Manual de Operación GD825A-2

SEAM021403T
Operation & Maintenance

Manual
GD825A-2
MOTOR GRADER
SERIAL NUMBERS GD825A-2 -12107 and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on
products sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It
is recommended that customers contact their distributor for information on the latest revision.
Copyright 2002 Komatsu

DataKom Publishing Division
October 2002
1. FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and
effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been
lost or has become dirty and can not be read, request a replacement manual from Komatsu or your
Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners.
Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available
information of your machine or for questions regarding information in this manual.
This manual may contain attachments and optional equipment that are not available in your area.
Consult Komatsu or your Komatsu distributor for those items you may require.
¤ WARNING
‡ Improper operation and maintenance of this machine can be hazardous and could result in serious
injury or death.
‡ Operators and maintenance personnel should read this manual thoroughly before beginning
operation or maintenance.
Keep this manual in the luggage box to the rear of the operator seat, and have all personnel
involved in working on the machine read the manual periodically.
‡ Some actions involved in operation and maintenance of the machine can cause a serious accident,
if they are not done in a manner described in this manual.
‡ The procedures and precautions given in this manual apply only to intended uses of the machine.
If you use your machine for any unintended uses that are not specifically prohibited, you must
be sure that it is safe for you and others. In no event should you or others engage in prohibited
uses or actions as described in this manual.
‡ Komatsu delivers machines that comply with all applicable regulations and standards of the
country to which it has been shipped. If this machine has been purchased in another country or
purchased from someone in another country, it may lack certain safety devices and specifications
that are necessary for use in your country. If there is any question about whether your product
complies with the applicable standards and regulations of your country, consult Komatsu or your
Komatsu distributor before operating the machine.
‡ The description of safety is given in SAFETY INFORMATION on page 0-4 and in SAFETY from page
1-1.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State
of California to cause cancer, birth
defects, and other reproductive
harm.
0-1
1. FOREWORD
0-2
1. FOREWORD
0-3
2. SAFETY INFORMATION
Most accidents are caused by the failure to follow fundamental safety rules for the operation and
maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings
in this manual and on the machine before performing operation and maintenance.
To identify safety messages in this manual and on machine labels, the following signal words are
used.
¤ DANGER – This word is used on safety messages and safety labels where there is a high
probability of serious injury or death if the hazard is not avoided. These safety
messages or labels usually describe precautions that must be taken to avoid the
hazard. Failure to avoid this hazard may also result in serious damage to the
machine.
¤ WARNING – This word is used on safety messages and safety labels where there is a
potentially dangerous situation which could result in serious injury or death if
the hazard is not avoided. These safety messages or labels usually describe
precautions that must be taken to avoid the hazard. Failure to avoid this hazard
may also result in serious damage to the machine.
¤ CAUTION – This word is used on safety messages and safety labels for hazards which could
result in minor or moderate injury if the hazard is not avoided. This word might
also be word for hazards where the only result could be damage to the machine.
NOTICE – This word is used for precautions that must be taken to avoid actions which
could shorten the life of the machine.
Safety precautions are described in SAFETY from page 1-1.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and
maintenance. Therefore the safety messages in this manual and on the machine may not include all
possible safety precautions. If any procedures or actions not specifically recommended or allowed in this
manual are used, you must be sure that you and others can do such procedures and actions safely and
without damaging the machine. If you are unsure about the safety of some procedures, contact Komatsu
distributor.
0-4
3. INTRODUCTION
3.1 INTENDED USE

This equipment can be used for the following work.
‡ Leveling operations
‡ Repair and maintenance of gravel roads
‡ Ditch digging
‡ Cutting slope faces
‡ Mixed operations
‡ Spreading operations
‡ Front wheel offset operations
For details of operating procedures, see “12.11 WORK POSSIBLE USING MOTOR GRADER” in the
operating section.
3.2 FEATURES
‡ Large blade load
‡ Blade accumulator (if equipped) to make it easy even for a beginners to operate the blade
‡ Blade float (if equipped) function to protect buried objects (by allowing blade to escape from
protruding objects)
‡ High operating speed
‡ Powerful engine with low fuel consumption
‡ Light-touch electric transmission control
‡ Roomy externally mounted ROPS cab
‡ Lift-up cab for ease of maintenance
3.3 BREAKING IN THE MACHINE

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

‡ Idle the engine for 5 minutes after starting it up.
‡ Avoid operation with heavy loads or at high speeds.
‡ Avoid sudden starts, sudden acceleratoin, sudden steering and sudden stops except in cases of
emergency.
The precautions given in this manual for operating, maintenance, and safety procedures are only
those that apply when this product is used for the specified purpose. If the machine is used for a purpose
that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of
safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be carried out under any circumstances.
0-5
4. LOCATION OF PLATES, TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION

This is on the left side of the front frame.
4.2 ENGINE SERIAL NO. PLATE POSITION

This is on the left side of engine cylinder block as seen from the
fan.
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.:
Engine serial No.:
Distributor name:
Address: Phone:
Service personnel for your machine:
REMARKS
0-6
5. CONTENTS
1. Foreword ............................................................................................................................................ 0- 1
2. Safety information ............................................................................................................................ 0- 4
3. Introduction ........................................................................................................................................ 0- 5
4. Location of plates, table to enter serial No. and distributor ...................................................... 0- 6
SAFETY
6. General precautions .......................................................................................................................... 1- 2
7. Precautions during operation .......................................................................................................... 1- 8

7.1 Before starting engine ............................................................................................................ 1- 8
7.2 After starting engine ............................................................................................................... 1-10
7.3 Transportation .......................................................................................................................... 1-17
7.4 Battery ....................................................................................................................................... 1-18
7.5 Towing ...................................................................................................................................... 1-20
8. Precautions for maintenance ........................................................................................................... 1-21

8.1 Before carrying out maintenance .......................................................................................... 1-21
8.2 During maintenance ................................................................................................................ 1-25
8.3 Tires .......................................................................................................................................... 1-31
9. Position for attaching safety labels ................................................................................................ 1-33
OPERATION
10. General view ...................................................................................................................................... 2- 2
10.1 General view of machine ....................................................................................................... 2- 2
10.2 General view of controls and gauges .................................................................................. 2- 3
11. Explanation of components ............................................................................................................. 2- 5

11.1 Monitor panel .......................................................................................................................... 2- 5
11.2 Cluster gauge and pilot lamps .............................................................................................. 2-17
11.3 Switches ................................................................................................................................... 2-18
11.4 Control levers and pedals ...................................................................................................... 2-24
11.5 Dust indicator ........................................................................................................................... 2-31
11.6 Articulate lock pin ................................................................................................................... 2-31
11.7 Fuse box ................................................................................................................................... 2-31
11.8 Operator’s cab lift mechanism .............................................................................................. 2-32
11.9 Backup alarm ........................................................................................................................... 2-32
11.10 Front glass ................................................................................................................................ 2-33
11.11 Tool bag ................................................................................................................................... 2-34
11.12 Storage box .............................................................................................................................. 2-34
11.13 Storage space behind seat ..................................................................................................... 2-34
11.14 Quick-fill fuel filler ................................................................................................................... 2-34
11.15 Air conditioner ......................................................................................................................... 2-35
0-7
5. CONTENTS
12. Operation ............................................................................................................................................ 2- 39

12.1 Checks before starting engine ............................................................................................... 2- 39
12.2 Starting engine ........................................................................................................................ 2- 54
12.3 Operations and checks after starting engine ....................................................................... 2- 56
12.4 Traveling posture for machine .............................................................................................. 2- 57
12.5 Moving machine ..................................................................................................................... 2- 58
12.6 Shifting gear ............................................................................................................................ 2- 59
12.7 Shifting between forward and reverse ................................................................................. 2- 60
12.8 Stopping machine ................................................................................................................... 2- 61
12.9 Turning machine ..................................................................................................................... 2- 62
12.10 Operating work equipment .................................................................................................... 2- 64
12.11 Work which can be carried out using a motor grader ...................................................... 2- 67
12.12 Recautions for operation ........................................................................................................ 2- 93
12.13 Adjusting work equipment posture ...................................................................................... 2- 96
12.14 Parking machine ...................................................................................................................... 2- 97
12.15 Check after finishing work ..................................................................................................... 2- 98
12.16 Stopping engine ...................................................................................................................... 2- 99
12.17 Check after stopping engine .................................................................................................. 2- 99
12.18 Locking ...................................................................................................................................... 2-100
12.19 Handling the tires .................................................................................................................... 2-100
12.20 Handling blade accumulator .................................................................................................. 2-101
12.21 Handling blade float ................................................................................................................ 2-103
13. Transportation ................................................................................................................................... 2-105

13.1 Loading, unloading work ........................................................................................................ 2-105
13.2 Precautions for loading .......................................................................................................... 2-106
13.3 Precautions for transportation ............................................................................................... 2-106
14. Cold weather operation ................................................................................................................... 2-107

14.1 Precautions for low temperature ........................................................................................... 2-107
14.2 Cautions after completion of work ....................................................................................... 2-109
14.3 After cold weather ................................................................................................................... 2-109
15. Long-term storage ............................................................................................................................ 2-110

15.1 Before storage ......................................................................................................................... 2-110
15.2 During storage ......................................................................................................................... 2-110
15.3 After storage ............................................................................................................................ 2-110
16. Troubleshooting ................................................................................................................................ 2-111

16.1 After running out of fuel ........................................................................................................ 2-111
16.2 When leaning piping is damaged ......................................................................................... 2-111
16.3 Towing the machine ............................................................................................................... 2-112
16.4 If battery is discharged ........................................................................................................... 2-116
16.5 Other trouble ............................................................................................................................ 2-120
0-8
5. CONTENTS
MAINTENANCE
17. Guides to maintenance .................................................................................................................... 3- 2
18. Outlines of service ............................................................................................................................ 3- 4

18.1 Handling oil, fuel, coolant, and performing oil clinic. ........................................................ 3- 4
18.2 Relating to electric system ..................................................................................................... 3- 7
19. Wear parts list ................................................................................................................................... 3- 8
20. Use of fuel, coolant and lubricants according to ambient temperature ................................... 3- 9
21. Standard tightening torques for bolts and nuts .......................................................................... 3-13
21.1 Introduction of necessary tools ............................................................................................. 3-13
21.2 Torque list ................................................................................................................................ 3-14
22. Periodic replacement of safety critical parts ................................................................................. 3-15
23. Maintenance schedule chart ............................................................................................................ 3-18

23.1 Maintenance schedule chart .................................................................................................. 3-18
24. Service Procedure ............................................................................................................................. 3-22

24.1 Initial 250 hours service ......................................................................................................... 3-22
24.2 When required ......................................................................................................................... 3-23
24.3 Check before starting .............................................................................................................. 3-36
24.4 Every 50 hours service ........................................................................................................... 3-42
24.5 Every 250 hours service ......................................................................................................... 3-43
24.6 Every 500 hours service ......................................................................................................... 3-58
24.7 Every 1000 hours service ....................................................................................................... 3-67
SPECIFICATIONS
25. Specifications ..................................................................................................................................... 4- 2
OPTIONS, ATTACHMENTS
26. Handling emergency steering device ............................................................................................. 5- 2
26.1 Checks ....................................................................................................................................... 5- 2
0-9
MEMO
0-10
SAFETY
¤ WARNING
Read and follow all safety precautions. Failure to do so may
result in serious injury or death.
This safety section also contains precautions for optional equip-

ment and attachments.
1-1
 WARNING: For reasons of safety, always
6. GENERAL PRECAUTIONS follow these safety precautions.
SAFETY RULES
‡ Only trained and authorized personnel can operate and maintain the machine.
‡ Follow all safety rules, precautions and instructions when operating or performing maintenance
on the machine.
‡ Do not operate the machine if you are feeling unwell, if you are taking medication that makes you
feel sleepy, if you have been drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgement in emergencies and may cause accidents.
‡ When working with another operator or with a person on worksite traffic duty, be sure that all
personnel know the nature of the work and understand all hand signals that are to be used.
‡ Always observe strictly any other rules related to safety.
SAFETY FEATURES
‡ Be sure that all guards and covers are installed in their proper position. Have guards and covers
repaired immediately if damaged.
‡ Be sure that you understand the method of use of safety features such as safety parking brake
and the seat belt, and use them properly.
‡ Never remove any safety features. Always keep them in good operating condition.
Parking brake ➞ See “12.14 PARKING MACHINE”.
Seat belt (if equipped) ➞ See “12.1.4 USING SEAT BELT”.
‡ Failure to use safety features according to the instructions in the Operation and Maintenance
Manual could result in serious bodily injury.
CLOTHING AND PERSONAL PROTECTIVE ITEMS

‡ Avoid loose clothing and jewelry. They can catch on controls or in protruding parts and cause
serious injury or death.
‡ Do not wear oily clothes. They are highly flammable.
‡ Wear a hard hat, safety glasses, safety shoes, mask, or gloves when operating or maintaining the
machine.
Always wear safety goggles, hard hat, gloves, and other protective equipment if your job involves
scattering metal chips or minute materials - particularly when driving in pins with a hammer and
when cleaning the air cleaner element with compressed air.
Check also that there is no one near the machine.
‡ Check that all protective equipment works properly before using it.
1-2
 WARNING: Failure to follow these safety precautions may lead
to a serious accident. 6. GENERAL PRECAUTIONS
UNAUTHORIZED MODIFICATION
Any modification made without authorization from Komatsu can create hazards. Before making a
modification, consult your Komatsu distributor.
Komatsu will not be responsible for any injury or damage caused by any unauthorized modification.
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT

‡ Always apply safety lock when standing up from or leaving operator’s seat
‡ When standing up from or leaving operator’s seat, always place shift lock lever securely in the
parking position and apply the parking brake. If you accidentally touch the work equipment levers
when they are not locked, the machine may suddenly move and cause serious injury or damage.
‡ When leaving the machine, lower the work equipment completely to the ground, then stop the
engine and use the key to lock all the equipment. Always remove the key and take it with you and
keep it in the specified place.
Work equipment posture ➞ See “12.14 PARKING MACHINE”.
Locks ➞ See “12.18 LOCKING”
1-3
MOUNTING AND DISMOUNTING

‡ Before getting on or off the machine, if there is any oil, grease, or mud on the handrails or steps,
wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose
bolts.
‡ Never jump on or off the machine. In particular, never get on or off a moving machine. These
actions may lead to serious injury.
‡ When getting on or off the machine, always face the machine, and maintain three-point contact
(both feet and one hand or one foot and both hands) with the handrails and steps to ensure that
you support yourself securely.
‡ Never hold any control levers when getting on or off the machine.
‡ Use the points marked by arrows in the diagram when getting on or off the machine.
1-4
FIRE PREVENTION FOR FUEL, OIL, AND ANTIFREEZE

Fuel, oil, and antifreeze will catch fire if it is brought close to a flame. Fuel is particularly flammable
and can be hazardous.
Always strictly observe the following.
‡ Keep any lighted matches or cigarettes away from flammable materials.
‡ Stop the engine and do not smoke when refueling.
‡ Tighten all fuel and oil caps securely.
‡ Use well-ventilated areas for adding or storing oil and fuel.
‡ Keep oil and fuel in the determined place and do not allow unauthorized persons to enter.
‡ Do not leave the area when supplying fuel or oil.
A0055020 A0055040
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURE

Immediately after operations are stopped, the coolant, engine oil, and hydraulic oil are at high
temperature and the radiator and hydraulic tank are still under pressure. Attempting to remove the
cap, drain the oil or coolant, or replace the filters may lead to serious burns. Always wait for the
temperature to go down, and follow the specified procedures when carrying out these operations.
‡ To prevent hot water from spurting out, stop the engine, wait for the water to cool, then loosen
the cap slowly to relieve the pressure before removing the cap.
(When checking how much the water temperature has gone down, bring your hand close to the
surface of the radiator without touching it, and check the temperature of the air at the radiator
surface.)
‡ To prevent hot oil from spurting out, stop the engine, wait for the oil to cool, then loosen the cap
slowly to relieve the pressure before removing the cap.
(When checking how much the oil temperature has gone down, bring your hand close to the
surface of the hydraulic tank without touching it, and check the temperature of the air at the
hydraulic tank surface.)
A0055050
1-5
ASBESTOS DUST HAZARD PREVENTION

Asbestos dust can be hazardous to your health if it is inhaled. Komatsu does not use asbestos in
its products, but if you handle materials containing asbestos fibers during demolition operations,
always do as follows.
‡ Never use compressed air for cleaning.
‡ Use water to keep down the asbestos dust when cleaning.
‡ If there is danger that there may be asbestos dust in the air, operate the machine with the wind
to your back whenever possible.
‡ Use an approved respirator if necessary.
‡ Do not allow any other person into the area during the operation.
‡ There is danger that non-genuine parts may contain asbestos, so use only Komatsu genuine parts.
‡ Always observe any rules and regulations related to the jobsite and working environment.
A0055060
INJURY FROM WORK EQUIPMENT

Do not enter or put your hand or arm or any other part of your
body between movable parts, such as between the work equip-
ment and cylinders, or between the machine and work equipment.
If the control levers are operated, the clearance between the
machine and the work equipment or between the cylinder and
work equipment will change and this may lead to serious damage
or personal injury.
If it is necessary to go between movable parts, always fix the work
equipment so that it cannot move. AE154960
FIRE EXTINGUISHER AND FIRST AID KIT

As a precaution if any injury or fire should occur, always do as follows.
‡ Be sure that fire extinguishers have been provided and read the labels to ensure that you know
how to use them.
‡ Provide a first aid kit at the storage point. Check the kit periodically and make any additions if
necessary.
‡ Know what to do in the event of injury or fire.
‡ Make a list of the phone numbers of persons you should contact in case of an emergency (doctor,
ambulance, fire station), and post the list at specified places to ensure that all workers can carry
out the emergency contact.
A0055070
1-6
PRECAUTIONS FOR ROPS

