PULLEY AND TENSION PULLEY

4- 63 4- 63 4- 63

4 - 15

. SERVICE PROCEDURE

MAINTENANCE

SERVICE PROCEDURE INITIAL 250 HOURS SERVICE (only after the first 250 hours) Carry out the following maintenance only after the first 250 hours of operation on new machines. REPLACE FUEL FILTER CARTRIDGE CHANGE OIL IN TRANSMISSION CASE CHANGE OIL IN FINAL DRIVE CASE CHANGE OIL IN CIRCLE REVERSE GEAR CASE CHANGE OIL IN HYDRAULIC TANK REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK CHANGE OIL IN TANDEM DRIVE CASE CHECK CIRCLE GUIDE CLEARANCE, ADJUST CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR CHECK ENGINE VALVE CLEARANCE, ADJUST For details of the method of replacing or maintaining, see EVERY 500 HOURS, EVERY 1000 HOURS and EVERY 2000 HOURS SERVICE.

4 - 16

.

MAINTENANCE

SERVICE PROCEDURE

WHEN REQUIRED CLEAN INSIDE OF COOLING SYSTEM

WARNING Immediately after the engine is stopped, the coolant is at high temperature and the radiator is under internal pressure. If the cap is removed and the coolant trained under these conditions, it will cause burns. Always wait for the temperature to go down, then turn the cap slowly to release the pressure. The washing operation is carried out with the engine running. When standing up or leaving the operator's seat, always place the speed lever at the P (parking) position. For details of starting the engine, see "CHECK BEFORE STARTING ENGINE (PAGE 3-44)" and "STARTING ENGINE (PAGE 3-59)". There is danger of touching the fan if the cover is left removed. When the engine is running, never enter the area at the rear of the machine.

Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the table below. Cleaning inside of cooling system and changing coolant Every year (autumn) or every 2000 hours, whichever comes first Every 6 months (spring, autumn) (Drain antifreeze in spring, add antifreeze in autumn) Every 6 months or every 1000 hours, whichever come first

Kind of coolant Permanent type antifreeze (All season type) Non permanent type antifreeze containing ethylene glycol (winter, one season type) When not using antifreeze

Replacing corrosion resistor

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

Stop the machine on level ground when cleaning or changing the coolant. Use a permanent type of antifreeze. If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol. The proportion of the mixture differs according to the ambient temperature, but to obtain the corrosion resistance effect, a minimum of 30% by volume is necessary. When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing rate table given below. It is actually better to estimate a temperature about 10°C (18°F) lower when deciding the mixing rate. Mixing rate of water and antifreeze Min. ambient temperature Amount of antifreeze Amount of water

°C

Above -10

-15

-20

-25

-30

°F

Above 14

5

-4

-13

-22

Liters

17.5

21.0

24.0

27.0

29.0

US gal

4.62

5.55

6.34

7.13

7.66

Liters

40.5

37.0

34.0

31.0

29.0

US gal

10.70

9.77

8.98

8.19

7.66

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WARNING Antifreeze coolant is flammable, so keep it away from flame. Antifreeze coolant is toxic. When removing the drain plug, be careful not to get water containing antifreeze coolant on you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.

Use city water for the coolant. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions. 1. Stop the engine and turn radiator cap (1) slowly to remove it. 2. Tighten corrosion resistor cartridge (2) of valve (3).

3. Set a container in position to catch the coolant, then open drain valve (4) at the bottom of the radiator and drain plug (5) at the side face of the cylinder block, and drain the water. 4. After draining the water, close drain valve (4) and drain plug (5), and fill with city water. 5. When the radiator is full, start the engine, and run it at low idle. Keep the engine running at low idle for 10 minutes until the coolant temperature reaches more than 90°C (194°F). 6. Stop the engine, open drain valve (4) and drain plug (5), and drain the water. 7. After draining the water, clean the cooling system with cleaning agent. For the cleaning method, see the instructions for the cleaning agent. 8. Close drain valve (4) and drain plug (5). 9. Replace corrosion resistor (2), then open valve (3). For details of the procedure for replacing the corrosion resistor, see "REPLACE CORROSION RESISTOR CARTRIDGE (PAGE 4-58)". 10. Add coolant until it overflows from the water filler. Decide the proportions of antifreeze and water according to the table for the mixing rate of water and antifreeze. 11. To remove air in the cooling system, run the engine for 5 minutes at low idle, then for 5 minutes at high idle. (While doing this, leave the radiator cap removed.) 12. Stop the engine. About 3 minutes later, supply city water up to the water filler, then close radiator cap.

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13. Drain the coolant inside sub-tank (6), clean the inside of the sub-tank, then fill again with cooling water to a point midway between the FULL and LOW marks.

CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT

WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury. Always use protective glasses, dust mask, and other protective equipment.

NOTICE Do not clean the air cleaner element before the dust indicator becomes red. If the element is cleaned frequently before the dust indicator becomes red, the performance of the air cleaner is not used perfectly and the cleaning effect is lowered. In addition, dust sticking to the element falls into the inner element each time the element is cleaned.

CHECKING Clean the air clearner element if the dust indicator (1) shows red.

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. SERVICE PROCEDURE

CLEANING OR REPLACING OUTER ELEMENT 1. Loosen wing bolt (2), remove cover (3) and the outer element. 2. Clean the air cleaner body interior and the cover.

