Komatsu GD655-3C
Komatsu GD655-3C
Komatsu GD655-3C
MOTOR GRADER
GD655 -3C
SERIAL NUMBERS 51001 and up
WARNING
Unsafe Use of this machine may cause serious injury or
Death.Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel
who will come into contact with it .
NOTICE
Komatsu has Operation & Maintenance Manuals written
in some other languages. if a foreign language manual
is necessary, contact your local distributor for
availability.
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FOREWORD FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand them fully.
Keep this manual in the storage location for the operation and maintenance manual given below, and have all personnel read it
periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
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FOREWORD FOREWORD
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FOREWORD FOREWORD
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SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
WARNING
To avoid hitting unlocked operation levers, lower equipment to ground and
move SAFETY LOCK LEVER to LOCK position before starting up from
operator's seat.
Sudden and unwanted machine movement can cause serious injury or
death.
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
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Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when 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.
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 -> (1))
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INTENDED USE
This Komatsu machine is designed to be used mainly for the following work:
Smoothing
Repair and maintenance of gravel roads
Snow-clearing operations
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 3-68)" for further
details.
DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
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Distributor name
Address
Service Personnel
Phone/Fax
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CONTENTS FOREWORD
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTENDED USE 1- 7
DIRECTIONS OF MACHINE 1- 7
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 8
MACHINE SERIAL NO. PLATE POSITION 1- 8
ENGINE SERIAL NO. PLATE POSITION 1- 8
SERVICE METER POSITION 1- 9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9
SAFETY 2- 1
SAFETY INFORMATION 2- 2
SAFETY LABELS 2- 4
POSITION FOR ATTACHING SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 11
PRECAUTIONS DURING OPERATION 2- 20
STARTING ENGINE 2- 20
OPERATION 2- 22
TRANSPORTATION 2- 26
BATTERY 2- 27
TOWING 2- 29
PRECAUTIONS FOR MAINTENANCE 2- 30
PRECAUTIONS WITH TIRES 2- 36
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 6
METERS AND LAMPS 3- 6
SWITCHES 3- 13
CONTROL LEVERS, PEDALS 3- 24
DUST INDICATOR 3- 33
ARTICULATE LOCK PIN 3- 33
FUSE BOX 3- 33
OPERATION 3- 35
CHECK BEFORE STARTING ENGINE 3- 35
STARTING ENGINE 3- 47
OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 51
STOPPING ENGINE 3- 53
CHECK AFTER STOPPING ENGINE 3- 53
TRAVELING POSTURE FOR MACHINE 3- 54
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING 3- 55
TURNING MACHINE 3- 59
OPERATING WORK EQUIPMENT 3- 62
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER 3- 68
PRECAUTIONS WHEN OPERATION 3- 89
ADJUSTING WORK EQUIPMENT POSTURE 3- 93
PARKING MACHINE 3-103
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FOREWORD CONTENTS
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CONTENTS FOREWORD
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SAFETY INFORMATION
SAFETY LABELS 2- 4
POSITIONS OF SAFETY PICTOGRAMS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 11
SAFETY RULES 2- 11
IF PROBLEMS ARE FOUND 2- 11
CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 11
FIRE EXTINGUISHER AND FIRST AID KIT 2- 11
SAFETY FEATURES 2- 11
KEEP MACHINE CLEAN 2- 12
INSIDE OPERATOR'S COMPARTMENT 2- 12
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 12
HANDRAILS AND STEPS 2- 13
MOUNTING AND DISMOUNTIN 2- 13
DO NOT GET CAUGHT IN ARTICULATED PORTION 2- 13
PREVENTION OF BURNS 2- 14
FIRE PREVENTION 2- 15
ACTION IF FIRE OCCURS 2- 15
WINDOW WASHER LIQUID 2- 16
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 16
PRECAUTIONS FOR ATTACHMENTS 2- 16
UNAUTHORIZED MODIFICATION 2- 16
SAFETY AT WORKSITE 2- 17
WORKING ON LOOSE GROUND 2- 17
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 18
ENSURE GOOD VISIBILITY 2- 18
VENTILATION FOR ENCLOSED AREAS 2- 18
CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 19
EMERGENCY ESCAPE FROM OPERATOR'S CAB 2- 19
ASBESTOS DUST HAZARD PREVENTION 2- 19
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SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
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 LABELS
(1) Caution before operating (09651-03001) (2) Caution for opening hydraulic cap (09653-03001)
(3) Caution when driving in reverse (09802-43000) (4) Danger when approaching (09812-13000)
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(5) Warning for high voltage (09801-43001) (6) Articulate lock (09161-33000)
(7) Warning for handling accumulator (09659-53000) (8) Caution for high temperature cooling water
(09668-03001)
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(11) Caution when engine running (09667-03001) (12) Caution when handling booster cable and
battery cable (09808-03000)
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(13) Prohibited to enter (09162-33000) (14) Caution when startling and traveling
(23B-53-31740)
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(17) Caution when handling battery (18) Caution when handling battery (09664-30082)
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GENERAL PRECAUTIONS
SAFETY RULES
Only trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.
If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may
be severly impaired putting yourself and everyone else on your jobsite in danger.
When working with another operator or with a person on worksite traffic duty, be sure that all personnel
understand all hand signals that are to be used.
SAFETY FEATURES
Be sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if
they are damaged.
Understand the method of use of safety features and use them properly.
Never remove any safety features. Always keep them in good operating condition.
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PREVENTION OF BURNS
Hot coolant
To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to a
temperature where it is possible to touch the radiator cap by
hand before starting the operation. Even when the coolant has
cooled down, loosen the cap slowly to relieve the pressure
inside the radiator before removing the cap.
Hot oil
To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to a temperature where it
is possible to touch the cap or plug by hand before starting the
operation. Even when the oil has cooled down, loosen the cap
or plug slowly to relieve the internal pressure before removing
the cap or plug.
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FIRE PREVENTION
Fire caused by fuel 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.
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UNAUTHORIZED MODIFICATION
Any modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.
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SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.
Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do
not operate where there is a hazard of landslides or falling rocks.
If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify their
locations. Be careful not to sever or damage any of these lines.
Take action to prevent unauthorized people from approaching
the jobsite.
When working on public roads, position flagmen and erect
barriers to ensure the safety of passing traffic and pedestrians.
When traveling or operating in shallow water or on soft ground,
check the shape and condition of the bedrock, and the depth
and speed of flow of the water before starting operations.
In order that travel operations can be carried out safely, always
keep the roads on the jobsite properly maintained.
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OPERATION
Always be sure to carry out the above precautions even when the machine is equipped with mirrors.
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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 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.
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PROHIBITED OPERATIONS
When operating at the bottom of a cliff, there is danger that the soil may collapse or that rocks may fall. Never
operate in such places.
The edge of cliffs or road shoulders may easily collapse, and there is danger of falling. Do not go close to such
places.
Avoid sudden starts, sudden stops, and sudden steering.
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PARKING MACHINE
Park the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground.
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TRANSPORTATION
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 3-106)" in the OPERATION section.
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BATTERY
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TOWING
WHEN TOWING
Serious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection
or inspection of the wire rope.
For towing, see "TOWING THE MACHINE (PAGE 3-113)".
Always wear leather gloves when handling wire rope.
During the towing operation, never stand between the towing
machine and the machine being towed.
Never tow a machine on a slope.
Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope may
break during the towing operation.
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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.
Lock the frame with articulate lock pin (1) to prevent the machine
from articulating.
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Never drop or insert tools or other objects into the fan or fan belt.
Parts may break or be sent flying.
PROPER TOOLS
Use only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.
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ACCUMULATOR
The accumulator is charged with high-pressure nitrogen gas.
When handling the accumulator, careless procedure may cause
an explosion which could lead to serious injury or property
damage. For this reason, always observe the following
precautions.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it, weld it, or use a cutting torch.
Do not hit or roll the accumulator, or subject it to any impact.
When disposing of the accumulator, the gas must be released.
Please contact your Komatsu distributor to have this work
performed.
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorized personnel into the area.
If necessary, employ an observer.
ATTACHMENTS
Appoint a leader before starting removal or installation
operations for attachments.
Place attachments that have been removed from the machine in
a stable condition so that they do not fall. And take steps to
prevent unauthorized persons from entering the storage area.
NOISE
If the noise from the machine is too loud, it may cause temporary or permanent hearing problems. When carrying
out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs
while working.
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REPAIR WELDING
Welding operations must always be 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.
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WASTE MATERIALS
To prevent pollution, pay careful attention to the method of disposing of waste materials.
Always put oil drained from your machine in containers. Never
drain oil directly onto the ground or dump into the sewage
system, rivers, the sea, or lakes.
Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
COMPRESSED AIR
When 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.
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 time specified
interval.
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GENERAL VIEW
GENERAL VIEW OF MACHINE
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EXPLANATION OF COMPONENTS
The following is an explanation of devices needed for operating the machine.
To perform suitable operations correctly and safely, it is important to completely understand methods of operating
the equipment, and the meanings of the displays.
(1) Engine water temperature gauge (13) Differential control (if equipped)
(2) Speedometer (if equipped) (14) Blade accumulator (if equipped)
(3) Turn signal pilot lamp (if equipped) (15) Working lamp (if equipped)
(4) Fuel gauge (16) Blade float (if equipped)
(5) Message center (17) Preheating lamp
(6) Battery charge (18) High beam of front lamp (if equipped)
(7) Engine oil pressure lamp (19) Parking brake
(8) Brake oil pressure lamp (20) Articulation gauge
(9) Transmission system electric circuit monitor (21) Torque converter oil temperature gauge
(10) Lift arm lock (22) Service meter (to the left side of the steering
(11) Torque converter oil temperature wheel column)
(12) Differential oil temperature (if equipped)
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SPEEDOMETER
(If equipped)
This meter (2) displays the travel speed of the machine.
There is an odometer at the bottom of the meter.
REMARK
If there is a disconnection in the turn signal lamp, the flashing
interval becomes shorter.
FUEL GAUGE
This gauge (4) indicates the amount of fuel in the fuel tank.
E: Little fuel remaining
F: Full tank
If the gauge comes close to the E mark, add fuel.
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MESSAGE CENTER
This meter (5) indicates the engine speed, transmission range,
error code, and machine travel speed.
REMARK
AUTO always shows the engine speed, but when changing to the transmission range, the transmission range
is displayed for 3 seconds, and then the display returns to the engine speed display. If any failure occurs in the
transmission control, the error code is displayed.
When adjusting the brightness of the monitor, press the SCROLL button to change the brightness of the
message center as follows: 100% -> 25% -> 50% -> 100%.
The error code always displays [E--0]. If any other display appears, see "OTHER TROUBLE (PAGE 3-118)", and
contact your Komatsu distributor for repairs.