‡ Do not operate machine with ROPS removed if equipped.
‡ The ROPS is installed to protect the operator if the machine should overturn. It is designed not
only to take the load when the machine overturns, but also to absorb the impact energy.
‡ The Komatsu ROPS fulfills all worldwide regulations and standards, but if any unauthorized
modification is carried out on it, or if it is damaged when the machine overturns, its strength will
be reduced and it will not be able to provide its original capacity. It will be able to provide this
capacity only if modifications and repairs are carried out in the specified way.
‡ When carrying out modification or repairs, always consult your Komatsu distributor first.
‡ Even when the ROPS is installed, if you do not fasten your seat belt securely, it cannot protect
you properly. Always fasten your seat belt when operating the machine.
Seat belt ➞ See “12.1.4 ADJUSTMENTS BEFORE OPERATION”.
PRECAUTIONS FOR ATTACHMENTS

‡ When installing and using optional parts or attachments, read the instruction manual for the
attachment and the information related to attachments in this manual.
‡ Do not use attachments that are not authorized by Komatsu or your Komatsu distributor.
Use of unauthorized attachments could create a safety problem and adversely affect the proper
operation and useful life of the machine.
‡ Any injuries, accidents, or product failures resulting from the use of unauthorized attachments will
not be the responsibility of Komatsu.
INDOOR VENTILATION
‡ When starting the engine, or using fuel, flushing oil, or paint indoors or in areas with poor
ventilation, always open the windows and doors to improve the ventilation and prevent the danger
of gas poisoning.
‡ If the ventilation is still insufficient even when the windows and doors are opened, use a ventilation
fan.
A0055060
1-7
7. PRECAUTIONS DURING  WARNING: For reasons of safety, always
OPERATION follow these safety precautions.
7.1 BEFORE STARTING ENGINE

SAFETY AT WORKSITE
‡ Before starting operations, thoroughly check the area for any unusual conditions that could be
dangerous.
‡ Check the terrain and condition of the ground at the worksite, and determine the best and safest
method of operation.
‡ Make the ground surface as hard and horizontal as possible before carrying out operations. If there
is a lot of dust and sand on the jobsite, spray water before starting operations.
‡ If you need to operate on a street, protect pedestrians and cars by designating a person for
worksite traffic duty or by erecting fences and posting “No Entry” signs around the worksite.
‡ If water lines, gas lines, and high-voltage electrical lines may be buried under the worksite, contact
each utility and identify their locations. Be careful not to damage or cut any of these lines.
‡ Erect fences, post “No Entry” signs, and take other steps to prevent people from coming close
to or entering the jobsite. If people come close to a moving machine, they may be hit or caught
by the machine, and this may lead to serious personal injury or death.
‡ Check the condition of the river bed, and the depth and flow of the water before operating in water
or crossing a river. NEVER be in water which is in excess of the permissible water depth.
1-8
¤ WARNING: Failure to follow these safety precautions may lead
to a serious accident. 7. PRECAUTIONS DURING OPERATION
CHECKS BEFORE STARTING ENGINE

Every day before starting the engine for the first time, carry out the following checks. If these checks
are not carried out properly, there is danger of serious injury.
‡ Completely remove all wood chips, leaves, grass, paper and other flammable materials accumu-
lated in the engine compartment and around the battery. They could cause a fire. Remove any
dirt from the window glass, mirrors, handrails, and steps.
‡ Do not leave tools or spare parts lying around in the operator’s compartment. The vibration of
the machine when traveling or during operations may cause them to fall and damage or break
the control levers or switches. They may also get caught in the gap of the control levers and cause
the work equipment to malfunction or move dangerously. This may lead to unexpected accidents.
Walk-around check ➞ See “12.1.1 WALK AROUND CHECK”.
‡ Check the coolant level, fuel level, and hydraulic tank oil level, and check for clogging of the air
cleaner and damage to the electrical wiring.
Check before starting ➞ See “12.1.2 CHECK BEFORE STARTING”.
‡ Adjust the operator’s seat to a position where it is easy to operate the machine, and check the
seat belt and mounts for damage and wear.
Adjusting operator’s seat ➞ See “12.1.4 ADJUST BEFORE OPERATION”.
Seat belt ➞ See “12.1.4 USING SEAT BELT”.
‡ Check the operation of the gauges and the angle of the mirrors, and check that the control levers
are at the LOCK position.
Method of checking actuation of gauges ➞ See “12.1.5 OPERATIONS AND CHECKS BEFORE
STARTING ENGINE”.
If any abnormalities are found in the above checks, carry out repairs immediately.
A0055020
WHEN STARTING ENGINE

‡ Walk around your machine again just before mounting it, and check for people and objects that
might be in the way.
‡ Never start the engine if a warning tag has been attached to the control levers.
‡ When starting the engine, sound the horn as an alert.
‡ Start and operate the machine only while seated.
‡ Do not allow anyone other than the operator to ride in the cab or on the machine body.
‡ Do not short circuit the starting motor to start the engine. This is not only dangerous, but may
also damage the machine.
DO NOT operate
When this plate is not being used
keep it in the storage compartment.
09963-03000
1-9
¤ WARNING: For reasons of safety, always
7. PRECAUTIONS DURING OPERATION follow these safety precautions.
7.2 AFTER STARTING ENGINE

CHECKS AFTER STARTING ENGINE
If checks are not carried out properly after starting the engine, it may result in a delay in discovering
abnormalities in the machine, and this may lead to personal injury or damage to the machine.
Carry out the checks in an open area where there are no obstructions. Do not let any one near the
machine when carrying out the checks.
‡ Check the operating condition of the equipment, and the actuation of the blade, brake, travel, and
swing systems.
‡ Check the machine for any abnormal noise, vibration, heat, smell, or abnormality with the gauges.
Check also for leakage of air, oil, and fuel.
‡ If any abnormality is found, repair the problem immediately.
If the machine is used without repairing the problems, it may lead to unexpected injury or failure.
‡ When traveling for work, check that the articulate lock pin is removed and set in the storage
position.
‡ When traveling on a road, check that the articulate lock pin is set in the lock position.
CHECK DIRECTION BEFORE STARTING MACHINE

‡ Before moving the machine off, check again that there is no person or obstacle in the surrounding
area.
‡ Before operating the machine or work equipment, sound the horn to warn people in the area.
‡ Always set in the operator’s seat when operating the machine.
‡ Fasten the seat belt securely.
‡ If another person is allowed on the machine, that person may sit only in the assistant’s seat.
‡ Check that the travel alarm and other alarms work properly.
‡ On machines equipped with a back-up alarm, check that the warning devices work properly.
1-10
PRECAUTIONS WHEN SWINGING OR CHANGING

DIRECTION OF TRAVEL
Before operating the machine or the work equipment, always
observe the following precautions in order to prevent serious
injury or death.
‡ When changing the direction of travel from forward to reverse
or from reverse to forward, reduce speed early and stop the
machine before changing the direction of travel.
‡ Sound the horn to warn people in the area.
‡ Check that there is no one in the area around the machine.

There are blind spots behind the machine, so if necessary,
swing the upper structure to check that there is no one behind
the machine before traveling in reverse.
AE154980
‡ When operating in areas that may be hazardous or have poor
visibility, designate a person to direct worksite traffic.
‡ Ensure that no person can come within the turning radius or

direction of travel.
Be sure to observe the above precautions even if a travel alarm
or mirrors are installed.
1-11
PRECAUTIONS WHEN TRAVELING

‡ Set the machine in the travel posture and travel on a flat road.
Travel posture ➞ See “12.4 TRAVEL POSTURE FOR MACHINE”.
‡ It is dangerous to look around you when operating. Always concentrate on your work.
‡ It is dangerous to drive too fast, or to start suddenly, stop suddenly, turn sharply, or zigzag.
‡ If you find any abnormality in the machine during operation (noise, vibration, smell, incorrect
gauges, air leakage, oil leakage, etc.), move the machine immediately to a safe place and look for
the cause.
‡ Do not steer the machine sharply. If steered sharply, the work equipment may touch the ground
and the machine may be unbalanced or the machine and structures around it may be broken.
‡ When traveling on rough ground, travel at low speed and avoid turning sharply when changing
direction.
‡ If the engine stops when the machine is traveling, the steering cannot be operated, so operation
is dangerous. Apply the brake immediately and stop the machine.
‡ Operate carefully when the wheels are leaning. It is prohibited to travel on roads with the wheels
leaning.
‡ Travel at a maximum speed of 10 km/h (6.2 MPH) when using the articulation. If the articulation
is used when traveling at a speed of over 10 km/h (6.2 MPH), there is danger that the machine
may overturn. Never use the articulation at speeds of over 10 km/h (6.2 MPH).
‡ Keep the machine at a sufficient distance from the other machines during travel and work to avoid
contact with those machines.
‡ When crossing a private bridge or structure, first check that it can stand the weight of the machine.
When traveling along public roads, ask the governmental offices for instructions.
‡ When traveling along public roads, observe traffic regulations. Since the machine travels slower
than the general automobiles, take the slower lane of the road and make way for the other
automobiles.
‡ If the machine travels at high speed for several hours, the tires will become overheated and the
pressure in them rises abnormally to cause serious injury.
‡ When traveling continuously, observe the following items.
• Ask your Komatsu distributor or the tire shop about the speed limit and necessity of adjustment
of tire inflation pressure.
• Stop the machine for 30 minutes to cool the tires after traveling 1 hour.
• Do not lower the tire inflation pressure.
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TRAVELING ON SLOPES
‡ Traveling on hills, banks or slopes that are steep could result in the machine tipping over or
slipping.
‡ Do not change direction on slopes. Avoid sideways travel whenever possible: rather travel up and
down the slopes.
‡ Do not travel up and down on grass, fallen leaves, and wet steel plates. These materials may cause
the machine to slip if it is traveling sideways. Keep travel speed very low.
‡ When traveling downhill, do not change the gear speed or set the transmission to the neutral
position. If this is done, the braking force of the engine cannot be used. Be sure to set the
transmission to a lower gear speed and apply the brake and use the engine as a brake, if necessary.
‡ Be sure to change the gear speed step by step to prevent overrun. If the machine overruns, the
engine and transmission will be damaged.
If the engine stops on a slope, immediately apply the brakes fully to stop the machine.
INHIBITION OF DANGEROUS WORK

When using the machine, do not exceed the stability determined from the structure of the machine,
maximum using load and other performance values to prevent the tipping of the machine and
breakage of the work equipment caused by an overload.
PRECAUTIONS DURING OPERATION

‡ Cars often travel along the part of the road being leveled by the motor grader, so always pay
attention to the area behind the machine when carrying out operations.
‡ If a load is applied to only one side of the side cutter or blade, the rear part of the machine may
swing. Be careful.
‡ Do not use the machine for work other than the specified work. If it is used so, trouble may
develop.
Specified works ➞ See “12.11 WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER”.
‡ Observe the following items to secure sufficient visibility
• Turn ON the working lamps and head lamp when working on dark sites. Provide additional
lights for the job site if necessary.
• If visibility is diminished by fog, snow or rain, stop operations. Wait until there is adequate
visibility for safe operation.
‡ Observe the following items to avoid hitting the work equipment
• Be extremely careful not to hitting the blade, etc. when moving the machine in places where
there are height limits, such as when working in tunnels, under bridges or electric wires, or
when parking the machine indoors.
• When traveling the machine on a narrow job site, indoors or a crowded place, limit the travel
speed to avoid contact accidents.
• When operating the blade, be careful not to let it hit the tire.
1-13
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

‡ Do not let the machine touch overhead electric wires. In the case of high-voltage cables, even
going close can cause electric shock.
‡ To prevent accidents, always do the following.
• On jobsites where there is danger of the machine contacting electric wires, consult with the
electric power company and check that the actions required by law are being taken before
starting operations.
• Wear shoes with rubber soles and rubber gloves, spread a rubber sheet on the seat and be
careful not to let any part of your body not protected by rubber touch the machine.
• Use a signalman to give warning if the machine approaches too close to the electric cables.
• Check with the electricity company about the voltage of the cables before starting operations.
Voltage Min. safety distance

voltage
100 · 200 V 2m
Low
6,600 V 2m
22,000 V 3m
Very high voltage
66,000 V 4m
154,000 V 5m
187,000 V 6m
275,000 V 7m
500,000 V 11 m
METHOD OF USING BRAKES

‡ Place your foot on the brake pedal only when required during travel. If the machine travels with
your foot placed on the brake pedal, the brake operates constantly, then it will overheat and will
not work any more. This can cause an accident.
‡ If the brake pedal is depressed lightly to control the machine speed, the brakes will overheat and
will not work any more.
‡ When traveling downhill, use the braking force of the engine, and use the brake pedal if necessary.
1-14
OPERATE CAREFULLY ON SNOW

‡ When working on snow or icy roads, even a slight slope may cause the machine to slip to the side,
so always travel at low speed and avoid sudden starting, stopping, or turning. There is particular
danger of the machine slipping to the side when traveling up or down hills.
‡ When the temperature rises, frozen road surfaces become soft, so the machine travel becomes
unstable.
‡ When there has been heavy snow, the road shoulder and objects placed beside the road are buried
in the snow and cannot be seen, so always carry out snow-clearing operations carefully.
‡ When traveling on snow-covered roads, always fit tire chains.
‡ When traveling on snow-covered slopes, never use the brakes to stop the machine suddenly, but
lower the speed and use both braking force of the engine and brake pedal (Depress the brake pedal
several times to stop the machine).
‡ The load differs greatly according to the quality of the snow, so be careful not to slip when
adjusting the load.
WORKING ON LOOSE GROUND

‡ Avoid entering soft ground. It will be difficult for the machine to escape.
‡ Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse, the machine could fall or tip
over and this could result in serious injury or death.
Remember that the soil after heavy rain or blasting or after earthquakes is weakened in these
areas.
‡ Earth laid on the ground and the soil near ditches is loose. It can collapse under the weight or
vibration of your machine and cause your machine to tip over.
‡ Install the head guard if working in areas where there is danger of falling rocks.
‡ When working in places where there is danger of falling rocks or danger of the machine turning
over, install ROPS and a seat belt.
For installation of ROPS and the seat belt, ask your Komatsu distributor.
1-15
PARKING MACHINE
‡ Park on level ground where there is no danger of falling rocks or landslides. When parking on low
ground, park in a place where there is no problem of flooding. When parking the machine, lower
the work equipment to the ground.
‡ If the machine must be parked on a slope, block the tires, lower the work equipment and thrust
the work equipment into the ground.
‡ After stopping the engine, operate the right work equipment control lever to the RAISE and LOWER
positions 2 or 3 times to release the pressure remaining in the hydraulic circuit.
‡ When parking on public roads, provide fences, signs, flags, or lights, and put up any other
necessary signs to ensure that passing traffic can see the machine clearly, and park the machine
so that the machine, flags, and fences do not obstruct traffic.
Parking procedure ➞ See “12.14 PARKING MACHINE”.
‡ When leaving the machine, set the gear shift lever to the P position, then stop the engine and use
the key to lock all the equipment. Always remove the key and take it with you and keep it in the
specified place.
‡ Always close the door of the operator’s compartment.
PRECAUTIONS IN COLD WEATHER

‡ After completing operations, remove any drops of water, snow, or mud stuck to the wiring
harnesses, connector 1, switches, or sensors, and cover these parts.
If drops of water get in and freeze, the machine may malfunction when it is next used, and this
may lead to an unexpected accident.
‡ Carry out the warming-up operations thoroughly. If the control levers are operated before the
machine is fully warmed up, the response of the machine will be slow, and this may lead to an
unexpected accident.
‡ If the battery electrolyte is frozen, do not charge the battery or start the engine with power from
another source. There is danger that the battery may catch fire.
When charging the battery or starting with power from another source, let the battery electrolyte
melt and check that there is no leakage of battery electrolyte before starting the operation.
Battery charge ratio ➞ See “14.1.3 BATTERY”.
1-16
7.3 TRANSPORTATION
LOADING AND UNLOADING
‡ Loading and unloading the machine always involves potential hazards. EXTREME CAUTION
SHOULD BE USED.
‡ When loading or unloading the machine, run the engine at low idling and travel at low speed.
‡ Perform loading and unloading on firm, level ground only. Maintain a safe distance from the edge
of the road.
‡ ALWAYS use ramps of adequate strength. Be sure that the ramps are wide, long, and thick enough
to provide a safe loading slope. If there is excessive deflection of the ramps, strengthen the ramp
with blocks.
‡ When loading or unloading the machine on piled soil or temporarily structure, be careful to ensure
that the width, strength, and angle of the slope fulfill the limits.
To prevent the machine from slipping, remove all oil, grease, or other material from the surface
of the ramps. Remove all mud from the undercarriage of the machine. Be particularly careful on
rainy days because the machine is more likely to slip.
‡ NEVER correct your steering on the ramps. If necessary, drive away from the ramps and climb
again.
‡ The center of gravity of the machine will change suddenly at the joint between the ramps and the
track or trailer, and there is danger of the machine losing its balance. Travel slowly over this point.
‡ After loading, block the machine tracks and secure the machine with wire rope.
Loading and unloading ➞ See “13. TRANSPORTATION”.
Tie-downs ➞ See “13. TRANSPORTATION”.
CORRECT
SHIPPING
‡ When shipping the machine on a hauling vehicle, obey all state and local laws governing the
weight, width, and length of a load. Also obey all applicable traffic regulations.
‡ Take into account the width, height and weight of the load when determining the shipping route.
Height, width, weight limits ➞ See “13. TRANSPORTATION”.
‡ When traveling over bridges or structures on private land, check first that the bridge or structure
can withstand the weight of the machine. When traveling on public roads, check with the local
authorities and follow their instructions.
1-17
7.4 BATTERY
BATTERY HAZARD PREVENTION
Battery electrolyte contains dilute sulfuric acid and batteries generate hydrogen gas. Hydrogen gas
is highly explosive, and mistakes in handling can cause serious injury or fire. To prevent problems,
always do as follows.
‡ Do not smoke or bring any flame near the battery.
‡ When working with batteries, ALWAYS wear safety glasses and rubber gloves.
‡ If you spill battery electrolyte on yourself or your clothes, immediately flush the area with water.
‡ If battery electrolyte gets into your eyes, flush them immediately with large quantities of water
and see a doctor at once.
‡ If you accidentally drink battery electrolyte, drink a large quantity of water or milk, raw egg or
vegetable oil. Call a doctor or poison prevention center immediately.
A0055110
A0055090 A0055100
STARTING WITH BOOSTER CABLES

