Page 1 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.
Page 2 1 - 1...
Page 3: Before Reading This Manual
Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
Page 4: Safety Information
FOREWORD SAFETY INFORMATION SAFETY INFORMATION To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the precautions and warnings included in this manual and the safety signs attached to the machine must always be followed.
Page 5: Intended Use
FOREWORD INTENDED USE INTENDED USE USE OF MACHINE 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 See the section "WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER (PAGE 3-129)"...
Page 6: Visibility From Operator's Seat
FOREWORD INTENDED USE VISIBILITY FROM OPERATOR'S SEAT The visibility standards (ISO 5006) for this machine require a view shown in the diagram below. VISIBILITY IN IMMEDIATE AREA The visibility of this machine in the area 1 m (3 ft 3in) from the outside surface of the machine at a height of 1.5 m (4 ft 11 in) is shown in the diagram below.
Page 7: Location Of Plates, Table To Enter Serial No. And Distributor
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following items. PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE This is at the front of the rear frame on the left side of the machine.
Page 8: Service Meter Position
FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR SERVICE METER POSITION The service meter is displayed on the character display of the machine monitor. TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No. Engine serial No. Distributor name Address Service Personnel...
Page 9: Table Of Contents
FOREWORD CONTENTS CONTENTS FOREWORD BEFORE READING THIS MANUAL SAFETY INFORMATION INTENDED USE USE OF MACHINE DIRECTIONS OF MACHINE VISIBILITY FROM OPERATOR'S SEAT LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE EPA REGULATIONS, ENGINE NUMBER PLATE SERVICE METER POSITION TABLE TO ENTER SERIAL NO.
Page 10 FOREWORD CONTENTS SLOW BLOW FUSE 3- 65 ELECTRIC POWER TAKEOFF 3- 66 HANDLING BATTERY DISCONNECT SWITCH 3- 67 OPENING, CLOSING CAB DOORS 3- 68 BACKUP ALARM 3- 69 AM/FM RADIO 3- 70 AIR CONDITIONER 3- 76 OPERATION MANUAL STORAGE 3- 80 TOOL BOX 3- 80 GREASE PUMP HOLDER...
Page 11 RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 10 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 11 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL 4- 12 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 13 TORQUE LIST...
Page 12 2 - 1...
Page 13 SAFETY SAFETY INFORMATION SAFETY INFORMATION SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS SAFETY LABELS GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 14 PRECAUTIONS BEFORE STARTING OPERATION 2- 14 ENSURING SAFE OPERATION 2- 14 UNDERSTANDING THE MACHINE 2- 14 PREPARATIONS FOR SAFE OPERATION 2- 14 PRECAUTIONS REGARDING SAFETY-RELATED EQUIPMENT 2- 14...
Page 14: Safety
SAFETY SAFETY INFORMATION PRECAUTIONS FOR OPERATION 2- 21 PRECAUTIONS FOR JOBSITE 2- 21 INVESTIGATE AND CONFIRM JOBSITE CONDITIONS 2- 21 WORKING ON LOOSE GROUND 2- 21 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 22 ENSURE GOOD VISIBILITY 2- 22 CHECKING SIGNS AND SIGNALMAN'S SIGNALS 2- 22 BEWARE OF ASBESTOS DUST...
Page 15: Safety Information
SAFETY SAFETY INFORMATION PRECAUTIONS FOR MAINTENANCE 2- 32 PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 32 DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE 2- 32 KEEP WORKPLACE CLEAN AND TIDY 2- 32 SELECT SUITABLE PLACE FOR INSPECTION AND MAINTENANCE 2- 32 ONLY AUTHORIZED PERSONNEL 2- 32 APPOINT LEADER WHEN WORKING WITH OTHERS...
Page 16: Safety Labels
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. 2 - 5...
Page 17: Position For Attaching Safety Labels
SAFETY SAFETY LABELS POSITION FOR ATTACHING SAFETY LABELS 2 - 6...
Page 18: Safety Labels
SAFETY SAFETY LABELS SAFETY LABELS (1) Caution before operating (09651-03001) (2) Caution for opening hydraulic cap (09653-03001) (3) Caution when driving in reverse (09802-43000) 2 - 7...
Page 19 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (4) Danger when approaching (09812-13000) (5) Warning for high voltage (09801-43001) (6) Articulate lock (09161-33000) (7) Caution for handling accumulator (09659-53000) 2 - 8...
Page 20 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (8) Warning for hot cooling water (09668-03001) (9) Roll-over protective structure (09620-A2000) (10) Prohibited to walk (23B-53-31740) (11) Caution when engine running (09667-03001) (12) Caution when handling booster cable and battery cable (09808-03000) 2 - 9...
Page 21 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (13) Prohibited to enter (09162-33001) (14) Caution when startling and traveling (23B-53-31740) 2 - 10...
Page 22 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (15) Exhaust pipe is hot ! (09817-A0753) (16) Caution in carrying out gear shift, downhill travel, brake operation, and bank pin operation (23B-53-71170) (17) Precautions when handling battery (This plate is stick on the machine by the battery maker.) 2 - 11...
Page 23 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (18) Caution when handling battery (09664-30011) (19) Prohibited to start by short-circuiting (09842-A0481) Safety label (19) is stick on the starting motor. (20) Warning when removing bank-control lock pin (09819-03000) (21) Caution to prevent falling (09805-13000) (22) Caution for rotating parts (09667-23001) 2 - 12...
Page 24 SAFETY SAFETY SAFETY LABELS SAFETY LABELS (23) Caution for blast site (09845-00480) (only when equipped with KOMTRAX) 2 - 13...
Page 25: General Precautions Common To Operation And Maintenance
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Mistakes in operation, inspection, or maintenance may result in serious personal injury or death. Before carrying out operation, inspection, or maintenance, always read this manual and the safety labels on the machine carefully and obey the warnings.
Page 26: Keep Machine Clean
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE KEEP MACHINE CLEAN If you get on or off the machine or carry out inspection and maintenance when the machine is dirty with mud or oil, there is a hazard that you will slip and fall. Wipe off any mud or oil from the machine. Always keep the machine clean.
Page 27: Fire Prevention
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE FIRE PREVENTION ACTION IF FIRE OCCURS Turn the start switch OFF to stop the engine. Use the handrails and steps to get off the machine. Do not jump off the machine. There is the danger of falling and suffering serious injury. PRECAUTIONS TO PREVENT FIRE Fire caused by fuel, oil, coolant or window washer fluid Do not bring any flame or fire close to flammable substances...
Page 28: Precautions When Getting On Or Off Machine
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE Explosion caused by lighting equipment When checking fuel, oil, battery electrolyte, or coolant, always use lighting with anti-explosion specifications. PRECAUTIONS WHEN GETTING ON OR OFF MACHINE USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE To prevent personal injury caused by slipping or falling off the machine, always do as follows.
Page 29: Precautions When Standing Up From Operator's Seat
SAFETY GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT Before standing up from the operator's seat, such as when adjusting the position of the seat, always lower the work equipment completely to the ground, set gearshift lever (1) to the P (Parking) position, then stop the engine.
Page 30: Do Not Get Caught In Work Equipment
If the protective structure is damaged or deformed by falling objects or by rolling over, its strength will be reduced and it will not be able to fulfill its function properly. In such cases, always contact your Komatsu distributor for advice on the method of repair.
Page 31: Unauthorized Modification
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE UNAUTHORIZED MODIFICATION Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifications made without authorization from Komatsu. Any modification made without authorization from Komatsu can create hazards. Before making a modification, consult your Komatsu distributor.
Page 32: Precautions For Operation
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS FOR OPERATION PRECAUTIONS FOR JOBSITE INVESTIGATE AND CONFIRM JOBSITE CONDITIONS On the jobsite, there are various hidden dangers that may lead to personal injury or death. Before starting operations, always check the following to confirm that there is no danger on the jobsite. When carrying out operations near combustible materials such as attatched roofs, dry leaves or dry grass, there is a hazard of fire, so be careful when operating.
Page 33: Do Not Go Close To High-Voltage Cables
SAFETY PRECAUTIONS FOR OPERATION DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES Do not travel or operate the machine near electric cables. There is a hazard of electric shock, which may cause serious personal injury or death. On jobsites where the machine may go close to electric cables, always do as follows.
Page 34: Starting Engine
Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine Komatsu parts. STARTING ENGINE USE WARNING TAGS If there is any "DANGER! Do NOT operate!"...
Page 35: Inspection And Maintenance Before Starting Engine
SAFETY PRECAUTIONS FOR OPERATION INSPECTION AND MAINTENANCE BEFORE STARTING ENGINE Carry out the following checks before starting the engine at the beginning of the day's work to ensure that there is no problem with the operation of the machine. If this inspection is not carried out properly, problems may occur with the operation of the machine, and there is danger that this may lead to serious personal injury or death.
Page 36: Precautions In Cold Areas
SAFETY PRECAUTIONS FOR OPERATION PRECAUTIONS IN COLD AREAS Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the control levers are operated, the reaction of the machine will be slow, and this may lead to unexpected accidents. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
Page 37: Operation
SAFETY PRECAUTIONS FOR OPERATION OPERATION CHECKS BEFORE OPERATION If the checks before starting are not carried out properly, the machine will be unable to display its full performance, and there is also danger that it may lead to serious personal injury or death. When carrying out the checks, move the machine to a wide area where there are no obstructions, and pay careful attention to the surrounding area.
Page 38: Precautions When Traveling
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.
Page 39: Traveling On Slopes
SAFETY PRECAUTIONS FOR OPERATION Do not move the gear shift lever to the N position when traveling on level ground or when traveling downhill. Always keep the transmission in the gear when traveling. Failure to do this may cause the following problems. There is danger that the steering will become heavy and that it will be impossible to use the braking force of the engine.
Page 40: Traveling On Snow-Covered Or Frozen Surfaces
SAFETY PRECAUTIONS FOR OPERATION TRAVELING ON SNOW-COVERED OR FROZEN SURFACES Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine, and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly careful when working on slopes.
Page 41: Transportation
When traveling on public roads, apply to the local authorities to obtain permission to transport the machine. The machine can be divided into parts for transportation, so when transporting the machine, please contact your Komatsu distributor to have the work carried out. Lock the frame with the articulate lock pin to prevent the machine from articulating.
Page 42: Towing
SAFETY PRECAUTIONS FOR OPERATION TOWING PRECAUTIONS WHEN TOWING Always use the correct towing equipment and towing method. Any mistake in the selection of the wire rope or towing bar or in the method of towing a disabled machine may lead to serious personal injury or death. For towing, see "TOWING THE MACHINE (PAGE 3-178)".
Page 43: Precautions For Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE DISPLAY WARNING TAG DURING INSPECTION AND MAINTENANCE Always display the "DANGER! Do NOT operate" warning tag during the inspection and maintenance. If there is any "DANGER! Do NOT operate!" warning tag displayed, it means that someone is carrying out inspection and maintenance of the machine.
Page 44: Stop Engine Before Carrying Out Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE Lower the work equipment completely to the ground and stop the engine before performing any inspection and maintenance. To return the oil inside the accumulator to the tank, stop the engine and then depress the brake pedal approximately 20 times.
Page 45: Two Workers For Inspection And Maintenance When Engine Is Running
SAFETY SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR MAINTENANCE To prevent the machine from articulating, set the articulation lock pin (2) to the LOCK position (L). TWO WORKERS FOR INSPECTION AND MAINTENANCE WHEN ENGINE IS RUNNING To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried out with the engine running, carry out the operation with at least 2 workers and do as follows.
Page 46: Precautions When Working At High Places
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN WORKING AT HIGH PLACES When working at high places, use a step ladder or other stand to ensure that the work can be carried out safely. PRECAUTIONS WHEN WORKING ON TOP OF MACHINE Clean up the machine to prevent falling off when performing maintenance, always do as follows.