BATTERY CHARGE
This lamp (6) warns of any problem in the charging system when
the engine is running.
If it flashes, check the charging circuit. Stop the engine, and check
for any looseness of the V-belt. If any problem is found, see
"OTHER TROUBLE (PAGE 3-118)".
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DIFFERENTIAL CONTROL
(If equipped)
This lamp (13) lights up when the differential is locked.
BLADE ACCUMULATOR
(If equipped)
This lamp (14) lights up when the blade accumulator/float switch is
turned ON.
This protects the operator and work equipment when carrying out
leveling work on road surfaces where there are many rocks.
WORKING LAMP
(If equipped)
This lamp (15) lights up when the working lamp switch is turned
ON.
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BLADE FLOAT
(If equipped)
This lamp (16) lights up when the blade accumulator/float switch
switch is turned ON.
This is effective for snow-clearing operations.
PREHEATING LAMP
This lamp (17) displays the preheating time when starting the
engine at temperatures of 5C (41F) or below.
When the starting switch is turned to the HEAT position, the lamp
lights up for approx. 20 seconds.
When it goes out, it shows that the preheating has been
completed.
PARKING BRAKE
This lamp (19) lights up to indicate that the gearshift lever is at the
P (Parking) position.
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ARTICULATION GAUGE
This gauge (20) indicates the angle between the front frame and
rear frame.
When the key is at the OFF position, the gauge indicator is at the
left side, and when the switch is at the ON position, it shows the
angle of the machine body.
SERVICE METER
This meter (22) displays the accumulated hours of operation of the
machine.
The service meter reading advances by 1 for every hour that the
engine is running, regardless of the engine speed.
The service meter will advance while the engine is running even if
the machine is not moving.
The meter is installed to the left side of the steering wheel column.
REMARK
When the engine is running, the operation display at the top of the
meter rotates to indicate that the meter is advancing.
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SWITCHES
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STARTING SWITCH
This switch (1) is used to start or stop the engine.
OFF position
The key can be inserted or with drawn. The switches for the electric
system are all turned off and the engine is stopped.
ON
Electricity flows to the charging circuit and lamp circuit.
START
This is the position for starting the engine. Keep the key at this
position while cranking the engine. When the engine starts,
release the key immediately.
The key returns automatically to the ON position.
HEAT position
Set to this position when starting the engine in cold weather.
If the key is held at the HEAT position, the electrical heater will be heated and the preheat monitor will light up.
When the preheating is completed, the preheating monitor will go out.
When the preheating monitor goes out, release the key immediately.
If the key is released, it will return to the OFF position. Stop the engine with the key at the OFF position, then turn
the key to the START position to start the engine.
REMARK
When the preheating lamp goes out in cold weather, continue preheating for a further 10 seconds before releasing
the key.
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REMARK
The blade accumulator is effective in leveling road surfaces on
jobsites where there are many rocks or when clearing
compressed snow.
The blade float is effective when clearing fresh snow.
CIGARETTE LIGHTER
This cigarette lighter (6) is used to light cigarettes. When the
cigarette lighter is pushed in, it will return to its original position after
several seconds, so pull it out and use it to light your cigarette.
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WARNING
Use the hazard lamp only in emergencies. Using the hazard lamp when traveling may cause confusion for other machine
operators.
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! : Manual gearshifting uses the torque converter lock-up from the beginning
With automatic gearshifting, when the travel speed rises and the torque converter slippage is reduced, the
transmission is automatically locked up.
" : Remains in torque converter drive (torque converter drive is held, regardless of travel speed or engine speed)
Manual gearshifting: Transmission is held in same gear range as position of gearshift lever
Automatic gearshifting: Transmission is automatically shifted according to travel speed within maximum range set
by position of gearshift lever
REMARK
When Mode 1 is selected, the engine may stall because of the use of direct power shift.
When Mode 2 is selected and work is carried out in F1 with the engine at low idle, it becomes easier to perform
light load operations, such as finishing work at low travel speed (approx. 1 km/h (0.6 MPH)).
When Mode 2 is selected and the gear speed range is set between F5 and F8, the transmission is shifted
automatically. With automatic transmission, the transmission starts in F4 torque converter drive, and shifts up
automatically as necessary through the gear speeds to the set gear speed range.
Even if the gearshift lever is shifted, if there is danger of overrun, the overrun inhibitor is actuated to prevent
gearshifting. When the travel speed drops to a speed where there is no danger of overrun, the transmission
starts to shift again.
DIMMER SWITCH
(If equipped)
This switch (11) is used to switch the head lamps between high
beam and low beam.
(a) High beam
(b) Low beam
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HORN BUTTON
When horn button (14) in the center of the steering wheel is
pressed, the horn will sound.
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REMARK
The yellow rotating lamp is used when carrying out operations, but
follow the guidance of the supervisor.
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This is the switch installed to the defroster and can be used to stop
or start operation of the defroster.
This is the switch installed to the defroster and can be used to stop
or start operation of the defroster.
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(1) Left blade lift cylinder control lever (10) Right blade lift cylinder control lever
(2) Ripper/Scarifier control lever (if equipped) (11) Inching pedal
(3) Blade side shift control lever (12) Steering console tilt pedal
(4) Power tilt control lever (13) Brake pedal
(5) Blade rotation control lever (14) Accelerator pedal
(6) Articulate control lever (15) Decelerator pedal
(7) Front attachment control lever (16) Gearshift lever
(8) Drawbar side shift control lever (17) Fuel control lever
(9) Leaning control lever
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.
WARNING
Operate this lever only when traveling at a speed of below 10 km/h (6.2 MPH). If the articulation is operated at a speed of over 10
km/h (6.2 MPH), there is danger that the machine may overturn.
NOTICE
To prevent damage to the tires, be careful not to let the blade hit the tires when articulating the machine.
3 - 28
.
3 - 29
.
INCHING PEDAL
NOTICE
Do not operate continuously for more than 10 seconds. If the inching operation is used continuously for more than 10 seconds,
it will cause serious damage to the clutch, such as abnormal wear or seizure.
This pedal (11) cuts off the power from the engine.
Use this pedal when stopping the machine, starting the machine
off, or when shifting the direction between forward and reverse.
When the pedal is depressed, the power is cut off.
When the transmission is in F1 - F4 or in R2, operating this pedal
makes it possible to make fine movements of the machine.
REMARK
The steering wheel, instrument panel, and work equipment control
levers also move forward or backward at the same time.
3 - 30
.
BRAKE PEDAL
WARNING
Do not place your foot on this pedal unnecessarily.
ACCELERATOR PEDAL
This pedal (14) adjusts the engine speed.
It is interconnected with the fuel control lever, and it can be used
freely to operate from the position set by the fuel control lever to the
full speed position.
DECELERATOR PEDAL
This pedal (15) is used to adjust the engine speed.
It is interconnected with the fuel control lever; when the fuel control
lever is pulled, the decelerator pedal rises.
When the decelerator pedal has risen and it is depressed, the
engine speed will go down.
3 - 31
.
GEARSHIFT LEVER
WARNING
When standing up from the operator's seat, always set the gearshift lever
to the P (Parking) position.
REMARK
The gearshift lever must be placed at the P (Parking) position to
start the engine.
The gearshifting pattern differs according to the position of the
transmission mode selector switch. For details, see
"TRANSMISSION MODE SELECTOR SWITCH (PAGE 3-18)".
REMARK
Use the fuel control lever only when starting the engine or
during operations. For general travel, use the accelerator
pedal.
3 - 32
.
DUST INDICATOR
This device checks the condition of clogging of the air cleaner
element.
It displays five levels for the amount of clogging.
When the yellow display panel showing the clogging reaches the
red line, clean the element.
After cleaning the element, press the reset button to return the
yellow display panel to its original position.
This pin (1) 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.
FUSE BOX
WARNING
If the fuse blows again immediately after it is replaced, please contact your Komatsu distributor.
NOTICE
Always keep the hood locked except when opening it.
Check the direction of the key slot in the opening knob to check that it is locked.
The fuses protect the electrical equipment and wiring from burning
out.
If the fuse becomes corroded, or white powder can be seen, or the
fuse is loose in the fuse holder, replace the fuse.
Remove the cover, and replace the fuse.
Replace the fuse with another of the same capacity.
3 - 33
.
Fuse II
3 - 34
.
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.
4. Check for oil leakage of oil from transmission case, final drive case, tandem drive case, hydraulic tank, circle
reverse gear case, hose, joints.
Check that there is no oil leakage. If any problem is found, repair the place where the oil is leaking.
6. Check for 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.
3 - 35
.
OPERATION OPERATION
WARNING
If worn or damaged tires are used, they may burst and cause serious injury
or death.
To ensure safety, do not use the following tires.
Wear:
Tires with a tread grooves of less than 15% of that of a new tire
Tires with extreme uneven wear or with stepped-type wear
Damage:
Tires with damage that has reached the cords, or with cracks in the
rubber
Tires with cut or pulled cords
Tires with peeled (separated) surface
Tires with damaged bead
Leaking or improperly repaired tubeless tires
Deteriorated, deformed or abnormally damaged tires, which do not
seem usable
WARNING
Check the rims (wheels) and rings for deformation, corrosion and cracks.
In particular, check the side rings, lock rings and rim flanges thoroughly.
3 - 36
.
OPERATION OPERATION
WARNING
Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool down and check
the sub tank.
Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
If the cap is removed to check the coolant level in this condition, there is a hazard of burns. Wait for the temperature to go
down, then turn the cap slowly to release the pressure and remove it carefully.
NOTICE
If the volume of coolant added is more than usual, check for possible water leakage.
Confirm that there is no oil in the coolant.
1. Check that the cooling water in sub tank (1) is between the H
and L marks. If the level is low, open the cover and add water
through the water filler of sub tank (1) to between the H and L
marks.
2. After adding coolant, tighten the cap securely.
3 - 37
.
OPERATION OPERATION
WARNING
When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. Never bring 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.
2. After completing work, fill the fuel tank through fuel filler port
(F).
3. After adding fuel, tighten the cap securely.
Fuel capacity: 340 liters (89.76 US gal)
3 - 38
.
OPERATION OPERATION
REMARK
If water collects in the water separator, the red ring floats up. The
area below the red ring is water.
3. If red ring (1) floats up, loosen drain valve (2) and drain the
water.
4. If the ring floats up to the standard line, carry out cleaning. For
details, see Section "CLEAN, CHECK WATER SEPARATOR
(PAGE 4-26)".
3 - 39
.
OPERATION OPERATION
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 at the front of the rear left side of the machine.
2. Remove dipstick (G), and wipe the oil off with a cloth.
3. Fully insert dipstick (G) into filler pipe (F), then remove it.
4. The oil level should be between the marks on dipstick (G).
If the oil level is below the mark, add engine oil through oil filler
(F).