If any mistake is made in the method of connecting the booster cables, it may cause fire. Always
do as follows.
‡ Use two workers for the starting operation: one of these sits in the operator’s seat.
‡ When using another machine to start a problem machine, be careful not to let the normal machine
and problem machine touch each other.
‡ When connecting the booster cables, turn the starting switches OFF on both the normal machine
and the problem machine.
‡ Be sure to connect the positive + cable first when installing the booster cables. Disconnect the
ground or negative - cable first when removing them.
‡ Finally, when connecting the ground cable to the frame of the upper structure, sparks will be
caused, so be sure to connect it as far as possible from the battery.
Starting with booster cables ➞ See ”16.4 IF BATTERY IS DISCHARGED”.
‡ When removing the booster cable, be careful not to let the booster cable clips contact each other
or let the clip contact the machine.
INCORRECT
A0067320
1-18
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 for use of the battery and the instruction manual
accompanying the charger, and do as follows.
‡ Take the charger to a well-ventilated place and remove the battery caps.
This is to disperse the hydrogen gas and prevent explosion.
‡ Set the voltage of the charger to match the voltage of the battery to be charged. If the voltage
is not selected correctly, the charger may overheat and cause an explosion.
‡ Connect the positive + charger clip of the charger to the positive + terminal of the battery, then
connect the negative - charger clip of the charger to the negative - terminal of the battery. Be
sure to fix the clips securely.
‡ Set the charging current to 1/10 of the value of the rated battery capacity; when carrying out rapid
charging, set it to less than the rated battery capacity.
If the charger current is too high, the electrolyte will leak or dry up, and this may cause the battery
to catch fire and explode.
A0055110
1-19
7.5 TOWING
PRECAUTIONS WHEN TOWING
If any mistake is made in the method of selecting or inspecting the towing wire or in the method
of towing, it may lead to serious personal injury. Always do as follows.
‡ Always use the method of towing given in this Operation and Maintenance Manual. Do not use
any other method.
Method of towing ➞ See “16.3 TOWING THE MACHINE”.
‡ Use leather gloves when handling the wire rope.
‡ When carrying out the preparation work for towing with two or more workers, determine the
signals to use and follow these signals correctly.
‡ If the engine on the problem machine will not start or there is a failure in the brake system, always
contact your Komatsu distributor.
‡ It is dangerous to carry out towing on slopes, so select a place where the slope is gradual. If there
is no place where the slope is gradual, carry out operations to reduce the angle of the slope before
starting the towing operation.
‡ When towing a problem machine, always use a wire rope with a sufficient towing capacity.
‡ Do not use a frayed A, kinked B rope or a rope with any loss of diameter C.
AE155030
1-20
8. PRECAUTIONS FOR  WARNING: Failure to follow these safety
MAINTENANCE precautions may lead to a serious accident.
8.1 BEFORE CARRYING OUT MAINTENANCE

CONTACT WHEN THERE IS FAILURE
Carrying out maintenance that is not listed in the Komatsu Operation and Maintenance Manual may
cause unexpected failure. Please contact your Komatsu distributor for repairs.
WARNING TAG
ALWAYS attach the “DO NOT OPERATE” warning tag to the gearshift lever in the operator’s cab to
alert others that you are working on the machine. Attach additional warning tags around the machine
if necessary.
If others start the engine or operate the controls while you are performing inspection or maintenance,
you could suffer serious injury.
Warning tag part No. 09963-03000
DO NOT operate
When this plate is not being used
keep it in the storage compartment.
09963-03000
CLEAN BEFORE INSPECTION OR MAINTENANCE

‡ Clean the machine before carrying out inspection and maintenance. This prevents dirt from getting
into the machine and also ensures safety during maintenance.
‡ If inspection and maintenance are carried out when the machine is dirty, it will become more
difficult to locate the problems, and also there is danger that you may get dirt or mud in your eyes
or that you may slip and injure yourself.
‡ When washing the machine, do as follows.
• Wear shoes with non-slip pads to prevent yourself from slipping and falling on wet places.
• Wear protective clothing when washing the machine with high-pressure steam.
• Take action to prevent touching high-pressure water and cutting your skin or having mud fly
into your eyes.
• Do not spray water directly on electrical components (sensors, connector) 1.

If water gets into the electrical system, there is danger that it will cause defective operation and
malfunction.
A0055150
1-21
8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions.
NEAT CLEAN WORK PLACE

Tidy any tools or hammers that are lying in the work place, wipe up any grease or oil or any other
slippery substances, and clean the area to make it possible to carry out the operation in safety.
If the work place is left untidy, you may trip or slip and suffer injury.
FOLLOW LEADER IN OPERATIONS WITH OTHER WORKERS

When carrying out repairs of the machine or removal and installation of components, decide a leader
and follow the instructions of the leader.
There is danger that differences of opinion between workers when working together may lead to
misunderstandings and cause an expected accident.
RADIATOR WATER LEVEL

‡ When checking the radiator water level, stop the engine, let the engine and radiator cool down,
then check the sub tank. If the water level in the sub tank is near the upper limit, there is enough
water in the radiator.
‡ If there is no sub tank, or if it is necessary to remove the radiator cap, do as follows.
‡ Wait for the radiator water temperature to go down, then check the water level.
(When checking how much the water temperature has gone down, bring your hand close to the
surface of the engine or radiator without touching it, and check the temperature of the air at the
engine or radiator surface.)
‡ Loosen the radiator cap gradually to release the internal pressure before removing the radiator
cap.
A0055050 A0067380
1-22
to a serious accident. 8. PRECAUTIONS FOR MAINTENANCE
PREVENTION OF FALL OF WORK EQUIPMENT

When carrying out the maintenance with the blade raised, place a stand under the blade to prevent
the blade from falling. Set the work equipment control lever to the HOLD position, the gear shift lever
to the parking position.
A0055140
PROPER TOOLS
Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools could cause
personal injury. There is danger that pieces from chisels with crushed heads or hammers may get
into your eyes and cause blindness.
Tools ➞ See “21.1 INTRODUCTION OF NECESSARY TOOLS”.
A0055120
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS

Hoses in the fuel system, hydraulic system, and brake system are important parts for safety, so they
must be replaced at periodic intervals.
The replacement of such safety critical parts requires skill and experience, so please contact your
Komatsu distributor for replacement.
‡ Replace these components periodically with new ones, regardless of whether or not they appear
to be defective. These components deteriorate over time, and leakage of oil may cause fire or
failure of the work equipment system.
‡ Replace or repair any such components if any defect is found, even though they have not reached
the time specified.
Replacement of safety critical parts ➞ See “22. PERIODIC REPLACEMENT OF SAFETY CRITI-
CAL PARTS”.
1-23
USE OF LIGHTING
‡ When checking fuel, oil, battery electrolyte, or window washing fluid, always use lighting with anti-
explosion specifications. If such lighting equipment is not used, there is danger of explosion.
‡ If work is carried out in dark places without using lighting, it may lead to injury, so always use
lighting.
‡ Even if the place is dark, never use a lighter or flame instead of lighting. There is danger of fire.
There is also danger that the battery gas may catch fire and cause an explosion.
‡ When taking the power for the lighting from the machine itself, follow the instructions in this
Operation and Maintenance Manual.
A0055160
FIRE PREVENTION
During maintenance, fuel, batteries, and other materials which may catch fire are handled, so always
do as follows.
‡ Store flammable materials such as fuel, oil, and grease away from frame.
‡ Use non flammable oil as the oil for washing parts. Diesel oil and gasoline may catch fire, so do
not use them.
‡ Do not smoke when carrying out inspection and maintenance. Always smoke in the specified
smoking areas.
‡ When carrying out inspection of fuel, oil, or battery electrolyte, use lighting with anti-explosion
specifications. Never use lighters or matches as lighting.
Loose or damaged electrical connections may cause short circuits which may lead to fire. Always
check during check before starting.
‡ When grinding or welding the machine body, move flammable materials away from machine.
‡ Check that there is a fire extinguisher close to the location for carrying out inspection and
maintenance.
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1-24
8.2 DURING MAINTENANCE

PERSONNEL
Only authorized personnel can enter the area during the maintenance operation. If necessary, have
a guard supervise the area.
Extra precaution should be used when grinding, welding, and using a sledge-hammer.
PRECAUTIONS FOR REMOVAL, INSTALLATION, AND STORAGE OF ATTACHMENTS

‡ Before starting removal and installation of attachments, decide the team leader.
‡ Do not allow anyone except the authorized workers close to the machine or attachment.
Place attachments that have been removed from the machine in a safe place so that they do not
fall. Put up a fence around the attachments and take other measures to prevent unauthorized
persons from entering.
A0055130
WORK UNDER MACHINE

‡ Stop the machine on firm, flat ground and lower the work equipment to the ground.
‡ Always block the tires of the machine securely.
‡ It is extremely dangerous to work with the tires jacked up from the ground using the work
equipment. Never work with the machine raised in this way.
A0055140
NOISE
If the surrounding noise is loud it may cause hearing problems or even loss of hearing.
‡ When carrying out maintenance of the engine or other operations with long exposure to noise,
wear ear muffs or ear plugs.
1-25
PRECAUTIONS WHEN WORKING ON MACHINE

‡ When carrying out maintenance operations on the machine, keep the area around your feet clean
and tidy to prevent you from falling. Always do as follows.
• Do not spill oil or grease.
• Do not leave tools lying about.
• Watch your step when walking.
‡ Never jump down from the machine. When getting on or off the machine, use the steps and
handrails, and maintain three-point contact (both feet and one hand or both hands and one foot)
to support yourself securely.
‡ If the job requires it, wear protective clothing.
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING

To prevent accidents, do not carry out maintenance with the engine running. If it is necessary to carry
out maintenance with the engine running, always do as follows.
‡ One worker sits in the operator’s seat so that it is possible to stop the engine immediately
whenever necessary. The workers confirm their actions with each other.
‡ When working near rotating parts, be particularly careful. There is danger of getting caught.
‡ When cleaning the inside of the radiator, set the gear shift lever to the parking portion to secure
the machine.
‡ Be careful not to touch the control levers. If a control lever has to be operated, always signal your
partner to move to a safe place.
‡ Never touch the fan blade or fan belt with your body or tools. There is danger of losing fingers
or limbs.
A0055210
1-26
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE

‡ When carrying out inspection with the inspection window or tank oil filler open, be careful not to
drop bolts, nuts, or tools inside the machine.
If any part is dropped inside the machine, it will cause breakage or malfunctioning of the machine,
which may lead to a serious accident. If you drop anything, always be sure to remove it.
‡ When carrying out inspection, put only the things necessary for inspection in your pockets.
FLYING PIECES WITH HAMMER WORK

‡ When working with hammers, wear protective glasses, helmet, and other protective clothing. Put
a brass rod between the hammer and the object when hitting with the hammer.
‡ If hard metal parts such as pins, edges, teeth, and bearings are hit with a hammer, there is danger
that small pieces will fly off and get into your eyes.
WELDING REPAIRS
When carrying out welding repairs, carry out the welding in a properly equipped place. The welding
should be performed by a qualified worker. During welding operations, there is the danger of
generation of gas, fire, or electric shock, so never let an unqualified worker do welding.
The qualified welder must do as follows.
‡ To prevent explosion of the battery, remove the battery terminals.
‡ To prevent generation of gas, remove the paint from the location of the weld.
‡ If hydraulic equipment or piping or places close to them are heated, a flammable gas or mist will
be generated and there is danger of it catching fire. To avoid this, never subject these places to
heat.
‡ If heat is applied directly to rubber hoses or piping under pressure, they may suddenly break, so
cover them with a fireproof covering.
‡ Wear protective clothing.
‡ Make sure there is good ventilation.
‡ Remove all flammable objects and provide a fire extinguisher.
REMOVE BATTERY TERMINALS

When repairing the electrical system or when carrying out electric welding, remove the negative -
terminal of the battery to stop the flow of electricity.
Handling battery ➞ See “16.4 IF BATTERY IS DISCHARGED”.
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1-27
ACTION WHEN ABNORMALITY IS FOUND DURING INSPECTION

‡ If any abnormality is found during inspection, always carry out repairs. In particular, if the machine
is used when there are still problems with the brake or work equipment systems, it may lead to
serious injury.
‡ If necessary depending on the type of failure, please contact your Komatsu distributor for repairs.
RULES TO FOLLOW WHEN ADDING FUEL OR OIL

If flame is brought close to fuel or oil, there is danger that it will catch fire. Always do as follows.
‡ Stop the engine when adding fuel or oil.
‡ Do not smoke.
‡ Wipe up spilled fuel and oil immediately.
‡ Always tighten the caps of the fuel and oil fillers securely.
‡ Always add fuel and oil in a well-ventilated place.
Do not leave the work place when adding fuel or oil.
A0055020
A0055040
HANDLING HIGH-PRESSURE HOSES

‡ If oil or fuel leaks from high-pressure hoses, it will cause serious injury through fire or defective
actuation. If any damage to the hoses or loose bolts are found, stop operations immediately and
‡ Experience and skill is required when replacing high pressure hoses. The tightening torque is
determined according to the type and size of the hose, so please contact your Komatsu distributor.
1-28
PRECAUTIONS WITH HIGH-PRESSURE OIL

When inspecting or replacing high-pressure piping or hoses, check that the pressure has been
released from the circuit. Failure to release the pressure may lead to serious injury. Always do as
follows.
‡ For details of the method of releasing the pressure: see “INSPECTION AND MAINTENANCE WITH
ENGINE STOPPED”. Do not carry out any inspection or replacement operation before the pressure
has been completely removed.
‡ Wear protective glasses and leather gloves.
‡ If there is any leakage from the piping or hoses, the piping and hoses and the area around them
will be wet, so check for cracks in the piping or cracks or swelling in the hoses.
If it is difficult to find the location, please contact your Komatsu distributor.
‡ If oil is leaking under high pressure from small holes, it is dangerous if it hits your skin or enters
your eyes. It may make holes in your skin or cause blindness. If you are hit by a jet of high-pressure
oil and suffer serious injury to your skin or eyes, wash off the oil with large amounts of water,
then consult a doctor immediately for medical attention.
INCORRECT CORRECT
A0055180 A0055190
PRECAUTIONS WHEN CARRYING OUT

MAINTENANCE AT HIGH TEMPERATURE
‡ Immediately after stopping operations, the engine coolant, oil at all parts, and the exhaust
manifold and muffler are at high temperature.
In this condition, if the cap is removed, or the oil or water is drained, or the filters are replaced,
it may result in burns or other injury. Wait for the temperature to go down, then carry out the
inspection and maintenance in accordance with the procedures given in this manual.
Cleaning inside of cooling system ➞ See “24.2 WHEN REQUIRED”.
Checking coolant, hydraulic tank oil level ➞ See “24.3 CHECK BEFORE STARTING”.
Checking lubricating oil level, adding oil ➞ See “24.3 CHECK BEFORE STARTING”. – “24.6
EVERY 500 HOURS SERVICE”.
Changing oil, replacing filters ➞ See “24.7 EVERY 1000 HOURS SERVICE”. – “24.8 EVERY 2000
HOURS SERVICE”.
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1-29
CHECKS AFTER INSPECTION AND MAINTENANCE

If inspection and maintenance items are forgotten or the function of the maintenance locations is
not checked properly, unexpected problems may occur and this may lead to serious personal injury.
Always do as follows.
‡ Checks after stopping engine
• Has any inspection or maintenance location been forgotten?
• Have any tools or parts been dropped? This is particularly dangerous if they get caught in the
link mechanism for the levers.
• Is there any leakage of water or oil? Have all the bolts been tightened properly?
‡ Checks when engine is running
• For details of the checks when the engine is running: see “TWO WORKERS FOR MAINTENANCE
WHEN ENGINE IS RUNNING”, and pay full attention to safety.
• Is the actuation of the inspection and maintenance locations correct?
• Is there any oil leakage when the engine speed is raised and load is applied to the hydraulic
system?
WASTE MATERIALS
To prevent pollution of the environment, always do as follows.
‡ Never dump waste oil in a sewer system, rivers, etc.
‡ Always put oil drained from your machine in containers. Never drain oil directly onto the ground.
‡ Obey appropriate laws and regulations when disposing of harmful materials such as oil, fuel,
solvent, filters, and batteries.
INCORRECT
A0055220
MAINTENANCE OF AIR CONDITIONER

If the air conditioner refrigerant gets into your eyes or touches your skin, it may cause blindness or
frostbite.
‡ When handling the refrigerant, follow the precautions given on the container.
‡ To prevent the refrigerant from leaking into the atmosphere, use a recovery recycling system.
‡ Never touch the refrigerant.
1-30
8.3 TIRES
HANDLING TIRES
If a tire or a rim is handled wrongly, the tire may burst or may be damaged and the rim may be broken
and scattered, and that can cause serious injury and death.
To maintain safety, always observe the following.