3. Direct dry compressed air (Max. 0.69 MPa (7 kg/cm2, 99.4 PSI)) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside. 1) Remove one seal from the element whenever the element has been cleaned. 2) Replace the outer element if it has been cleaned 6 times repeatedly or used throughout a year. Replace the inner element at the same time. 3) If the dust indicator shows red immediately after the outer element has been cleaned, replace both the inner and outer elements even if the outer element has not been cleaned 6 times. 4) Check inner element mounting nuts for looseness and, if necessary, retighten. 5) Replace seal washer (5) or wing nut (6) with new parts if they are broken.

NOTICE If small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning and drying, replace the element. When cleaning the element, do not hit it or beat it against something. Do not use an element whose folds or gasket or seal are damaged. 4. Set the cleaned element.

5. Press the button of dust indicator (1) to return the red piston to its original position.

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REPLACING INNER ELEMENT NOTICE The inner element must not be used again even after cleaning. When replacing the outer element, replace the inner element at the same time. 1. First remove the outer element, and then remove the inner element. 2. To prevent dust from getting in, use a clean cloth or tape to cover the air connector (outlet side). 3. Clean the air cleaner body interior, then remove the cover installed in Step 2. 4. Fit a new inner element to the connector and tighten it with nuts. 5. Install the outer element and the cover. 6. After replacing the element, return the red piston in the dust indicator to its original position.

CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections.

REVERSE AND REPLACE THE END BITS AND CUTTING EDGES

WARNING Do not raise the blade unnecessarily high. Be sure not to put any part of your body underneath the blade when blocking it.

Replace the cutting edge before it wears to the end face of the blade. 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.

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SERVICE PROCEDURE

REPLACING RIPPER POINT

WARNING If the pin is hit out with strong force, there is danger that the pin may fly out. Check that there is no one in the surrounding area. There is danger of pieces flying during the replacement operation, so always wear protective clothing, such as safety glasses and gloves.

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)

CHECK INCHING PEDAL If any of the following problems have occurred, please contact your Komatsu distributor for inspection and adjustment. If the machine does not stop even the inching pedal is depressed. If the machine does not move or lacks power even the inching pedal is released.

CLEAN ELEMENT OF AIR CONDITIONER FRESH AIR FILTER

WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask.

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. Direct dry compressed air (Max. 0.69 MPa (7 kg/cm2, 99.4 PSI)) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside.

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SERVICE PROCEDURE

CLEAN ELEMENT OF AIR CONDITIONER RECIRCULATION AIR FILTER

WARNING If compressed air scattered around dust and debris, there is danger of injury. Always wear protective equipment such as protective glasses and mask.

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. 1. Loosen bolt (1) and remove cover (2). 2. Loosen bolt (3) and pull out bracket (4). 3. Loosen bolt (6) and remove air conditioner unit (5). 4. Loosen bolt (7) and remove cover (8). 5. Pull filter (9) out to the side and filter (10) out to the top. 6. Direct dry compressed air (Max. 0.69 MPa (7 kg/cm2, 99.4 PSI)) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside. If the filter is extremely dirty, rinse it in water. After rinsing it in water, dry it thoroughly before assembling again.

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SERVICE PROCEDURE

CHECK REFRIGERANT (GAS) LEVEL

WARNING If the refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant. Never loosen any part of the refrigerant circuit. Do not bring any flame close to any point where the refrigerant gas is leaking.

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.

Position of receiver drier Specification with air conditioner condenser installed in front of radiator

Specification with air conditioner condenser installed on top of cab

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SELECTION AND INSPECTION OF TIRES

WARNING If a tire or a rim is handled improperly, the tire may burst or may be damaged and the rim may be broken and scattered, and that can cause serious injury or death. Since maintenance, disassembly, repair and assembly of the tires and rims require special equipment and skill, be sure to ask a tire repair shop to do the work. Do not heat or weld the rim to which the tire is installed. Do not make a fire near the tire.

SELECTION OF TIRES

WARNING Select the tires according to the conditions of use and 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.

Tire size

Remarks

23.5-25-12PR

Type 2 for construction equipment

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MAINTENANCE

SERVICE PROCEDURE

CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM

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.

CHECK Measure the inflation pressure with a tire pressure gauge, while the tires are cool, before starting work.

INFLATION OF TIRES Adjust the inflation pressure properly. When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not work in front of the rim but work on the tread side of the tire. The proper inflation pressure is shown below.

Tire size

Inflation pressure MPa (kgf/cm2, PSI)

23.5-25-12PR

0.25 (2.6, 36.9)

NOTICE The optimum inflation pressure differs according to the type of work. For details, see "HANDLING THE TIRES (PAGE 3-115)".

INSPECTING CORROSION, WEAR OF WHEEL RIM, LOCK RING, SIDE RING If the wheel rim, lock ring and side ring are heavily corroded, ask the tire manufacturer or your Komatsu distributor for inspection.

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CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-47)" in the OPERATION section. Check coolant level, add water Check fuel level, add fuel Drain water and sediment in fuel tank Check engine oil pan level, add oil Check dust indicator Check and adjust steering wheel Check electric wiring Check breaking effect Check parking brake effect Check flashing of lamps, check for dirt and damage Check that all problems from previous day have been repaired Check that windshield wiper, window washer, and defroster work properly, check washer fluid level Drain water, sediment from water separator Check inflation pressure of tires Is the rise in the air pressure normal

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EVERY 50 HOURS SERVICE 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.

Apply grease all over the guide rail.