5. If the oil is above the H mark, open drain plug (P) at the rear
right of the machine, drain the excess oil into a container, and
check the oil level again.
6. If the oil level is correct, tighten the oil filler cap securely and
close the engine side cover.
REMARK
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before
checking. If the machine is at an angle, make it horizontal before
checking.
When adding oil, remove the dipstick from the guide to release the
air inside the crankcase.
3 - 40
.
OPERATION OPERATION
3 - 41
.
OPERATION OPERATION
WARNING
If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause and immediately
perform repairs, or contact your Komatsu distributor for repairs.
Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash
the battery cap to clean the breather hole.
Check that there is no damage to the fuses; that fuses of the specified capacity are used; that there is no
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.
CHECK THAT ALL PROBLEMS FROM PREVIOUS DAY HAVE BEEN REPAIRED
CHECK THAT WINDSHIELD WIPER, WINDOW WASHER, AND DEFROSTER WORK PROPERLY, CHECK WASHER
FLUID LEVEL
3 - 42
.
OPERATION OPERATION
ADJUSTMENTS
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.
3 - 43
.
OPERATION OPERATION
WARNING
Do not adjust the instrument panel when traveling.
WARNING
Do not adjust the instrument panel when traveling.
Turn knob (1) to the left to release the lock, set the top of the panel
to the desired position, then tighten the knob.
The drawing shows the machine with the cab (if equipped) installed
3 - 44
.
OPERATION OPERATION
3 - 45
.
OPERATION OPERATION
3 - 46
.
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.
2. Turn the key in starting switch (2) to the START position. The
engine will start.
3 - 47
.
OPERATION OPERATION
3. When the engine starts, release the key in starting switch (2).
The key will return automatically to the ON position.
NOTICE
If there is no combustion in the engine (no smoke comes out from the
exhaust pipe) when the starting motor is cranked, do not keep the
starting motor rotating continuously for more than 20 seconds.
If the engine fails to start, repeat steps 1 - 3 after waiting for about 2
minutes.
Do not start the engine with the fuel control lever and the accelerator
pedal depressed to the FULL OPEN position.
3 - 48
.
OPERATION OPERATION
2. Turn the key in the starting switch (2) to the HEAT position.
Even after preheating lamp (3) goes out, keep the key at the
HEAT position for approx. 10 seconds.
REMARK
The preheating lamp goes out after 20 seconds, but in cold
weather, continue the preheating for a further 10 seconds.
4. Keep starting aid switch (4) pressed and turn the key in the
starting switch (2) to the START position. The engine will start.
3 - 49
.
OPERATION OPERATION
5. When the engine starts and the speed rises strongly, release
starting switch (2). The key will return automatically to the ON
position. Keep starting aid switch (4) pressed.
3 - 50
.
OPERATION OPERATION
NOTICE
Before operating the machine for the first time, check that there is coolant in the radiator. If the machine has been delivered
without coolant in the radiator, run water through the system to flush the system thoroughly, then fill the radiator with coolant.
3 - 51
.
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.
3 - 52
.
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).
3 - 53
.
OPERATION OPERATION
NOTICE
Pay careful attention to the clearance between the blade and the front tire.
If articulation is carried out with the blade at the propulsion angle, the blade may cut the tire or bend the step.
1. During general travel operations, raise the front and rear ends
of the blade equally and set so that the blade does not extend
outside the machine, as shown in the diagram on the right.
3 - 54
.
OPERATION OPERATION
NOTICE
Before starting the machine off, check that the brake oil pressure warning buzzer is not sounding.
3. Always check that parking brake lamp (4) has gone out.
3 - 55
.
OPERATION OPERATION
4. Let inching pedal (3) back and depress accelerator pedal (6) to
move the machine off.
NOTICE
When shifting gear, always shift one gear at a time.
INCREASE SPEED
Let back accelerator pedal (1) and shift gearshift lever (2) up to the
next speed range.
REDUCING SPEED
Release accelerator pedal (1) to reduce speed, then shift gearshift
lever (2) down one range.
3 - 56
.
OPERATION OPERATION
REMARK
When switching between forward and reverse travel when the machine is traveling, to protect the operator and the
machine, the speed may gradually be decreased and the direction of travel switched, but this is not a problem.
3 - 57
.
OPERATION OPERATION
STOPPING MACHINE
WARNING
Avoid stopping suddenly. Give yourself ample room when stopping.
2. Depress brake pedal (3) to reduce speed, then just before the
machine stops, depress inching pedal (4) and stop the
machine.
3 - 58
.
OPERATION OPERATION
TURNING MACHINE
WARNING
It is dangerous to turn the machine suddenly at high speed or to turn the
machine on steep slopes.
If the engine stops when the machine is traveling, the steering will
become heavy, so never stop the engine.
This is particularly dangerous on slopes, so never allow the engine to
stop while traveling on slopes under any circumstance.
If the engine stops, immediately apply the brake and stop the machine
in a safe place.
To turn the machine when traveling, turn steering wheel (1) in the
direction of the turn.
LEANING OPERATION
Operate leaning control lever (2) to change the angle of the front
tires as follows.
Pull BACK to lean to RIGHT.
Push FORWARD to lean to LEFT.
When traveling forward and turning the machine, the radius of the
turn becomes smaller if the tires are leaned in the direction of the
turn.
When traveling in reverse and turning the machine, the radius of
the turn becomes smaller if the tires are leaned in the opposite
direction to the turn.
3 - 59
.
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 23 to the left or right, and the turning radius is 6.9 m (22 ft 8
in).
1. Stop the machine, remove pin (1), and insert it in the storage
position.
3 - 60
.
OPERATION OPERATION
3. When not operating the articulation, set the front frame and
rear frame straight, align the pin holes, and fix the front and rear
frames in the original position with pin (1).
3 - 61
.
OPERATION OPERATION
(1) Left blade control lever (5) Power tilt control lever
(2) Right blade control lever (6) Drawbar side shift control lever
(3) Blade side shift control lever (7) Ripper/Scarifier control lever (if equipped)
(4) Blade rotation control lever
3 - 62
.
OPERATION OPERATION
BLADE OPERATION
3 - 63
.
OPERATION OPERATION
3 - 64
.
OPERATION OPERATION
Use a larger cutting angle when cutting hard soil and a smaller
cutting angle when cutting soft soil.
The distance between the cutting surface and the blade edge can
be changed, so it is possible to carry out fine adjustment of the
height of the cutting surface
3 - 65
.
OPERATION OPERATION
3 - 66
.
OPERATION OPERATION
OPERATING RIPPER/SCARIFIER
When the machine is equipped with a ripper
Use ripper/scarifier control lever (7) to operate the ripper as
follows.
RAISE: Pull lever back
LOWER: Push lever forward
3 - 67
.
OPERATION OPERATION
2. Set the blade so that the earth is discharged outside the rear
left wheel.
3. Operate the blade lift cylinder so that the blade is at the desired
digging depth, then set it horizontal.
REMARK
Leaning the wheels to the left prevents the machine from being
pushed to the right by the load acting on the left side of the
machine.
5. Rotate so that the blade is at the optimum position for the soil. (Be careful not to let the rear left wheel run over
the windrow discharged from the blade.)
3 - 68
.
OPERATION OPERATION
6. Operate the power tilt so that the top of the blade is slightly in
front of the cutting edge, then start operation.
7. Discharge the soil to the side to prevent any excessive load
from bearing on the machine.
8. Spread fine crushed loose soil over the ground surface until it is level.
REMARK
Generally speaking, carry out operations on flat ground with the frame straight to the blade. Articulate the frame
to deal with the force in the side direction caused by the load on the blade.
If the tires start to spin, turn the blade to a greater angle to reduce the digging width, thereby reducing the load
on the machine.
In leveling operations, discharge the soil outside the rear wheels. This makes it easier to steer with the rear
wheels.
3 - 69
.
OPERATION OPERATION
2. Set the blade so that the earth is discharged outside the rear
right wheel.
3. Operate the blade lift cylinder so that the blade is at the desired
digging depth, then set it horizontal.
3 - 70
.
OPERATION OPERATION
1. Rotate the blade and set at an angle so that the soil will be
discharged on the inside of the rear left wheel.
2. Set the right edge of the blade in line with the outside of the
front right wheel.
3. Operate the power tilt so that the top of the blade is slightly in
front of the cutting edge.
4. 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.)
3 - 71
.
OPERATION OPERATION
5. Lean the front tire to the left to prevent the tire from rubbing
against the side face of the ditch.
6. Operate the right blade lift cylinder and set the right end of the blade to a digging depth of 50 to 100 mm (2.0 to
3.9 in).
7. Operate the right blade lift cylinder while traveling to set the
right edge of the blade to the desired digging depth.
8. Align the front right wheel with the bottom of the ditch and dig a ditch of the desired depth.
First, dig to depth of 50 mm (2.0 in) to determine the line of the ditch.
The chassis is in an unstable position when digging ditches, so align the front and rear wheels with the bottom
of the ditch when carrying out such operations.
3 - 72
.
OPERATION OPERATION
1. Rotate the blade and set at an angle so that the soil will be
discharged on the inside of the rear right wheel.
2. Set the left edge of the blade in line with the outside of the front
left wheel.
3. Operate the power tilt so that the top of the blade is slightly in
front of the cutting edge.
4. 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.)
3 - 73
.
OPERATION OPERATION
5. Lean the front tire to the right to prevent the tire from rubbing
against the side face of the ditch.
6. Operate the left blade lift cylinder and set the right end of the blade to a digging depth of 50 to 100 mm (2.0 to
3.9 in).
7. Operate the left blade lift cylinder while traveling to set the left end of the blade to the desired digging depth.
8. Align the front right wheel with the bottom of the ditch and dig
a ditch of the desired depth.
First, dig to depth of 50 mm (2.0 in) to determine the line of
the ditch.
The chassis is in an unstable position when digging ditches,
so align the front and rear wheels with the bottom of the ditch
when carrying out such operations.
3 - 74
.
OPERATION OPERATION
2. Operate the right blade lift cylinder and set the blade to the
depth of the ditch.
3. Be careful not to let the rear left wheel run over the window
discharged from the blade.
Operate the blade lift cylinder and blade rotation to set the
blade in position.
4. Lean the front wheels slightly to the left.
5. To push out the soil to the top of the slope face and the road shoulder, a separate pass is needed. Spread the
soil, then carry out final finishing with the grader.
3 - 75
.
OPERATION OPERATION
2. Operate the left blade lift cylinder and set the blade to the depth
of the ditch.
3. Be careful not to let the rear right wheel run over the windrow
discharged from the blade.
Operate the blade lift cylinder and blade rotation to set the
blade in position.
4. Lean the front wheels slightly to the right.
5. To push out the soil to the top of the slope face and the road shoulder, a separate pass is needed. Spread the
soil, then carry out final finishing with the grader.
3 - 76
.