‡ Since maintenance, disassembly, repair and assembly of the tires and rims require special
equipment and skill, be sure to ask them a tire repair shop to carry out the work.
‡ Use only the specified tires and inflate them to the specified pressure.
Selection of tires ➞ See “24.2.11 SELECTION AND INSPECTION OF TIRES”.
Suitable inflation pressure ➞ See “24.3.17 CHECK INFLATION PRESSURE OF TIRES”.
‡ When inflating a tire, check that no one will enter the working area and use an air chuck which
has a clip and which can be fixed to the air valve.
While inflating the tire, check the inflation pressure occasionally so that it will not rise too high.
If the rim is not fitted normally, it may be broken and scattered while the tire is inflated. To ensure
safety, place a guard around the tire and do not work in front of the rim but work on the tread side
of the tire.
‡ Abnormal drop in the inflation pressure and abnormal fitting of the rim indicate a trouble in the
tire or rim. In such cases, be sure to ask a tire repair shop to carry out repairs.
‡ Do not adjust the inflation pressure of the tires just after high-speed travel or heavy-duty work.
‡ Do not heat or weld the rim to which the tire is installed. Do not make a fire near the tire.
1-31
PRECAUTIONS FOR STORAGE OF TIRES

‡ As a basic rule, store the tires in a warehouse which unauthor-
ized persons cannot enter. If you must store the tires outside,
always erect a fence around the tires and put up a “No Entry”
sign.
‡ Stand the tire on level ground, and block it securely so that it

will not roll or fall over even if an unauthorized person touches
it. If the tire is placed on its side, it will be flattened and will
deteriorate.
‡ If the tire should fall over, get out of the way quickly. Tires for
construction equipment are extremely heavy, so trying to hold
the tire may lead to serious injury.
1-32
9. POSITION FOR ATTACHING SAFETY LABELS
Always keep these labels clean. If they are lost or damage, attach them again or replace them with
a new label.
There are other labels in addition to the safety labels listed as follows, so handle them in the same
way.
Safety labels may be available in languages other than English. To find out what labels are available,
9.1 POSITION FOR ATTACHING SAFETY LABELS
1-33
1. Precautions before starting 3. Precautions for opening hydraulic tank cap

(14X-98-11580) (14X-98-11521)
Hot oil hazard.

Improper operation and
maintenance can cause serious To prevent hot oil from
injury or death. spurting out:
• Turn engine off.
• Allow oil to cool.
Read manual and labels before • Slowly loosen cap to
operation and maintenance. relieve pressure
Follow instructions and warnings in before removing
manual and in labels on machine.
14X-98-11521
Keep manual in machine cab near
operator.
Contact Komatsu distributor for a
replacement manual.
14X-98-11580
2. Warning for opening radiator cap 4. Warning for leaving operator’s seat,
(14X-98-11531) starting engine, and driving
(235-53-31140)
Hot water hazard. Improper use of booster cables

and battery cables can cause an
To prevent hot water from explosion resulting in serious
spurting out: injury of death.
• Turn engine off.
• Allow water to cool. Follow instructions in manual
• Slowly loosen cap to when using booster cables and
relieve pressure battery cables.
235-53-31140
before removing
14X-98-11531
1-34
5. Precautions when traveling in reverse 7. Warnings for handling accumulator

(235-53-31230) (235-53-31130)
Explosion hazard.
Accumulator is charged with high-pressure

nitrogen gas.
Handle with care:

• Do not hit
• Keep away from flame
• Do not weld or drill accumulator
Before moving machine or its
attachments: Filling and discharging of gas in this accumulator
• Honk horn to alert people nearby must only be done by trained Komatsu service
• Be sure no one is behind personnel.
machine.
Max. operating pressure 29.4 MPa (300 kg/cm2)
• Use spotter if necessary,
Proof test pressure 44.1 MPa (450 kg/cm2)
particularly if you are moving in
reverse.
Follow above even if equipped with
back-up alarm and mirrors.
235-53-31230 235-53-31130
8. Articulate lock
6. Warning of compressed spring
(235-53-31170)
(235-53-31160)
Compressed spring inside If safety pin is unlocked, machine can

cover. jackknife unexpectedly when it is
Can cause serious injury. traveling, being transported or hoisted.
Only Komatsu service Jackknifing can cause serious injury or

personnel should death to the operator or bystanders.
disassemble this spring.
235-53-31160 • Always lock safety pin when machine is
traveling, being transported or hoisted.
• If necessary, lock safety pin during

servicing or maintenance.
235-53-31170
1-35
9. Cab lift mechanism 11. Precautions when handling battery

(235-53-31180) (235-53-31210)
EXPLOSIVE GAS HAZARD

• Cigarettes, flames or sparks could cause battery
to explode.
• Do not charge battery, use booster cables or
disconnect battery cables unless you have
received safety instructions.
(See machine manual)
• Keep vents tight and level.
• Do not store tools or inflammable materials
around or on battery.
235-53-31210
Improper lifting of operator cab with

lifting mechanism can cause cab to
drop, resulting in serious injury or
death.
12. Precautions when handling battery
Before using lifting mechanism, ask (235-53-31220)
Komatsu distributor for instructions on
the safe and proper way to lift cab.
Do not use lifting mechanism unless

you have received safety instructions
CHEMICAL BURN HAZARD
from Komatsu distributor. • Battery contains sulfuric acid which can cause
235-53-31180
severe burns.
• Avoid contact with skin, eyes or clothing.
In the event of accident, flush your skin or eyes
with water for 10 to 15 minutes, apply baking
soda or lime to neutralize acid, and immediately
call a physician.
10. Do not enter • Keep children away from battery.
(235-53-31190)
235-53-31220
13. Warning before removing bank-control lock pin

(235-53-31150)
Crush Hazard. Can cause severe

injury or death. Always lower the blade to the
around before removing the bank-
When machine is being operated, control lock pin.
never place yourself in articulated If the blade is raised, it may rotate
area of machine. and fall, possibly causing serious
235-53-31190 injury or death.
235-53-31150
1-36
14. ROPS
(09620-30200)
ROLL-OVER PROTECTIVE STRUCTURE (ROPS)

THE ROLL-OVER PROTECTIVE STRUCTURE OF THIS MACHINE COMPLIES WITH THE
FOLLOWING STANDARDS OR (RECOMMENDED PRACTICES)
INTERNATIONAL STANDARD : ISO 3471 (ROPS) & ISO 3449 (FOPS)
1
AMERICAN STANDARD : SAJ & SAEJ
MACHINE SERIAL MAX.

MODEL
MODEL NO. MASS
• Altering ROPS may weaken it. Consult Komatsu Distributor

before altering.
 WARNING • ROPS may provide less protection if it has been structurally
damaged or involved in roll-over.
• Always wear seat belt when moving.
Komatsu Ltd. Japan 2-3-6 Akasaka, Minato-ku, Tokyo, Japan 09620-30200
15. Prohibition of operation with engine cover

open (235-53-31240)
NEVER OPERATE WITH ENGINE COVER OPEN

• Never open the cover when operating the machine.
• Touching the high temperature parts may burn you.
• Rotating parts may injure you.
235-53-31240
1-37
MEMO
1-38
OPERATION
2-1
10. GENERAL VIEW
10.1 GENERAL VIEW OF MACHINE

If directions are indicated in this section, they refer to the directions shown by the arrows in the
diagram below.
2-2
10. GENERAL VIEW
10.2 GENERAL VIEW OF CONTROLS AND GAUGES
2-3
10. GENERAL VIEW
2-4
11. EXPLANATION OF COMPONENTS
The following is an explanation of the devices needed for

operating the machine.
To carry out suitable operations correctly and safely, it is impor-
tant to understand fully the methods of operating the equipment and
the meanings of the displays.
11.1 MONITOR PANEL
A CHECK MONITOR GROUP

(Check items before starting)(11.1.1)
This displays the basic items that need to be checked before the
engine is started.
If there is any abnormality, the appropriate monitor lamp will
flash.
When the engine is started, these monitor lamps will go off even
if there are abnormalities.
NOTICE
Do not rely on the “CHECK MONITOR GROUP (Check items
before starting)” only for the check before starting. Always make
the check by referring to “MAINTENANCE” or “12.1 CHECKS BE-
FORE STARTING ENGINE”.
2-5
B CAUTION MONITOR GROUP

(Caution items)(11.1.2)
 CAUTION
If these monitor lamps flash, inspect and repair the appropriate
place as soon as possible.
This displays the caution items that need to be repaired as soon

as possible if any abnormality occurs while the engine is running.
If there is any abnormality, the appropriate monitor lamp and the
central warning lamp will flash.
C CAUTION MONITOR GROUP

(Emergency stop items)(11.1.3)
 CAUTION
If any of these caution lamps flash, stop operations immedi-
ately, and check and repair the appropriate place.
This displays the caution items that need to be repaired imme-

diately if any abnormality occurs while the engine is running.
If there is any abnormality, the alarm buzzer will sound intermit-
tently, and the appropriate monitor lamp and the central warning
lamp will flash.
D METER GROUP (11.1.4)

This group consists of the differential control, absorber (accumu-
lator), blade float, parking, preheating, engine water temperature
gauge, fuel gauge, speedometer, turn signal pilot lamp, and service
meter.
E CENTRAL WARNING LAMP

This will flash under the following conditions.
‡ When any abnormality occurs in the CAUTION items in B.
This will flash and the alarm buzzer will sound intermittently
under the following conditions.
‡ When any abnormality occurs in the EMERGENCY STOP items
in C.
2-6
To check the monitor system

Turn the starting switch to ON before starting the engine.
Then all the monitor lamps, the gauges and the warning lamp
light up for about 3 seconds and the alarm buzzer sounds for about
2 seconds. After that all lamps go off and the buzzer stops.
‡ Three figures, 188, are displayed on the speedometer while the

monitor system is being checked.
‡ If any monitor lamp does not light up, there is probably a failure
or disconnection, so ask your Komatsu distributor to carry out an
inspection.
‡ To check the monitor when the engine is stopped, wait for at
least 30 seconds after the engine is stopped.
2-7
11.1.1 A: CHECK MONITOR GROUP

(Check items before starting)
NOTICE
‡ Do not rely on the “CHECK MONITOR GROUP (Check items
before starting)” only for the check before starting.
Always make the check by referring to “MAINTENANCE” or
“12.1 CHECKS BEFORE STARTING ENGINE”.
‡ Park the machine on level ground and check the monitor lamps.
‡ Confirm that these monitor lamps light for about 3 seconds after
turning the starting switch to ON. If any monitor lamp does not
light, ask your Komatsu distributor to inspect that monitor
lamp.
1. HYDRAULIC OIL LEVEL MONITOR

This monitor indicates a low hydraulic oil level.
If the monitor lamp flashes, check the oil level and add oil as
required.
2. ENGINE OIL LEVEL MONITOR

This monitor indicates a low oil level in the engine oil pan.
If the monitor lamp flashes, check the oil level in the engine oil pan
and add oil as required.
3. RADIATOR COOLANT LEVEL MONITOR

This monitor indicates a low radiator coolant level.
If the monitor lamp flashes, check the coolant level and add water
as required.
2-8
11.1.2 B: CAUTION MONITOR GROUP

(Caution items)
 CAUTION
If these monitor lamps flash, inspect and repair the appropriate
place as soon as possible.
NOTICE
turning the starting switch to ON while the engine is at rest. If
any monitor lamp does not light, ask your Komatsu distributor
to inspect that monitor lamp.
1. CHARGE MONITOR
This monitor indicates an abnormality in the charging system
while the engine is running.
If the lamp flashes during operation, stop the engine and check the
V-belt tension. If any abnormality is found, see “16. TROUBLE-
SHOOTING”.
REMARK
The monitor lamps and central warning lamp may flash when
the engine is started, but if they go out when the engine speed is
increased, there is no abnormality.
2-9
2. RADIATOR COOLANT LEVEL MONITOR

This monitor indicates a low radiator coolant level.
If the monitor lamp flashes, stop the engine, check the coolant level,
and add water as required.
3. HYDRAULIC OIL TEMPERATURE MONITOR

This lamp flashes if the hydraulic oil temperature goes above
108°C. If it flashes, stop the engine and ask your Komatsu distributor
to carry out an inspection.
4. EMERGENCY STEERING (IF EQUIPPED)

This lights up when the emergency steering is actuated.
The alarm buzzer sounds continuously at the same time.
The emergency steering uses an electric motor pump to provide
hydraulic power to the steering system. This prevents any sudden
increase in the operating effort of the steering wheel if the engine
stops or there is a failure in the hydraulic pump when the machine
is traveling.
Action when emergency steering is actuated

1. If the emergency steering is actuated, move the machine quickly
to a safe place and stop the machine.
2. After stopping the machine, turn the main switch OFF, stop the
emergency steering, then contact your Komatsu distributor for
inspection.
NOTICE
To protect the electric motor pump for the emergency steering,
do not run it for more than 30 seconds.
2-10
11.1.3 C: CAUTION MONITOR GROUP

(Emergency stop items)
 CAUTION
If any of these monitor lamps flash, stop the engine immediately
or run it at low idling and do as follows.
NOTICE
turning the starting switch to ON while the engine is at rest. If
any monitor lamp does not light, ask your Komatsu distributor
to inspect that monitor lamp.
1. FINAL DRIVE OIL TEMPERATURE MONITOR

This warns of any rise in the final drive oil temperature.
If it starts to flash, stop the machine, turn the differential control
switch to OFF and wait for the monitor to go out.
2. ENGINE OIL PRESSURE MONITOR

This monitor indicates a low engine oil pressure.
If the lamp flashes, the engine oil pressure is below the lower limit.
Immediately stop the engine and look for the cause. For details, see
“16. TROUBLESHOOTING”.
REMARK
This monitor lamp flashes and the alarm buzzer sounds when
the starting switch is turned to ON immediately after the engine is
started or immediately before the engine is stopped. It does not
indicate an abnormality.
2-11
3. HYDRAULIC OIL LEVEL

This flashes if the level of the oil in the hydraulic tank is too low.
If it flashes, stop the engine and check the oil level in the oil tank,
then add oil.
4. COOLANT TEMPERATURE MONITOR

This monitor indicates a rise in the cooling water temperature.
When the monitor lamp flashes, stop the machine, run the engine
with no load at midrange speed until the green range of the engine
water temperature gauge lights.
5. AIR PRESSURE MONITOR

This monitor indicates a drop in the air pressure in the air tank.
If the lamp flashes, stop the machine, increase the engine speed and
wait until the lamp goes out.
AD132390
2-12
11.1.4 D: METER GROUP
PILOT DISPLAY
When the starting switch is turned to ON, this lights up to
indicate that the display items are working.
1. DIFFERENTIAL CONTROL INDICATOR LAMP

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

This lights up when the absorber switch is turned ON.
2-13
3. BLADE FLOAT
This lights up when the blade float switch is set to the ON
position.
4. PARKING
This lights up when the parking brake is actuated.
A0061040
5. ENGINE PREHEATING MONITOR

This shows the preheating time when starting the engine in
temperatures of below 5°C.
It lights up for about 36 seconds when the starting switch is turned
to HEAT, then flashes for about 16 seconds.
Finally, it goes out, indicating that the preheating is completed.
2-14
METERS
6. ENGINE COOLING WATER TEMPERATURE GAUGE
 CAUTION
If the alarm buzzer sounds, the central warning lamp lights up,
or the engine water temperature monitor flashes, stop the
machine, run the engine at low idling, and wait for the green
range to light up.
This shows the temperature of the engine cooling water.

The green range should be lighted up during normal operations.
If the top level lights up, the alarm buzzer will sound, the central
warning lamp will light up, and the engine water temperature
monitor will flash.
7. FUEL GAUGE
This gauge indicates the amount of fuel in the fuel tank.
If there is enough fuel in the tank while the engine is running, the
green range lights.
If the red range lights, there is less than 70 liters of fuel in the tank.
When the red range lights, add fuel.
8. TURN SIGNAL PILOT LAMP

When the turn signal lamp flashes, the pilot lamp also flashes.
NOTICE
If there is a disconnection in the turn signal pilot lamp, the
flashing interval is reduced, so check for a disconnection or blown
bulb.
9. HIGH BEAM PILOT LAMP

This lamp lights up when the head lamp is at high beam.
10. SPEEDOMETER
This meter indicates the travel speed of the machine.
REMARK
A speedometer for MPH is also available.
2-15
11. SERVICE METER

This meter shows the total operating hours of the machine.
Set the periodic maintenance intervals using this display.
The service meter advances while the engine is running - even if the
machine is not traveling.
While engine is running, the green pilot lamp on the service meter
flashes to show that the service meter is advancing.
The meter will advance by 1 for each hour of operation regardless
of the engine speed.
2-16
11.2 CLUSTER GAUGE AND PILOT LAMPS
1. AIR PRESSURE GAUGE

This indicates the air pressure inside the air tank.
It should indicate the green range during normal operations.
If it drops to the red range during operations, the warning buzzer will
sound, the central warning lamp will flash, and the air pressure
monitor will also flash.
If this happens, stop the machine, increase the engine speed and
wait for the indicator to return to the green range.
NOTICE
If the warning buzzer frequently sounds, the piping joints may
be loose, so check for the cause.
2. LIFT ARM LOCK PILOT LAMP

This lights up when the lift arm lock pin is not locked.
2-17
11.3 SWITCHES
1. STARTING SWITCH
This switch is used to start the engine.
OFF position:
At this position, the starting switch key can be inserted or
removed. When the switch is turned to this position, the electrical
circuits are switched off, and the engine stops.
ON position:
In this position, electric current flows in the charging and lamp
circuits.
START position:
This is the position to start the engine. Hold the key at this
position while cranking. Release the key immediately after the
engine has been started. The key will return to ON position when
released.
2-18
HEAT position:
Use this position when starting in cold weather.
If the key is held at the HEAT position, the electrical heater will
be heated and the preheat monitor will light up.
When the preheating monitor flashes and then goes out, release
the key immediately.
If the key is released it will return to the OFF position, so turn it
immediately to the START position to start the engine.
2. BANK SWITCH
 WARNING
Lower the blade completely to the ground before removing the
pin.
This is used when setting the blade to the bank-cut position.
1 RETRACT : The pin securing the frame and blade lift cylinder
mount is removed.
2 LOCK : The pin is locked.
3 INDEX : Set to this position when aligning the position be-
fore securing the pin.
3. WORKING LAMP SWITCH (Front)

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

This is the switch for the rear working lamp.
lamps off.
2-19
5. WORKING LAMP SWITCH (Cab)

This switch is for the cab working lamp.
lamps off.
6. FRONT WIPER SWITCH (Front upper side)

This activates the front wiper.
Position 1 : Washer liquid is sprayed out.
OFF position : Wiper stop.
Position 2 : Wiper is operated.
Position 3 : Wiper is operated and washer liquid is sprayed out.
7. FRONT WIPER SWITCH (Front lower side)

This activates the front wiper.
Position 1 : Washer liquid is sprayed out.
OFF position : Wiper stop.
Position 3 : Wiper is operated and washer liquid is sprayed out.
8. DOOR WIPER SWITCH

This activates operates the rear wiper.
OFF position : Wiper stops.
2-20
9. REAR WIPER SWITCH

This activates the rear wiper.
OFF position : Wiper stops.
10. EMERGENCY STEERING SWITCH (IF EQUIPPED)

 WARNING
Never run the electric motor for the emergency steering for
more than 30 seconds.
1 AUTO position : If the hydraulic pressure in the steering circuit

goes below 7 kg/cm2, the electric motor is
automatically actuated to rotate the hydraulic
pump.
2 MANU position : This actuates the electric motor regardless of
the hydraulic pressure, and rotates the hydrau-
lic pump.
When the machine is stopped or is traveling at a speed of less

than 1 km/h, the emergency steering is not actuated automatically.
11. DIFFERENTIAL CONTROL SWITCH

This switch is used when the wheel on one side is in mud and
starts to slip.
ON position : The differential is locked and the indicator lamp

lights up.
OFF position : The differential is switched on (the differential
mechanism operates), and the lamp goes off.
Normally, the differential is on.