INSPECT WEAR OF BLADE GUIDE


1. Check if distances (wear tolerances) (a1), (a2) and (a3) between the sliding surface of rail guide (1) and guide holder plate (2) have become 0 at any point. (There are 5 rail guides; check all 5 rail guides.) Replace rail guide (1) before there is any interference between rail (3) and guide holder plate (2). 2. Please contact your Komatsu distributor to have the rail guide replaced.

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EVERY 250 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time.

LUBRICATING


CAUTION Do not insert your finger into any of the holes at the 17 greasing points.

1. Using a grease pump, pump in grease through the grease fittings shown by arrows. 2. After greasing, wipe off any old grease that was pushed out.

(1) Leaning cylinder pin (1 place) (2) Tie rod (2 places) (3) Steering linkage (2 places) (4) Steering cylinder pin (4 places) (5) Drawbar ball joint (1 place) (6) Front axle center pin (2 places) (7) Front axle king pin (6 places)

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. SERVICE PROCEDURE

(8) Blade lift cylinder yoke (4 places) (9) Blade lift cylinder ball joint (2 places) (10) Drawbar side shift cylinder ball joint (2 places) (11) Bank control guide (2 places) (12) Articulation center pin and articulation cylinder pin (6 places) (13) Blade lifter guide (2 places) (14) Ripper cylinder (3 places) (15) Ripper rod (8 places) (16) Power tilt cylinder (2 places) (17) Bank control lock pin (2 places) With the lifter guide pin removed, grease the bushings starting from the front. For details, see "EXTREME SIDE REACH (PAGE 3-105)". There is no grease nipple and at the lock pin portion. Use a brush or spatula to coat with grease as shown in the diagram on the right.

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MAINTENANCE

SERVICE PROCEDURE

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE

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. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.

Refill capacity: 34 liters (8.98 US gal) Prepare a filter wrench 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, please 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)".

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MAINTENANCE

SERVICE PROCEDURE

CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL

WARNING Immediately after the engine is stopped, the parts or oil are at high temperature. Wait for the temperature to go down before starting the operation. Check the oil level with the engine stopped. If the oil level is checked with the engine idling, do as follows. ·Before checking, to make sure that the machine does not move, place the speed lever at the P (parking) position and check that all levers are at the neutral position. ·After starting the engine, wait for 5 minutes after the oil level becomes stable before checking.

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 filler 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.

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SERVICE PROCEDURE

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

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. Stop the engine, and leave it for 5 minutes. 2. Open the right side cover and lower plate. 3. Remove dipstick (G) and wipe the oil off with a cloth. 4. Fully insert dipstick (G) into filler pipe, then remove it. 5. The oil level should be between the H and L marks on dipstick (G). If the oil level is below the L mark, add engine oil through oil filler (F). 6. If the oil level is above the H mark, remove the cover, and drain the excess gear oil from drain plug (P), then check the oil level again. 7. If the oil level is correct insert dipstick (G) the oil filler pipe.

CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL


1. Stop the engine and leave for at least 5 minutes. 2. Remove dipstick (G) and wipe the oil off with a cloth. 3. Fully insert dipstick (G) into filler pipe, then remove it. 4. The oil level should be between the H and L marks on dipstick (G). If the oil level is below the L mark, add engine oil through oil filler (F). 5. If the oil is above the H mark, drain the excess engine oil from drain plug (P), and check the oil level again. 6. If the oil level is correct, insert dipstick (G) in the oil filler guide, then install the oil filler cap.

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MAINTENANCE

SERVICE PROCEDURE

CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL


1. Stop the engine and leave for at least 5 minutes. 2. Remove oil filler plug (F), and check that the oil level is up to the top surface of the gear inside. 3. If the oil level is not up to the top surface of the gear, add engine oil through the oil filler port. 4. If the oil level is correct, install oil filler plug (F). REMARK There may be wear particles in the oil, but there is no problem using the oil as it is.

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL


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. 1. Set the machine in position as follows to check the oil level. Return the leaning of the front tires to the upright position and face the wheels straight to the front. Set the front frame and rear frame facing straight (articulated angle = 0°). Install the articulate lock pin. Return the blade sideshift to the center of the machine, set the blade at right angles to the chassis and lower it lightly to the ground. Raise the ripper to the maximum height, and put a block under the ripper. 2. Open the side panel. 3. Stop the engine, wait for 5 minutes, then check that the oil level is between the H and L marks on sight gauge (G). 4. If the oil level is below the L mark, add engine oil through oil filler (F). 5. If the oil is above the H mark, drain the excess engine oil from drain plug (P), and check the oil level again.

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SERVICE PROCEDURE

CHECK LEVEL OF BATTERY ELECTROLYTE Carry out this procedure before operating the machine.

WARNING Do not use the battery if the battery electrolyte level is below the 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 fire 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 the UPPER LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts.

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.

WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is possible to check the electrolyte level from the side of the battery, check as follows. 1. Use a wet cloth to clean the area around the electrolyte level lines and check that the electrolyte level is between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines. If the battery is wiped with a dry cloth, static electricity may cause a fire or explosion.

2. If the electrolyte level is below the midway point between the U.L and L.L lines, remove cap (1) and add distilled water to the U.L line. 3. After adding distilled water, tighten cap (1) securely. REMARK If distilled water is added to above the U.L. line, use a syringe to lower the level to the 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.

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. SERVICE PROCEDURE

MAINTENANCE

WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM SIDE OF BATTERY If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on the side of the battery, check as follows. 1. Remove cap (1) at the top of the battery, look through the water filler port, and check the electrolyte surface. If the electrolyte does not reach the sleeve, add distilled water so that the level reaches the bottom of the sleeve (UPPER LEVEL line) without fail.

Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.

2. After adding distilled water, tighten cap (1) securely. 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.

WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level, follow the instructions given.

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SERVICE PROCEDURE

CHECK BALL JOINT CLEARANCE, ADJUST Check and adjust all locations with ball joints at the links of the work equipment. Prepare a thickness gauge 1. Remove all the shims (1) from the ball joint. 2. Tighten the caps with bolts (2) to make the same clearance on the left and right. 3. Measure the clearance with a thickness gauge, then insert one shim more than this dimension, and tighten the cap. Thickness of one shim : 0.2 mm (0.008 in), 0.5 mm (0.020 in)

CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT NOTICE Loose wheel hub nuts (1) will result in shortened life of tires or other troubles. 1. Carefully check for loose bolts (1). When checking for loose borts (1), always turn the borts (1) in the tightening direction to check. Tightening torque: 1960 to 2450 Nm (200 to 250 kgm , 1446.6 to 1808.3 lbft) 2. If a hub bolt is broken, replace all the hub bolts.

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. SERVICE PROCEDURE

CHECK FAN BELT TENSION, ADJUST TESTING 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.

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MAINTENANCE

SERVICE PROCEDURE

CHECK ALTERNATOR BELT TENSION, ADJUST 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.

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. SERVICE PROCEDURE

CHECK AIR CONDITIONER BELT TENSION, ADJUST 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.

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MAINTENANCE

SERVICE PROCEDURE

CHECK, ADJUST FOOT BRAKE

WARNING Since a small amount of oil may come out from inspection plug hole (2), do not peep through the plug wheel when the brake is being applied.

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. 2. Remove cage (1) inspection plug (2). 3. Depress the brake pedal and keep the brake applied.

4. Carry out inspection as illustrated below. If the gap disappears between the inspection hole edge and separator plate (3), ask a Komatsu distributor to replace the disc. 5. Remove the drain plug (P) from the cage (1), and measure the amount of oil leaking into the piston chamber. 6. If there is no leakage, the seal is functioning properly. 7. If the amount of leakage is more than 0.02 liters , please contact your Komatsu distributor for replacement of the seal. 8. Install cage (1) inspection plug (2) and the drain plug (P). 9. Install the tire.

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MAINTENANCE

SERVICE PROCEDURE

EVERY 500 HOURS SERVICE Maintenance for every 50 and 250 hours service should be carried out at the same time.

REPLACE FUEL FILTER CARTRIDGE

WARNING The oil is at high temperature after the engine has been operated, so never replace the filter immediately after finishing operations. Wait for the parts to cool down before changing the filter. Do not bring fire or sparks near the fuel.

Prepare a filter wrench 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. 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.

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MAINTENANCE

SERVICE PROCEDURE

CLEAN, CHECK RADIATOR FINS

WARNING If compressed air, steam, or water hit your body directly, there is danger of injury. Always wear protective glasses, mask, and safety shoes. When cleaning, use a maximum pressure of less than 0.2 MPa (2.0 kg/cm2, 28.4 PSI).

Clean the radiator fins if any mud or dirt is stuck to the radiator. 1. Remove bolts (1) to remove panel (2). 2. Clean the radiator fins clogged with mud, dust and leaves with compressed air. Steam or water may be used instead of compressed air. 3. Check the rubber hose. Replace with a new one if the hose is found to have cracks or to be hardened by ageing. Further, check hose clamps for looseness.

CAUTION When cleaning the radiator fins, clean the air conditioner condenser fins at the same time.

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MAINTENANCE

SERVICE PROCEDURE

CHECK CIRCLE GUIDE CLEARANCE, ADJUST

WARNING When raising the blade, do not raise it higher than necessary.

NOTICE Before stating the adjustment, confirm that there are gaps between the tooth crest of the circle gear and root of the circle pinion and between the tooth crest of the circle pinion and root of the circle gear. If there is no gap, replace the guide before starting the adjustment. Prepare the following: Feeler gauge Shims (thickness: 1 mm (0.039 in), 0.5 mm (0.020 in); 2 types)

CHECKING 1. Raise the blade from the ground. 2. Measure the clearance at portion P with a feeler gauge. Standard clearance: 1.5 ± 0.5 mm (0.059 ± 0.020 in) (6 places) 3. Measure the clearances at portions F, C, and R. Standard value: F = 0, C = 0.7 mm (0.028 in), R = 1.5 mm (0.059 in) or F = C = R = 1 mm (0.039 in) F is the clearance for the guide at the front. C is the clearance for the guide at the center. R is the clearance for the guide at the rear. 4. If the clearance for portions P, F, C, and R are not the above values, adjust as follows.

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MAINTENANCE

SERVICE PROCEDURE

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. 1. Raise the blade so that the drawbar is parallel to the ground surface, then set dimension E between the ground surface and the end of the blade edge to approx. 30 mm (1.2 in).