OPERATION OPERATION
2. Align the center of the machine with the line of the soil
discharged when digging the ditch.
3. Operate the left and right blade lift cylinders to keep the blade
horizontal and at the desired digging depth.
3 - 77
.
OPERATION OPERATION
2. Set so that the left end of the blade is in line with the outside of
the left tire. Set the blade so that the soil is discharged between
the two wheels. (The soil can be moved more smoothly if the
blade is at a small propulsion angle.)
3. Align the center of the machine with the line of the soil
discharged when digging the ditch.
4. Operate the left and right blade lift cylinders to keep the blade
horizontal and at the desired digging depth.
3 - 78
.
OPERATION OPERATION
3 - 79
.
OPERATION OPERATION
5. Leveling center
8. Spreading to center
3 - 80
.
OPERATION OPERATION
11. Ditch digging pass (finishing and shaping inside of the slope
face)
3 - 81
.
OPERATION OPERATION
FLAT-BOTTOMED DITCH
When there is no V-ditch, make a V-ditch at the depth of the
flat-bottomed ditch.
The slope face of the road shoulder must be flatter than normal.
1. Operate the power tilt and angle the blade to the front.
2. Operate the drawbar shift cylinder and set the circle fully to the
left of the machine.
5. Operate the right blade lift cylinder to lower the right end of the
blade, and set it to the digging depth.
6. Operate the left blade lift cylinder to raise the right end of the
blade, and set it to the desired angle for the slope face of the
road shoulder.
3 - 82
.
OPERATION OPERATION
7. Lean the front wheels to the left. Dig the No. 2 V-ditch to the
same depth or slightly deeper than the No. 1 ditch.
8. Dig the flat bottom. Set the right blade lift cylinder to the desired
depth.
9. Operate the left blade lift cylinder as required.
10. Set the front right tire at the bottom of the first V-ditch and start
the operation.
11. Set the right edge of the blade at the bottom of the slope.
12. Lower the right blade lift cylinder so that the tip of the blade is
the set precision for the ditch.
13. Lower the left lift cylinder to the desired digging depth. Lean the
front wheels to the left.
14. Set the blade at an acute angle and push up the soil to the top of the ditch slope.
15. Spread the windrow and finish to the final precision.
3 - 83
.
OPERATION OPERATION
2. Dig the width and depth of the bottom of the ditch with the left
ditching method.
3 - 84
.
OPERATION OPERATION
3 - 85
.
OPERATION OPERATION
FINISHING WITH GRADER FOR DITCHES WHERE WET ROAD SHOULDER IS LOOSE
This method is used when avoiding hanging trees or protruding rocks which are obstacles when cleaning old
ditches.
1. Articulate the machine so that the front wheels and blade
remain in the ditch. Steer with the front wheels.
2. Keep the rear wheels on the road shoulder and be careful that
the wheels do not slip on the soft weak soil of the ditch.
3 - 86
.
OPERATION OPERATION
4. Rotate the circle and extend or retract the left and right blade lift cylinders to set to the bank slope face posture.
5. From the high bank position, rotate the blade so that the top of
the blade is at the front. This sets it to the low bank posture,
which is suited for scraping operations.
REMARK
If the top of the blade is rotated to the rear, the blade can be set to
the reverse low bank posture, which makes it possible to cut the
slope face while scraping up the soil.
To scrape up the soil smoothly, a shallow angle slope is needed.
Rotate the blade until the bottom of the blade is close to the front
tires. Be careful not to let the blade hit the tires.
6. 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.
7. The rear right wheel must be in the V at the base of the slope
face.
8. Extend the right blade lift cylinder and set the angle to the desired bank slope face.
9. Gradually progress with the cutting.
REMARK
The wheels should normally be almost perpendicular.
3 - 87
.
OPERATION OPERATION
REMARK
The procedure in the diagram is for the right side. For the left side,
set the blade in the opposite position.
3 - 88
.
OPERATION OPERATION
TRAVELING DOWNHILL
When traveling downhill, use the same speed range as when traveling uphill, and make full use of the braking force
of the engine.
If the machine travel speed is still too fast, use the foot brake.
REMARK
If there is danger of overrunning, a short warning will be sounded and the transmission will automatically shift up to
the next speed range, but this does not indicate any problem. When the travel speed is reduced, the transmission
will automatically return to the speed range set by the gearshift lever.
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.
3 - 89
.
OPERATION OPERATION
NOTICE
If the parking brake has been used as an emergency brake, contact your Komatsu distributor to have the parking brake checked
for any abnormality.
3 - 90
.
OPERATION OPERATION
3 - 91
.
OPERATION OPERATION
Keep the ripper at a depth where there is no tire slip and where the
engine horsepower can be used to its full.
NOTICE
To prevent damage, raise the ripper from the ground before turning the
machine.
3 - 92
.
OPERATION OPERATION
BLADE PROTRUSION
The degree of protrusion is controlled by the control lever during
operation. If further protrusion is needed, stop the grader for a
while and change the installing position of the blade horizontal
shifting cylinder piston rod, as follows.
1. Lower the blade to the ground.
2. Loosen the bolt holding the blade to the bracket at the tip of the
cylinder rod, then remove the bolt and lock washer.
3. Pull in the cylinder rod.
4. Align the bolt hole in the bracket with a hole in another place on
the blade.
5. Install the lock washer and bolt, then tighten the bolt.
Protrusion to right: Position (1)
Protrusion to left: Position (2)
Standard position: Center
3 - 93
.
OPERATION OPERATION
The power tilt blade can carry out normal blade operation, and also has the following advantages.
It is possible to set to the optimum blade cutting angle to match
the type of soil simply by operating one lever.
3 - 94
.
OPERATION OPERATION
When scooping up soil or snow with the low bank posture, the optimum blade cutting angle is selected, so work
can be carried out efficiently.
3 - 95
.
OPERATION OPERATION
WARNING
Check that the surrounding area is safe before replacing the shear pin.
3 - 96
.
OPERATION OPERATION
Examples of problems
Even when the circle rotation lever is operated, the circle does not rotate.
The motor is turning, but the clutch slips and the circle does not turn.
-> There is serious danger of the clutch burning out, so it must be adjusted.
The hydraulic pressure is relieved and the circle does not turn.
-> The condition is normal, but if the slip torque is at the maximum, it may cause damage.
3 - 97
.
OPERATION OPERATION
NOTICE
When shifting to the bank cut posture, be careful not to let the blade hit any other part of the machine.
If the bank pin passes over the hole in the lifter guide, do not rotate the lifter any further. There is danger that the frame and bank
pin case will come into contact and that the bank pin case will be broken.
1. Extend the blade and drawbar fully to the right, rotate the circle
and set the end of the blade at the side of the front right wheel,
then lower the blade so that it is lightly in contact with the
ground.
2. Push the bank control lock pin switch and remove lock pin (1).
If lock pin (1) is held by lifter (2) and will not come out, operate
the blade lift cylinder to make it possible to remove the pin.
3. Check that indicator pin (3) at the rear of the lock pin has come
out fully and that the lock pin has been removed, then extend
the right blade lift cylinder and retract the left blade lift cylinder
to rotate lifter (2) counterclockwise.
Operate lifter (2) to the desired counter mark (A), then lock with
lock pin (1).
Check that the protrusion of indicator pin (3) has been removed
and that the lock pin is completely locked.
NOTICE
If the lock pin switch is kept pushed in the pin lock direction while the lifter
is being rotated, there is danger that the bushing or lifter ring will be
damaged. Rotate the lifter to the specified counter mark, then lock the lock
pin.
3 - 98
.
OPERATION OPERATION
4. Retract the right lift cylinder and extend the left lift cylinder
repeatedly, then raise the blade and rotate it to the right side of
the machine to set the blade to the bank cut position.
When setting to the bank cut posture on the left side, use the
same procedure as above, but in the opposite direction.
REMARK
The banking performance can be improved by changing the
mounting position of the piston rod of the blade side shift cylinder
to the left for right side banking and to the right for left side banking.
3 - 99
.
OPERATION OPERATION
NOTICE
When shifting to the shoulder reach posture, be careful not to let the blade hit any other part of the machine.
If the bank pin passes over the hole in the lifter guide, do not rotate the lifter any further. There is danger that the frame and bank
pin case will come into contact and that the bank pin case will be broken.
1. Extend the blade and drawbar fully to the right, rotate the circle
and set the end of the blade at the side of the front right wheel,
then lower the blade so that it is lightly in contact with the
ground.
2. Push the bank control lock pin switch and remove lock pin (1).
If lock pin (1) is held by lifter (2) and will not come out, operate
the blade lift cylinder to make it possible to remove the pin.
3. Check that indicator pin (3) at the rear of the lock pin has come
out fully and that the lock pin has been removed, then extend
the right blade lift cylinder and retract the left blade lift cylinder
to rotate lifter (2) counterclockwise.
Operate lifter (2) to the desired counter mark (A), then lock with
lock pin (1).
Check that the protrusion of indicator pin (3) has been removed
and that the lock pin is completely locked.
NOTICE
If the lock pin switch is kept pushed in the pin lock direction while the lifter
is being rotated, there is danger that the bushing or lifter ring will be
damaged. Rotate the lifter to the specified counter mark, then lock the lock
pin.
3 - 100
.
OPERATION OPERATION
When setting to the shoulder reach posture on the left side, use the same procedure as above, but in the opposite
direction.
REMARK
If it is desired to make the shoulder reach posture even larger, change the mounting position of the piston rod for
the blade side shift cylinder.
For details, see "BLADE PROTRUSION (PAGE 3-93)".
ADJUSTING SCARIFIER
Adjustment
Remove bolt (1), then move the position of the hole to the desired
position.
3 - 101
.
OPERATION OPERATION
3 - 102
.
OPERATION OPERATION
PARKING MACHINE
WARNING
Avoid stopping suddenly; give yourself ample room when stopping.
Do not park the machine on slopes.
If the machine has to be parked on a slope, set it at right angles to the
slope, put blocks under the tires, and dig the blade into the ground
surface to prevent the machine from moving.
If the control levers are not locked and they are touched by accident
when starting the engine, the work equipment may move unexpectedly,
and this may lead to a serious accident.
When standing up from the operator's seat, always set the gearshift
lever to the P (Parking) position.
2. Depress brake pedal (3) to reduce speed, then just before the
machine stops, depress inching pedal (4) and stop the
machine.
3 - 103
.
OPERATION OPERATION
4. Operate the work equipment control lever, and lower the blade
and the ripper to the ground.
3 - 104
.
OPERATION OPERATION
LOCKING
Always lock the following parts.
(1) Cab door (left, right)
(2) Front side cover (left, right)
(3) Rear side cover (left, right)
(4) Fuel filler cap
REMARK
The starting switch key is used also for locks (1), (2), (3), and (4).