Page 47: Precautions For Inspection And Maintenance
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS FOR INSPECTION AND MAINTENANCE PRECAUTIONS WHEN 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.
Page 48: Precautions When Using Hammer
SAFETY PRECAUTIONS FOR MAINTENANCE Removing battery cables Before repairing the electrical system or carrying out electrical welding, turn the starting switch OFF. Wait for approximately 1 minute, then remove the negative (-) battery cable to stop the flow of electricity. For machines equipped with a battery disconnector switch, set the battery disconnector switch to the OFF position.
Page 49: Precautions With High-Temperature Oil
If the hose or piping mounts are loose or oil or fuel is found to be leaking from the mount, stop operations and tighten to the specified torque. If any damaged or deformed hoses or piping are found, please consult your Komatsu distributor. Replace the hose if any of the following problems are found.
Page 50: Noise
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. PRECAUTIONS WITH COMPRESSED AIR When carrying out cleaning with compressed air, there is a hazard of serious personal injury caused by flying dust or particles.
Page 51: Periodic Replacement Of Safety Critical Parts
SAFETY PRECAUTIONS FOR MAINTENANCE PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS For using the machine safely for an extended period of time, replace safety-critical parts like hoses and seat belts periodically. Replacement of safety-critical parts: See "PERIODIC REPLACEMENT OF CRITICAL PARTS (PAGE 4-14)". The material of these components naturally changes over time, and repeated use causes deterioration, wear, and fatigue.
Page 52: Tires
Komatsu distributor to carry out these operations. Always use the tires specified by Komatsu and maintain the specified inflation pressure. Suitable tire inflation pressure: see "HANDLING THE TIRES (PAGE 3-168)"...
Page 53: Precautions When Storing Tires
SAFETY PRECAUTIONS FOR MAINTENANCE PRECAUTIONS WHEN STORING TIRES Tires for construction equipment are extremely heavy, it may lead to serious personal injury or death. To maintain safety, always do as follows. As a basic rule, store the tires in a warehouse which unauthorized persons cannot enter.
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Page 55: General View
OPERATION GENERAL VIEW GENERAL VIEW GENERAL VIEW OF MACHINE Front wheel Head lamp Blade lift cylinder Blade Rear wheel 3 - 2...
Page 56: General View Of Controls And Gauges
OPERATION GENERAL VIEW GENERAL VIEW OF CONTROLS AND GAUGES Inching pedal Differential lock switch (if equipped) Steering wheel (10) Turn signal lever Horn button (11) Accelerator pedal Machine monitor mode selector switch 2 (12) Gear shift lever Machine monitor mode selector switch 1 (13) Right side panel Work equipment control lever...
Page 57 OPERATION GENERAL VIEW Machine monitor Engine coolant temperature gauge (18) Differential oil temperature caution lamp Torque converter oil temperature gauge (if equipped) Turn signal pilot lamp (19) Torque converter oil temperature caution lamp Engine tachometer (20) Battery charge circuit caution lamp Head lamp high beam pilot lamp (21) Economy operation display lamp...
Page 58 OPERATION GENERAL VIEW Right side panel (33) RPM SET mode selector switch (41) Lift arm lock switch (34) RPM SET switch (42) Power mode selector switch (35) Blade accumulator switch (if equipped) (43) Front working lamp switch (36) Rear working lamp switch (44) Front lamp switch (37)
Page 59: Explanation Of Components
After the system check has been carried out for 3 seconds, the meters start operation. The character display displays "KOMATSU" for 3 seconds. If any lamp or other part does not work, there is probably a failure or disconnection, so ask your Komatsu distributor to carry out inspection.
Page 60 OPERATION EXPLANATION OF COMPONENTS CHARACTER DISPLAY Normally, the service meter/odometer is displayed on the character display. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed to recommend suitable action. When the time for replacing the filter or changing the oil is reached, after completion of the system check with the starting switch at the ON position, the maintenance caution lamps flash or light up, and at the same time, the filter or oil to be replaced is displayed.
Page 61 ( ) of machine monitor mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor for inspection. ODOMETER This display (2) shows the total distance that the machine has traveled in units of km.
Page 62 CAUTION If action code E03 is displayed, stop the machine immediately and ask your Komatsu distributor to carry out repairs. If the machine has failed, or if there has been excessive load on the machine, or if it is necessary to carry out inspection and maintenance, an action code is displayed on this panel (3) to recommend suitable action.
Page 63 OPERATION EXPLANATION OF COMPONENTS If the maintenance location is displayed and the maintenance caution lamp lights up, carry out inspection and maintenance for the item given after completing the day's operations or when the operators change shifts. If "MAINTENANCE" is displayed together with E01, check the failure code and ask for repairs to be carried out.
Page 64 OPERATION EXPLANATION OF COMPONENTS FILTER, OIL REPLACEMENT TIME DISPLAY After the system check is completed, this display (4) displays the filter and type of oil for 30 seconds for items where the replacement interval is close. When this happens, the maintenance caution lamp also flashes or lights up.
Page 65 OPERATION EXPLANATION OF COMPONENTS REMARK See the section below for details of procedure for replacing the filter and oil. Engine oil "CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-57)" Engine oil filter "CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (PAGE 4-57)" Fuel prefilter "REPLACE FUEL PREFILTER CARTRIDGE (PAGE 4-58)"...
Page 66 OPERATION EXPLANATION OF COMPONENTS CAUTION ITEMS CAUTION If the monitor lights up during travel, inspect the location of the problem quickly and take the necessary action. (3) Water separator monitor Parking brake pilot lamp Maintenence caution lamp PARKING BRAKE PILOT LAMP This monitor (1) lights up when the parking brake has been applied.
Page 67 OPERATION EXPLANATION OF COMPONENTS MAINTENANCE CAUTION LAMP CAUTION If the caution monitor lamp lights up, repair the problem as soon as possible. When the starting switch is turned ON, this monitor (2) flashes or lights up for approximately 30 seconds after the system check has been completed if the oil change time is close.
Page 68 OPERATION EXPLANATION OF COMPONENTS EMERGENCY STOP ITEMS CAUTION If the monitor lights up, stop operations immediately, then check the corresponding area and carry out the action. If any problem is found in the emergency stop items, the alarm buzzer will sound intermittently, and the monitor for the location of the problem and the centralized warning lamp will light up.
Page 69 OPERATION EXPLANATION OF COMPONENTS ENGINE WATER TEMPERATURE CAUTION LAMP This monitor (1) warns the operator that the engine coolant temperature has risen. When it lights up, "E02 ENGINE OVERHEAT" is displayed on the character display at the same time, and the engine output is automatically limited.
Page 70 OPERATION EXPLANATION OF COMPONENTS TORQUE CONVERTER OIL TEMPERATURE CAUTION LAMP This monitor (5) warns the operator that the torque converter oil temperature has risen. When it lights up, "E02 TC OVERHEAT" is displayed on the character display at the same time. Move the machine immediately to a safe place, stop the machine, then move the gear shift lever to P (Parking) and run the engine under no load at a mid-range speed until the lamp goes out.
Page 71 OPERATION EXPLANATION OF COMPONENTS INCHING CLUTCH OVERHEAT CAUTION LAMP This monitor (8) warns the operator that the clutch temperature in the transmission rose due to partially applied clutch operations. Measures to be taken when the inching clutch overheat caution lamp lights up 1.
Page 72 OPERATION EXPLANATION OF COMPONENTS METER GROUP PILOT DISPLAY When starting switch is ON, the pilot display lights up when display items are functioning. Engine preheating pilot lamp Blade accumulator pilot lamp (if equipped) Differential lock pilot lamp (if equipped) Lift arm lock pin pilot lamp Turn signal pilot lamp RPM SET pilot lamp Head lamp high beam pilot lamp...
Page 73 OPERATION EXPLANATION OF COMPONENTS DIFFERENTIAL LOCK PILOT LAMP (If equipped) This monitor (2) lights up when the differential lock switch is set to differential lock. TURN SIGNAL PILOT LAMP This monitor (3) flashes at the same time when the turn signal lamp (hazard display lamp) flashes.
Page 74 OPERATION EXPLANATION OF COMPONENTS BLADE FLOAT PILOT LAMP This monitor (6) lights up when the right and left blade lift cylinder control levers are set to the FLOAT position. When this monitor is lit, the engine does not start even if the starting switch is turned to the START position.
Page 75 OPERATION EXPLANATION OF COMPONENTS ECONOMY OPERATION DISPLAY LAMP This monitor (10) lights up during economy operations. As this monitor lights up and goes out in conjunction with the accelerator pedal, use it as an indicator of energy saving operations. COOLING FAN REVERSE ROTATION PILOT LAMP This monitor (11) lights up when the cooling fan is rotating in reverse after the cooling fan reverse rotation switch is operated.
Page 76 OPERATION EXPLANATION OF COMPONENTS METERS Speedometer Torque converter oil temperature gauge Engine tachometer Fuel gauge Engine coolant temperature gauge Shift indicator Articulation gauge SPEEDOMETER This meter (1) indicates the travel speed of the machine. When it is changed to the shift indicator display, the shift position is displayed.
Page 77 OPERATION EXPLANATION OF COMPONENTS ENGINE TACHOMETER This meter (2) indicates the engine speed. ENGINE COOLANT TEMPERATURE GAUGE This meter (3) shows the engine coolant temperature. During operations, the indicator should be in green range (B). If it enters red range (C) during operations, at the same time, the alarm buzzer sounds, the centralized warning lamp lights up, and "E02 ENGINE OVERHEAT"...
Page 78 OPERATION EXPLANATION OF COMPONENTS FUEL GAUGE This meter (6) shows the fuel level in the fuel tank. During operations, the indicator should be in green range (B). If it enters red range (A) during operations, it indicates that the remaining amount of fuel is low. If it comes close to the red range, add fuel as soon as possible.
Page 79: Other Functions Of Machine Monitor
OPERATION EXPLANATION OF COMPONENTS OTHER FUNCTIONS OF MACHINE MONITOR The machine monitor also has the following functions. Use them if necessary. When the ( ) portion of the machine monitor mode selector switch 1 (1) is pressed from the standard screen (service meter/odometer display) or warning screen (action code display), the display changes to "OPERATION INFO"...
Page 80 OPERATION EXPLANATION OF COMPONENTS 3 - 27...
Page 81 OPERATION EXPLANATION OF COMPONENTS DISPLAY METHOD OF OPERATION INFORMATION (FUEL CONSUMPTION) Use to confirm the fuel consumption. 1. Check that the character display is showing the service meter/odometer, or the action code. If it is giving any other display, turn the starting switch OFF, then turn the starting switch to the ON position and wait for the above display to be given.
Page 82 OPERATION OPERATION EXPLANATION OF COMPONENTS EXPLANATION OF COMPONENTS 6. When the ( ) of the machine monitor mode selector switch 1 is pressed on the screen of procedure 3 to 5, the screen in the right figure is shown. When the ( ) of the machine monitor mode selector switch 1 is pressed again, the value on the screen of procedure 3 to 5 is reset and the screen of procedure 2 is displayed.
Page 83 OPERATION EXPLANATION OF COMPONENTS RESET METHOD FOR FILTER, OIL REPLACEMENT TIME The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced, reset the filter and oil change time. 1. Press the ( ) of the machine monitor mode selector switch 1 and display "OPERATION INFO". 2.
Page 84 OPERATION EXPLANATION OF COMPONENTS INPUT METHOD FOR TELEPHONE NUMBER When an error for action code "E03" occurs, it is possible to display the telephone number. 1. Press the ( ) of the machine monitor mode selector switch 1 and display "OPERATION INFO". 2.