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. SERVICE PROCEDURE

MAINTENANCE

2. Loosen bolt (1), put portions F, C, and R of circle (5) and circle guide (2), (3), and (4) in contact, then adjust shim (6) so that clearance P between the top face of the circle and bottom face of the drawbar is 1 to 2 mm (0.039 to 0.079 in). 3. Loosen locknut (7), then tighten pushing bolt (8) of rear circle guide (4) to move the whole circle to the rear and adjust to give dimension H of 20 to 21 mm (0.79 to 0.82 in) between machined surface (9) of the case at the bottom of the pinion gear and the circle and circle guide contact surface (10). REMARK When not using circle guide pusher bolt (8) to carry out the movement, use a lever block. 4. Loosen locknut (12) of front circle guide (2), tighten pusher bolt (13), maintain clearance H between pinion gear (9) and the circle (10), set clearance F between the circle guide (2) and circle (5) to 0 mm, then tighten locknut (12). 5. Check clearance H between machined surface (9) of the case at the bottom of pinion gear and the circle and circle guide contact surface (10) again. Then loosen locknut (14), tighten pusher bolt (15) of center circle guide (3), set clearance C between center circle guide (3) and circle (5) to 0.7 mm (0.028 in), then tighten locknut (14). 6. Adjust pusher bolt (8) so that clearance R between rear circle guide (4) and circle (5) is 1.5 mm (0.059 in), then tighten locknut (7). 7. Tighten bolt (1) and locknuts (7), (12), and (14). 8. Coat the sliding surface 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 circle guide. When dimension A of wear plate (16) or dimensions B or C of wear plate (17) become 2 mm (0.079 in).

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MAINTENANCE

SERVICE PROCEDURE

CHECK PARKING BRAKE LEVEL STROKE, ADJUST CHECKING

CAUTION The parking brake effect test applies a large force to the drive system, and also applies excessive force to the transmission, so do not check more than necessary.

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°. 3. When checking the effect of the parking brake, place the gearshift lever at the P (parking) position set the gear at forward 8th, run the engine at full throttle, then slowly release the inching pedal and check that the engine stops within 3 seconds of the power being transmitted.

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).

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MAINTENANCE

SERVICE PROCEDURE

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. Method of jacking up front wheels 1) Lower the work equipment, and place the gear shift lever at the P (parking) position. 2) Lower the blade and raise the front tires from the ground. 3) Put a block under the frame at the center of the front axle. 3. Operate the blade rotation lever and check if the clutch slips. Method of checking slip 1) If there is slippage, a sliding noise can be heard, and when the blade turns a little at a time, vertical shaft end holder (4) turns more than the blade. Return the blade rotation control lever to neutral to stop the slippage. (Check the condition at the border point between slippage and no slippage.) 2) In this condition, loosen bolt (3), remove holder (4), then take out one shim (5) (0.2 mm (0.008 in)). 3) Install holder (4), tighten bolt (3), then install cover (2) with bolt (1).

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MAINTENANCE

SERVICE PROCEDURE

ADJUSTING IF CLUTCH DOES NOT SLIP 1. Loosen bolts (3) and remove holder (4), then add one 0.2 mm (0.008 in) shim (5). 2. Tighten holder (4) with mounting bolt (3). 3. Repeat the operation until there is slippage to match with the slip limit. For details, see the section on inspection.

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.

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MAINTENANCE

SERVICE PROCEDURE

EVERY 1000 HOURS SERVICE Maintenance for every 50, 250 and 500 hours should be carried out at the same time.

GREASE DRIVE SHAFT

WARNING Apply 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.

1. Using a grease pump, pump in grease through the grease fittings shown by arrows. 2. After greasing, wipe off any old grease that was pushed out.

GREASE FAN PULLEY AND TENSION PULLEY 1. Using a grease pump, pump in grease through the grease fittings shown by arrows. 2. After greasing, wipe off any old grease that was pushed out.

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MAINTENANCE

SERVICE PROCEDURE

REPLACE TRANSMISSION OIL FILTER ELEMENT


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 4-32)".

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MAINTENANCE

SERVICE PROCEDURE

CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER


Refill capacity: 25 liters (6.61 US gal) 1. Set a container under the transmission case to catch the oil. 2. To prevent getting oil on yourself, loosen drain plug (P) and drain the oil. To prevent the oil from spurting out, loosen drain plug (P), then gradually remove it. 3. After draining the oil, install drain plug (P). Tightening torque: 127 to 177 Nm (13 to 18 kgm, 94.0 to 130.2 lbft) 4. After removing bolts (1), remove tube (2), then remove bolts (4) and cover (3). 5. Remove strainer (5). 6. Remove all the dirt stuck to the strainer, then wash it in clean diesel oil or flushing oil. If the strainer is damaged, replace it with a new part. 7. After washing strainer (5), install it, then install cover (3) with bolts (4), and install tube (2) with bolts (1). 8. Pour in the specified amount of engine oil from oil filler (F). 9. After refilling, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL (PAGE 4-32)". 10. Check that there is no leakage of oil from the transmission case or oil filter.

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MAINTENANCE

SERVICE PROCEDURE

CHANGE OIL IN FINAL DRIVE CASE, CLEAN STRAINER


Refill capacity: 57 liters (15.06 US gal) 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 amount of engine 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 4-33)". 9. Check for oil leakage from the final drive case.

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MAINTENANCE

SERVICE PROCEDURE

REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK


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.

3. Remove 4 bolts (5), then remove filter head cover (6). 4. Remove the filter element, clean the filter case and the removed parts, then install a new filter element. 5. Install filter head cover (6) with bolts (5). 6. Install filter assembly (3) to the hydraulic tank.

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MAINTENANCE

SERVICE PROCEDURE

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).