Even when the differential lock switch is at the ON position, if the
gear shift lever is at position 5 or above, the differential lock is
canceled and the differential is made free. To engage the differential
lock again, shift the gear shift lever down
to position 4 or below.
REMARK
Using the differential for normal travel and usual operations
reduces tire wear during the operation.
2-21
12. ACCUMULATOR AND BLADE FLOAT SWITCH (IF EQUIPPED)

‡ ACCUMULATOR SWITCH
This is used when actuating the accumulator.
ON position : The accumulator is actuated, and the absorber pilot
lamp lights up at the same time.
OFF position : The accumulator is canceled.
For details of handling the accumulator, see “12.20 Handling

blade accumulator”.
‡ BLADE FLOAT SWITCH

 WARNING
Lower the blade completely to the ground before removing the
pin.
This switch is used when actuating the blade float.
ON position : The blade moves freely under external force, re-

gardless of the position of the blade control lever.
OFF position : The blade is moved by operating the blade control
lever.
For details of handling the blade float, see “12.21 Handling blade
float”.
13. HEAD LAMP SWITCH

This is the switch for the head lamp.
Position 1 : Lamps are out.
Position 2 : Lamps light up.
14. DIMMER SWITCH

This switches the head lamp between high beam and low beam.
Position 1 : High beam
Position 2 : Low beam
2-22
15. TURN SIGNAL LEVER

This lever operates the turn signal lamps.
1 LEFT TURN : Push lever up.

2 RIGHT TURN : Push lever down.
When the lever is operated, the turn signal pilot lamp will also
light up.
The turn signal is not canceled when the steering wheel is returned.
Return the lever by hand.
16. HORN BUTTON

When the button in the center of the steering wheel is pressed,
the horn will sound.
17. ROOM LAMP SWITCH

This lights up the room lamp.
ON position : Lamp lights up.
OFF position : Lamp goes out.
18. EMERGENCY FLASHER SWITCH

 WARNING
Never use the flasher except in emergencies. If it is used while
traveling when there is no abnormality, it may cause misunder-
standing for drivers of other vehicles.
Use this switch only in emergencies, such as when the machine

has to be stopped on the road because of a failure. When the switch
is pressed, all the turn signal indicator lamps will start to flash.
2-23
11.4 CONTROL LEVERS AND PEDALS
1. LEFT BLADE LIFT CYLINDER CONTROL LEVER

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

2 HOLD : The blade stops and is held in the same position.
3 RAISE : The left side of the blade goes up.
2-24
2. RIPPER LIFT CYLINDER CONTROL LEVER

This lever operates the ripper.
1 LOWER : The ripper goes down.

2 HOLD : The ripper stops and is held in the same position.
3 RAISE : The ripper goes up.
3. BLADE SIDE SHIFT CONTROL LEVER

This lever shifts the blade to the side.
1 LEFT SHIFT : The blade is shifted to the left position.

3 RIGHT SHIFT : The blade is shifted to the right.
4. POWER TILT CONTROL LEVER

This lever changes the cutting angle of the blade.
1 Max. cutting angle : This makes the blade cutting angle bigger.
This is effective when operating on hard
ground.
Max. cutting angle: 115°
2 HOLD : The blade stops and is held in the same
position.
3 Min. cutting angle : This makes the blade cutting angle smaller.
This is effective when operating on soft
ground.
Min. cutting angle: 58°
REMARK
The distance between the cutting surface and the blade edge can
be changed, so it is possible to carry out fine adjustment of the
height of the cutting surface.
2-25
5. BLADE ROTATION CONTROL LEVER

This lever rotates the blade.
1 LEFT ROTATION : The blade is rotated to the left.

2 HOLD : The blade stops and is held in the same
position.
3 RIGHT ROTATION : The blade is rotated to the right.
NOTICE
To prevent damage to the tires, be careful not to let the blade
hit the tires when rotating the blade.
6. DRAWBAR SIDE SHIFT CONTROL LEVER

This lever shifts the drawbar to the side.
1 LEFT SHIFT : The drawbar is shifted to the left.

2 HOLD : The drawbar stops and is held in the same
position.
3 RIGHT SHIFT : The drawbar is shifted to the right.
2-26
7. ARTICULATE CONTROL LEVER

 WARNING
Operate this lever only when traveling at a speed of below 10
km/h. If the articulation is operated at a speed of over 10 km/h,
there is danger that the machine may overturn.
This lever is used to operate the articulation.

If the machine is articulated in the direction of turning, the
turning radius can be made smaller.
1 Left articulation: The machine is articulated to the left

2 HOLD: The articulated condition is maintained
3 Right articulation: The machine is articulated to the right
Max. articulating angle: 25° to left or right
Min. turning radius: 7.9 m when turning to left or right
(when also using leaning)
NOTICE
To prevent damage to the tires, be careful not to let the blade
hit the tires when articulating the machine.
2-27
8. LEANING CONTROL LEVER
1 RIGHT TURN
2 HOLD : The leaning is kept in the same condition.
3 LEFT TURN
If the leaning is used, it is possible to turn the machine to the left

or right without operating the steering wheel.
During blade operations, force is generated by the digging
resistance to turn the machine to one side, but by using a suitable
leaning angle, this force can be canceled out and the machine can
continue to travel in a straight line.
If the leaning is operated in the same direction as steering, the
turning radius can be made smaller. (Turn the steering to the left
(right) and lean the front wheels to the left (right).)
9. OPTION LEVER
This lever is used to operate any optional equipment or attach-
ment.
10. RIGHT BLADE LIFT CYLINDER CONTROL LEVER

This lever operates the right blade lift cylinder.
1 LOWER : The right side of the blade goes down.

3 RAISE : The right side of the blade goes up.
2-28
11. FUEL CONTROL LEVER

This lever is used to control the engine speed and output.
1 Low idling position: Push the lever forward fully.

2 High idling position: Pull the lever fully back from the low idling
position.
REMARK
‡ The fuel control lever is used only during operations with the
work equipment. For general travel, use the accelerator pedal.
‡ In 5th or above for both FORWARD and REVERSE, the fuel
control lever is interconnected with the gearshift lever, and the
engine speed does not rise to full throttle. This is to prevent
overrun caused by shifting down at high speed.
12. GEARSHIFT LEVER

 WARNING
When parking the machine, always set the gearshift lever to the
P position to apply the parking brake.
This lever is used to shift the travel speed range and to apply or
release the parking brake.
There are 8 speeds in FORWARD and REVERSE, and the gear can
be shifted simply by moving the gearshift lever to the desired
position.
P position: Parking brake applied
The parking brake is applied. When the gearshift lever is set to
the P position, the parking brake is applied and the parking brake
indicator lamp on the machine monitor lights up.
When applying or releasing the parking brake, press lever button
1 and operate the gearshift lever.
N position: Neutral
Position 1: 1st
Position 2: 2nd
Position 3: 3rd
Position 4: 4th
Position 5: 5th
Position 6: 6th
Position 7: 7th
Position 8: 8th
Groove on F side: FORWARD
Groove on R side: REVERSE
To prevent the engine from overrunning, there is a shift lock

device.
In both FORWARD and REVERSE, press lever button 1 when
shifting gear to the following positions.
When shifting down 7th ➞ 6th ➞ 5th, or
when shifting up 5th ➞ 6th ➞ 7th
REMARK
When starting the engine, if the gearshift lever is not at the P
position (parking brake applied), the engine will not start.
2-29
13. INCHING PEDAL

This pedal connects and disconnects the motive force from the
engine and is used when stopping or starting the machine, or when
switching between FORWARD and REVERSE.
When the pedal is depressed, the motive force is cut off.
In 1st, 2nd, and 3rd speeds, fine control of the machine is possible
using this pedal.
NOTICE
Continuous use of the inching pedal to give a partially engaged
clutch condition should be limited to 10 seconds.
14. BRAKE PEDAL

 WARNING
Do not put your foot on this pedal unnecessarily.
This applies the wheel brakes.
15. ACCELERATOR PEDAL

This pedal is used to control the engine speed and output.
This is interconnected with the fuel control lever, and can be
operated freely between the speed set by the fuel control lever and
the full speed position.
16. DECELERATOR PEDAL

This is used to reduce the engine speed.
It is possible to adjust the speed freely between the speed set by the
fuel control lever and the low idling speed.
2-30
11.5 DUST INDICATOR

This device indicates clogging of the air cleaner element. When
red piston 1 appears in the transparent part of this indicator, the
element is clogged. Immediately clean the element.
After cleaning, push indicator button 2 to return the red piston
to the original position.
AK069891
11.6 ARTICULATE LOCK PIN

 WARNING
‡ When servicing or transporting the machine always use this
lock pin.
‡ For normal travel, always use the lock pin.
This pin is used to lock the front frame and rear frame to prevent
the machine from bending during normal travel or when servicing
or transporting the machine.
Align the holes in the front frame and rear frame, then insert the
lock pin.
When not using the lock, always insert the lock pin in the storage
position.
11.7 FUSE BOX

 WARNING
If the fuse blows again immediately after it is replaced, please
NOTICE
Before replacing a fuse, be sure to turn off the starting switch.
The fuses protect the electrical equipment and wiring from

burning out.
If the fuse becomes corroded, or white powder can be seen, or
the fuse is loose in the fuse holder, replace the fuse.
Remove the bolt, open cover 1, and replace the fuse.
Replace a fuse with another of the same capacity.
2-31
11.7.1 FUSE CAPACITY AND CIRCUIT NAME

Fuse
No. Circuit name
capacity
1 10A Bank, Differential, Accumulator
2 15A Cab lamp
3 15A Front working lamp
4 20A Rear working lamp, Air conditioner
5 10A Horn, Turn signal lamp, Transmission control
6 10A Air pressure gauge
7 10A Brake lamp, Air dryer
8 10A Emergency steering
9 10A Auto drain
0 10A Cab (wiper, washer)
A 10A Cab (wiper)
B 15A Head lamp
C 10A Monitor
D 10A Transmission control, Parking
E 20A Air conditioner, Heater
11.8 OPERATOR’S CAB LIFT MECHANISM

By using the lift mechanism, it is possible to raise and hold the
operator’s cab in position without using a crane.
 WARNING
If the operator’s cab is not raised in the correct way, the cab may
fall and cause serious injury or even death.
Please contact your Komatsu distributor first before using he lift
mechanism. Be sure to follow all instructions regarding the
method of operation and safety precautions when lifting the
cab.
Do not use the lift mechanism without receiving guidance from
your Komatsu distributor.
Komatsu and Komatsu distributors cannot bear any responsibil-
ity of any injury or damage is caused due to incorrect use of the
lift mechanism.
11.9 BACKUP ALARM

The backup alarm sounds immediately when the gear shift lever
is placed in reverse.
If it does not sound, please contact your Komatsu distributor.
2-32
11.10 FRONT GLASS

It is possible to open the front glass to the front.
When opening
1. Remove lock 1 at the bottom left and right sides of the front
glass.
2. Push the bottom of the front glass out and open it to the desired
position.
3. Turn left and right lock knobs 2 in the direction of the arrow to
fix the glass in position.
When closing
1. Turn left and right lock knobs 2 in the direction of the arrow to
release the glass.
2. Pull the bottom of the front glass to close it.
3. Lock the front glass in position with lock 1 at the bottom left and
right sides of the front glass.
2-33
11.11 TOOL BAG

 WARNING
Do not leave the tool bag on the floor by your feet.
It will get in the way during operations.
A bag is provided to hold the tools supplied with the machine.

When not using the tools, put them in the tool bag and put the
tool bag behind the operator’s seat.
REMARK
‡ A tool box for holding the tool supplied with the machine is also
available as an option. This tool box can be installed to the
drawbar.
‡ The tool box already installed to the drawbar contains the tools
used when lifting the cab.
11.12 STORAGE BOX

There is a box for storing small articles at the top right of the cab.
11.13 STORAGE NET

Use this storage space to keep the Operation and Maintenance
Manual.
11.14 QUICK-FILL FUEL FILLER

A commercially available mount and relief valve can be installed
for use when filling quickly with fuel from a fuel tanker.
For details of the method of installing and handling, please see
the instruction manual provided with the quick tanker fill device.
2-34
11.15 AIR CONDITIONER

Outside air passes through the filter and is sent to the cab to
raise the pressure inside the cab. This ensures that the operator can
work under pleasant conditions even on dusty jobsites.
11.15.1 GENERAL LOCATIONS AND FUNCTION OF

CONTROL PANEL
1. FAN SWITCH
This can be used to adjust the air flow to 4 stages.
This switch also acts as the main switch for the air conditioner.
When the switch is pressed, the indicator lamp above the switch
lights up to indicate the air flow.
2. AIR CONDITIONER SWITCH

This is used to start or stop the cooling or dehumidifying
function.
When the fan switch is turned ON and the air conditioner switch
is pressed, the indicator lamp above the switch lights up.
When the switch is pressed again, the switch is turned OFF and
the indicator lamp goes out.
2-35
3. FRESH/RECIRC SELECTOR SWITCH

This switch is used to select between recirculating the air inside
the cab or taking in fresh air from outside.
When the RECIRC position is selected, the indicator lamp above
the switch lights up.
When the switch is pressed again, the indicator lamp goes out,
and fresh air is taken in.
4. TEMPERATURE CONTROL SWITCH

The temperature can be adjusted steplessly from low tempera-
ture to high temperature.
The temperature level indicator lamp light up to display the

temperature of the air coming fro the vents.
The more the blue lamps light up, the lower the temperature is.
The color of the indicator lamp changes while the switch is being
pressed.
When the temperature reaches the desired level, release the
switch to set the temperature.
The settings for each mode are retained in memory even when
the starting switch is turned OFF.
However, in the followig cases, the settings must be made again.
‡ When the machine has been out of use for more than 7 days
‡ When the battery voltage is extremely low
‡ When there has been abnormal interference from outside
‡ When the fan switch is turned OFF (the setting is not kept in
memory with only the air conditioner switch)
If the air conditioner is used at the FRESH position, the inside of

the cab will be pressurized and this will prevent the entry of dust.
The higher the position of the fan switch, the more effective the
pressurizing becomes.
2-36
11.15.2 METHOD OF OPERATION
Swich
Fan Air conditioner Temperature FRESH/RECIRC
Condition
switch switch control switch switch
of use
Rapid HI ON All blue RECIRC
Cooling More than
Normal HI-LO ON FRESH
half are blue
More than
Dehumidifying, heating HI-LO ON FRESH
half are red
Rapid HI OFF All red RECIRC
Heating More than
Normal HI-LO OFF FRESH
half are red
Defroster HI ON More than FRESH

half are red
Ventilation or pressurizing HI-LO OFF All blue FRESH
When carrying out the defrosting, if the temperature control

switch is set so that all lamps are red, this will improve the perform-
ance for defrosting and demisting.
11.15.3 PRECAUTIONS WHEN USING AIR

CONDITIONER
Carry out ventilation from time to time when using the cooling.
‡ If you smoke when using the cooling, your eyes may start to
sting, so in such a case, carry out ventilation and cooling for a
short time to remove the smoke.
‡ When using the air conditioner for a long time, carry out venti-
lation and cooling once every hour.
Be careful not to cool the cab too much.