Page 85 OPERATION EXPLANATION OF COMPONENTS METHOD FOR SELECTING LANGUAGE Use this when switching the language displayed on the character display. 1. Press the ( ) of the machine monitor mode selector switch 1 and display "OPERATION INFO". 2. Press part (>) or (<) of machine monitor mode selector switch 2 to display "LANGUAGE".
Page 86 OPERATION EXPLANATION OF COMPONENTS METHOD OF SWITCHING SPEEDOMETER/SHIFT INDICATOR 1. Press the ( ) of the machine monitor mode selector switch 1 and display "OPERATION INFO". 2. Press the (>) or (<) of machine monitor mode selector switch 2 to display "SELECT SPEEDOMETER" ("SELECT SHIFT INDIC"...
Page 87: Switches
OPERATION EXPLANATION OF COMPONENTS SWITCHES Starting switch (11) Machine monitor mode selector switch 2 Front lamp switch (12) Machine monitor mode selector switch 1 Front working lamp switch (13) Turn signal lever Blade accumulator switch (if equipped) (14) Horn botton Cigarette lighter (15) Additional car heater switch (if equipped)
Page 88 OPERATION EXPLANATION OF COMPONENTS Top right inside cab Top left inside cab (21) Room lamp switch (22) Intermittent wiper switch (23) Rear wiper switch (24) Door wiper switch (25) Front wiper switch (26) Yellow rotating lamp switch (if equipped) (27) Cab-mounted working lamp switch (if equipped) 3 - 35...
Page 89 OPERATION EXPLANATION OF COMPONENTS STARTING SWITCH Starting switch (1) is used to start or stop the engine. (A): OFF position The key can be inserted or withdrawn. Switches for the electrical system (except room lamp), are all turned off and the engine is stopped.
Page 90 OPERATION EXPLANATION OF COMPONENTS FRONT LAMP SWITCH Use this switch (2) to light up the front lamps, side clearance lamps and tail lamps. Position (A): Front lamps light up in addition to lamps at position (B). Position (B): Side clearance lamps and tail lamps light up Position (C): OFF FRONT WORKING LAMP SWITCH This switch (3) is used to light up the front working lamp.
Page 91 OPERATION EXPLANATION OF COMPONENTS LIFT ARM LOCK SWITCH This switch (6) is used to remove or insert the lifter lock pin. This switch is used when setting the blade to the bank cut posture or shoulder reach posture. Press the switch to remove the pin, and press the switch again to return the switch and insert the pin.
Page 92 OPERATION EXPLANATION OF COMPONENTS TRANSMISSION MODE SELECTOR SWITCH CAUTION When switching from torque converter Auto mode to Manual mode, set the gear shift lever to N (NEUTRAL) position while the machine stops, set the engine to low idle, and then switch over. When starting the machine off after switching over the mode, observe the items in "MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING (PAGE 3-108)".
Page 93 OPERATION EXPLANATION OF COMPONENTS 3 - 40...
Page 94 OPERATION EXPLANATION OF COMPONENTS REMARK Even in Manual mode, no engine stall occurs as this model has the linked control of torque converter and direct drive. When working at F1 and low idle of engine during selection of torque converter Auto mode, the machine can travel at very slow speeds through acceleration and brake operations.
Page 95 OPERATION EXPLANATION OF COMPONENTS DIFFERENTIAL LOCK SWITCH (If equipped) CAUTION To protect the differential device, operate the differential lock switch when the machine is stopping. Do not operate it when traveling or turning. Do not use the differential lock when travelling at high speeds. If a tire on either side slips, lower the engine speed and, after confirming that no tire is slipping, operate the differential lock.
Page 96 OPERATION EXPLANATION OF COMPONENTS MACHINE MONITOR MODE SELECTOR SWITCH 2 This switch (11) is used to switch the function of the character display. When the switch is released, it automatically returns to its original position. The basic operations are as follows. Position (A): Use this position when going to the next screen or advancing the cursor or going up to the next number when inputting numerals.
Page 97 OPERATION EXPLANATION OF COMPONENTS ADDITIONAL CAR HEATER SWITCH (If equipped) Use this switch (15) to turn the heater ON/OFF and to regulate the air flow (2 stages). Position (A): ON, low air flow Position (B): OFF Position (C): ON, high air flow RPM SET SWITCH Use this switch (16) when setting or adjusting the angle of the accelerator.
Page 98 OPERATION EXPLANATION OF COMPONENTS RPM SET MODE SELECTOR SWITCH This switch (17) is used to switch the power for the RPM SET system ON-OFF and to select the RPM SET mode. Position (A): The automatic mode is selected and the indicator on the (A) side of the switch lights up.
Page 99 OPERATION EXPLANATION OF COMPONENTS MANUAL mode Once the accelerator opening angle has been set, it is retained until the switch is turned OFF. After the accelerator opening angle is set, if the accelerator pedal is depressed beyond the set opening angle, the engine speed will rise.
Page 100 OPERATION EXPLANATION OF COMPONENTS REMARK To carry out operations with effective fuel consumption, normally set to the E mode. The maximum engine speed is set lower in E mode than in P mode, but it can display ample power and can also display good fuel consumption in working or traveling on flat ground.
Page 101 OPERATION EXPLANATION OF COMPONENTS Conditions for switching fan rotation Switching from normal rotation to reverse rotation The fan will switch from normal rotation to reverse rotation only if all the following conditions are fulfilled. If the direction is switched, the cooling fan reverse rotation pilot lamp on the machine monitor will change from flashing and will stay lighted up.
Page 102 OPERATION EXPLANATION OF COMPONENTS INTERMITTENT WIPER SWITCH This switch (22) switches between intermittent operation and normal operation for the front wiper, rear wiper, and door wiper. Position (A): Wipers operate intermittently Position (B): Wipers operate normally REAR WIPER AND WINDOW WASHER SWITCH This switch (23) actuates the rear wiper and window washer.
Page 103 OPERATION EXPLANATION OF COMPONENTS YELLOW ROTATING LAMP SWITCH (If equipped) This switch (26) is used to light up. Position (A): Rotating lamp lights up Position (B): OFF REMARK Use the yellow rotating lamp when carrying out operations. Follow the guidance of the supervisor when using. CAB-MOUNTED WORKING LAMP SWITCH (If equipped) This switch (27) is used to light up the cab-mounted working lamp.
Page 104: Control Levers, Pedals
OPERATION EXPLANATION OF COMPONENTS CONTROL LEVERS, PEDALS Left blade lift cylinder control lever Drawbar side shift control lever Ripper/Scarifier control lever (if equipped) Leaning control lever Blade side shift control lever (10) Right blade lift cylinder control lever Power tilt control lever (11) Inching pedal Blade rotation control lever...
Page 105 OPERATION EXPLANATION OF COMPONENTS LEFT BLADE LIFT CYLINDER CONTROL LEVER This lever (1) operates the left blade lift cylinder. (A) LOWER: The left side of the blade goes down. (B) HOLD: The blade stops and is held in the same position. (C) RAISE: The left side of the blade goes up.
Page 106 OPERATION EXPLANATION OF COMPONENTS RIPPER/SCARIFIER CONTROL LEVER (If equipped) This lever (2) is used to operate the ripper or scarifier. When the machine is equipped with a ripper (A) LOWER: The ripper is lowered. (B) HOLD: The ripper is stopped and held in position. (C) RAISE: The ripper is raised.
Page 107 OPERATION EXPLANATION OF COMPONENTS BLADE SIDE SHIFT CONTROL LEVER This lever (3) shifts the blade to the side. (A) LEFT SHIFT: The blade is shifted to the left position. (B) HOLD: The blade stops and is held in the same position. (C) RIGHT SHIFT: The blade is shifted to the right.
Page 108 OPERATION EXPLANATION OF COMPONENTS BLADE ROTATION CONTROL LEVER NOTICE To prevent damage to the tires, be careful not to let the blade hit the tires when rotating the blade. This lever (5) rotates the blade. (A) RIGHT ROTATION: The blade is rotated to the left. (B) HOLD: The blade stops and is held in the same position.
Page 109 OPERATION EXPLANATION OF COMPONENTS ARTICULATE CONTROL LEVER WARNING Operate this lever only when traveling at a speed of below 10 km/h (6.2 MPH). If the articulation is operated at a speed of over 10 km/h (6.2 MPH), there is danger that the machine may overturn. NOTICE To prevent damage to the tires, be careful not to let the blade hit the tires when articulating the machine.
Page 110 Only after the machine stops, use the parking brake. In case the parking brake was used as emergency brake during travels due to avoidable reasons, ask your Komatsu distributor to check the abnormality in the parking brake.
Page 111 OPERATION EXPLANATION OF COMPONENTS DRAWBAR SIDE SHIFT CONTROL LEVER This lever (8) shifts the drawbar to the side. (A) LEFT SHIFT: The drawbar is shifted to the left. (B) HOLD: The drawbar stops and is held in the same position. (C) RIGHT SHIFT: The drawbar is shifted to the right.
Page 112 OPERATION EXPLANATION OF COMPONENTS RIGHT BLADE LIFT CYLINDER CONTROL LEVER This lever (10) operates the right blade lift cylinder. (A) LOWER: The right side of the blade goes down. (B) HOLD: The blade stops and is held in the same position. (C) RAISE: The right side of the blade goes up.
Page 113 OPERATION EXPLANATION OF COMPONENTS INCHING PEDAL CAUTION Never continue stopping the machine on a slope for a long time, keeping the inching clutch slipping. When stopping on a slope, set the gear shift lever to P (PARKING) position. If not necessary, do not put your foot on this pedal. NOTICE Long time inching operations raise the clutch temperature excessively and cause the seizure or abnormal wear.
Page 114 OPERATION EXPLANATION OF COMPONENTS STEERING CONSOLE TILT PEDAL This pedal (12) can be used to adjust the angle of the steering console steplessly. Depress the tilt pedal, move the steering console to the desired position, then release the pedal. REMARK The steering wheel, instrument panel, and work equipment control levers also move forward or backward at the same time.
Page 115 OPERATION EXPLANATION OF COMPONENTS FRONT ATTACHMENT CONTROL LEVER (If equipped) This lever (15) is used to operate the front attachment. When the machine is equipped with a front blade (A) LOWER: The front blade is lowered. (B) HOLD: The front blade is stopped and held in position. (C) RAISE: The front blade is raised.
Page 116: Dust Indicator
OPERATION EXPLANATION OF COMPONENTS DUST INDICATOR This device checks the condition of clogging of the air cleaner element. It displays 5 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.
Page 117: Fuse Box
FUSE BOX WARNING If the fuse blows again immediately after it is replaced, please contact your Komatsu distributor. NOTICE Before replacing a fuse, be sure to cut the power off (turn the starting switch OFF and the battery disconnect switch OFF).
Page 118: Slow Blow Fuse
OPERATION EXPLANATION OF COMPONENTS Fuse II No. Capacity Name of circuit 20 A Air conditioner blower 10 A Continuous power supply for cab 10 A Room lamp Continuous power supply for engine 30 A controller 10 A Option (Heater) 10 A Option (12 V converter) Radio Air conditioner compressor, Clutch...
Page 119: Electric Power Takeoff
OPERATION EXPLANATION OF COMPONENTS ELECTRIC POWER TAKEOFF The cigarette lighter socket (1) can be used as a power source for 24 V equipment and the accessory socket (2) can be used for 12 V equipment. NOTICE The cigarette lighter is 24 V. Do not use it as the power source for 12 V equipments.
Page 120: Handling Battery Disconnect Switch
OPERATION EXPLANATION OF COMPONENTS HANDLING BATTERY DISCONNECT SWITCH This switch cuts the flow of electricity from the battery. This is inside the battery box on the left side of the machine. NOTICE When the battery disconnect switch is turned OFF, the memory and chronometric functions in the radio are reset.