3 - 105
.
TRANSPORTATION OPERATION
TRANSPORTATION
When transporting the machine, observe all related laws and regulations, and be careful to assure safety.
When loading or unloading, always use ramps or a platform and carry out the operations as follows.
1. Apply the brakes on the trailer securely and insert blocks under
the tires to ensure that the trailer does not move.
Then fix the ramps in line with the centers of the trailer and the
machine.
Be sure that the two sides are at the same height as one
another.
Make the angle of the ramps a maximum of 15.
Set the distance between the ramps to match the center of the
tires.
2. Set the machine in line with the ramps, then drive the machine
slowly to load or unload it.
3. Load the machine correctly in the specified position on the
trailer.
REMARK
When loading or unloading the machine, rotate the blade from the travel posture, then raise it fully. This makes
it easier to load or unload the machine.
If the ripper teeth make it difficult to load the machine, remove the ripper teeth or install them so that they face
the top inside. This makes loading easier.
3 - 106
.
OPERATION TRANSPORTATION
REMARK
The towing pin, hole in the frame under the operator's platform, and the drawbar hole can be used to hold the
machine in position.
3 - 107
.
COOLANT
WARNING
Keep antifreeze fluid away from open flames. Never smoke when using 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 4-19)".
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.
3 - 108
.
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 0 -10 -20
Charging (C)
Rate (%)
100 1.28 1.29 1.30 1.31
90 1.26 1.27 1.28 1.29
80 1.24 1.25 1.26 1.27
75 1.23 1.24 1.25 1.26
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the
electrolyte from freezing.
3 - 109
.
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 0C (32F), 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 -10C (14F).
If the temperature goes below -10C (14F), adjust the density. For details, see "CLEAN INSIDE OF COOLING
SYSTEM (PAGE 4-19)".
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.
3 - 110
.
OPERATION TROUBLESHOOTING
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
When starting after running out of fuel, fill the water separator and fuel filter cartridge with clean fuel, then fill the fuel
tank with fuel and bleed the air from the fuel system before starting the engine.
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.
7. Turn the key in the starting switch to the START position and start the engine.
When doing this, do not crank the starting motor continuously for more than 20 seconds. If the engine does not
start, wait for at least 2 minutes, then try again. Perform this operation a maximum of 4 times.
8. If the engine does not start, repeat the operation from Step 4.
3 - 111
.
TROUBLESHOOTING OPERATION
If the leaning piping is broken, call your Komatsu distributor for repair.
3 - 112
.
OPERATION TROUBLESHOOTING
NOTICE
Towing is to be used only for moving the machine to a safe place where it is possible to carry out inspection and maintenance.
Do not use towing to move a machine for a long distance.
Please consult your Komatsu distributor for details of the method of towing a machine that has broken down.
NOTICE
If the machine is towed without the engine running, no lubrication oil will be supplied to the transmission. The gears and bearings
are rotated, so this may cause them to be damaged.
3 - 113
.
TROUBLESHOOTING OPERATION
When moving a failed machine on a downhill slope, a larger towing machine must be used to ensure ample
control and braking power. Another method is to use a second towing machine at the rear of the failed machine.
In this way, it is possible to prevent the failed machine from going out of control and turning over.
It is impossible to determine the drawbar pull needed for various conditions. The minimum drawbar pull may be
sufficient on horizontal, flat ground, but the maximum drawbar pull is needed on slopes or on rough roads.
When towing a failed machine, please contact your Komatsu distributor.
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 engine will not run for some reason, use the following methods to release the parking brake and tow the
machine.
1. Remove cover plug (2) of parking brake (1) at the rear of the
final drive case.
2. Loosen adjustment bolt (4) and locknut (3) inside the spring
chamber until a clearance is formed between the disc and pad.
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.
3 - 114
.
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.
3 - 115
.
TROUBLESHOOTING OPERATION
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.
3 - 116
.
OPERATION TROUBLESHOOTING
CAUTION
Check that the gearshift levers on both the normal machine and problem machine are at the P (Parking) position. Check also that
all levers are at neutral.
1. Make sure the clips are firmly connected to the battery terminals.
2. Start engine of the normal machine and run it at high idle 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.
3 - 117
.
TROUBLESHOOTING OPERATION
OTHER TROUBLE
ELECTRICAL SYSTEM
( ): Always contact your Komatsu distributor when dealing with these items.
In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs.
3 - 118
.
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.
3 - 119
.
TROUBLESHOOTING OPERATION
3 - 120
.
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.
3 - 121
.
TROUBLESHOOTING OPERATION
3 - 122
.
OPERATION TROUBLESHOOTING
3 - 123
.
TROUBLESHOOTING OPERATION
ERROR CODES
If any problem occurs, stop the machine at a safe place, set the gearshift lever to the P (Parking) position, check the
error code, then contact your Komatsu distributor for repairs.
REMARK
If multiple failures occur at the same time, each service code is displayed in turn for 2 seconds each.
3 - 124
.
4-1
.
GUIDES TO MAINTENANCE
Do not perform any inspection and maintenance operation that is not found in this manual.
Welding instructions:
Turn off the engine starting switch.
Do not apply more than 200 V continuously.
Connect grounding cable within 1 m (3.3 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.
4-2
.
Dusty worksites:
When working at dusty worksites, do as follows:
Inspect the air cleaner clogging monitor frequently to see if the dust indicator is clogged.
Clean the air cleaner element at a shorter interval than specified.
Clean the radiator core frequently to avoid clogging.
Clean and replace the fuel filter frequently.
Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.
When inspecting or changing the oil, move the machine to a place that is free of dust to prevent dirt from getting
into the oil.
4-3
.
OUTLINES OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
OIL
Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high
pressure), and deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual.
Even if the oil is not dirty, always change the oil after the specified interval.
Oil corresponds to blood in the human body, always be careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from getting in.
The majority of problems with the machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
Never mix oils of different grades or brands.
Always add the specified 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 -15C (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 4-19)".
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 4-19)".
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
.
GREASE
Grease is used to prevent seizure and noises at the joints.
The nipples not included in the MAINTENANCE section are nipples used when overhauling, so they do not need
grease.
If any part becomes stiff or generates noise after being used for a long time, grease it.
Always wipe off all of the old grease that is pushed out when greasing.
Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause
wear of the rotating parts.
4-5
.
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.
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.
4-6
.
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.
4-7
.
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.
Replacement
Item Part No. Part Name Q'ty
interval
Engine oil filter 6742-01-4540 Cartridge 1 Every 250 hours
Fuel filter 600-311-8321 Cartridge 1 Every 500 hours
Corrosion resister 600-411-1191 Cartridge 1 Every 1000 hours
Transmission oil filter 714-07-28711 Cartridge 1 Every 1000 hours
Hydraulic filter 07063-51100 Element 1
Every 1000 hours
(07000-15155) (O-ring) (1)
Air cleaner 600-185-5100 Element ass'y 1 -
23B-70-31310 Edge 2
23B-70-31660 Side edge 2
(232-70-12550) (Bolt) (34)
232-70-31340 End bit 2
(232-70-12560) Bolt (10)
23B-70-31331 Guide bushing 4
Blade -
23B-735-3320 Guide bushing 1
23B-70-31630 Plate 6
23B-70-51560 Guide 6
234-71-13443 Shear pin 1
23B-70-51560 Wear piece 6
23B-70-31630 Wear plate 6
4-8
.
4-9
.
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 0C (32F), be sure to use engine oil
of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10C (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.
4 - 10
.
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT(Winter, one
EO15-40CD season type)
Diesel sigma S
super dieselmulti-
2 AGIP Rotra MP GR MU/EP -
grade
*Sigma turbo
Multi-purpose gear PYKON premium
3 AMOCO *Amoco 300 -
oil grease
Litholine HEP 2
4 ARCO *Arcofleet S3 pius Arco HD gear oil -
Arco EP moly D
Gear oil EP
5 BP Vanellus C3 Energrease LS-EP2 Antifreeze
Hypogear EP
*RPM delo 400 Universal thuban Marfak all purpose 2
6 CALTEX AF engine coolant
RPM delo 450 Universal thuban EP Ultra-duty grease 2
EP
*Turbomax EPX
MS3
7 CASTROL *RX super Hypoy Anti-freeze
Spheerol EPL2
CRD Hypoy B
Hypoy C
8 CHEVRON *Delo 400 Universal gear Ultra-duty grease 2 -
Universal gear
9 CONOCO *Fleet motor oil Super-sta grease -
lubricant
Multiperformance 3C Tranself EP
10 ELF - Glacelf
Performance 3C Tranself EP type 2
Essolube D3
*Essolube XD-3
EXXON Gear oil GP
11 *Essolube XD-3 Extra Beacon EP2 All season coolant
(ESSO) Gear oil GX
*Esso heavy duty
Exxon heavy duty
Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and
12 GULF
*Super duty plus lubricant Gulfcrown EP special coolant
Delvac 1300 Mobilux EP2
Mobilube GX
13 MOBIL *Delvac super Mobilgease 77 -
Mobilube HD
10W-30, 15W-40 Mobilgrease special
4 - 11
.
Engine Oil
Anti-freeze
[CD or CE]
Gear Oil Grease Coolant
SAE10W, 30, 40
No. Supplier [GL-4 or GL-5] [Lithium-Base] [Ethylene Glycol
10W30, 15W40
SAE80, 90, 140 NLGI No.2 Base]
(The 15W40 oil
Permanent Type
marked * is CE.)
Multi-purpose white
*Superme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White-bearing summer coolant
grease
PETROFIN FINA potonic N
15 FINA kappa TD FINA marson EPL2 FINA tamidor
E FINA potonic NE
Spirax EP
16 SHELL Rimura X Albania EP grease -
Spirax heavy duty
Sunoco ultra pres- Sunoco antifreeze
Sunoco GL5
17 SUN - tige 2EP and summer
gear oil
Sun prestige 742 coolant
*Ursa super plus Multifak EP2 Coda 2055 startex
18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total Transmission Multis EP2 Antigal/antifreeze
*Rubia X
TM
20 UNION *Guardol MP gear lube LS Unoba EP -
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B - Antifreeze
MDC Multigear C
4 - 12
.
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.
Taper seal
Thread Width Tightening torque
diameter across
Target value Permissible range
flats
a (mm) b (mm) Nm kgfm lbft Nm kgfm lbft
4 - 13
.
Face seal
13/16 -16UN 27 103 10.5 75.9 84 - 132 8.5 - 13.5 61.5 - 97.6
1 -14UNS 32 157 16.0 115.7 128 - 186 13.0 - 19.0 94.0 - 137.4
13/16 -12UN 36 216 22.0 159.1 177 - 245 18.0 - 25.0 130.2 - 180.8
4 - 14
.