CHANGE OIL IN HYDRAULIC TANK


Refill capacity: 80 liters (21.14 US gal) 1. Set the machine in position as follows to check the oil level. Return the leaning of the front tires to the upright position and face the wheels straight to the front. Set the front frame and rear frame facing straight (articulated angle = 0°). Install the articulate lock pin. Return the side shift of the drawbar and blade to the center of the machine, set the blade at right angles to the machine, then lower it lightly to the ground. 2. Loosen oil filler port (F) slowly to completely release the air inside the hydraulic tank. 3. Set the container under drain plug (P) to catch the oil. 4. 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. 5. After draining the oil, install drain plug (P). Tightening torque: 58.8 to 78.5 Nm (6 to 8 kgm , 43.4 to 57.9 lbft) 6. Pour in the specified amount of engine oil from oil filler (F). 7. After filling with oil, check that the oil is at the specified level. For details, see "CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL (PAGE 4-34)". 8. Install oil filler (F). 9. Run the engine at low idling, and extend and retract each cylinder 4 to 5 times to a point approx. 100 mm (3.9 in) before the end of its stroke. 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.

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. SERVICE PROCEDURE

MAINTENANCE

CHECK LOOSENESS IN DRAWBAR FRONT BALL JOINT AND BALL STUD Check ball joint connecting nut (1) and ball stud connecting bolt (2) at the front of the drawbar for loosening. If the connecting portion are loose, retighten them.

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

3. Mark the same dimension as measured in step 2 at about the center position of the tire width. Use the same procedure to mark both the left and right tires. 4. Measure the distance between the two marks. This distance is called "A".

5. Next, drive the machine forward slowly to move the marks on the tire to the rear, and stop the machine when the marks come to the same position as the height from the ground to the center of the front axle. Always travel forward when doing this.

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SERVICE PROCEDURE

6. Measure the distance between the two marks. This distance is called "B". 7. When toe-in (B - A) is adjusted to -5 ± 1 mm (-0.197 ± 0.039 in) of standard range, side slip is decreased to zero. If any value other than the standard range is measured, adjust toe-in using the following procedure.

HOW TO ADJUST TOE-IN: NOTICE When adjusting, make sure that the front axle is horizontal and that the front wheels are not leaning. 1. Loosen tightening nut (1), fit a wrench to corner (2) of the tie rod, then turn the left and right tie rods as shown in the diagram on the right to adjust as follows. To INCREASE toe-in, turn in DIRECTION OF ARROW To DECREASE toe-in, turn in OPPOSITE DIRECTION Amount of extension for one turn of left or right tie rod in direction of extension: 9 mm (0.355 in) 2. After adjusting, tighten tightening nut (1).

CHECK FRONT WHEEL BEARING PLAY, ADJUST Please ask your Komatsu distributor to inspect and adjust the front wheel bearing.

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MAINTENANCE

SERVICE PROCEDURE

REPLACE CORROSION RESISTOR CARTRIDGE

WARNING All the engine parts are at high temperature after the engine has been operated, so never replace the cartridge immediately after finishing operations. Wait for the oil to cool down before replacing the cartridge.

Prepare a filter wrench 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. 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.

CHECK FOR LOOSE ROPS MOUNT BOLTS Check that there are no loose or damaged bolts. Tighten any loose bolts. Tightening torque: 1520 to 1910 Nm (155 to 195 kgm , 1121.1 to 1410.4 lbft) If any damaged bolt is found, replace the bolt with a genuine Komatsu bolt.

REPLACING AIR DRYER DESICCANT Replace the desiccant every year even if the replacement time has not been reached. Loosen bolts (1) of the air dryer, take out the desiccant, and replace it with new desiccant. 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.

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MAINTENANCE

SERVICE PROCEDURE

EVERY 2000 HOURS SERVICE Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time.

CHANGE OIL IN FRONT WHEEL BEARING


Refill capacity: 0.9 liters (0.24 US gal) (each) 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.

CHANGE OIL IN CIRCLE REVERSE GEAR CASE


Refill capacity: 8 liters (2.11 US gal) 1. Set the container under drain plug (P) to catch the oil. 2. Remove drain plug (P) and drain the oil. 3. After draining the oil, clean drain plug (P) and install it again. 4. 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 4-34)" 6. Install oil filler plug (F).

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MAINTENANCE

SERVICE PROCEDURE

CHANGE OIL IN TANDEM DRIVE CASE


Refill capacity: 95 liters (25.10 US gal) (each) 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 amount of engine 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 4-33)".

CLEAN ENGINE BREATHER ELEMENT

WARNING Immediately after the engine is stopped, the parts or oil are at high temperature and may cause burns. Wait for the temperature to go down before starting the operation. If compressed air is used, there is danger of dirt flying and causing personal injury. Always wear safety glasses, dust mask, and other protective equipment.

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).

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MAINTENANCE

SERVICE PROCEDURE

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)

(2) Final drive case (1 place)

(3) Tandem case (2 places)

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. SERVICE PROCEDURE

MAINTENANCE

CLEAN AND INSPECT INCHING POTENTIOMETER SENSOR 1. Remove bolt (1) of the inching potentiometer sensor, then remove cover (2). 2. Use a brush to remove all the dirt stuck to the top surface of potentiometer sensor (3).

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).

CHECK ALTERNATOR, STARTING MOTOR The brushes may be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspection and repairs. If the engine is started frequently, have this inspection carried out every 1000 hours.

CHECK ENGINE VALVE CLEARANCE, ADJUST Special tools are needed for inspection and maintenance, so contact your Komatsu distributor.

CHECK ALL TIGHTENING PARTS OF TURBOCHARGER Please contact your Komatsu distributor to have the tightening portions checked.