Page 121: Opening, Closing Cab Doors
OPERATION EXPLANATION OF COMPONENTS OPENING, CLOSING CAB DOORS CAUTION Be sure to open or close the door on level ground. Avoid opening or closing the door on a slope. There is a danger that the operating effort changes suddenly. In addition, carefully open or close when it is windy around the machine.
Page 122: Backup Alarm
OPERATION EXPLANATION OF COMPONENTS WHEN CLOSING When closing the door from the ground, depress the release lever (5). The door locked in opening state is released. As the door starts closing at the same time as released, hold the door by hand and close.
Page 123: Am/Fm Radio
OPERATION EXPLANATION OF COMPONENTS AM/FM RADIO EXPLANATION OF COMPONENTS Power switch/Volume Preset switch Tone control knob Seek Display Band selector switch Clock button/Displaying frequency Tuning switch POWER SWITCH/VOLUME When this switch (1) is turned to the right, it clicks and the power is turned on.
Page 124 OPERATION EXPLANATION OF COMPONENTS TONE CONTROL KNOB If this knob (2) is turned to the right, the high tone is emphasized; if it is turned to the left, the high tone is reduced. DISPLAY This display (3) shows the radio reception frequency and the operating mode.
Page 125 OPERATION EXPLANATION OF COMPONENTS PRESET SWITCH With this switch (6), each button can be preset to 1 station each for FM and MW (AM). (For details of the method of presetting, see Section "METHOD OF PRESETTING STATION (PAGE 3-74)".) SEEK When this switch (7) ("SEEK") is pressed, it automatically searches for stations that can be received, and when it receives a station, it stops.
Page 126 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION LISTENING TO RADIO 1. Turn radio power switch (1) ON. 2. "BAND" switch (2) is used to select MW (AM) or FM. 3. Use the preset switch or tuning switch (3) to select the station. 4.
Page 127 OPERATION EXPLANATION OF COMPONENTS METHOD OF PRESETTING STATION 1. Select the desired preset station. Use the "BAND" button to select MW (AM) or FM, and use the "TUNE" button to select the frequency of the broadcasting station. 2. Decide the number of the button to be preset, and keep it pressed for 2 seconds.
Page 128 OPERATION EXPLANATION OF COMPONENTS METHOD OF SETTING TIME 1. Turn the power switch (1) of radio to the ON position. If the display (2) shows the frequency, press the CLOCK button (3) to display the time. 2. With CLOCK button (3) kept pressed: Press button (4) to set the minutes.
Page 129: Air Conditioner
OPERATION EXPLANATION OF COMPONENTS AIR CONDITIONER By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This makes it possible to provide a pleasant working environment even on dusty jobsites. LOCATIONS AND FUNCTIONS OF CONTROL PANEL Main power switch Temperature control switch...
Page 130 OPERATION EXPLANATION OF COMPONENTS FAN SWITCH Use this switch (2) to adjust the air flow from the fan. The air flow can be adjusted to 5 stages. When this switch (A) is pressed, the air flow increases; when switch (B) is pressed, the air flow decreases. LED display (C) shows the position set for the air flow.
Page 131 OPERATION EXPLANATION OF COMPONENTS TEMPERATURE CONTROL SWITCH Use this switch (4) to adjust the temperature between low temperature and high temperature. When switch (A) is pressed, the temperature of the air blowing out becomes higher; when switch (B) is pressed, the temperature of the air blowing out becomes lower.
Page 132 OPERATION EXPLANATION OF COMPONENTS METHOD OF OPERATION COOLING OPERATION 1. Press main power switch (1) of the air conditioner to turn the power ON. 2. Press fan switch (2) and set the air flow to "Hi". 3. Press temperature control switch (3) to set the LED display to the COOL side.
Page 133: Operation Manual Storage
When adding refrigerant or carrying out other maintenance, special tools and instruments are needed, so ask your Komatsu distributor to carry out inspection and repair. OPERATION MANUAL STORAGE A pocket is provided at the rear of the operator's seat backrest for keeping the Operation and Maintenance Manual.
Page 134: Grease Pump Holder
OPERATION EXPLANATION OF COMPONENTS GREASE PUMP HOLDER When opening the cover of the tool box, the compartment to stow the grease pump is found inside. CUP HOLDER This is on the left side of the operator's cab. ASHTRAY This is on the left side of the operator's cab. Always extinguish your cigarette before putting it in the ashtray, then be sure to close the lid.
Page 135: Handling Machines Equipped With Komtrax
Komatsu distributor before selling or exporting any machine equipped with KOMTRAX. When selling or exporting the machine or at other times when your Komatsu distributor considers it necessary, it may be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to stop communications.
Page 136: Operation
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.
Page 137 OPERATION OPERATION 9. Check for problem in gauges, monitor. Check for problem in the gauges and monitor in the operator's cab. If any problem is found, replace the parts. Clean off any dirt from the surface. 10. Check for damaged mirror, reflector, loose mounting bolts Check that there is no damage to the mirror or reflectors, and replace if there is any problem.
Page 138 OPERATION OPERATION OPERATION OPERATION 13. Clean cab window To ensure a good view during operations, always keep the cab windows clean. Working on the frame, tire, or hood is very dangerous. Be sure to carry out the cleaning operation from the ground by using a handled mop, etc.
Page 139 OPERATION OPERATION CHECK BEFORE STARTING Be sure to check the items listed here before starting the engine for the day's work. CHECK COOLANT LEVEL, ADD WATER WARNING Do not open the radiator cap unless necessary. Wait for the engine to cool down before checking the coolant in the sub-tank. Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure.
Page 140 OPERATION OPERATION CHECK FUEL LEVEL, ADD FUEL WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If any fuel is spilled, wipe it up completely. If fuel is spilled on earth and sand, be sure to remove them together. Never bring flames near fuel because it is highly flammable and dangerous.
Page 141 OPERATION OPERATION DRAIN WATER AND SEDIMENT IN FUEL TANK Loosen fuel tank drain valve (1) and drain the sediment and water which are accumulated at the bottom, together with fuel to a container. 3 - 88...
Page 142 OPERATION OPERATION CHECK ENGINE OIL PAN LEVEL, ADD OIL WARNING Parts and oil are at high temperature immediately after the engine is stopped and may cause serious burns. Wait for the oil temperature to go down before performing this operation. 1.
Page 143 Standard: Less than 25 mm (1.0 in). If the steering wheel play is out of the standard range, or if the steering wheel is waved, turned, or heavy to the abnormal extent, ask your Komatsu distributor for repairs. 3 - 90...
Page 144 OPERATION OPERATION CHECK WATER SEPARATOR, DRAIN WATER WARNING Each part of the engine is still highly heated immediately after the engine is stopped. Do not attempt to drain cooling water or remove the filter element cup. High pressure is generated inside the engine fuel piping, while the engine is running. Wait for more than 30 seconds after the engine stop for the engine to sufficiently cool down.
Page 145 If the fluid does not spray out properly, clean the washer nozzle with a safety pin or thin wire. If the condition is still not improved, please ask your Komatsu distributor to carry out inspection and repair. CHECK WIPING EFFICIENCY OF WIPER Operate the wiper and check that it wipes the window properly under each operating speed: Intermittent, low speed, high speed.
Page 146 Check that all places can be locked properly. (For details of the locations that can be locked, see "LOCKING (PAGE 3-167)".) If any abnormality is found, please ask your Komatsu distributor to carry out inspection and repair. 3 - 93...
Page 147 OPERATION OPERATION OPENING AND CLOSING LOWER COVER CAUTION Do not travel or work with the lower cover open. When the tandem swings, it may break the lower cover. After checking or servicing the inside of the engine compartment, do not close side panel (2) with lower cover (1) open.
Page 148 OPERATION OPERATION ADJUSTMENTS ADJUST OPERATOR'S SEAT WARNING Park the machine in a safe place and stop the engine when carrying out adjustment of the operator's seat. Adjust the seat position at the beginning of each shift or when operators change. Adjust the seat so that the brake pedal can be depressed all the way down with the operator's back against the backrest.
Page 149 OPERATION OPERATION (D) Adjusting armrest angle Armrest (4) can be made to spring up by hand approximately 90 deg. In addition, by turning the bottom (5) of the armrest by hand it is possible to make fine vertical adjustments of the armrest angle.
Page 150 OPERATION OPERATION ADJUSTING POSITION OF STEERING CONSOLE, WORK EQUIPMENT CONTROL LEVERS WARNING Do not carry out adjustments while traveling. Depress the pedal (1). When the steering console is set to a desired position, release the pedal. Adjust to a position that matches your physique and operating posture.
Page 151 OPERATION OPERATION ADJUSTING MIRROR WARNING Be sure to adjust the mirrors before starting operations. If not adjusting them properly, you cannot secure the visibility and may be injured or may injure someone seriously. When adjusting the mirrors, keep your scaffolding by using a stool before starting the work. Loosen mounting bolt (1) and nuts (2) of the mirror, then adjust the mirror to a position which gives the best view from the operator's seat.
Page 152 OPERATION OPERATION OPERATION OPERATION Visible range Mirror (C): The ground surface of 10 m (32 ft 10 in) width at 30 m (98 ft 5 in) distance to the rear of the machine can be seen. The position (a) (In 5 m (16 ft 5 in) width of ground surface at 30 m (98 ft 5 in) far from the rear of the machine) can be seen from the position (b) (at 1.5 m (4 ft 11 in) height and 0.75 m (2 ft 6 in) width of ground surface) at the rear of the machine.
Page 153 OPERATION OPERATION OPERATIONS, CHECKS BEFORE STARTING ENGINE WARNING When starting the engine, check that the gearshift lever is properly at the P (Parking) position. If the control levers are touched by accident when the engine is started, the work equipment may move suddenly and cause a serious accident. When standing up from the operator's seat, always set the gearshift lever to the P (Parking) position, regardless of whether the engine is running or stopped.
Page 154: Starting Engine
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.
Page 155 OPERATION OPERATION STARTING IN COLD WEATHER WARNING Start the engine only after sitting down in the operator's seat. Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious bodily injury or fire. Check that there are no persons or obstacles in the surrounding area, then sound the horn and start the engine.
Page 156 BREAKING-IN THE MACHINE CAUTION Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
Page 157: Operations, Checks After Starting Engine
Set to the machine on level ground with no obstacles in the surrounding area, then drive the machine slowly forward and in reverse and check the braking effect of the brakes. If there is any abnormality in the operation of the brakes, please ask your Komatsu distributor to carry out adjustment.
Page 158 If any problem is found, carry out maintenance or repair. Run the engine under low load until engine water temperature gauge (1) enters the green range. 3. Check for abnormal exhaust gas color, noise, or vibration. If any problem is found, contact your Komatsu distributor. 3 - 105...
Page 159: Stopping Engine
OPERATION OPERATION STOPPING ENGINE NOTICE If the engine stops abruptly, service lives of the various parts of the engine threaten to shorten. Never stop it abruptly except in emergencies. In case of overheat of the engine, do not try to stop it abruptly but run it at medium speeds to cool down gradually, and then stop it.
Page 160: Traveling Posture For Machine
OPERATION OPERATION TRAVELING POSTURE FOR MACHINE WARNING For general travel, always lock the front frame and rear frame with the articulate lock pin. Before moving any work equipment control lever, check the distance between the blade and tires. NOTICE 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.
Page 161: Moving Machine Off (Forward, Reverse, Shifting Gear), Stopping
OPERATION OPERATION MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING WARNING When moving off, check that the area around the machine is safe, and sound the horn before moving. Clear all personnel from the machine and the area. Use extreme care when reversing the machine. Note there is a blind spot behind the machine. When brake oil pressure alarm buzzer sounds due to lowering of brake oil pressure, do not operate the machine and wait with engine idle (low engine speed with no load) until brake oil pressure alarm buzzer stops.