‡ When cooling, it is said to be best for the health if it feels slightly
cool (5 or 6°C lower than the outside temperature) when you
enter the cab.
Be careful to adjust the temperature to suitable level.
2-37
11.15.4 HANDLING THE AIR CONDITIONER IN SEASON

To use the air conditioner comfortably during its season, ask
your Komatsu distributor to check the air conditioner and add the
refrigerant if necessary.
‡ The standard cleaning cycle for the fresh air filter is EVERY 100
HOURS, but if it becomes clogged, it will be impossible to
pressurize the inside of the cab, and in addition, it may cause
failures, so check and clean the filter immediately.
‡ If a large amount of dirt or dust collects on the condenser, the
cooling capacity drops, so check and clean when necessary For
details, see “24.2 WHEN REQUIRED”.
11.15.5 HANDLING THE AIR CONDITIONER IN OFF-

SEASONS
To lubricate each portion of the compressor, operate the
airconditioner for several minutes 2 – 3 times a month, even off
season.
NOTICE
If the compressor speed is raised sharply when the outside
temperature is low, the compressor may have trouble. When the
outside temperature is 2 – 6.5°C or less, the compressor does not
start even if the cooler switch is turned on.
2-38
12. OPERATION
12.1 CHECKS BEFORE STARTING ENGINE

12.1.1 WALK-AROUND CHECK
 WARNING
Leakage of oil or fuel, or accumulation of flammable material
around high temperature parts, such as the engine muffler may
cause fire. Check carefully, and if any abnormality is found,
always repair it or contact your Komatsu distributor.
Before starting the engine, look around the machine and under
the machine to check for loose nut or bolts, or leakage of oil, fuel,
or coolant, and check the condition of the work equipment and
hydraulic system.
Check also for loose wiring, play, and collection of dust at places
which reach high temperatures.
Carry out the checks in this section before starting the engine
each day.
2-39
12. OPERATION
1. Check for damage, wear, play in work equipment, cylinders,

linkage, hoses
Check that there are no cracks, excessive wear, or play in the
work equipment, cylinders, linkage, or hoses. If any abnormality is
found, repair it.
2. Remove dirt from around engine, radiator

Check that there is no dirt accumulated around the engine or
radiator. If any dirt is found, remove it.
3. Check for leakage of water or oil around engine

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

Check that there is no leakage of air or oil. If any abnormality is
found, repair the place where the air or oil is leaking.
6. Check for wear or damage to tires, loose mounting bolts

Check that there are no cracks or pealing of the tires. Tighten any
loose wheel nuts. If any abnormality is found, repair or replace.
7. Check for damage to handrail, steps, loose bolts

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

bolts
Check that there is no damage to the panel, gauges and lamps.
If any abnormality is found replace the parts. Clean off any dirt on
the surface. Tighten any loose bolts.
2-40
12. OPERATION
9. Check for damaged mirror, reflector, loose mounting bolts

Check that there is no damage to the mirror or reflectors, and
replace if there is any abnormality. Tighten any loose bolts.
Clean all dirt from the surface of the mirror and reflector.
10. Is door lock normal?

Check that there is no damage to the cab door lock. Repair or
replace if any abnormality is found.
11. Clean cab window

To ensure a good view during operations, always keep the cab
windows clean.
12. Check seat belt and clamps

 WARNING
Even if no abnormality can be seen in the seat belt, always
replace the seat belt every 3 years.
REMARK
The date of manufacture of the seat belt is printed on the label
shown by the arrow in the diagram on the right.
Check that there are no loose bolts in the damps and holder
installing the seat belt to the machine. Tighten any loose bolts.
Tightening torque: 24.5 ± 4.9 N·m (2.5 ± 0.5 kgf·m, 18.1 ± 3.6 lbft)
If the belt is damaged or has become fluffy, or if the clamps or

holders are damaged or deformed, replace the seat belt with a new
part.
AE061620
13. Check for loose ROPS mounting bolts

Tighten any loose ROPS mounting bolts.
2-41
12. OPERATION
14. Inspection of tires

 WARNING
If worn or damaged tires are used, they may burst and cause
serious injury or death.
To ensure safety, do not use the following tires.

Wear:
‡ Tires with a tread groove of less than 15% of that of a new
tire
‡ Tires with extreme uneven wear or with stepped-type wear
Damage:
‡ Tires with damage which has reached the cords, or with
cracks in the rubber
‡ Tires with cut or pulled cords.
‡ Tires with peeled (separated) surface
‡ Tires with damaged bead
‡ Leaking or improperly repaired tubeless tires
‡ Deteriorated, deformed or abnormally damaged tires which
do not seem usable
15. Inspection of rims

 WARNING
Check the rims (wheels) and rings for deformation, corrosion
and cracks.
In particular, check the side rings, lock rings and rim flanges
thoroughly.
2-42
12. OPERATION
12.1.2 CHECK BEFORE STARTING

Always carry out the checks in this section before starting the
engine each day.
CHECK COOLANT LEVEL, ADD WATER

 WARNING
Normally, do not open the radiator cap. When checking the
cooling water level, check the sub-tank when the engine is cold.
1. Check that the cooling water is between the FULL and LOW
marks on sub-tank 1. If the water level is low, add water to the
FULL level through the water filler port in sub-tank 1.
2. After adding water, tighten the cap securely.
3. If the sub-tank is empty, check for leakage of water and confirm

that the radiator main tank is full, then add water to the radiator
sub-tank.
NOTICE
If the volume of coolant added is more than usual, check for
possible water leakage.
Confirm that there is no oil in the coolant.
REMARK
In summer, the coolant may overflow from the sub-tank drain
hose. This is no problem. It occurs because too much coolant has
been added.
2-43
12. OPERATION
CHECK FUEL LEVEL, ADD FUEL

 WARNING
When adding fuel, never let the fuel overflow. This may cause
a fire. If you spill any fuel, thoroughly clean up all the spillage.
1. Turn the engine starting switch to the ON position and check the
fuel level with fuel level gauge G.
After checking, turn the switch back to the OFF position.
2. After completing work, fill the fuel tank through oil filler port F.
For details of the oil to use, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”.
3. After adding fuel, tighten the cap securely.
Fuel capacity: 500 ¬
NOTICE
If breather hole 1 in the cap becomes clogged, the pressure
inside the tank will go down and the fuel may not flow, so clean the
breather hole from time to time.
AD054210
DRAIN WATER AND SEDIMENT IN FUEL TANK

Loosen fuel tank drain valve 1 and drain the sediment and
water, accumulated at the bottom, together with fuel.
REMARK
The fuel will not be drained if it is not above the installation
position of drain valve 1 on the tank.
2-44
12. OPERATION
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

1. Open the side cover on the right side at the rear of the chassis.
2. Remove dipstick G and wipe the oil off with a cloth.
3. Insert dipstick G fully in the oil filler pipe, then take it out again.
4. The oil level should be between the H and L marks on dipstick

G.
If the oil level is below the L mark, and engine oil through oil filler
F.
H
5. If the oil is above the H mark, drain the excess engine oil from L
drain plug P, and check the oil level again. AD052340
6. If the oil level is correct, tighten the oil filler cap securely and
close the engine side cover.
REMARK
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before check-
ing. If the machine is at an angle, make it horizontal before checking.
2-45
12. OPERATION
CHECK DUST INDICATOR

1. Check that the red piston has not appeared in the transparent
portion of dust indicator 1.
2. If the red piston has appeared, clean or replace the element

immediately.
For details of the method of cleaning the element, see “24.2

WHEN REQUIRED”.
3. After checking, cleaning, and replacing, press the knob of dust

indicator 1 to return the red piston to its original position.
AE073060
CHECK ELECTRIC WIRING

 WARNING
‡ If fuses are frequently blown or if there are traces of short
circuit on the electrical wiring, locate the cause and carry out
repair.
‡ Accumulation of flammable material (dead leaves, twigs,
grass, etc.) around the battery may cause fires, so always,
check and remove such material.
‡ Keep the top surface of the battery clean and check the
breather hole in the battery cap. If it is clogged with dirt or
dust, wash the battery cap to clear the breather hole.
Check for damage and wrong capacity of the fuse and any sign
of disconnection or short circuit in the electric wiring. Check also for
loose terminals and tighten any loose parts.
Check the wiring of the “battery”, “starting motor” and “alter-
nator” carefully, in particular.
When carrying out walk-around checks or checks before starting,

always check if there is any accumulation of flammable material
around the battery, and remove such flammable material.
Please contact your Komatsu distributor for investigation and
correction of the cause.
2-46
12. OPERATION
HAVE ANY DEFECTS WHICH WERE FOUND DURING THE PREVI-

OUS DAY’S OPERATION BEEN CORRECTED?
CHECK AND REFILL WITH WINDOW WASHING FLUID

If the washer fluid level is low, and fluid through cap 1.
CHECK AND ADJUST STEERING WHEEL

Start the engine and check the steering wheel play.
Standard: 10 – 12 mm (0.4 – 0.5 in) maximum
If the steering wheel play is out of the standard range or the
steering wheel waves normally or is abnormally heavy, ask your
Komatsu distributor for repairs.
CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN

WATER
The water separator separates water mixed in the fuel. If float 2
is at or above red line 1, drain the water according to the following
procedure:
1. Loosen drain plug 3 and drain the accumulated water until the
float reaches the bottom.
AE082240
2. Tighten drain plug 3.
3. If the air is sucked into fuel line when draining the water, be sure
to bleed air in the same manner as for the fuel filter. See “24.6
2-47
12. OPERATION
CHECK THAT RISE IN AIR PRESSURE IS NORMAL

If the pressure inside the air tank is 0, it should be possible to
charge the tank with air to raise the indicator of the air pressure
gauge to the green range under the following conditions.
By running the engine at low idling for approx. 2 minutes, or
by running it at full throttle for less than 1.5 minutes.
CHECK THAT FLASHING OF LAMPS IS NORMAL, CHECK FOR DIRT

OR DAMAGE
CHECK THAT DIRECTION OF BACKUP MIRROR IS CORRECT, CHECK

FOR DIRT OR DAMAGE
CHECK OPERATION OF HORN
CHECK ENGINE EXHAUST COLOR AND SOUND
CHECK OPERATION OF GAUGES
CHECK INFLATION PRESSURE OF TIRES

Measure the inflation pressure with a tire pressure gauge while
the tires are cool before starting work.
Check for damage or wear to the tires and the rims.
Check for loose wheel hub nuts (bolts).
The proper inflation pressure is shown below.
Tire size Inflation pressure MPa (kgf/cm2)

23.50–25–12PR 0.16 MPa (1.6 kgf/cm2)
2-48
12. OPERATION
12.1.3 REMOVAL OF ARTICULAR LOCK PIN

 WARNING
For general travel, maintenance, and transportation, always
keep the articulate lock pin installed.
If the articulation is to be used during travel operations, remove

the articulate lock pin and keep it in the place shown by the arrow.
12.1.4 ADJUSTMENTS BEFORE OPERATION

ADJUST OPERATOR’S SEAT
 WARNING
‡ Adjust the seat position at the beginning of each shift or
when operators change.
‡ Adjust the seat so that the brake pedal can be depressed all
the way with the operator’s back against the backrest.
A: Seat height adjustment

To LOWER seat, turn lever 1 to RIGHT.
To RAISE seat, turn lever 1 to LEFT.
B: Forward-backward adjustment
Move lever 2 to the left, set the seat in the desired position, then
release the lever.
C: Adjusting angle of reclining

Pull lever 3 up, set the backrest to the desired position, the
release the lever.
Range of adjustment: 87° (17 stages)
2-49
12. OPERATION
ADJUSTING POSITION OF STEERING WHEEL AND GAUGE PANEL

 WARNING
Do not carry out adjustments while traveling.
Turn steering wheel tilt lever 1 to the left to release the lock,
then tilt the steering wheel and gauge panel to the desired position,
and lock in position with the lever.
Amount of adjustment: 20 (stepless)
ADJUSTING POSITION OF STEERING POST, WORK EQUIPMENT

CONTROL LEVERS
When steering post tilt pedal 1 is depressed, the steering post
will move towards you.
Adjust to a position that matches your physique and operating
posture.
Amount of adjustment: 5 stages
ADJUSTING MIRROR
Sit in the operator’s seat and adjust the mirrors so that you can
see the side and rear of the machine.
2-50
12. OPERATION
USING SEAT BELT

When operating a machine equipped with ROPS, be sure to use
the seat belt.
 WARNING
‡ Before fastening the seat belt, inspect the securing brackets
and belt for abnormal conditions.
Replace any worn or damaged seat belt or the securing
brackets.
‡ Adjust and fasten the seat belt before operating the machine.
‡ Always use seat belt when operating the machine.
‡ Do not use seat belt with either half of the belt twisted.
Fasten the belt and remove it in the following manner

Install the belts so that it fits you exactly without being too tight.
1. Adjust the seat so that the brake pedal can be depressed all the
way with the operator’s back against the backrest.
2. Sit in the seat. Hold buckle 1 with your left hand and tongue 2
with your right hand, and put tongue 2 into buckle 1. Pull the
belt to check that the belt has locked.
3. When removing the belt, raise the tip of the lever of buckle 2
to release it.
Fasten the belt along your body without twisting it. Adjust the
lengths of the belt on both the buckle and the tongue sides so that
the buckle is located at the mid-point of the front of your body.
Adjust the belt length in the following manner

To shorten the belt: Pull the free end of the belt on either the
buckle body or tongue side.
AE061720
To lengthen the belt: Pull the belt while holding it at a right angle
to the buckle or tongue.
AE061730
2-51
12. OPERATION
12.1.5 OPERATIONS AND CHECKS BEFORE STARTING

ENGINE
 WARNING
Before starting the engine, use a damp cloth to wipe off the dust
accumulated on the top surface of the battery or on the starting
motor and alternator.
1. Check that gearshift lever 1 is at the P position (parking brake

applied).
2. Lower the blade and ripper to the ground, and check that work
equipment control levers 2 are at the HOLD position.
3. Insert the key in starting switch 3, turn the key to the ON

position and check that all monitor lamps and warning lamps
light up for 3 seconds, and that the alarm buzzer sounds for 2
seconds.
1) The buzzer will sound for approx. 2 seconds, and the following
monitors and gauges will light up for approx. 3 seconds.
‡ Central warning lamp
‡ Parking breake pilot lamp
‡ Blade float pilot lamp
‡ Accumulator pilot lamp
‡ Differential control indicator pilot lamp
‡ Engine cooling water temperature gauge
‡ Fuel gauge
‡ Hydraulic oil level monitor
‡ Engine oil level monitor
‡ Radiator coolant level monitor
‡ Engine preheating monitor pilot lamp
‡ Final drive oil temperature monitor
‡ Engine oil pressure monitor
‡ Coolant temperature monitor
‡ Air pressure monitor
‡ Charge monitor
‡ Hydraulic oil temperature monitor
‡ Emergency steering
2-52
12. OPERATION
2) After approx. 3 seconds, the following gauges will remain on and

the other monitors will go out.
‡ Engine cooling water temperature gauge
‡ Fuel gauge
‡ Engine oil pressure monitor
‡ Charge monitor
When the engine starts, the engine oil pressure and battery
charge lamps go out.
REMARK
If the lamps do not light up, there is probably a failure or
disconnection in the monitor, so please contact your Komatsu
distributor for inspection.
4. Check if parking brake pilot lamp 4 on the machine monitor is

lighted up. If it is not lighted up, check if the gearshift lever is at
the P position. When starting the engine, if the parking brake is
not applied, the engine will not start.
A0061040
5. Press the horn switch 5 to check that the horn works.
6. Operate each lamp switch 6 to check that the lamps light up.
7. Operate each wiper switch 7 and check that the wiper and
washer equipment works properly.
2-53
12. OPERATION
12.2 STARTING ENGINE

12.2.1 NORMAL STARTING
 WARNING
Check that there are no persons or obstacles in the surrounding
area, then sound the horn and start the engine.
NOTICE
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine will not start, wait for at least 2 minutes before
trying to start the engine again.
1. Set fuel control lever 1 at the LOW IDLING position.
2. Insert the key into starting switch 2 and turn the key to the
START position. The engine will start.
3. When the engine starts, release the key in starting switch 2. The
key will return automatically to the ON position.
2-54
12. OPERATION
12.2.2 STARTING IN COLD WEATHER

 WARNING
‡ Check that there are no persons or obstacles in the surround-
ing area, then sound the horn and start the engine.
‡ Never use starting aid fluids as they may cause explosions.
NOTICE
Do not keep the starting motor rotating continuously for more
than 20 seconds.
If the engine fails to start, repeat steps 1 and 2 after waiting for
about 2 minutes.
When starting is low temperatures, do as follows.
1. Set fuel control lever 1 at the LOW IDLING position.
REMARK
Do not start the engine with the fuel control lever and accelerator
pedal at the FULL position.
2. Hold starting key 2 at the HEAT position until preheating

monitor 3 flashes.
If the preheating time is too short or too long, the engine will be
difficult to start, so always keep to the correct preheating time.
3. When preheating monitor 3 goes off, turn key 2 to the START

position to start the engine.
4. When the engine starts, turn key 2 to the ON position. When the
key is released, it will return automatically to ON.
2-55
12. OPERATION
12.3 OPERATIONS AND CHECKS AFTER

STARTING ENGINE
After starting the engine, do not immediately start operations.
First, carry out the following operations and checks.
NOTICE
Avoid abrupt acceleration until the warm-up run is completed.
Do not run the engine at low idling or high idling for more than
20 minutes.
If it is necessary to run the engine at idling, apply a load or run
at a medium speed from time to time.
1. Pull fuel control lever 1 to the center position between LOW

IDLING and HIGH IDLING and run the engine at medium speed
for about 5 minutes with no load.
2. After the warm-up run is completed, check gauges and caution

lamps for proper operation. If any abnormality is found, repair
it.
Continue to run the engine at light load until engine water
temperature gauge indicator 2 falls within the green range.
3. Check that there is no abnormal exhaust gas color, noise, or

vibration.
If any abnormality is found, repair it.
4. Watch air pressure gauge 3 and check that the air pressure rises
normally.
If the air pressure rises slowly, check the following.
When the pressure inside the air tank is 0, the time taken to fill
with air to a point where the indicator of the air pressure gauge
enters the green range is as follows.
Engine low idling: Approx. 3 min.
Engine high idling: Max. 1.5 min.
If the rise in pressure is too slow, contact your Komatsu distribu-
tor for inspection and repair.
2-56
12. OPERATION
12.4 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.
1. For general travel, raise the blade fully as shown in the diagram
on the right, and set so that the blade does not extend outside
the machine.
NOTICE
‡ Be careful of the clearance between the blade and front wheels.
If the blade is at a propulsion angle and the machine is articu-
lated, the blade may bend the steps.
‡ If the shank at the center of the ripper body is inserted from
above when the ripper is in the central position, it will interfere
with the cylinder, so move the ripper away from the center
position when installing the shank.
2. Insert the shank as shown in the diagram on the right.
3. Raise the ripper.
2-57
12. OPERATION
12.5 MOVING MACHINE

 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.
Clear all obstacles from the path of the machine.
Use extreme care when reversing the machine. Note there is
a blind spot behind the machine.
‡ If the air pressure is not normal, do not operate the machine.
‡ Before starting operations, check that the seat belt is properly
installed.
1. Check that warning pilot lamp 1 is not lighted up.
2. Depress inching pedal 2.
3. Operate gear shift lever 4 to the F (FORWARD) or R (REVERSE)

position, and set it at 1st speed or 2nd or 3rd speed.
 CAUTION
Do not try to start the machine with the transmission in 4th or
above.
4. Depress accelerator pedal 5 while releasing inching pedal 2,

and move the machine off.
2-58
12. OPERATION
12.6 SHIFTING GEAR

 WARNING
Do not shift gear suddenly when traveling at high speed.
Before shifting gear, apply the brake to reduce the travel speed.
NOTICE
When shifting gear, always shift one speed at a time.
Shift gear as follows.
12.6.1 ACCELERATION
Partially release the accelerator pedal 1 and shift the gear shift
lever 2 up to the next position.
12.6.2 DECELERATION
Release accelerator pedal 1 to reduce the travel speed, and
move gearshift lever 2 down to the next speed range.
Use the travel speeds in the table below as a guide when
reducing speed.
2-59
12. OPERATION
12.7 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.
 CAUTION
Always stop the machine when switching between FORWARD
and REVERSE.
1. Depress brake pedal 1 to reduce the travel speed, then depress

inching pedal 2 to stop the machine.
2. Operate gear shift lever 3 to the F (FORWARD) or R (REVERSE)

position, and set it at 1st or 2nd speed.
3. Depress accelerator pedal 4 while releasing inching pedal 2,

and move the machine off.
2-60
12. OPERATION
12.8 STOPPING MACHINE

 WARNING
‡ Avoid stopping suddenly. Give yourself ample room when
stopping.
‡ When stopping the machine, select flat hard ground and
avoid dangerous places.
If it is unavoidably necessary to park the machine on a slope,
place the safety lock lever in the LOCK position and insert
blocks underneath the tires. As an additional safety measure,
thrust the blade into the ground.
‡ If any control lever is touched by accident, the work equip-
ment may move suddenly, and this may lead to a serious
accident. Before leaving the operator’s seat, always operate
the safety lock lever to place it securely at the LOCK position.
1. Release accelerator pedal 1, then set fuel control lever 6 to the

low idling position.
 CAUTION
Applying the brakes with the fuel control lever still pulled
creates danger by increasing the stopping distance, and also
generates a large heat load on the brake clutch, which may lead
to deformation or damage of the clutch.
2. Depress brake pedal 2. Before the machine comes to a stop,

depress inching pedal 3.
3. Set gear shift lever 4 at the P position.
2-61
12. OPERATION
4. Press parking switch 5 to apply the parking brake.