CRITICAL PARTS
No. Safety critical parts for periodic replacement Q'ty Replacement interval
1 Fuel hose (fuel tank - fuel filter) 1
2 Fuel spill hose (nozzle - fuel tank) 1
3 Rod packing, piston seals, of steering cylinder 4
4 Dust seal for steering cylinder 2
5 O-ring for steering cylinder 4
6 Steering circuit rubber hose (steering pump - steering valve) 1
7 Steering circuit rubber hose (steering valve - steering cylinder) 8
Every 2 years
8 O-ring for steering valve 3 or
9 O-ring, seals, of steering valve 2 every 4000 hours,
whichever
10 Dust seal for steering valve 1
comes sooner.
Leaning circuit rubber hose
11 4
(right side of work equipment control valve - leaning cylinder)
12 Packing, dust seals, piston seals, of leaning cylinder 4
13 O-ring for leaning cylinder 2
14 Brake circuit rubber hose (governor valve - accumulator) 2
15 Brake circuit rubber hose (accumulator - slack adjuster) 5
16 Brake circuit rubber hose (slack adjuster - brake) 4
17 Seat belt 1 Every 3 years
4 - 15
.
INITIAL 250 HOURS SERVICE (only after the first 250 hours)
REPLACE FUEL FILTER CARTRIDGE 4- 49
CHANGE OIL IN TRANSMISSION CASE 4- 57
CHANGE OIL IN FINAL DRIVE CASE 4- 58
CHANGE OIL IN CIRCLE REVERSE GEAR CASE 4- 64
CHANGE OIL IN HYDRAULIC TANK 4- 63
REPLACE HYDRAULIC TANK FILTER ELEMENT 4- 58
CHANGE OIL IN TANDEM DRIVE CASE 4- 65
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 68
WHEN REQUIRED
CLEAN INSIDE OF COOLING SYSTEM 4- 19
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 4- 22
CLEAN, CHECK WATER SEPARATOR 4- 26
CHECK ELECTRICAL INTAKE AIR HEATER 4- 27
REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT 4- 27
CHECK INCHING PEDAL 4- 27
CLEAN AIR CONDITIONER AIR FILTER 4- 28
CHECK REFRIGENT (GAS) LEVEL 4- 29
CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT 4- 29
SELECTION AND INSPECTION OF TIRES 4- 30
4 - 16
.
4 - 17
.
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 HYDRAULIC TANK FILTER ELEMENT
CHANGE OIL IN TANDEM DRIVE CASE
Check engine valve clearance, adjust
For details of the method of replacing or maintaining, see the section on EVERY 250 HOURS, EVERY 500 HOURS,
1000 HOURS AND 2000 HOURS SERVICE.
4 - 18
.
WHEN REQUIRED
Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the table
below.
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.
Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect.
The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect,
a minimum ratio 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 10C (50F) lower when deciding the mixing rate.
Min. ambient C - 10 - 15 - 20 - 25 - 30
temperature F 14 5 -4 - 13 - 22
Amount of Liters 13 16 18 20 22
antifreeze US gal 3.43 4.23 4.76 528 5.81
Amount of Liters 31 28 26 24 22
water US gal 8.19 7.39 6.86 6.34 5.81
4 - 19
.
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.
2. Open cover (2), turn cap (3) of the upper tank slowly, then
remove it.
4 - 20
.
4 - 21
.
CHECKING
1. Open engine side cover.
2. If yellow display panel (2) in the transparent portion of dust
indicator (1) reaches red line (3), clean the air cleaner element.
NOTICE
Do not clean the element before the yellow display panel of the dust
indicator reaches the red line.
If the element is cleaned frequently before the yellow display panel of the
dust indicator reaches the red line, the air cleaner will not be able to display
its performance fully and the cleaning efficiency will also go down.
In addition, during the cleaning operation, more dirt stuck to the element
will fall inside the inner element.
4 - 22
.
NOTICE
Never remove inner element (6). If it is removed, dust will enter and cause
engine trouble.
NOTICE
When cleaning the dust cup, do not remove evacuator valve (7).
4. Clean the inside of the air cleaner body and dust cup.
4 - 23
.
5. Direct dry compressed air (less than 0.69 MPa (7 kgf/ cm2, 99.4
PSI)) to the element from inside along its folds, then direct it
from outside along its folds and again from inside.
1) 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.
2) If the yellow display panel of the dust indicator reaches the
center of the scale (5 kPa) immediately after the outer
element has been cleaned, replace both the inner and
outer elements, even when the outer element has not been
cleaned 6 times.
6. If small holes or thinner parts are found on the element when
it is checked by shining a light through it after cleaning, replace
the element.
NOTICE
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.
If force is used when assembling, the clip or air cleaner body will be
damaged, so push it in straight when installing it.
Do not operate the machine with the inner element removed. This will
damage the engine.
7. Set the cleaned outer element and install dust cup (4), then secure them with clips (3).
CAUTION
If the inner and outer element have been replaced, always replace O-ring (8) with a new part.
8. Press the button on dust indicator (1) to return the yellow display panel to its original position.
9. Close engine side cover.
4 - 24
.
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.
NOTICE
When cleaning the dust cup, do not remove evacuator valve (7).
4. Clean the inside of the air cleaner body and dust cup.
5. Remove inner element (6), then install a new inner element immediately.
6. Set new outer element (5) and install dust cup (4), then secure them with clips (3).
CAUTION
If the inner and outer element have been replaced, always replace O-ring (8) with a new part.
7. Press the button on dust indicator (1) to return the yellow display panel to its original position.
8. Close engine side cover.
4 - 25
.
If the engine does not run smoothly, there is probably water mixed in the fuel, so check and clean the water separator
as follows.
1. Open the engine side cover on the right side of the chassis.
2. Check the water separator to see that a red ring inside has
come up to the standard line.
3. If red ring (1) has come up to the standard line, carry out the
operation from Step 4 below.
4. Prepare a container to catch the drained fuel and set it under
the water separator.
5. Loosen drain valve (1) at the bottom of the water separator and
drain the water and fuel into the container.
6. Loosen ring nut (2), then remove element cup (3).
7. Remove element (4) from the separator base.
8. Wash the interior of filter element (4) and element cup (3) with
clean fuel.
9. Check element (4) and replace it if it is damaged.
10. Clean the water separator base, then fill washed element cup
(3) with clean fuel and install it on the water separator base.
Be sure to use clean fuel for filling the element cup and take
care so that no dust will mix with it.
REMARK
Be careful not to lose the O-ring, float, or spring. Be sure to
assemble them after washing.
4 - 26
.
13. Loosen air bleed plug (5) of the water separator and air bleed
plug (6) of the fuel filter.
14. Operate priming pump (7) up and down until no more bubbles
come out with the fuel from air bleed plugs (5) and (6).
15. Tighten air bleed plug (5) and (6).
Tightening torque
Water separator: 2.9 to 3.1 Nm (0.29 to 0.31 kgfm, 2.1 to 2.2
lbft)
Fuel filter: 7.8 to 9.8 Nm (0.8 to 1 kgfm, 5.8 to 7.2 lbft)
Replace the cutting edge before it wears to the end face of the blade.
Always replace the cutting edge and side edge when the distance from the blade holder is less than 10 mm (0.4 in).
If the wear extends to the mounting surface, correct the mounting surface before carrying out the turning on
replacement operation.
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 end bit and the cutting
edge.
3. Clean the mounting face for cutting edge.
4. Install a new cutting edge to the blade.
5. If the cutting portion (outside) of the side edge is worn, reverse
the side edges and install them on the opposite side, or replace
the side edges.
Tightening torque of mounting nut : 260 34.3 Nm
(26.5 3.5 kgfm,
191.7 25.3 lbft)
6. After several hours of running, retighten the nuts.
4 - 27
.
3. Pull up the fresh air filter under the left rear of the operator's
seat to remove it.
4. Use a weak jet of compressed air to remove the dust stuck to
the fresh air filter.
4 - 28
.
If the cooling effect is poor, the refrigerant (gas) level may be low.
If this is the case, check the sight gauge of the receiver dryer under
the right side of the cab.
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.
Check each pulley for damage, wear of the V-groove, and wear of the V-belt. Be particularly careful to check that
the V-belt does not contact the bottom of the V-groove.
If the belt is stretched and there is no allowance for adjustment, or it is cut or cracked, replace it with a new belt.
When adjusting the V-belt, do not push the compressor directly with a bar; use a wrench.
4 - 29
.
SELECTION OF TIRES
WARNING
Select the tires according to the conditions of use and the weight of the attachments on the machine. Use only specified tires and
inflate them to the specified pressure.
Select the tires according to the conditions of use and the weight of the attachments of the machine. Use the
following table.
Since the travel speed indicated on the speedometer varies with the tire size, consult your Komatsu distributor when
using optional tires.
4 - 30
.
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.
NOTICE
The optimum inflation pressure differs according to the type of work. For details, see "HANDLING THE TIRES (PAGE 3-105)".
4 - 31
.
4 - 32
.
LUBRICATING
WARNING
Apply the parking brake, and secure the front and rear frame with the articulate lock pin.
Set the work equipment in a stable condition, and stop the engine.
4 - 33
.
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.
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.
Front axle center pin (2 places)
4 - 34
.
4 - 35
.
4 - 36
.
4 - 37
.
4 - 38
.
4 - 39
.
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.
2. Set the container to catch the oil immediately under drain plug
(P) on the rear right side of the machine.
3. Loosen drain plug (P), and drain the oil.
4. Check the drained oil, and if there are excessive metal
particles or foreign material, please contact your Komatsu
distributor.
5. Install drain plug (P).
4 - 40
.
9. After replacing the filter cartridge, add engine oil through oil
filler (F) until the oil level is between the marks on the dipstick
(G).
10. Run the engine at idle for a short time, then stop the engine,
and check that the oil level is between the marks on the
dipstick. For details, see "CHECK ENGINE OIL PAN LEVEL,
ADD OIL (PAGE 3-40)".
1. Start the engine and run at low idle. Remove the transmission case oil filler cap, then leave in this condition for
at least 5 minutes.
2. Remove dipstick (G) from oil filler port (F), then wipe the oil off
with a cloth.
3. Fully insert dipstick (G) into filler pipe (F), then remove it.
4. Check that the oil is between the marks on dipstick (G).
If the oil is below the bottom mark, add engine oil through oil
filler port (F).
5. If the oil is above the top mark, drain the excess oil from drain
plug (P), then check the oil level again.
6. If the oil level is correct, insert dipstick (G) in the oil filler guide,
then install the oil filler cap.
4 - 41
.
5. 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.
6. If the oil level is correct, insert dipstick (G) in the oil filler pipe,
then install the oil filler cap.
4 - 42
.
NOTICE
If the oil level is too high, the pressure inside the blade rotation gear case will become high when the oil temperature rises, and
this will cause leakage of oil.
REMARK
There may be wear particles in the oil, but there is no problem using the oil as it is.