Page 162 OPERATION OPERATION OPERATION OPERATION 4. Return inching pedal (2) back gradually, while keeping brake pedal (1) depressed. By returning inching pedal (2) back, the transmission starts to transmit the power. NOTICE In starting operations of the machine, provide an interval of at least 2 seconds between the operations of procedure 2.
Page 163 OPERATION OPERATION OPERATION OPERATION 3. Always check that parking brake lamp (4) has gone out. 4. Return brake pedal (1) back, depress accelerator pedal (3) and starts off the machine. 3 - 110...
Page 164 OPERATION OPERATION SHIFTING GEAR ON MACHINE WARNING Avoid sudden gear shifts when traveling at high speeds. Before shifting down the gear, apply the brake to reduce the travel speed. Do not set the gear shift lever to the N (Neutral) position when traveling or going downhill. The braking force of the engine cannot be applied and there is danger of unexpected accidents.
Page 165 OPERATION OPERATION WARNING When going downhill, shift down the transmission to use the engine brake. To prevent the engine from overrunning, the rotation range enabling downshifts is limited. Reduce the travel speed by depressing the brake pedal and, after the speed becomes within the range where downshifts are possible, carry out the downshift operation.
Page 166 OPERATION OPERATION SHIFTING BETWEEN FORWARD AND REVERSE WARNING When shifting between forward and reverse, always check that it is safe to travel in the new direction. Use extreme care when reversing the machine. Note there is an blind spot behind the machine. Do not shift between forward and reverse when traveling at high speed.
Page 167 OPERATION OPERATION OPERATION OPERATION 3. Return inching pedal (2) back gradually, while keeping brake pedal (1) depressed. By returning inching pedal (2) back, the transmission starts to transmit the power. NOTICE In starting operations of the machine, provide an interval of at least 2 seconds between the operations of procedure 2.
Page 168 OPERATION OPERATION OPERATION OPERATION 2. Switch over gear shift lever (2) to F (FORWARD) or R (REVERSE) and set it to the 1st or 2nd speed. 3. Return brake pedal (1) back and depress accelerator pedal (3). The machine starts. REMARK If carrying out a direction switching operation during travels, the gear speed probably shift down sequentially before the directional change, for the protection of the passenger and machine.
Page 169 OPERATION OPERATION STOPPING MACHINE WARNING Avoid stopping suddenly. Give yourself ample room when stopping. WHEN SELECTING MANUAL MODE 1. Release accelerator pedal (1). 2. Depress brake pedal (2). Before the machine comes to a stop, depress inching pedal (3). REMARK As this model has the linked control function of torque converter with direct drive, the engine does not stop even if depressing the inching pedal belatedly or not depressing it at all.
Page 170 OPERATION OPERATION OPERATION OPERATION 3. Set gear shift lever (4) to the P (PARKING) position while pressing its knob. The parking brake lamp lights up at the same time. WHEN SELECTING TORQUE CONVERTER AUTO MODE 1. Release accelerator pedal (1). 2.
Page 171 OPERATION OPERATION OPERATION OPERATION 3. Set gear shift lever (3) to the P (PARKING) position while pressing its knob. The parking brake lamp lights up at the same time. 3 - 118...
Page 172: Turning Machine
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.
Page 173 OPERATION OPERATION ARTICULATING OPERATION WARNING Do not remove the lock pin for general travel. NOTICE When turning with the machine articulated, pay particular attention to the clearance between the blade end and the wheel. Before carrying out articulation operations, remove the lock pin on the left side of the machine. 1.
Page 174 OPERATION OPERATION OPERATION OPERATION 2. When articulation control lever (2) is pushed forward (A), the machine articulates to the left; when it is pulled back (C), the machine articulates to the right. 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).
Page 175: Operating Work Equipment
OPERATION OPERATION OPERATING WORK EQUIPMENT Left blade lift cylinder control lever Power tilt control lever Right blade lift cylinder control lever Drawbar side shift control lever Blade side shift control lever Ripper/Scarifier control lever (if equipped) Blade rotation control lever Front attachment control lever (if equipped) 3 - 122...
Page 176 OPERATION OPERATION BLADE OPERATION BLADE LIFT OPERATION When left blade lift cylinder control lever (1) is pushed forward (A), the left end of the blade goes down; when it is pulled back (C), the left end of the blade goes up. When right blade lift cylinder control lever (2) is pushed forward (A), the right end of the blade goes down;...
Page 177 OPERATION OPERATION OPERATING BLADE SIDE SHIFT When blade side shift control lever (3) is pushed forward (A), the blade shifts to the left; when it is pulled back (C), the blade shifts to the right. OPERATING BLADE ROTATION When blade rotation control lever (4) is pushed forward (A), the blade rotates to the left;...
Page 178 OPERATION OPERATION CHANGING BLADE CUTTING ANGLE When power tilt control lever (5) is pushed forward (A), the cutting angle becomes larger; when it is pulled back (C), the cutting angle becomes smaller. When cutting hard soil (D), make the cutting angle larger. When cutting soft soil (E), make the cutting angle smaller.
Page 179 OPERATION OPERATION OPERATING DRAWBAR SIDE SHIFT When drawbar side shift control lever (6) is pushed forward (A), the drawbar shifts to the left; when it is pulled back (C), the drawbar shifts to the right. 3 - 126...
Page 180 OPERATION OPERATION OPERATING RIPPER/SCARIFIER When the machine is equipped with a ripper When ripper/Scarifier control lever (7) is pushed forward (A), the ripper goes down; when it is pulled back (C), the ripper goes up. When the machine is equipped with a scarifier When ripper/Scarifier control lever (7) is pushed forward (A), the scarifier goes down;...
Page 181 OPERATION OPERATION OPERATING FRONT ATTACHMENT When the machine is equipped with a front blade When front attachment control lever (8) is pushed forward (A), the front blade goes down; when it is pulled back (C), the front blade goes up. 3 - 128...
Page 182: Work Which Can Be Carried Out Using A Motor Grader
OPERATION OPERATION WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER LEVELING GROUND TO RIGHT 1. Operate the drawbar side shift and move the circle approximately 200 mm (7.9 in) to the left. 2. Set the blade so that the earth is discharged outside the rear left wheel.
Page 183 OPERATION OPERATION 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.
Page 184 OPERATION OPERATION LEVELING GROUND TO LEFT 1. Operate the drawbar side shift and move the circle approximately 200 mm (7.9 in) to the right. 2. Set the blade so that the earth is discharged outside the rear right wheel. 3. Operate the blade lift cylinder so that the blade is at the desired digging depth, then set it horizontal.
Page 185 OPERATION OPERATION DIGGING RIGHT V-DITCHES NOTICE Set the frame straight. If the machine is articulated, the side of the tire will be pushed against the opposite slope face (back slope), and this will cause damage to the side face of the tire. In addition, mud will be pushed in between the tire and rim, and this will cause problems such as leakage of air and flat tires.
Page 186 OPERATION OPERATION 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).
Page 187 OPERATION OPERATION DIGGING LEFT V-DITCHES NOTICE Set the frame straight. If the machine is articulated, the side of the tire will be pushed against the opposite slope face (back slope), and this will cause damage to the side face of the tire. In addition, mud will be pushed in between the tire and rim, and this will cause problems such as leakage of air and flat tires.
Page 188 OPERATION OPERATION 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 left end of the blade to a digging depth of 50 to 100 mm (2.0 to 3.9 in).
Page 189 OPERATION OPERATION RIGHT DITCH FINISHING 1. Set the right side of the blade behind the front right wheel. 2. Operate the right blade lift cylinder and set the blade to the depth of the ditch. 3. Be careful not to let the rear left wheel run over the window discharged from the blade.
Page 190 OPERATION OPERATION LEFT DITCH FINISHING 1. Set the left side of the blade behind the front left wheel. 2. Operate the left blade lift cylinder and set the blade to the depth of the ditch. 3. Be careful not to let the rear right wheel run over the windrow discharged from the blade.
Page 191 OPERATION OPERATION FINISHING RIGHT ROAD SHOULDER 1. Operate the drawbar shift cylinder to set the circle to the right end. 2. Set so that the right end of the blade is in line with the outside of the right tire. Set the blade so that the soil is discharged between the 2 wheels.
Page 192 OPERATION OPERATION FINISHING LEFT ROAD SHOULDER 1. Operate the drawbar shift cylinder to set the circle to the left end. 2. Set so that the left end of the blade is in line with the outside of the left tire. Set the blade so that the soil is discharged between the 2 wheels.
Page 193 OPERATION OPERATION CONSTRUCTING ROAD - METHOD OF MAKING V-DITCH The procedure shown in the diagrams is for one side of the road. Repeat the same operation on the opposite side of the road. When carrying out Steps 4 and 7, articulate the frame. 1.
Page 194 OPERATION OPERATION OPERATION OPERATION 5. Leveling center 6. Fourth digging pass: Heavy-duty digging 7. Finishing road shoulder 8. Spreading to center 9. Slope face and bank Use the bank cutting posture. 3 - 141...
Page 195 OPERATION OPERATION OPERATION OPERATION 10. Finishing bottom of ditch 11. Ditch digging pass (finishing and shaping inside of the slope face) 12. Finishing slope face 13. Finishing road shoulder 14. Leveling and finishing 3 - 142...
Page 196 OPERATION OPERATION FLAT-BOTTOMED DITCH If there is no V-groove, make a V-groove at depth (A) of the flat-bottomed ditch. The slope of the road shoulder must be flatter than usual. 1. Operate the power tilt and angle the blade to the front. 2.
Page 197 OPERATION OPERATION OPERATION OPERATION 7. Lean the front wheels to the left. Dig the second V-groove (2) at the same depth or slightly deeper than the first V-groove (1). 8. Dig the flat bottom. Set the right blade lift cylinder to the desired depth.
Page 198 OPERATION OPERATION CONSTRUCTING ROAD - METHOD FOR MAKING FLAT-BOTTOMED DITCH The procedure shown in the diagrams is for one side of the road. Repeat the same operation on the opposite side of the road. 1. Make the slope face on the inside flat. 2.
Page 199 OPERATION OPERATION OPERATION OPERATION 5. Finish the slope face on the bank. 6. Make the bottom of the ditch flat. 7. Finish the ditch. 8. Finish the slope face on the inside. 9. Finishing slope face 3 - 146...
Page 200 OPERATION OPERATION OPERATION OPERATION 10. Leveling and finishing. FINISHING WITH GRADER FOR DITCHES WHERE WET ROAD SHOULDER IS LOOSE This method is used when avoiding hanging trees or protruding rocks which are obstacles when cleaning old ditches. 1. Articulate the machine so that the front wheels and blade remain in the ditch.
Page 201 OPERATION OPERATION BANK CUTTING METHOD - RIGHT SIDE WARNING Lower the blade to the ground before removing the bank control lock pin. 1. The roadbed where the foundation is to be dug must be uniform. 2. If the soil is hard, angle the roadbed slightly towards the bank to prevent the machine from sliding to the side away from the bank.
Page 202 OPERATION OPERATION OPERATION OPERATION 10. If the digging is comparatively heavy duty, angle the wheels towards the slope face. 11. If the digging is comparatively light duty, angle the wheels away from the slope face. Discharge the soil from the slope face to the outside of the rear wheels.
Page 203: Precautions When Operation
OPERATION OPERATION PRECAUTIONS WHEN OPERATION PRECAUTIONS WHEN TRAVELING UPHILL OR DOWNHILL WARNING Never shift gear or place the transmission in neutral when traveling on a slope. It is dangerous to do this, as the engine cannot be used to brake the machine. Always place the transmission in the appropriate speed range before starting to travel down a hill.
Page 204 NOTICE If the parking brake has been used as an emergency brake, please contact your Komatsu distributor to have the parking brake checked for any problem. PRECAUTIONS WHEN USING ARTICULATED STEERING When the articulation is used to steer the machine, the machine will turn sharply, so at high speed there is a danger that it will turn over.