CHECK PLAY OF TURBOCHARGER ROTOR Please contact your Komatsu distributor to have the rotor play checked.

CLEAN, CHECK TURBOCHARGER If there is carbon or oil sludge stuck to the blower impeller, it will lower the performance of the turbocharger or cause it to break, so ask your Komatsu distributor to carry out the cleaning.

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MAINTENANCE

SERVICE PROCEDURE

EVERY 4000 HOURS SERVICE Maintenance for every 50, 250, 500, 1000 and 2000 hours service should be carried out at the same time.

CHECK WATER PUMP Check that there is no play in the pulley or any grease leakage, water leakage, or clogging of the drain hole. If any abnormality is found, contact your Komatsu distributor for disassembly and repair or replacement.

CHECK VIBRATION DAMPER Check that there is no reduction in the damper fluid level, and that there are no dents or face run out. If any abnormality is found, contact your Komatsu distributor to have the parts replaced.

CHECK FAN PULLEY AND TENSION PULLEY Check for play of the pulley and leakage of grease. If any problem is found, please contact your Komatsu distributor.

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5-1

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SPECIFICATIONS

SPECIFICATIONS

SPECIFICATIONS GD825A-2 Item

Unit

Operating weight (including operator 55 kg (121 lb))

kg (lb)

29,700 (65,489)

-

Komatsu S6D140E-2 diesel engine

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 (to bottom surface of final drive case)

mm (ft in)

440 (1' 5")

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)

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)

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)

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)

Engine model Flywheel horsepower

Forward

Travel speeds

Reverse

5-2

.

SPECIFICATIONS

SPECIFICATIONS

5-3

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6-1

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ATTACHMENTS, OPTIONS

HANDLING EMERGENCY STEERING DEVICE

HANDLING EMERGENCY STEERING DEVICE CAUTION The emergency steering motor must not be operated continuously for more than 30 seconds.

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. Action to take when actuated 1. If the emergency steering is actuated, move the machine quickly to a safe place and stop the machine. 2. After stopping the machine, turn the starting switch to the OFF position to stop the emergency steering, then ask your Komatsu distributor to carry out inspection.

CHECKING EVERY 500 HOURS SERVICE 1. Check that the emergency steering switch is at the AUTO position (1). 2. Start the engine and lower the blade to jack up the front wheels from the ground. Normally, keep the emergency steering switch at the AUTO position (1). 3. Turn the starting switch to the OFF position and stop the engine. 4. After stopping the engine, turn the starting switch to the ON position. 5. Set the emergency steering switch to the MANUAL position (2). 6. Check that the alarm buzzer sounds continuously and the electric motor for the emergency steering is actuated when this happens. 7. Turn the steering wheel and check that the machine can be steered properly. 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

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AIR CONDITIONER

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.

LOCATIONS AND FUNCTIONS OF CONTROL PANEL

(1) (2) (3)

Fan switch Air conditioner switch FRESH/RECIRC selector switch

(4) (A)

Temperature control switch The temperature level indicator lamp

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

. AIR CONDITIONER


AIR CONDITIONER SWITCH This switch (2) is used to start or stop the cooling or dehumidifying function. When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out.

FRESH/RECIRC SELECTOR SWITCH This switch (3) changes between internal air circulation and external air intake. When pressing the switch, the indicator lamp on the top of switch lights up.

TEMPERATURE CONTROL SWITCH This switch (4) is used to adjust the temperature steplessly from low temperature to high temperature. The temperature level indicator lamps (A) light up to display the temperature of the air coming from the vents. The more blue lamps on, the lower the temperature is. 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

.


AIR CONDITIONER

METHOD OF OPERATION Switch

Fan switch

Air conditioner switch

High speed

HI

ON

All green

RECIRC

Normal

HI - LO

ON

More than half green

FRESH

HI - LO

ON

More than half red

FRESH

High speed

HI

OFF

All red

RECIRC

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

Condition of use Cooling

Dehumidification + heating Heating

Temperature control FRESH/RECIRC switch selector switch

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.

PRECAUTIONS WHEN USING Carry out ventilation from time to time when using the cooling. If you smoke when using the cooling, your eyes may start to sting, so in such a case, carry out ventilation and cooling for a short time to remove the smoke. When the air conditioner is used for long periods, carry out ventilation once every hour. Be careful not to cool the cab too much. For reasons of health, it is recommended that the cab should feel pleasantly cool when you enter it from the outside (5 to 6°C (9.0 to 10.8°F) lower than the outside temperature). Pay attention to the temperature when carrying out cooling.

HANDLING THE AIR CONDITIONER IN SEASON To use the air conditioner comfortably during its season, ask your Komatsu distributor to check the air conditioner and add the refrigerant if necessary. 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 4-22)". If large amounts of dust or dirt accumulate on the condenser, the cooling capacity will drop, so carry out inspection and cleaning periodically.

HANDLING THE AIR CONDITIONER IN OFF-SEASONS To lubricate each portion of the compressor, operate the airconditioner for several minutes 2 to 3 times a month, even off season. 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

.


HANDLING AIR-SUSPENSION SEAT

HANDLING AIR-SUSPENSION SEAT ADJUST OPERATOR'S SEAT

WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. 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.