Check that the lamp inside parking switch 5 lights up at the
same time.
A0061040
12.9 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 steer-
ing 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 circum-
stance.
If the engine stops, immediately apply the brake and stop the
machine in a safe place.
To turn the machine when traveling, turn steering wheel 1 in the

direction of the turn.
12.9.1 LEANING OPERATION

Operate leaning control lever 2 to change the angle of the front
tires as follows.
Pull BACK to lean to RIGHT.
Push FORWARD to lean to LEFT
When traveling forward and turning the machine, the radius of
the turn becomes smaller if the tires are leaned in the direction of
the turn.
When traveling in reverse and turning the machine, the radius
of the turn becomes smaller if the tires are leaned in the opposite
direction to the turn.
2-62
12. OPERATION
12.9.2 ARTICULATING OPERATION

 WARNING
Do not remove the lock pin for general travel.
NOTICE
When turning with the machine articulated, pay particular at-
tention to the clearance between the blade end and the wheel.
To carry out articulation operations, remove the lock pin on the

left side of the chassis.
The machine can be articulated up to a maximum of 25° to the
left or right, and the turning radius becomes 7.9 m (25 ft 11 in).
1. Stop the machine, remove pin 1, and insert it in the storage

position.
2. Operate articulate control lever as follows.

Pull BACK to articulate to LEFT.
Push FORWARD to articulate to 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.
2-63
12. OPERATION
12.10 OPERATING WORK EQUIPMENT
12.10.1 OPERATING BLADE

BLADE LIFT OPERATION
Operate left blade control lever 1 as follows.
Pull BACK to RAISE left end of blade
Push FORWARD to LOWER left end of blade
Operate right blade control lever 2 as follows.

Pull BACK to RAISE right end of blade
Push FORWARD to LOWER right end of blade
2-64
12. OPERATION
OPERATING BLADE SIDE SHIFT

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

Operate blade rotation control lever 4 as follows.
Pull BACK to rotate blade to RIGHT
Push FORWARD to rotate blade to LEFT
CHANGING BLADE CUTTING ANGLE

Operate power tilt control lever 5 as follows.
Pull BACK to make cutting angle SMALLER
Push FORWARD to make cutting angle LARGER
2-65
12. OPERATION
Use a larger cutting angle when cutting hard soil and a smaller
cutting angle when cutting soft soil.
The distance between the cutting surface and the blade edge can
be changed, so it is possible to carry out fine adjustment of the
height of the cutting surface.
12.10.2 OPERATING DRAWBAR SIDE SHIFT

Operate drawbar side-shift control lever 6 as follows.
Pull BACK to shift drawbar to RIGHT
Push FORWARD to shift drawbar to LEFT
12.10.3 OPERATING RIPPER

Operate ripper control lever 7 as follows.
Pull BACK to RAISE ripper
Push FORWARD to LOWER ripper
2-66
12. OPERATION
12.11 WORK WHICH CAN BE CARRIED OUT

USING A MOTOR GRADER
12.11.1 LEVELING GROUND TO RIGHT
1. Operate the drawbar side shift and move the circle approx. 200
mm (7.9 in) to the left.
2. Set the blade so that the earth is discharged outside the rear left
wheel.
3. Operate blade lift cylinder 2 so that the top of blade 1 is at the

desired digging position.
If only the blade cylinder is extended or retracted, the blade will
move slightly to the left or right. If necessary, adjust with
drawbar shift cylinder 3.
‡ Example of lift cylinder and drawbar shift cylinder extended a

suitable amount and lowered directly.
‡ When the drawbar shift cylinder is not extended and only the lift
cylinder is extended.
4. Lean the front wheels to the left.
REMARK
Leaning the wheels to the left prevents the machine from being
pushed to the right by the load acting on the left side of the machine.
2-67
12. OPERATION
5. Rotate so that the blade is at the optimum position for the soil.
(Be careful not to let the rear left wheel run over the windrow A
discharged from the blade.)
6. Operate the power tilt so that the top of the blade 1 is slightly
in front of the cutting edge, then start operation.
7. Spread fine crushed loose soil over the ground surface until it is
level.
REMARK
‡ Generally speaking, carry out operations on flat ground with the
frame straight to the blade. Articulate the frame to deal with the
force in the side direction caused by the load on the blade.
‡ If the tires start to spin, turn the blade to a greater angle to
reduce the digging width, thereby reducing the load on the
machine.
‡ In leveling operations, discharge the soil outside the rear wheels.
This makes it easier to steer with the rear wheels.
2-68
12. OPERATION
12.11.2 LEVELING GROUND TO LEFT

1. Operate the drawbar side shift and move the circle approx. 200
mm (7.9 in) to the right.
2. Set the blade so that the earth is discharged outside the rear
right wheel.
3. Operate the blade lift cylinder so that the blade is at the desired
digging depth, then set it horizontal.
4. Lean the front wheels to the right.
5. Carry out the operation in the same way as when leveling to the
right.
2-69
12. OPERATION
12.11.3 DIGGING RIGHT V-DITCHES

NOTICE
Drive straight forward without articulating the machine. If the
machine is articulated, the side of the tires will be pushed against
the back slope and this will cause damage to the side face of the
tires. In addition, it may cause mud to be pushed in between the tire
and rim, and may also cause leakage of air which will lead to flat
tires (the rounding of the tires will be lost and the surface will
become flat).
1. Align the right edge of the blade with the outside edge of the
front right tire.
2. Set the cutting angle at approx. 40°. Operate the power tilt so
that the top of the blade is slightly in front of the cutting edge.
3. Operate the left blade cylinder to raise the left edge of the blade.
(The right side of the blade determines the depth of the ditch.
The left side of the blade determines the shape of the ditch.)
4. Angle the blade so that a windrow is formed at the center of the

chassis.
5. Operate the right blade lift cylinder and dig the right edge of the
blade 50 – 100 mm (2.0 – 3.9 in) into the ground.
6. Lean the front wheels to the left.
7. Start the digging operation.

‡ The first digging pass acts as a guide for the 2nd and later
passes. (Cutting the guide groove.)
2-70
12. OPERATION
8. Set the machine with both the front and rear tires on the bottom
of the groove formed in the 1st digging pass, then continue the
digging operation until the ditch is the desired depth. (Heavy-
duty digging)
‡ Lean the front wheels so that they are perpendicular.
9. Before the rear wheels start to run over the windrow, move it
from the load shoulder and spread it.
2-71
12. OPERATION
12.11.4 DIGGING LEFT V-DITCHES

NOTICE
Drive straight forward without articulating the machine. If the
machine is articulated, the side of the tires will be pushed against
the back slope and this will cause damage to the side face of the
tires. In addition, it may cause mud to be pushed in between the tire
and rim, and may also cause leakage of air which will lead to flat
tires (the rounding of the tires will be lost and the surface will
become flat).
1. Align the left edge of the blade with the outside edge of the front
left tire.
2. Set the cutting angle at approx. 40°. Operate the power tilt so
that the top of the blade is slightly in front of the cutting edge.
3. Operate the right blade cylinder to raise the right edge of the
blade. (The left side of the blade determines the depth of the
ditch. The right side of the blade determines the shape of the
ditch.)
4. Angle the blade so that a windrow is formed at the center of the

chassis.
5. Operate the left blade lift cylinder and dig the left edge of the
blade 50 – 100 mm (2.0 – 3.9 in) into the ground.
6. Lean the front wheels to the right.
7. Start the digging operation.

‡ The first digging pass acts as a guide for the 2nd and later
passes. (Cutting the guide groove.)
2-72
12. OPERATION
8. Set the machine with both the front and rear tires on the bottom
of the groove formed in the 1st digging pass, then continue the
digging operation until the ditch is the desired depth. (Heavy-
duty digging)
‡ Lean the front wheels so that they are perpendicular.
9. Before the rear wheels start to run over the windrow, move it
from the load shoulder and spread it.
2-73
12. OPERATION
12.11.5 RIGHT DITCH FINISHING

1. Set the right side of the blade behind the front right wheel.
2. Operate the right blade lift cylinder and set the blade to the depth
of the ditch.
3. Be careful not to let the rear left wheel run over windrow A
formed by the blade.
Operate the blade lift cylinder and blade rotation to set so that
the windrow is pushed to the outside of the rear left wheel.
4. Lean the front wheels slightly to the left.
5. Move the earth piled up on the road shoulder away from the
ditch and spread it.
2-74
12. OPERATION
12.11.6 LEFT DITCH FINISHING

1. Set the left side of the blade behind the front left wheel.
2. Operate the left blade lift cylinder and set the blade to the depth
of the ditch.
3. Be careful not to let the rear right wheel run over the windrow
discharged from the blade.
Operate the blade lift cylinder and blade rotation to set the blade
in position.
4. Lean the front wheels slightly to the right.
5. To push out the soil to the top of the slope face and the road
AE156110
shoulder, a separate pass is needed. Spread the soil, then carry
out final finishing with the grader.
2-75
12. OPERATION
12.11.7 FINISHING RIGHT ROAD SHOULDER

1. Move the drawbar to the right.
2. Move the right edge of the blade to the outside of the front right
wheel and adjust (reduce) the propulsion angle so that the
windrow comes between the rear wheels (chassis).
3. Adjust the blade height to move the windrow to the center of the
road.
Set the position of the machine as follows.
1) If the road shoulder is hard, travel with the wheels on either
side of the windrow at the road edge to process it. (Spread-
ing posture)
2) If the road shoulder is soft, use the extreme side reach
posture to process it. (Shoulder reach posture)
‡ Be careful not to let the rear wheels run over the windrow.
4. Spread the windrow from the road shoulder to the center of the
road.
‡ Make the propulsion angle as large as possible to push the
windrow to one side.
‡ Set the digging angle to the maximum.
‡ For the finishing operation, travel at a speed of 2 – 6 km/h.
2-76
12. OPERATION
12.11.8 FINISHING LEFT ROAD SHOULDER

1. Move the drawbar to the left.
2. Move the left edge of the blade to the outside of the front left
wheel and adjust (reduce) the propulsion angle so that the
windrow comes between the rear wheels (chassis).
3. Adjust the blade height to move the windrow to the center of the
road.
Set the position of the machine as follows.
1) If the road shoulder is hard, travel with the wheels on either
side of the windrow at the road edge to process it. (Spread-
ing posture)
2) If the road shoulder is soft, use the extreme side reach
posture to process it. (Shoulder reach posture)
4. Spread the windrow from the road shoulder to the center of the
road.
‡ Make the propulsion angle as large as possible to push the
windrow to one side.
‡ Set the digging angle to the maximum.
‡ For the finishing operation, travel at a speed of 2 – 6 km/h.
2-77
12. OPERATION
12.11.9 CONSTRUCTING ROAD – METHOD OF

MAKING V-DITCH
1. Set the blade to the ditch-digging posture, and carry out digging
to a maximum digging depth of approx. 10 cm to make a line
along the stakes erected as the planned line for the ditch (mark-
ing cut).
2. Set the front and rear wheels in the groove made by the marking
cut, open the blade slightly, and dig the blade deep to cut along
the line of stakes. When doing this, set the blade so that the
windrow is formed between the rear wheels.
3. Normally, a ditch is dug on both sides, so do a U-turn and

continue to carry out the operation driving forward. When mak-
ing comparatively short ditches on one side only, operations are
carried out in reverse, but carry out the main digging traveling
forward at least one time to form the basic shape of the ditch
before traveling in reverse.
4. Move the windrow formed on the road shoulder and spread it

from the road shoulder to the center of the road. If the road
shoulder is comparatively hard, travel with the wheels on either
side of the windrow at the road shoulder to process it. If the road
shoulder is soft, use the shoulder reach posture to process it.
5. To cut the outside slope of the ditch to the determined grade, use
the bank-cut posture. Align the blade with the grade of the slope
and set so that the rear end of the blade is at the bottom of the
ditch slope.
2-78
12. OPERATION
The order shown in the diagram is the procedure for one side.
Repeat the same procedure to carry out the operation on the
opposite side of the road.
When carrying out Steps 4 and 7, articulate the machine.
1. Line of ditch: Light-duty digging

‡ Determine the line of the ditch along the measured points.
Depth: 30 – 50 mm (1.2 – 2.0 in)
Travel speed: 0.5 km/h (0.3 MPH)
AE156160
2. Second digging pass: Heavy-duty digging
AE156170
3. Third digging pass: Heavy-duty digging
AE156180
4. Finishing road shoulder
AE156190
5. Leveling center
AE156200
2-79
12. OPERATION
6. Fourth digging pass: Heavy-duty digging
AE156210
AE156220
8. Spreading to center
AE156230
9. Slope face and bank
AE156240
10. Finishing bottom of ditch
AE156250
11. Ditch digging pass (finishing and shaping inside of the slope
face)
AE156260
2-80
12. OPERATION
12. Finishing slope face
AE156270
AE156280
14. Leveling and finishing
AE156290
2-81
12. OPERATION
12.11.10 FLAT-BOTTOMED DITCH

When there is no V-ditch, make a V-ditch at the depth of the flat-
bottomed ditch.
The slope face of the road shoulder must be flatter than normal.
1. Operate the power tilt and angle the blade to the front.
2. Operate the drawbar shift cylinder and set the circle fully to the
left of the machine.
3. Place the front right tire in the bottom of the V-ditch.
4. Set the blade so that the right edge of the blade comes to the
inside of the front right tire at the width of the flat-bottomed
ditch.
5. Operate the right blade lift cylinder to lower the right end of the
blade, and set it to the digging depth.
6. Operate the left blade lift cylinder to raise the right end of the
blade, and set it to the desired angle for the slope face of the road
shoulder.
7. Lean the front wheels to the left. Dig the No. 2 V-ditch to the
same depth or slightly deeper than the No. 1 ditch.
8. Dig the flat bottom. Set the right blade lift cylinder to the desired
depth.
9. Operate the left blade lift cylinder as required.
2-82
12. OPERATION
10. Set the front right tire at the bottom of the first V-ditch and start
the operation.
11. Set the right edge of the blade at the bottom of the slope.
12. Lower the right blade lift cylinder so that the tip of the blade is
the set precision for the ditch.
13. Lower the left lift cylinder to the desired digging depth. Lean the
front wheels to the left.
14. Set the blade at an acute angle and push up the soil to the top
of the ditch slope.
15. Spread the windrow and finish to the final precision.
2-83
12. OPERATION
12.11.11 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.
AE156380
2. Dig the width and depth of the bottom of the ditch with the left
ditching method.
AE156390
3. Finish the road shoulder.
AE156400
4. Spread the soil to the center.
AE156410
5. Finish the slope face on the bank.
AE156420
2-84
12. OPERATION
6. Make the bottom of the ditch flat.
AE156430
7. Finish the ditch.
AE156440
8. Finish the slope face on the inside.
AE156450
9. Finish the road shoulder.
AE156460
10. Carry out leveling and finishing.
AE156470
2-85
12. OPERATION
12.11.12 FINISHING WITH GRADER FOR DITCHES

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

 WARNING
‡ When operating on slopes where the machine may slip to the
side, make sure that you understand the operation of the
machine completely.
‡ Do not articulate the machine fully on steep slopes.
‡ On steep slopes, lower the engine speed and operate in 1st
gear.
‡ When operating on slopes, use the accelerator to control the
machine speed.
2-86
12. OPERATION
12.11.14 BANK CUTTING METHOD - RIGHT SIDE

 WARNING
Lower the blade to the ground before removing the bank control
lock pin.
1. The roadbed where the foundation is to be dug must be uniform.
2. If the soil is hard, angle the roadbed slightly towards the bank
to prevent the machine from sliding to the side away from the
bank.
3. Operate the blade shift cylinder and shift the blade to the right.
4. Operate the drawbar shift cylinder and shift the drawbar to the
right.
5. Rotate the circle and set the end of the blade at the side of the
front right wheel.
6. With the work equipment in this position, lower the blade so that
it is lightly in contact with the ground.
7. Move the bank switch from the LOCK position to the RETRACT
position, then remove the lock pin from the lifter.
8. Extend the right blade lift cylinder, retract the left blade lift
cylinder, and rotate the lifter guide to the left.
2-87
12. OPERATION
9. When the lifter has rotated, move the bank switch from the
RETRACT position to the INDEX position.
10. Operate the lifter to the specified position, then insert the lifter
guide pin.
11. When the lifter guide is at the specified position, move the bank
switch from the INDEX position to the LOCK position.
12. Retract the right lift cylinder and extend the left lift cylinder to set
the blade to the bank slope position.
13. Rotate the circle to the right.
14. While rotating the circle, extend or retract the left and right blade
lift cylinders to set to the posture for the bank slope face.
15. Angle the blade at 3/4 to the front from the high bank position
to set to the low bank posture.
2-88
12. OPERATION
16. Extend the left blade lift cylinder, set the tip of the left cutting
edge of the blade in line with the outside of the rear wheels at
the bottom of the slope face.
17. The rear right wheel must be in the V at the base of the slope
face.
18. Extend the right blade lift cylinder and set the angle to the
desired bank slope face.
19. Gradually progress with the cutting.
REMARK
The wheels should normally be almost perpendicular.
20. If the digging is comparatively heavy duty, angle the wheels

towards the slope face.
21. If the digging is comparatively light duty, angle the wheels away
from the slope face.
Discharge the soil from the slope face to the outside of the rear
wheels.
REMARK
The procedure in the diagrams is for the right side. For the left
side, set the blade in the opposite position.
2-89
12. OPERATION
12.11.15 EXTREME SIDE REACH

 WARNING
Lower the blade to the ground before removing the bank control
lock pin.
1. Lower the blade so that it is lightly in contact with the ground.
2. Move the bank switch from the LOCK position to the RETRACT
position, then remove the lock pin from the lifter.
3. Extend the right blade lift cylinder, retract the left blade lift
cylinder, and rotate the lifter guide to the left.
4. When the lifter has rotated, move the bank switch from the
RETRACT position to the INDEX position.
5. Operate the lifter to the specified position (match mark), then

insert the lifter guide pin.
6. When the lifter guide is at the specified position, move the bank
switch from the INDEX position to the LOCK position.
2-90
12. OPERATION
7. Shift the blade to the side as shown in the diagram.