Page 205 OPERATION OPERATION CAUTIONS IN OPERATION OF WORK EQUIPMENT When operating the work equipment control lever, always pay careful attention to the movement of the work equipment and do not move it more than necessary as the work equipment or the hydraulic cylinder may hit and damage other parts.
Page 206 OPERATION OPERATION RIPPER OPERATIONS - WITH FRAME STRAIGHT CAUTION When using the ripper, set the frame straight. For heavy-duty conditions, use 1 to 3 shanks. For general soil condition, use 3 to 5 shanks. Keep the ripper at a depth where there is no tire slip and where the engine horsepower can be used to its full.
Page 207 OPERATION OPERATION PRECAUTIONS WHEN INSTALLING FRONT BLADE WARNING Machine equipped with front blade has a blind spot in front of tire due to interruption by blade. Operate the machine carefully. Confirm that there are no person and other obstacles around the machine before starting. Sound the horn to warn the people around before starting.
Page 208: Adjusting Work Equipment Posture
OPERATION OPERATION ADJUSTING WORK EQUIPMENT POSTURE Move the work equipment to the most suitable position for each operation and carry out operations efficiently. BLADE PROTRUSION The degree of protrusion is controlled by the control lever during operation. If further protrusion is needed, stop the grader for a while and change the installing position of the blade horizontal shifting cylinder piston rod, as follows.
Page 209 OPERATION OPERATION ADJUSTING BLADE CUTTING ANGLE Generally, the operating efficiency is better if the blade cutting angle is large when cutting hard soil and small when cutting soft soil. The blade cutting angle is installed to the power tilt blade, and it can be freely changed within the range below.
Page 210 A slip clutch is installed to the circle to prevent accidents when an abnormal impact load is applied to the end of the blade during work. If any problem occurs in the slip clutch, the following problems may appear, so please contact your Komatsu distributor for repairs and adjustment.
Page 211 OPERATION OPERATION BANK CUTTING POSTURE (RIGHT SIDE) WARNING Lower the blade to the ground before removing the bank control lock pin. Do not remove it at any other position. There is danger that it will rotate and the blade will fall. NOTICE When shifting to the bank cut posture, be careful not to let the blade hit any other part of the machine.
Page 212 OPERATION OPERATION 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.
Page 213 OPERATION OPERATION SHOULDER REACH POSTURE (RIGHT SIDE) WARNING Lower the blade to the ground before removing the bank control lock pin. Do not remove it at any other position. There is danger that it will rotate and the blade will fall. NOTICE When shifting to the shoulder reach posture, be careful not to let the blade hit any other part of the machine.
Page 214 OPERATION OPERATION OPERATION OPERATION 4. Shift the blade to the side as shown in the diagram. Shift the blade fully to the right. Shift the drawbar fully to the right. 5. Rotate the circle and set to the desired position. When setting to the shoulder reach posture on the left side, use the same procedure as above, but in the opposite direction.
Page 215 OPERATION OPERATION ADJUSTING SCARIFIER ADJUSTING CUTTING ANGLE In general, on hard ground, the larger the cutting angle is, the more efficient the operation becomes. Adjustment Remove bolt (1), then move the position of the hole to the desired position. The angle can be adjusted to 3 positions: 58º, 60º, 71º. 60º is the standard position.
Page 216 OPERATION OPERATION PRECAUTIONS WHEN HANDLING OR OPERATING SCARIFIER If the scarifier is fully raised and the blade is lowered to raise the body, the scarifier and drawbar will hit, and the drawbar will be damaged. If the blade is raised a few centimeters from the ground surface and rotated, the blade and scarifier will hit, and the blade will be damaged.
Page 217: Parking Machine
OPERATION OPERATION PARKING MACHINE WARNING Avoid stopping suddenly. Leave an adequate margin when stopping. Avoid parking the machine on a slope. 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.
Page 218 OPERATION OPERATION OPERATION OPERATION 3. Set gear shift lever (4) to the P (PARKING) position while pressing its knob. The parking brake lamp lights up at the same time. 4. Operate the work equipment control lever, and lower the blade and the ripper (or the scarifier) to the ground.
Page 219: Checks After Completion Of Operation
OPERATION OPERATION OPERATION OPERATION 2. Depress brake pedal (2) and stop the machine. 3. Set gear shift lever (3) to the P (PARKING) position while pressing its knob. The parking brake lamp lights up at the same time. 4. Operate the work equipment control lever, and lower the blade and the ripper (or the scarifier) to the ground.
Page 220: Locking
OPERATION OPERATION LOCKING Always lock the following parts. (1) Cab door (left, right) (2) Engine side cover (left, right) (3) Battery cover (4) Fuel filler cap (5) Transmission oil filler cover (right side of the machine) (6) Tool box REMARK The starting switch key is used also for locks at (1) - (5) portions.
Page 221: Handling The Tires
Tires where radial cracks extend to the carcass Tires where there is abnormal deterioration, deformation, and damage, and the tire cannot withstand use. Please contact your Komatsu distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. 3 - 168...
Page 222: Combination Of Snow Radial Tire And Chain
In addition, use the rims designated by Komatsu. Do not use the combinations marked x in the following table.
Page 223: Transportation
OPERATION TRANSPORTATION TRANSPORTATION When transporting the machine, observe all related laws and regulations, and be careful to assure safety. STEPS FOR TRANSPORTATION As a basic rule, always transport the machine on a trailer. When selecting the trailer, see the weights and dimensions given in "SPECIFICATIONS (PAGE 5-2)". Note that the specifications for the weights and dimensions for transportation differ according to the type of tires and type of blade.
Page 224: Precautions For Loading
OPERATION TRANSPORTATION PRECAUTIONS FOR LOADING After placing the machine on the specified position of the trailer, secure it according to the following procedure. 1. Lower the work equipment slowly. 2. Set the gear shift lever at the P (parking) position. 3.
Page 225: Lifting Machine
This method of lifting applies to the standard specification machine. The method of lifting differs according to the attachments and options installed. For details of the procedure for machines that are not the standard specification, please consult your Komatsu distributor. For weight, see "SPECIFICATIONS (PAGE 5-2)".
Page 226 OPERATION TRANSPORTATION The machine can be lifted only if it has hook mark labels. When lifting the machine, stop the machine on level ground and do as follows. 1. Start the engine, make sure that the machine is horizontal, then set the work equipment to the travel posture. 2.
Page 227: Cold Weather Operation
Do not let it flow into drainage ditches or spray it onto the ground surface. NOTICE Please use Komatsu genuine SUPERCOOLANT (AF-NAC) for the coolant. As a basic rule, we do not recommend the use of any coolant other than SUPERCOOLANT (AF-NAC).
Page 228: Cautions After Completion Of Work
OPERATION COLD WEATHER OPERATION BATTERY WARNING The battery generates flammable gas. Do not bring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.
Page 229: Long-Term Storage
1 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.
Page 230: Troubleshooting
Repair the faulty leaning pipe quickly. If the leaning piping is broken, call your Komatsu distributor for repair. METHOD OF USING LEANING STOPPER Fix the front axle and hole (1) in the leaning rod with the bolt in the tool box.
Page 231: Towing The Machine
The machine must not be towed for long distances. For details of the procedure for towing a machine when it has broken down, please contact your Komatsu distributor. WHEN ENGINE CAN BE USED Always keep the engine running when towing the machine, so that the steering and braking can be used.
Page 232 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. METHOD OF RELEASING PARKING BRAKE WARNING When releasing the parking brake, stop the machine on level ground and check that the surrounding area is safe.
Page 233: If Battery Is Discharged
OPERATION TROUBLESHOOTING IF BATTERY IS DISCHARGED WARNING It is dangerous to charge a battery when installed on a machine. Make sure that it is removed before charging. When checking or handling the battery, stop the engine and turn the starting switch key to OFF position. The battery generates hydrogen gas, so there is a hazard of explosion.
Page 234 OPERATION TROUBLESHOOTING PRECAUTIONS WHEN CHARGING BATTERY When charging the battery, if the battery is not handled correctly, there is danger that the battery may explode. Always follow the instructions in "IF BATTERY IS DISCHARGED (PAGE 3-180)" and the instruction manual accompanying the charger, and do as follows.
Page 235 OPERATION TROUBLESHOOTING STARTING ENGINE WITH BOOSTER CABLE When starting the engine with a booster cable, do as follows: PRECAUTIONS WHEN CONNECTING AND DISCONNECTING BOOSTER CABLE WARNING When connecting the cables, never contact the positive (+) and negative (-) terminals. When starting the engine with a booster cable, wear safety glasses and rubber gloves.
Page 236: If The Gear Shift Lever Of The Transmission Has Any Trouble
OPERATION TROUBLESHOOTING STARTING THE ENGINE CAUTION Check that the gearshift levers on both the normal machine and problem machine are at the P (Parking) position. Check also that all levers are at neutral. 1. Make sure the clips are firmly connected to the battery terminals. 2.
Page 237: Lowering Work Equipment When Engine Is Stopped (Release Work Equipment Oil Pressure)
OPERATION OPERATION TROUBLESHOOTING TROUBLESHOOTING During operations of the restart mode, a flashing display appears on the shift indicator display of the machine monitor. LOWERING WORK EQUIPMENT WHEN ENGINE IS STOPPED (RELEASE WORK EQUIPMENT OIL PRESSURE) WARNING Check that the surrounding area is safe, then lower the work equipment. Remove the cover using a step.
Page 238 OPERATION TROUBLESHOOTING WHEN LOWERING THE RIPPER OR SCARIFIER (If equipped) 1. Slowly loosen the pressure releasing plug (1) in the control valve. 2. Lower the ripper or scarifier to the ground. 3. Tighten the pressure releasing plug (1). Tightening torque: 19.6 to 24.5 Nm (2.0 to 2.5 kgm, 14.5 to 18.1 lbft) WHEN LOWERING THE FRONT BLADE (If equipped)
Page 239: Other Trouble
TROUBLESHOOTING OTHER TROUBLE ELECTRICAL SYSTEM ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Lamp does not glow brightly even...
Page 240 OPERATION TROUBLESHOOTING CHASSIS ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy Even when engine is running,...
Page 241 OPERATION TROUBLESHOOTING Problem Main causes Remedy Worn lining ( Check, repair) Even when brake pedal is Oil leakage in brake piping ( Check, repair) depressed, braking effect is poor Defective brake valve ( Check, repair) Defective piston seal ( Replace) Clogging of the vent hole of the Cleaning Brake is dragging or always applied...
Page 242 OPERATION TROUBLESHOOTING ENGINE ( ): Always contact your Komatsu distributor when dealing with these items. In cases of problems or causes which are not listed below, contact your Komatsu distributor for repairs. Problem Main causes Remedy After warming-up operation, engine...
Page 243 OPERATION TROUBLESHOOTING Problem Main causes Remedy Engine does not start when starting Lack of fuel Add fuel. For details, see motor is turned CHECK BEFORE STARTING Air in fuel system ( Repair place where air is sucked in) Defective fuel supply pump or ( Replace pump or nozzle) nozzle Starting motor cranks engine...
Page 244 OPERATION TROUBLESHOOTING Problem Main causes Remedy Does not reach rated speed when Defective actuation of tachometer ( Check, replace) there is load Lack of fuel Add fuel. See CHECK BEFORE STARTING Air in fuel line ( Repair location of air entry) Defective fuel supply pump, ( Replace) nozzle...
Page 245 FAILURE CODES If any abnormality occurs, stop the machine in a safe place, set the gear shift lever to the P (Parking) position, then check the failure code and ask your Komatsu distributor to carry out repairs. Character display Centralized warning lamp...
Page 246 Top line: Displays E01 continuing operations, be extremely careful Bottom line: Displays service of location of failure. After completing meter operations, contact Komatsu distributor for repairs Serious failure in part of function, stops. Top line: Displays E02 When continuing operations, be extremely...