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. (A) Fore-and-aft adjustment Pull lever (1) up, move the seat to the desired position, then release the lever. Fore-and-aft adjustment: 160 mm (6.3 in) (16 stages) (B) Adjusting reclining angle 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. (C) Adjusting seat tilt Front tilt Push lever (3) down and adjust the angle of the front of the seat. To raise the front of the seat, keep the lever pushed down and apply your weight to the rear of the seat. To lower the front of the seat, keep the lever pulled up and apply your weight to the front of the seat. 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°, down 13° Adjusting seat height It is possible to raise or lower the seat by combining the front tilt and rear tilt. Use the front (rear) tilt operation to set the seat to the desired height, then use the rear (front) tilt to make the seat horizontal. Height adjustment: 60 mm (2.4 in)

6-6

.


HANDLING AIR-SUSPENSION SEAT

(D) Adjusting armrest angle Armrest (4) can be made to spring up by hand approx. 90°. In addition, by turning the bottom (5) of the armrest by hand it is possible to make fine vertical adjustments of the armrest angle. Armrest adjustment angle: 25°. REMARK If the seat back is tipped to the front without raising the armrest(4), the armrest will rise automatically. (E) Adjusting suspension To select the optimum suspension, turn knob (6) to adjust the dial for the suspension to the operator's weight as follows. Turn CLOCKWISE to make HARDER Turn COUNTERCLOCKWISE to make SOFTER 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).

6-7

.

.

INDEX

INDEX ADJUSTING WORK EQUIPMENT POSTURE AIR CONDITIONER LOCATIONS AND FUNCTIONS OF CONTROL PANEL METHOD OF OPERATION PRECAUTIONS WHEN USING ARTICULATE LOCK PIN BACKUP ALARM CHECK AFTER STOPPING ENGINE CHECK BEFORE STARTING ENGINE CHECKS AFTER COMPLETION OF OPERATION COLD WEATHER OPERATION AFTER COLD WEATHER CAUTIONS AFTER COMPLETION OF WORK PRECAUTIONS FOR LOW TEMPERATURE CONTROL LEVERS, PEDALS CRITICAL PARTS

3-111 6- 3 6- 3 6- 5 6- 5 3- 38

3- 41

3- 64 3- 44 3-114 3-122 3-123 3-123 3-122 3- 29 4- 13

DUST INDICATOR

3- 38


3-

FOREWORD FRONT GLASS FUSE BOX GENERAL PRECAUTIONS GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES GENERAL VIEW OF MACHINE GUIDES TO MAINTENANCE

6

1- 2 3- 42 3- 39

2- 12 3- 2 334-

3 2 2

HANDLING AIR-SUSPENSION SEAT ADJUST OPERATOR'S SEAT HANDLING BLADE ACCUMULATOR HANDLING BLADE FLOAT HANDLING EMERGENCY STEERING DEVICE CHECKING HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC HANDLING THE TIRES INTENDED USE DIRECTIONS OF MACHINE LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ENGINE SERIAL NO. PLATE POSITION PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE SERVICE METER POSITION TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR LOCKING LONG-TERM STORAGE AFTER STORAGE BEFORE STORAGE DURING STORAGE MAINTENANCE SCHEDULE CHART METERS AND LAMPS MONITOR PANEL MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING OPERATING WORK EQUIPMENT OPERATION OPERATIONS, CHECKS AFTER STARTING ENGINE OPERATOR'S CAB LIFT MECHANISM

6- 6 6- 6 3-116 3-118 66-

2 2

4- 4 3-115

11-

5 5

1-

6

1-

6

11-

6 7

1- 7 3-114 3-124 3-124 3-124 3-124

4- 14 3- 19 3- 6

3- 66

3- 74 3- 44 3- 62 3- 41

7-1

.

INDEX

OUTLINES OF SERVICE
PARKING MACHINE PERIODIC REPLACEMENT OF CRITICAL PARTS PRECAUTIONS DURING OPERATION BATTERY TOWING TRANSPORTATION PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN OPERATION PRECAUTIONS WITH TIRES QUICK-FILL FUEL FILLER RELATING TO ELECTRIC SYSTEM SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS SERVICE PROCEDURE CHECK BEFORE STARTING EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE EVERY 250 HOURS SERVICE EVERY 4000 HOURS SERVICE EVERY 50 HOURS SERVICE EVERY 500 HOURS SERVICE INITIAL 250 HOURS SERVICE (only after the first 250 hours) WHEN REQUIRED SPECIFICATIONS STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS STARTING ENGINE STOPPING ENGINE STORAGE BOX SWITCHES

7-2

4-

4

3-112 4- 13 2- 20 2- 27 2- 29 2- 26 2- 30 3-107 2- 36

TOOL BAG TORQUE LIST TRANSPORTATION LOADING, UNLOADING WORK PRECAUTIONS FOR LOADING TRAVELING POSTURE FOR MACHINE TROUBLESHOOTING AFTER RUNNING OUT OF FUEL IF BATTERY IS DISCHARGED OTHER TROUBLE TOWING THE MACHINE TRANSMISSION CONTROLLER WHEN LEANING PIPING IS DAMAGED TURNING MACHINE

3- 43 4- 12 3-120 3-120 3-121 3- 65 3-125 3-125 3-129 3-132 3-126 3-137 3-125 3- 72

3- 43

4-

6

122-

3 2 4

2244444444-

5 6 16 27 50 59 29 63 28 42

4- 16 4- 17 5- 2 43333-

12 59 64 43 20

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE WEAR PARTS WEAR PARTS LIST WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER

4-

8

44-

7 7

3- 79

.

.

GD825A-2 MOTOR GRADER Form No. TEN00334-00

©

2009 KOMATSU All Rights Reserved Printed in Japan 03-09

O&M GD825A-2 12503-UP TEN00334-00

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