4 - 43
.
NOTICE
If oil has been added to above the window in the gauge, stop the engine, wait for the hydraulic oil to cool, then drain the excess
oil from the drain plug. If the oil level is too high, it will damage the hydraulic circuit and cause the oil to spurt out.
5. If the oil is above the window of the gauge, drain the excess oil
from drain plug (P), then check the oil level again.
4 - 44
.
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
When adding distilled water (for example, commercially available water for filling batteries), if there is danger of the battery
electrolyte freezing, refill with diluted water before starting operations on the next day. This will prevent the electrolyte from
freezing.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
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.
4 - 45
.
Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.
REMARK
If water is added to above the bottom tip of the sleeve, use a pipette to remove electrolyte. Neutralize the removed
electrolyte with sodium bicarbonate, then flush it away with a large amount of water. If necessary, contact your
Komatsu distributor or your battery maker.
4 - 46
.
CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION AND WEAR
If the wheel rim, lock ring and side ring are heavily corroded, ask the tire manufacturer or your Komatsu distributor
for inspection.
4 - 47
.
TESTING
Check the belt tension. Press the belt at a point (A) midway
between the tension pulley and fan pulley and check that the
deflection is 14 to 16 mm (0.55 to 0.63 in) (new belt: 12 to 13 mm
(0.47 to 0.51 in)) when pushed with a finger force of approx. 98 N
(10 kgf).
ADJUSTING
1. When adjusting, loosen nuts (1) and (2), and the nut at the
fulcrum of the tension pulley, then move tension pulley (4) to
adjust.
2. 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.
3. If the belt has elongated and there is no more allowance for
adjustment, or if the belt is cut or cracked, replace the belt.
4. When adjusting the V-belt, tighten nut (1) or (2) (the nut in the
opposite direction from the direction to move the tesion pulley),
then move tesion pulley (4).
When the position is fixed, tighten the other nut and the fulcrum
nut (3) to hold tesion pulley (4) in position.
5. After replacing the V-belt, operate for one hour, then adjust again.
4 - 48
.
1. Set the container under the filter cartridge to catch the drained oil.
2. Using a filter wrench, turn filter cartridge (1) counterclockwise
to remove it.
3. Clean the filter head, fill the new filter cartridge with clean fuel,
coat the packing surface thinly with oil, and install it to the filter
holder.
Always use clean fuel when filling with fuel, and be careful not
to let any dirt or dust get in.
Add fuel from small hole (A) (dirty side) at eight places. Do not
add fuel from hole (B) (clean side) at the center.
4. When installing the seal, tighten it so its surface comes into
contact with the filter holder, then tighten another 3/4 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.
5. After replacing filter cartridges (1), loosen air bleed plugs (2), (3).
4 - 49
.
6. Operate priming pump (4) up and down and check that bubbles
are discharged from air bleed plugs (2), (3), and that fuel
comes out.
7. Tighten air bleed plug (2), (3).
Tightening torque: 7.8 to 9.8 Nm (0.8 to 1 kgfm, 5.8 to 7.2 lbft)
8. 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 1 and 2 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 3 - 8 to install the filter cartridge.
4 - 50
.
NOTICE
When cleaning, be careful not to put the nozzle in contact with the fin.
When cleaning, direct the nozzle at right angles to the radiator and
aftercooler.
5. Check the rubber hose. Replace with a new one if the hose is
found to have cracks or to be hardened by aging.
Also, check hose clamps for looseness.
6. Install panels (2), (4), and (6) with bolts (1), (3), and (5).
4 - 51
.
NOTICE
If the condition remains as below even after maintenance is carried out, replace the circle guide.
When there is no clearance (R) between the circle and circle guide.
When there is no clearance between the root of the teeth (or the tip of the teeth) of the pinion gear of the circle rotator and the
tip of the teeth (or the root of the teeth) of the circle gear.
CHECKING
1. Raise the blade and use a feeler gauge to measure clearance (P) between the bottom face of the drawbar and
the top face of the swing circle as shown in the diagram. The standard clearance is 1.5 0.5 mm (0.059
0.020 in).
2. Keep the blade raised and use a feeler gauge to measure clearance (Q) F (front), (Q) C (center), and (Q) R (rear)
between the circle and circle guide as shown in the diagram when force is applied at the rear.
Standard clearances (Q) F, (Q) C, and (Q) R are as follows.
(Q) F = 0 mm, (Q) C = 0.7 mm (0.028 in), (Q) R = 1.5 mm (0.059 in), or (Q) F = (Q) R = 1 mm (0.039 in)
4 - 52
.
ADJUSTING
Adjusting top and bottom position
1. Raise the blade, remove bolts (1), (5), and (9) for clearance (P),
remove circle guides (2), (6), and (10), then adjust the shim
thickness. (Shim thickness: 1 mm (0.039 in), 0.5 mm (0.020
in); 2 types)
4 - 53
.
4 - 54
.
LUBRICATING
WARNING
Apply the parking brake, and secure the front and rear frame with the articulate lock pin.
Set the work equipment in a stable condition, and stop the engine.
1. 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.
Drive shaft (2 places)
4 - 55
.
1. Set the container under the filter cartridge to catch the drained
oil.
2. Using a filter wrench, turn filter cartridge (1) counterclockwise
to remove it.
3. Clean the filter holder, coat the seal surface of the new filter
cartridge thinly with clean engine oil, then install to the filter
holder.
4 - 56
.
4. Remove bolt (1), then remove tube (2), take out the strainer,
and wash it.
5. Remove all the dirt stuck to the strainer, then wash it in clean
diesel oil or flushing oil. If the strainer is damaged, replace it
with a new part.
6. After washing the strainer, install it, then install tube (2) with
bolts (1).
7. Refill the specified quantity of engine oil through oil filler (F).
8. After refilling, check that the oil is at the specified level. For
details, see "CHECK OIL LEVEL IN TRANSMISSION CASE,
ADD OIL (PAGE 4-41)".
9. Check that there is no leakage of oil from the transmission
case or oil filter.
4 - 57
.
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 kgfm, 43.4 to 57.9 lbft)
4. Refill the specified quantity of engine oil through oil filler (F).
5. After refilling, check that the oil is at the specified level. For
details, see "CHECK OIL LEVEL IN FINAL DRIVE CASE,
ADD OIL (PAGE 4-42)".
6. Check for oil leakage from the final drive case.
4 - 58
.
Check for play of the ball joint, and if the play to the front and rear
is more than 2 mm (0.079 in), remove a shim and adjust to 0.5 to
2 mm (0.020 to 0.079 in).
If it is tightened without any clearance, there is danger that the ball
joint will break.
4 - 59
.
4 - 60
.
1. Loosen tightening nut (1), fit a wrench to corner (2) of the tie
rod, then turn the left and right tie rods as shown in the diagram
on the right to adjust as follows.
To INCREASE toe-in, turn in DIRECTION OF ARROW
To DECREASE toe-in, turn in OPPOSITE DIRECTION
Amount of extension for 1/3 turn of left or right tie rod in
direction of extension: 6 mm (0.236 in)
2. After adjusting, tighten tightening nut (1).
4 - 61
.
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.
4 - 62
.
4. Put an oil container under drain plug (P) to catch the oil.
5. 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.
6. After draining the oil, install drain plug (P).
7. Refill the specified quantity of engine oil through oil filler (F).
8. After filling with oil, check that the oil is at the specified level.
For details, see "CHECK OIL LEVEL IN HYDRAULIC TANK,
ADD OIL (PAGE 4-44)".
9. Install oil filler (F).
4 - 63
.
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 4-43)"
6. Install oil filler plug (F).
4 - 64
.
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. Refill the specified quantity of engine oil through 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 4-43)".
4 - 65
.
4 - 66
.
3. Depress the brake pedal, then push in pin (2) of the wear
indicator.
4. If the tip of pin (2) is level with the end face of guide (3), the disc
wear limit has been reached, so please contact your Komatsu
distributor for replacement.
4 - 67
.
4 - 68
.
CHECK INJECTOR
Check the exhaust gas color visually. If there is any problem in the exhaust gas color, please contact your Komatsu
distributor for inspection or replacement. For details of the action to take if there is a problem, see "ENGINE (PAGE
3-121)".
Check visually and touch with your fingers to check that there are no loose bolts or hardening of rubber parts at
clamps (1) to (4). If there is any looseness or hardened rubber, contact your Komatsu distributor for replacement.
4 - 69
.
Check if any of fuel spray prevention caps (1) through (12) is missing, or if any part of the rubber is hardened. If either
of the cases is found, call your Komatsu distributor for the installation or replacement.
4 - 70
.
4 - 71
.
5-1
.
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS
Item Unit
Operating weight (including operator 75 kg (165 lb)) kg (lb) 15,000 (33,000)
5-2
.
SPECIFICATIONS SPECIFICATIONS
5-3
.
6-1
.
SAFETY, PROTECTION
Reduction in shock on road surfaces with many rocks or boulders (protection of operator and machine)
Protection of buried structures (mounts and avoids protruding objects)
6-2
.
REMARK
In the condition Step 6, the pressure is maintained at the bottom end of the blade lift cylinder so the blade pushes
at a certain pressure.
If operations are carried out in the condition in Step 6, the blade will be able to follow a rise or fall of approx. 50
mm (2.0 in) in the ground surface, so uniform accumulator operations can be carried out.
In actual fact, by operating the blade lift cylinder lever in a suitable way, work is carried out within a certain up-
down follow-up range with a small pushing pressure.
Once the accumulator is set, there is no need to operate the blade lift cylinder when starting operations. If the
operation is stopped and the switch is turned OFF, raise the blade and put the blade in contact with the ground
again, then turn the switch ON to make it possible to set the accumulator to the same setting.
6-3
.
6-4
.
POWER SWITCH/VOLUME
Turn this knob (1) to the right until it clicks to turn the power on.
Turn it further to increase the volume.
REMARK
The auto-store function cannot be used when the channel display
is flashing.
When the display is flashing, the preset scan function is being
used.
Preset scan
If this button is pressed for less than 0.5 second while in radio reception, programs from the six preset stations
in the same band will be broadcast one after another for 5 seconds each, starting from No. 1 through No. 6
stations consecutively.
When the desired station is found, press the button again. This stops the preset scan tuning process and switches
to ordinary broadcasting. The same process will be repeated continuously until the button is pressed again.
6-5
.
LOUDNESS BUTTON
This button (5) is used when playing at low volume. It makes it
possible to hear more easily by emphasizing the low tone when the
low tones are weak.
Push button: Actuated (ON)
Push button again: Canceled (OFF)
Correcting time
Press the button to set to the time display.
(A) Correcting hour :
Keep the DISP button pressed and press the bottom tuning
button (H) to correct the hour.