Page 247 If 2 or more failures are occurring, the next failure code is displayed. 3. Check the failure code, then contact your Komatsu distributor for repairs. REMARK The failure code is the code displayed in the 6-digit area on the left side of the top line of character display (1).
Page 248 4 - 1...
Page 249: Maintenance
Komatsu genuine replacement parts: Use Komatsu genuine parts specified in the Parts Book as replacement parts. Komatsu genuine oils: Use Komatsu genuine oils and grease. Choose oils and grease with proper viscosities specified for ambient temperature. Always use clean washer fluid: Use automobile window washer fluid, and be careful not to let any dirt get into it.
Page 250 MAINTENANCE GUIDES TO MAINTENANCE Dusty worksites: When working at dusty worksites, do as follows: Inspect the air cleaner clogging monitor frequently to see if the dust indicator is clogged. Clean the air cleaner element at a shorter interval than specified. Clean the radiator core frequently to avoid clogging.
Page 251: Outlines Of Service
Komatsu distributor. When using commercially available oil, it may be necessary to reduce the oil change interval. We recommend that you use the Komatsu oil clinic to carry out a detailed checks of the characteristics of the oil. 4 - 4...
Page 252 If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability. COOLANT AND WATER FOR DILUTION Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing.
Page 253 Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts. CARRYING OUT KOWA (Komatsu Oil Wear Analysis) KOWA is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed.
Page 254: Relating To Electric System
Service relating to the electric system is checking fan belt tension, checking damage or wear to the fan belt and checking battery fluid level. Never install any electric components other than those specified by Komatsu. External electro-magnetic interference may cause malfunction of the control system controller, before installing a radio receiver or other wireless equipment, contact your Komatsu distributor.
Page 255: Wear Parts
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.
Page 256 MAINTENANCE WEAR PARTS 232-70-12193 Edge 232-70-52190 End bit Blade 4.3m t19 (232-70-12450) (Bolt) (32) Blade without side edges (232-70-12460) (Bolt) but with end bits (232-70-12480) (Nut) (36) (01643-31645) (Washer) (36) 23B-70-31331 Guide bushing Blade 23B-735-3320 Guide bushing 23B-70-31680 Wear plate Circle 23B-70-51560 Guide...
Page 257: Recommended Fuel, Coolant, And Lubricant
RECOMMENDED FUEL, COOLANT, AND LUBRICANT RECOMMENDED FUEL, COOLANT, AND LUBRICANT Komatsu genuine oils are adjusted to maintain the reliability and durability of Komatsu construction equipment and components. In order to keep your machine in the best conditioner for long periods of time, it is essential to follow the instructions in this Operation and Maintenance Manual.
Page 258: Use Of Fuel, Coolant And Lubricants According To Ambient Temperature
MAINTENANCE RECOMMENDED FUEL, COOLANT, AND LUBRICANT USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE ASTM: American Society of Testing and Material 4 - 11...
Page 259: Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil
G2-T or G2-TE is recommended. Note 4: Coolant 1) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential.
Page 260: Standard Tightening Torques For Bolts And Nuts
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.
Page 261: Periodic Replacement Of Critical Parts
These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. Material quality of these parts can change as time passes and they are likely to wear out or deteriorate. However, it is difficult to determine the extent of wear or deterioration at the time of periodic maintenance.
Page 262: Critical Parts
MAINTENANCE PERIODIC REPLACEMENT OF CRITICAL PARTS CRITICAL PARTS Safety critical parts for periodic replacement Q'ty Replacement interval 1 Fuel hose (fuel tank - fuel filter) 2 Fuel hose (fuel filter - engine) 3 Fuel hose (engine - fuel tank) 4 Rod packing, piston seals, of steering cylinder 5 Dust seal for steering cylinder 6 O-ring for steering cylinder 7 Steering circuit rubber hose (steering pump - steering valve)
Page 263: Maintenance Schedule Chart
MAINTENANCE MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART MAINTENANCE SCHEDULE CHART INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) Change oil in transmission case, clean strainer 4- 65 Change oil in final drive case 4- 66 Clean final drive breather 4- 67 Change oil in circle reverse gear case 4- 73...
Page 264 MAINTENANCE MAINTENANCE SCHEDULE CHART EVERY 500 HOURS SERVICE Change oil in engine oil pan, replace engine oil filter cartridge 4- 57 Replace fuel prefilter cartridge 4- 58 Check circle guide clearance, adjust 4- 60 EVERY 1000 HOURS SERVICE Replace fuel main filter cartridge 4- 63 Replace transmission oil filter cartridge 4- 64...
Page 265: Service Procedure
MAINTENANCE SERVICE PROCEDURE 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. CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER CHANGE OIL IN FINAL DRIVE CASE CLEAN FINAL DRIVE BREATHER CHANGE OIL IN CIRCLE REVERSE GEAR CASE REPLACE HYDRAULIC TANK FILTER ELEMENT...
Page 266: When Required
(AF-NAC) Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with SUPERCOOLANT (AF-NAC).
Page 267 When changing the coolant or when handling the cooling water containing coolant that has been drained during repair of radiator, please contact your Komatsu distributor or request a specialist company to carry out the operation. Coolant is toxic. Do not let it flow into drainage ditches or spray it onto the ground surface.
Page 268 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 13. Drain the coolant from sub tank (5), wash the inside of the sub tank, then add water to between the FULL and LOW marks. 14. Stop the engine, wait for approximately 3 minutes, add coolant up to the mouth of the filler port, and tighten the cap.
Page 269 MAINTENANCE SERVICE PROCEDURE CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Always stop the engine before carrying out these operations. When using compressed air, there is danger that dirt may be blown around and cause serious injury.
Page 270 MAINTENANCE SERVICE PROCEDURE CLEANING OR REPLACING OUTER ELEMENT 1. Open the engine side cover on the right side of the machine. 2. Remove clips (3), then remove dust cup (4). NOTICE Never remove inner element (6). If it is removed, dust will enter and cause engine trouble.
Page 271 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 5. Direct dry compressed air (less than 0.2 MPa {2.1 kg/cm , 30.0 PSI}) to the outer element from inside along its pleats, then direct it from outside along its pleats and again from inside. 1) Replace the outer element if it has been cleaned 6 times repeatedly or used throughout 1 year.
Page 272 MAINTENANCE SERVICE PROCEDURE REPLACING INNER ELEMENT NOTICE The inner element must not be used again even after its cleaning. When replacing the outer element, replace the inner element at the same time. 1. Open the engine side cover on the right side of the machine. 2.
Page 273 MAINTENANCE SERVICE PROCEDURE DRAIN WATER FROM FUEL PREFILTER WARNING After the engine is stopped, all parts are at high temperature, so do not drain the water or remove the element cup immediately after stopping the engine. Wait for all parts to cool down before starting the operation. When the engine is running, the engine fuel line is under high-pressure.
Page 274 SERVICE PROCEDURE CHECK ELECTRICAL INTAKE AIR HEATER Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater repaired or checked for dirt or disconnections. REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT WARNING Do not raise the blade unnecessarily high.
Page 275 MAINTENANCE SERVICE PROCEDURE CHECK INCHING PEDAL If any of the following problems have occurred, please contact your Komatsu distributor for inspection and adjustment. If the machine does not stop even the inching pedal is depressed. If the machine does not move or lacks power even the inching pedal is released.
Page 276 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 TENSION OF AIR CONDITIONER COMPRESSOR BELT If the belt is loose, it will slip and it will become impossible to carry out cooling properly.
Page 277 MAINTENANCE SERVICE PROCEDURE CLEAN AIR CONDITIONER CONDENSER WARNING Do not wash the condenser with a steam cleaner. There is danger that the condenser could overheat. If high-pressure water hits your body directly or dirt is sent flying, there is danger of personal injury. Always wear protective glasses, dust mask, and other protective equipment.
Page 278 MAINTENANCE SERVICE PROCEDURE CLEAN RADIATOR FINS AND COOLER FINS WARNING If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it may lead to personal injury. Always wear safety glasses, dust mask, or other protective equipment. Clean the radiator fins if any mud or dirt is stuck to the radiator.
Page 279 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 4. After the cooling fan reverse rotation pilot lamp on the machine monitor flashes, check that it lights up. The fan is set to rotate in reverse. 5. Run the engine at high idle. Select the time for running the engine at high idle as follows according to the condition of clogging.
Page 280 MAINTENANCE SERVICE PROCEDURE Major portions to check Center of the fin Surrounding area of the bracket 4 - 33...
Page 281 MAINTENANCE SERVICE PROCEDURE Lower part of the cooling room Surrounding area of the exhaust manifold Lower part of the engine room Upper part of the engine hood Surrounding area of the turbo charger After cleaning, close engine side covers (8) and covers (9) on the right and left sides of the machine respectively. In addition, clear the flown dirt, etc.
Page 282 MAINTENANCE SERVICE PROCEDURE CLEAN AND CHECK RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS AND CONDENSER FINS WARNING If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it possibly leads to personal injury. Always wear safety glasses, dustproof mask and other protective equipments. When using compressed air for cleaning, make sure the maximum pressure of it is less than 0.2 MPa (2.1 kg/cm2, 30.0 PSI).
Page 283 MAINTENANCE SERVICE PROCEDURE 5. Check the rubber hose. Replace with a new one if the hose is found to have cracks or to be hardened by ageing. Further, check hose clamps for looseness. 6. Install panels (4) and (2), then tighten the bolts (3) and (1) to the specified tightening torque. 4 - 36...
Page 284 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.
Page 285 MAINTENANCE SERVICE PROCEDURE CHECK OF INFLATION PRESSURE OF TIRES AND INFLATION OF THEM WARNING When inflating a tire, check that no one will enter the working area. Use an air chuck which has a clip and which can be fixed to the air valve. While inflating the tire, check the inflation pressure occasionally so that it will not rise too high.
Page 286: Checking Function Of Accumulator
If any change is felt in the smoothness of the brake operation during daily operations, the gas pressure in the accumulator has probably dropped. Please contact your Komatsu distributor to have the accumulator inspected. REMARK Even if there is any change in smoothness, there is no drop in brake performance including braking force.
Page 287: Check Window Washer Fluid Level, Add Fluid
MAINTENANCE SERVICE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL , ADD FLUID If there is air in the window washer fluid, remove screws (1) (2 places) to open cover (2), and check the level of the fluid in window washer fluid tank (3) (2 places). Add automobile window washer fluid if necessary.
Page 288: Check Before Starting
MAINTENANCE SERVICE PROCEDURE CHECK BEFORE STARTING For details of the following items, see "CHECK BEFORE STARTING (PAGE 3-86)" in the OPERATION section. Check coolant level, add water Check fuel level, add fuel Drain water and sediment in fuel tank Check engine oil pan level, add oil Check dust indicator Check and adjust steering wheel Check water separator, drain water...
Page 289: Every 50 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 50 HOURS SERVICE LUBRICATING WARNING Set the gear shift lever to the P (Parking) position and fix the front and rear frames by using the articulate lock pin. Lower the work equipment to the ground and stop the engine. Grease on flat ground.
Page 290 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Steering linkage (6 places) Steering cylinder pin (4 places) Tie rod (2 places) Leaning rod end (2 places) 4 - 43...
Page 291 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Leaning cylinder pin (2 places) 4 - 44...
Page 292: Every 250 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 250 HOURS SERVICE Maintenance for every 50 hours service should be carried out at the same time. LUBRICATING WARNING Set the gear shift lever to the P (Parking) position and fix the front and rear frames by using the articulate lock pin. Lower the work equipment to the ground and stop the engine.