(B) Correcting minute :
Keep the DISP button pressed and press the top tuning
button (M) to correct the minute.
6-6
.
CASSETTE DOOR
Set the cassette with the exposed portion of the tape on the right
side and insert it through the cassette door (8).
PRESET BUTTONS
These buttons (10) are used to call up the broadcast station
frequencies preset in memory for each of buttons No. 1 to No. 6.
It is possible to preset 18 stations (FM: 12; AM: 6) with these
buttons.
6-7
.
6-8
.
METHOD OF OPERATION
1. If you are playing a cassette, press the tape eject button to stop
the tape.
2. Select the station to be preset.
Use band selector button (1) to select MW (AM), FM1, or FM2,
then use the manual tuning button to select the frequency of
the broadcasting station.
3. Press manual memory button (2) or seek tuning button (3).
4. Press preset button (4) of the number to be preset for 2
seconds while the frequency display is being shown on the
display. (The preset channel and frequency are displayed and
the presetting is completed).
5. Repeat Steps 2 to 4 to preset other stations.
REMARK
Use Steps 2 to 4 also when changing the setting of a preset
switch to another station.
When the power is disconnected, such as when the battery is
replaced, all the settings are deleted, so preset the stations
again.
6-9
.
LISTENING TO RADIO
1. Turn the starting switch ON, then turn power switch (1) ON.
2. Set band selector button (2) to AM or FM.
3. Select the station with the preset buttons or manual tuning
button (3).
4. Adjust the volume, balance, and tone as desired.
5. When turning the radio OFF, turn power switch (1) to the left
until it clicks.
REMARK
To switch to the radio when listening to a cassette, press the cassette eject button to stop the tape.
If you insert a cassette when listening to the radio, the tape will start to play.
6 - 10
.
REVERSING TAPE
When listening to the tape, press both FAST FORWARD,
REWIND buttons (A) and (B) at the same time lightly.
When this is done, the tape direction display will be reversed.
6 - 11
.
NOTICE
Handling cassette tape
Clean the tape head approx. once a month with a commercially available head cleaning tape.
Do not leave the tape any place where it is exposed to direct sunlight, any place that is excessively dusty, or any place where
there is a magnetic field.
Do not use 120-minute tapes. The tape is thin and it easily gets caught up inside the machine.
If the tape is slack, it easily gets caught up inside the machine. Use a pencil to wind in the tape to remove any slack.
Do not use any cassette tape if the label has started to come off. It may cause defective rotation, or it may be impossible to get
the tape out of the machine.
6 - 12
.
AIR CONDITIONER
LOCATIONS AND FUNCTIONS OF CONTROL PANEL
FAN SWITCH
This switch (1) is used to adjust the air flow to 4 levels.
It also acts as the main switch for the air conditioner.
>: When this switch is pressed, the lighted display moves one
position to the right.
<: When this switch is pressed, the lighted display moves one
position to the left.
OFF: When this switch is pressed, the air conditioner stops.
6 - 13
.
REMARK
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.
CAUTION
When leaving the machine, always turn the air conditioner off and stop the engine.
If the air conditioner is used for a long period at RECIRC, the window glass may mist up and reduce the visibility, so normally
use the air conditioner at FRESH.
If the air conditioner temperature is set too low, condensation may form on the outside of the window glass and reduce the
visibility, so adjust the temperature of the air flow.
If any problem is found in the operation of the air conditioner, contact your Komatsu distributor as soon as possible.
This switch (4) is used to stop and start the cooling and
dehumidification functions.
If the fan switch is turned ON and air conditioner switch (A) is
pressed, air conditioner display lamp (B) will light up.
It is pressed again, the air conditioner display will go out.
6 - 14
.
METHOD OF OPERATION
Switch
FRESH/RECIRC
Fan switch Temperature control switch
selector switch
Condition of use
High speed HI 1 lamp lights up RECIRC
Cooling
Normal HI-LO Less than half lamps light up FRESH
Dehumidification + heating HI-LO More than half lamps light up FRESH
High speed HI All lamps light up RECIRC
Heating
Normal HI-LO More than half lamps light up FRESH
If the outside air is dirty or it is desired to carry out cooling quickly, set to the RECIRC position.
Be careful, do not set the cooling temperature too low.
For health reasons, it is recommended that the cooling temperature in the cab should not vary more than 5 to 6
C (41 to 42.8F) from the outside temperature.
If you are smoking when using the cooling your eyes may sting. When smoking, open the window slightly or
switch to FRESH to clear the smoke from the operator's cab.
Do not use the FACE mode for long periods with the setting at RECIRC.
REMARK
If the temperature inside the cab is low, the air conditioner may not work. In such cases, use the recirculated air to
warm up the inside of the cab, then turn the air conditioner switch on. The air conditioner will be run.
For details of the procedure for cleaning the air filter and checking the refrigerant, see "CLEAN AIR CONDITIONER
AIR FILTER (PAGE 4-28)" and "CHECK REFRIGERANT (GAS) LEVEL (PAGE 4-29)".
To enable the air conditioner to perform to the full and to maintain a pleasant working environment, always contact
your Komatsu distributor to have the air conditioner refilled with refrigerant and to carry out other checks.
6 - 15
.
NOTICE
When the seat is pushed forward, the available reclining angle becomes greater; when the seat is pushed back, the available
reclining angle becomes smaller. When moving the seat back, return the seat back to its original position before moving the seat.
Pull lever (2) up, set the seat back to a position where it is easy to
carry out operations, then release the lever.
When doing this, keep your back pressed against the seat back.
If your back is not against the seat back, the seat back may spring
back suddenly.
Rear tilt
Pull lever (3) up and adjust the angle of the rear of the seat.
To raise the rear of the seat, keep the lever pulled up and raise yourself slightly from the rear of the seat.
To lower the rear of the seat, keep the lever pulled up and apply your weight to the rear of the seat.
Amount of tilt: Up 13, down 13
6 - 16
.
REMARK
If the seat back is tipped to the front without raising the armrest(4), the armrest will rise automatically.
REMARK
To adjust to the optimum setting, turn knob (6) so that the indicator in the transparent portion inside the knob
indicates the same as the operator's weight (kg).
6 - 17
.
BASIC PRECAUTIONS
WARNING
Never disassemble, repair, modify, or move the communications terminal, antenna, or cables. This may cause failure or fire
on the KOMTRAX equipment or the machine itself. (Your Komatsu distributor will carry out removal and installation of
KOMTRAX.)
Do not allow cables or cords to become caught; do not damage or pull cables or cords by force. Short circuits or disconnected
wires may cause failure or fire on the KOMTRAX equipment or the machine itself.
For anyone wearing a pacemaker, make sure that the communications antenna is at least 22 cm (8.7 in) from the pacemaker.
The radio waves may have an adverse effect on the operation of the pacemaker.
NOTICE
Even when the key in the starting switch of the KOMTRAX system is at the OFF position, a small amount of electric power is
consumed. When putting the machine into long-term storage, take the action given in "LONG-TERM STORAGE (PAGE 3-110)".
Please contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof.
Be careful not to get water on the communications terminal or wiring.
REMARK
The KOMTRAX system uses wireless communications, so it cannot be used inside tunnels, underground, inside
buildings, or in mountain areas where radio waves cannot be received. Even when the machine is outside, it
cannot be used in areas where the radio signal is weak or in areas outside the wireless communication service
area.
There is absolutely no need to inspect or operate the KOMTRAX communications terminal, but if any abnormality
is found, please consult your Komatsu distributor.
6 - 18
.
INDEX
INDEX
<A>
ADJUSTING WORK EQUIPMENT <H>
POSTURE 3- 93 HANDLING AIR-SUSPENSION SEAT 6- 16
AIR CONDITIONER 6- 13 ADJUST OPERATOR'S SEAT 6- 16
LOCATIONS AND FUNCTIONS OF HANDLING BLADE ACCUMULATOR 6- 2
CONTROL PANEL 6- 13 HANDLING MACHINES EQUIPPED
METHOD OF OPERATION 6- 15 WITH KOMTRAX 6- 18
PRECAUTIONS WHEN USING 6- 15 BASIC PRECAUTIONS 6- 18
TESTING AND MAINTENANCE 6- 15 HANDLING OIL, FUEL, COOLANT, AND
AM/FM RADIO-CASSETTE STEREO 6- 4 PERFORMING OIL CLINIC 4- 4
EXPLANATION OF COMPONENTS 6- 4 HANDLING THE TIRES 3-105
METHOD OF OPERATION 6- 9
PRECAUTIONS WHEN USING 6- 12 <I>
ARTICULATE LOCK PIN 3- 33 INTENDED USE 1- 7
DIRECTIONS OF MACHINE 1- 7
<C>
CHECK AFTER STOPPING ENGINE 3- 53 <L>
CHECK BEFORE STARTING ENGINE 3- 35 LOCATION OF PLATES, TABLE TO
CHECKS AFTER COMPLETION OF ENTER SERIAL NO. AND
OPERATION 3-104 DISTRIBUTOR 1- 8
COLD WEATHER OPERATION 3-108 ENGINE SERIAL NO. PLATE
AFTER COLD WEATHER 3-109 POSITION 1- 8
CAUTIONS AFTER COMPLETION OF MACHINE SERIAL NO. PLATE
WORK 3-109 POSITION 1- 8
PRECAUTIONS FOR LOW SERVICE METER POSITION 1- 9
TEMPERATURE 3-108 TABLE TO ENTER SERIAL NO. AND
CONTROL LEVERS, PEDALS 3- 24 DISTRIBUTOR 1- 9
CRITICAL PARTS 4- 15 LOCKING 3-105
LONG-TERM STORAGE 3-110
<D> AFTER STORAGE 3-110
DUST INDICATOR 3- 33 BEFORE STORAGE 3-110
DURING STORAGE 3-110
<E>
EXPLANATION OF COMPONENTS 3- 6 <M>
MAINTENANCE SCHEDULE CHART 4- 16
<F> METERS AND LAMPS 3- 6
FEATURES OF BLADE ACCUMULATOR 6- 2 METHOD OF OPERATING BLADE
FOREWORD 1- 2 ACCUMULATOR 6- 3
FUSE BOX 3- 33 MOVING MACHINE OFF (FORWARD,
REVERSE, SHIFTING GEAR),
<G> STOPPING 3- 55
GENERAL PRECAUTIONS 2- 11
GENERAL VIEW 3- 2 <O>
GENERAL VIEW OF CONTROLS AND OPERATING WORK EQUIPMENT 3- 62
GAUGES 3- 3 OPERATION 3- 35
GENERAL VIEW OF MACHINE 3- 2 OPERATIONS, CHECKS AFTER
GUIDES TO MAINTENANCE 4- 2 STARTING ENGINE 3- 51
7-1
.
INDEX
7-2
.
2006 KOMATSU
All Rights Reserved
Printed in Japan 08-06