Page 293 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Blade lift cylinder ball joint (2 places) Drawbar ball joint (1 place) Drawbar side shift cylinder ball joint (2 places) Adjuster bracket (2 places) Power tilt cylinder pin (2 places) 4 - 46...
Page 294 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Lifter bracket (3 places) REMARK When greasing the center of the lifter bracket (1 place), use a footstool or turn the lifter bracket fully to the left end for easier greasing. Ripper linkage pin (8 places) (Machines equipped with ripper) Ripper cylinder pin (3 places) (Machines equipped with ripper)
Page 295 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Scarifier shaft (2 places) (Machines equipped with scarifier) Scarifier ball joint (4 places) (Machines equipped with scarifier) Scarifier cylinder pin (2 places) (Machines equipped with scarifier) Front blade pin (4 places) (Machines equipped with front blade) (*: left and right, 1 place each) 4 - 48...
Page 296: Check Oil Level In Transmission Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL WARNING Parts and oil are still heated for some time after the engine stops. Start operations after the temperature drops. Before the check, set the gear shift lever to the P (PARKING) position to prevent the machine from moving and confirm that the respective levers are placed in the neutral position.
Page 297 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 7. If the oil level is correct, insert dipstick (G) in the oil filler pipe, then install the oil filler cap. On each surface of dipstick (G), the oil level for the time (A) when the engine is stopping (ENG STOP) or (B) when the engine is running at idle (ENG IDOLING) is stamped.
Page 298: Check Oil Level In Final Drive Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. 1.
Page 299: Check Oil Level In Tandem Drive Case, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. 1.
Page 300: Check Oil Level In Hydraulic Tank, Add Oil
MAINTENANCE SERVICE PROCEDURE CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL WARNING The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil filler cap, turn it slowly to release the internal pressure, then remove it.
Page 301: Check Level Of Battery Electrolyte
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 - 54...
Page 302 If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the sleeve. 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. WHEN IT IS POSSIBLE TO USE INDICATOR TO CHECK ELECTROLYTE LEVEL If it is possible to use an indicator to check the electrolyte level, follow the instructions given.
Page 303: Check And Tighten Wheel Hub Nut And Hub Bolt
2. If a hub bolt is broken, replace all the hub bolts. 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.
Page 304: Every 500 Hours Service
(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).
Page 305: Replace Fuel Prefilter Cartridge
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 306 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 5. Remove hose (6) connected to drain plug (5). 6. Using a filter wrench, turn filter cartridge (3) counterclockwise to remove it. 7. After removing the cartridge, turn cup (4) of the water separator installed to the bottom of the cartridge counterclockwise.
Page 307: Check Circle Guide Clearance, Adjust
MAINTENANCE SERVICE PROCEDURE CHECK CIRCLE GUIDE CLEARANCE, ADJUST WARNING If 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 after maintenance has been carried out, replace the guide. When raising the blade, do not raise it higher than necessary.
Page 308 MAINTENANCE SERVICE PROCEDURE ADJUSTING Adjusting top and bottom position 1. Raise the blade, remove bolts (1) and (5) for clearance (P), remove circle guides (2) and (6), then adjust the shim thickness. (Shim thickness: 1 mm (0.039 in), 0.5 mm (0.020 in);...
Page 309 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE Adjusting front and rear position 2. Lower the blade lightly to the ground, loosen bolt (1), then loosen locknut (4), turn back bolt (3), push open circle guide (2), and make (Q) F = 0. (When doing this, push open the left and right bolts uniformly.) 3.
Page 310: Every 1000 Hours Service
The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle. If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.
Page 311: Replace Transmission Oil Filter Cartridge
MAINTENANCE SERVICE PROCEDURE 7. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
Page 312 MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER 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. Refill amount of oil: 45 liters (11.88 US gal) 1.
Page 313: Clean Transmission Breather
MAINTENANCE SERVICE PROCEDURE CLEAN TRANSMISSION BREATHER 1. Stop the engine and wait for the temperature at all parts to go down. 2. Remove all mud and dirt from around the breather. 3. Remove the breather and fit a cover to the breather mounting hole to prevent dirt from entering.
Page 314: Clean Final Drive Breather
MAINTENANCE SERVICE PROCEDURE CLEAN FINAL DRIVE BREATHER 1. Stop the engine and wait for the temperature at all parts to go down. 2. Remove all mud and dirt from around the breather. 3. Remove the breather and fit a cover to the breather mounting hole to prevent dirt from entering.
Page 315: Check Looseness, Play Of Ball Joint At Front Of Drawbar
MAINTENANCE SERVICE PROCEDURE CHECK LOOSENESS, PLAY OF BALL JOINT AT FRONT OF DRAWBAR Turn nut (1) at the mounting portion of the ball joint at the front of the drawbar to check if it is loose. If it is loose, tighten it. 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).
Page 316: Check Front Wheel Bearing Play, Adjust
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). CHECK FRONT WHEEL BEARING PLAY, ADJUST Please ask your Komatsu distributor to carry out this inspection and adjustment. 4 - 69...
Page 317 MAINTENANCE SERVICE PROCEDURE CHECK OF ENGINE AIR INTAKE PIPING CLAMP FOR LOOSENESS Check the clamps between the air cleaner, turbocharger, aftercooler, and engine for looseness. If any clamp is loosened, retighten it. Tightening torque clamp (1): 10.0 to 11.0 Nm (102 to 112 kgm, 737.8 to 810.1 lbft) clamp (2): 8.3 to 9.3 Nm (85 to 95 kgm, 614.8 to 687.1 lbft) 4 - 70...
Page 318: Every 2000 Hours Service
MAINTENANCE SERVICE PROCEDURE EVERY 2000 HOURS SERVICE Maintenance for every 50, 250, 500 and 1000 hours service should be carried out at the same time. CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER 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.
Page 319 MAINTENANCE MAINTENANCE SERVICE PROCEDURE SERVICE PROCEDURE 7. After draining the oil, remove bolts (3) (6 pieces) to take cover (4) off. At this time, cover (4) possibly jumps out by the force of gas spring (5). While pushing down cover (4), remove bolts (3). 8.
Page 320: Change Oil In Circle Reverse Gear Case
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN CIRCLE REVERSE GEAR CASE 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. Refill amount of oil: 7 liters (1.85 US gal) (Slip clutch type) 1.
Page 321: Change Oil In Tandem Drive Case
MAINTENANCE SERVICE PROCEDURE CHANGE OIL IN TANDEM DRIVE CASE 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. Refill amount of oil: 57 liters (15.06 US gal) each of right and left 1.
Page 322: Check Disc Brake
MAINTENANCE SERVICE PROCEDURE CHECK DISC BRAKE WARNING A small amount of oil will come out from the inspection plug hole, so do not look through the plug hole when the brake is applied. PERIODICAL REPLACEMENT OF DISC BRAKE Inspection: Every 12 months or 2000 hours. Disassembly: If the disc brake has reached the wear limit or there is any problem in the brake system, judge if it is necessary to carry out disassembly or maintenance.
Page 323: Check Alternator, Starting Motor
SERVICE PROCEDURE CHECK ALTERNATOR, STARTING MOTOR The brushes may be worn or the bearing may have run out of grease, contact your Komatsu distributor for inspection and repairs. If the engine is started frequently, have this inspection carried out every 1000 hours.
Page 324: Every 4000 Hours Service
Komatsu distributor for disassembly and repair or replacement. CHECK ACTUATION OF COMPRESSOR Check the following items. If any problem is found, please ask your Komatsu distributor to carry out disassembly, repair, or replacement. Are the compressor and magnet clutch turned ON-OFF when the air conditioner switch is turned ON-OFF?
Page 325 Check visually and touch by hand to check that there are no missing caps, loose bolts or hardening of the rubber. If there are any problems, the parts must be replaced. In this case, please ask your Komatsu distributor to carry out replacement. LUBRICATING WARNING Set the gear shift lever to the P (Parking) position and fix the front and rear frames by using the articulate lock pin.
Page 326: Every 8000 Hours Service
Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be carried out at the same time. REPLACE HIGH-PRESSURE PIPING CLAMP Ask your Komatsu distributor to carry out this work. REPLACE FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor to carry out this work.
Page 328 5 - 1...
Page 329: Specifications
SPECIFICATIONS Item Unit GD555-5 Operating weight (including operator 75 kg (165 lb)) kg (lb) 15,160 (33,428) Engine model Komatsu SAA6D107E-1 diesel engine Flywheel horsepower kW{HP} 104-118-131-144{140-158-176-193} A Overall length mm (ft in) 8,995 (29' 6") B Overall height (Tail pipe) mm (ft in) 2,995 (9' 10")
Page 330 SPECIFICATIONS SPECIFICATIONS 5 - 3...
Page 332 6 - 1...
Page 333: Attachments, Options
ATTACHMENTS, OPTIONS HANDLING BLADE ACCUMULATOR HANDLING BLADE ACCUMULATOR FEATURES OF BLADE ACCUMULATOR IMPROVEMENT IN EASE OF SNOW-CLEARING OPERATION No need to operate blade No need to employ experienced operator (relief of condition) 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) IMPROVEMENT IN STEERING ABILITY Improvement in steering when operating on curves...
Page 334: Method Of Operating Blade Accumulator
ATTACHMENTS, OPTIONS HANDLING BLADE ACCUMULATOR METHOD OF OPERATING BLADE ACCUMULATOR 1. Lower the blade to the ground and stop the engine. 2. Turn the starting switch to ON position (electricity flows in the electrical circuit), then turn the accumulator switch ON. 3.
Page 335: Machine Equipped With "Intelligent Machine Control" Device
ATTACHMENTS, OPTIONS MACHINE EQUIPPED WITH "INTELLIGENT MACHINE CONTROL" DEVICE MACHINE EQUIPPED WITH "INTELLIGENT MACHINE CONTROL" DEVICE PRECAUTION FOR THE MACHINE EQUIPPED WITH "INTELLIGENT MACHINE CONTROL" DEVICE For the machine equipped with "Intelligent Machine Control" device, special kit provided by Topcon Co. Ltd. can be installed without additional work.
Page 336 ATTACHMENTS, OPTIONS MACHINE EQUIPPED WITH "INTELLIGENT MACHINE CONTROL" DEVICE REMARK GNSS is the abbreviation for Global Navigation Satellite System. It is the general term for positioning satellite ( Global Navigation Satellite System) such as GPS. 6 - 5...
Page 338: Index
INDEX INDEX <A> PRECAUTIONS BEFORE STARTING ADJUSTING WORK EQUIPMENT OPERATION 2- 14 POSTURE 3-155 PRECAUTIONS RELATED TO AIR CONDITIONER 3- 76 ATTACHMENTS AND OPTIONS 2- 20 AM/FM RADIO 3- 70 PRECAUTIONS RELATED TO ARTICULATE LOCK PIN 3- 63 PROTECTIVE STRUCTURES 2- 19 ASHTRAY 3- 81...
Page 339 AFTER STORAGE 3-176 RECOMMENDED QUALITY FOR BEFORE STORAGE 3-176 PRODUCTS OTHER THAN DURING STORAGE 3-176 KOMATSU GENUINE OIL 4- 12 USE OF FUEL, COOLANT AND <M> LUBRICANTS ACCORDING TO MACHINE EQUIPPED WITH "INTELLIGENT AMBIENT TEMPERATURE 4- 11 MACHINE CONTROL" DEVICE...
Page 340 INDEX TROUBLESHOOTING 3-177 AFTER RUNNING OUT OF FUEL 3-177 IF BATTERY IS DISCHARGED 3-180 IF THE GEAR SHIFT LEVER OF THE TRANSMISSION HAS ANY TROUBLE 3-183 LOWERING WORK EQUIPMENT WHEN ENGINE IS STOPPED (RELEASE WORK EQUIPMENT OIL PRESSURE) 3-184 OTHER TROUBLE 3-186 TOWING THE MACHINE 3-178...

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