‡ Shift the blade fully to the right
‡ Shift the drawbar fully to the right
‡ Set the blade propulsion angle to approx. 60°
8. Lower the blade to the desired depth, then set the blade at an
angle to discharge the soil to the side.
2-91
12. OPERATION
12.11.16 RIPPER OPERATIONS - WITH FRAME

STRAIGHT
 WARNING
When using the ripper, set the frame straight.
For heavy-duty conditions, use 1 to 3 shanks.
For general soil condition, use 3 to 5 shanks.
Keep the ripper at a depth where there is no tire slip and where
the engine horsepower can be used to its full.
Travel in a straight line at approx. 2 – 4 km/h, and gradually insert

the points into the ground.
On slopes, carry out ripping downhill to use the weight of the

machine.
NOTICE
To prevent damage, raise the ripper from the ground before
turning the machine.
Carry out cross ripping only when there is a special purpose.
When breaking up a paved surface, raise the ripper after digging

up the ground under the surface.
2-92
12. OPERATION
12.12 PRECAUTIONS FOR OPERATION

12.12.1 PRECAUTIONS WHEN TRAVELING UP OR
DOWNHILLS
 WARNING
‡ Do not shift gear or place the transmission in neutral when
going downhill. The braking effect of the engine cannot be
used, so this is dangerous. Always keep the gear shift lever
in a travel position when going downhill.
‡ Failure to do this may result in engine overrun and damage
to the engine or transmission.
To prevent engine overrun, always shift down one gear at a
time.
Traveling downhill
When traveling downhill, select the same gear range as when
traveling uphill, and make full use of the engine to reduce the travel
speed.
If the machine still travels too fast, use the foot brake also to slow
it down.
When engine stops

 CAUTION
If the engine stops, the brake booster will not work, so the
operating effort of the pedal will become heavier and the effect
of the brake will become lower even when the pedal is de-
pressed with the same force.
If the engine stops on a slope, immediately depress the brake

pedal fully to stop the machine, then move the gear shift lever to the
N position and start the engine again.
12.12.2 PRECAUTIONS WHEN USING INCHING PEDAL

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

TRANSMISSION
Pay careful attention to the following points to protect the engine
and transmission.
Precautions when moving machine off

‡ Check that the central warning lamp on the instrument panel is
not flashing.
‡ Depress the inching pedal, place the gearshift lever at 1, 2, or 3
in F or R, then release the inching pedal slowly to move the
machine off. Moving the machine off suddenly will cause
damage to the transmission.
2-93
12. OPERATION
Precautions when shifting gear

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

speed in each speed range.
Precautions when traveling downhill

‡ If the inching pedal is operated when traveling downhill, the flow
of lubricating oil in the engine and transmission will drop, and
this will lead to internal wear. To prevent this, the caution lamp
on the instrument panel or the alarm buzzer may be actuated. If
the caution lamp or alarm buzzer are actuated, release the
inching pedal immediately.
‡ If the transmission is shifted down when traveling downhill, the
engine and transmission may overrun, and this will cause dam-
age to the engine and transmission. To prevent this, the caution
lamp on the instrument panel or the alarm buzzer may be
actuated. If the caution lamp or alarm buzzer are actuated,
depress the brake immediately.
‡ It is extremely dangerous to set the gearshift lever to the N
position when traveling downhill, because the engine cannot be
used as a brake. In addition, if the machine travels with the
gearshift lever at the N position, the flow of lubricating oil in the
transmission will drop, and this will lead to internal wear.
2-94
12. OPERATION
12.12.4 PRECAUTIONS WHEN USING ARTICULATED

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

EQUIPMENT
When operating the work equipment control lever, always pay
careful attention to the movement of the work equipment and do not
move it more than necessary as the work equipment or the hydraulic
cylinder may hit and damage other parts.
When the work equipment is operated, special attention should

be given to avoiding contact between the following parts.
‡ Front wheel and blade

‡ Rear wheel and blade
‡ Blade and step
12.12.6 PERMISSIBLE WATER DEPTH

When crossing rivers, do not operate the machine in places
where the water is above the permissible depth (up to the bottom
face of the tandem case).
Raise the work equipment (blade, ripper) to the maximum height.
After crossing the river, check the effect of the brakes, and if
necessary clean or dry them.
Wash the work equipment carefully and carry out greasing
thoroughly for greasing points that went under water.
2-95
12. OPERATION
12.13 ADJUSTING WORK EQUIPMENT POSTURE

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

The angle between the blade and the center line of the machine
body is called the blade propulsion angle.
Set the blade propulsion angle to about 60° for general cutting
work, but set it narrower in the following cases.
1) When the cutting resistance is high.

2) When the soil is hard.
3) When the soil accumulated in front of the blade dose not flow
smoothly.
2-96
12. OPERATION
12.14 PARKING MACHINE

 WARNING
‡ Avoid stopping suddenly. Give yourself ample room when
stopping.
‡ When stopping the machine, select flat hard ground and
avoid dangerous places. If it is unavoidably necessary to park
the machine on a slope, place the safety lock lever in the
LOCK position and insert blocks underneath the tires. As an
additional safety measure, thrust the blade into the ground.
‡ If any control lever is touched by accident, the work equip-
ment may move suddenly, and this may lead to a serious
accident. Before leaving the operator’s seat, always operate
the safety lock lever to place it securely at the LOCK position.
1. Release accelerator pedal 1.
2. Depress brake pedal 2. Before the machine comes to a stop,

depress inching pedal 3.
3. Set gear shift lever 4 at the P position.
2-97
12. OPERATION
4. Press parking switch 5 to apply the parking brake.

Check that the lamp inside parking switch 5 lights up at the
same time.
A0061040
5. Operate the work equipment control lever, and lower the blade
and scarifier to the ground.
12.15 CHECK AFTER FINISHING WORK

Check the gauges and caution lamps for engine water tempera-
ture, engine oil pressure and fuel level.
In particular, if the engine has overheated, do not abruptly stop
it but run it at medium speed to allow it to cool gradually, then stop
it.
2-98
12. OPERATION
12.16 STOPPING ENGINE

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

1. Walk around the machine and check the work equipment,
paintwork, and undercarriage, and check also for leakage of oil
or water.
2. Fill the fuel tank.
3. Check the engine compartment for paper and debris. Clean out
any paper and debris to avoid a fire hazard.
4. Remove any mud stuck to the undercarriage.
5. Depress the brake pedal several times, and drain the water from
the drain valve.
2-99
12. OPERATION
12.18 LOCKING
Always lock the following place.
1 Fuel filler cap
2 Engine side cover
3 Cab door
4 Hydraulic oil filler cap
5 Radiator water filler cap
REMARK
The starting switch key is also used for these locks.
12.19 HANDLING THE TIRES

12.19.1 PRECAUTIONS WHEN HANDLING TIRES
If a tire or a rim is handled wrongly, the tire may burst or may
be broken and the rim may be broken and scattered, and that can
cause serious injury and death.
To maintain safety, always observe the following items.

‡ Since maintenance, disassembly, repair and assembly of the
tires and rims require special equipment and technology, be sure
to ask them for a tire repair shop.
‡ Use only the specified tires and inflate them to the specified
pressure.
Selection of tires, See “24.2.11 SELECTION AND INSPECTION OF
TIRES”.
‡ When inflating a tire, check that any person will not enter the
working area and use an air chuck which has a clip and which
can be fixed to the air valve.
While inflating the tire, check the inflation pressure occasionally

so that it will not rise too high.
If the rim is not fitted normally, it may be broken and scattered

while the tire is inflated. Accordingly, place a guard around the tire
and do not work in front of the rim but work on the tread side of the
tire.
‡ Abnormal drop of inflation pressure and abnormal fitting of the

rim indicate a trouble in the trouble or rim. In such cases, be sure
to ask a tire repair shop for repair.
‡ Do not adjust the inflation pressure of the tires just after high-
speed travel or heavy-load work.
‡ Do not heat or weld a rim to which the tire is installed. Do not

make a fire near the tire.
2-100
12. OPERATION
12.20 HANDLING BLADE ACCUMULATOR

12.20.1 OPERATION
 WARNING
The accumulator is charged with high-pressure nitrogen gas, so
it is extremely dangerous if handled incorrectly. Always obey
the following rules strictly.
‡ Never make a hole in the accumulator or bring it does to any
flame or fire.
‡ Do not weld any boss to the accumulator.
‡ When discarding the accumulator, the gas must be released,
so contact your Komatsu distributor.
1. Lower the blade to the ground and stop the engine.
2. Turn starting switch 1 to the ON position to supply power to the

electric circuits, then turn on accumulator switch 2. Next, move
the right and left blade lift levers forward and backward to
release the residual pressure in the accumulator and the hydrau-
lic circuits.
3. Turn off accumulator switch 2, then start the engine.
4. Next, extend the right and left blade lift cylinders about 50 mm
(2 in).
At this time, holding pressure is produced at the bottom of the
blade lift cylinders.
5. Turn on the accumulator switch to operate the accumulator. The

oil in the bottom of the right and left blade lift cylinders will flow
into the accumulator, both blade lift cylinders will retract, and
the front wheels will lower to the ground.
2-101
12. OPERATION
REMARK
‡ At this time, a pressure is maintained at the bottom of the blade
lift cylinders, that is, a pressure acts on the blade. When the
machine is operated under this condition, the blade can follow
a difference in ground level of about 150 mm (5.9 in), which is
the standard operation when an accumulator is in use.
‡ In actual operation, the blade lift cylinder levers will move
properly so that the blade can follow the required difference in
ground level with the proper pressing force.
‡ Once the accumulator is set and the machine is started, the blade
lift levers do not need to be operated. When stopping the work
for a time, the accumulator can be reset to the same condition
as before stopping the work by turning off the switch, lifting the
blade, lowering it to the ground again, and turning on the switch
again.
12.20.2 FEATURES OF THE BLADE ACCUMULATOR

Ease of work
‡ The blade does not need to be operated.
‡ This work does not require a lot of skill.
Safety and protection

‡ Shocks are reduced.
‡ The machine is protected from buried objects. (The machine
runs over projecting objects.)
‡ The work equipment is protected (the impact load is reduced).
Improved steering performance

‡ Steering performance on curves is improved.
‡ Side slips on curves are reduced.
‡ Steering performance with the leaning system is improved.
‡ Side slips made while using the leaning system are reduced.
‡ Trouble with front wheels (floating or unstable wheels) is elimi-
nated.
Improved workability
‡ The pressing force of the blade is improved.
‡ The relief of the blade is improved.
2-102
12. OPERATION
12.21 HANDLING BLADE FLOAT

12.21.1 OPERATION
 WARNING
If the blade float switch is turned ON when the blade is raised,
the pressure will be released from the left cylinder and the blade
will fall suddenly. Never allow anyone near the machine when
turning the blade float switch ON.
1. Lower the blade to the ground and stop the engine.
2. Turn starting switch 1 ON (electric current flows through the

circuit), then set the blade lift control lever to the HOLD position
and turn blade float switch 2 ON. In this condition, the pressure
is released from the head and bottom ends of the blade lift
cylinder, so the blade is placed in the float condition.
3. If the blade lift control lever is operated to the RAISE position

when blade float switch 2 is ON, the blade will rise, and if it is
operated to the LOWER position, the blade will go down.
4. If the blade lift control lever is returned to the HOLD position

when the blade is raised or lowered, the pressure in the lift
cylinder will be released and the blade will suddenly drop to the
ground.
REMARK
When the starting switch is ON (current flowing through the
circuit), it is possible to switch the float condition at any time by
operating the blade float switch ON/OFF.
2-103
12. OPERATION
12.21.2 FEATURES OF BLADE FLOAT

Ease of operation
‡ Unnecessary to operate blade
‡ Operating skill not needed (need is reduced)
Safety, protection
‡ Shock reduced
‡ Buried object protected )blade moves away when mounting
projecting objects)
‡ The work equipment is protected (the impact load is reduced).
Improvement in ease of steering

‡ Easy steering when operating on curves
‡ Reduced side slippage when operating on curves
‡ Easy steering when using leaning
‡ Reduced side slippage when using leaning
‡ No loss of control of front wheels (front wheels floating, safety)
Improvement in ease operation

‡ Good blade pushing
‡ Good blade escape
‡ Priority system for lever control
2-104
13. TRANSPORTATION
When transporting the machine, observe all related laws and

regulations, and be careful to ensure safety.
13.1 LOADING, UNLOADING WORK

 WARNING
‡ Make sure the ramp has sufficient width, length and thick-
ness to enable the machine to be safely loaded and unloaded.
‡ When loading and unloading the machine, park the trailer on
a flat firm roadbed. Keep a fairly long distance between the
road shoulder and the machine.
‡ Remove the mud from the undercarriage to prevent the
machine from slipping to the side on slopes.
Be sure the ramp surface is clean and free of grease, oil, ice
and loose materials.
‡ Never change the direction of travel when on the ramps. If it
is necessary to change direction, drive off the ramps and
correct the direction, then drive on to the ramps again.
‡ Do not install the shank in the center of the ripper body with
the point facing to the front. In this position, there is danger
that the shank will break the ripper cylinder.
When loading or unloading, always use ramps or a platform and

carry out the operations as follows.
1. Insert the shank as shown in the diagram on the right.

Do not insert the shank in the center of the ripper body.
2. Properly apply the brakes on the trailer and insert blocks beneath
the tires to ensure that it does not move. Then fix the ramps in
line with the centers of the trailer and the machine.
If the ramp sags appreciably, reinforce it with blocks, etc.
3. Determine the direction of the ramps, then slowly load or unload

the machine.
4. Load the machine correctly in the specified position on the

trailer.
2-105
13. TRANSPORTATION
13.2 PRECAUTIONS FOR LOADING

After loading to the specified position, secure the machine as
follows.
1. Lower the work equipment carefully.
2. Set the gear shift lever at the N position.
3. Turn the starting switch to the OFF position, and stop the engine,
then remove the key.
4. When transporting the machine, place wooden blocks under-

neath the front and rear tires to prevent the machine from
moving about.
Also, hold it down with chairs or rope.
5. Always retract the car radio antenna.
13.3 PRECAUTIONS FOR TRANSPORTATION

 WARNING
Determine the route for transporting the machine by taking into
account the width, height and weight of the machine.
Obey all state and local laws governing the weight, width and
length of a load. Observe all regulations governing wide loads.
2-106
14. COLD WEATHER OPERATION
14.1 PRECAUTIONS FOR LOW TEMPERATURE

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

Change to fuel and oil with low viscosity for all components. For
details of the specified viscosity, see “20. USE OF FUEL, COOLANT
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”
14.1.2 COOLANT
 WARNING
Keep antifreeze fluid away from open flames. Never smoke
when using antifreeze.
NOTICE
Never use methanol, ethanol or propanol based antifreeze.
Where no permanent antifreeze is available, an ethylene glycol

antifreeze without corrosion inhibitor may be used only for the cold
season. In this case, clean the cooling system twice a year (in spring
and autumn). When refilling the cooling system, add antifreeze in
autumn, but do not add any in spring.
Absolutely avoid using any water leak preventing agent irrespec-
tive of whether it is used independently or mixed with an antifreeze.
Do not mix one antifreeze with a different brand.
For details of the antifreeze mixture when changing the coolant,
see “24.2 WHEN REQUIRED”.
Use a Permanent Antifreeze (ethylene glycol mixed with corro-
sion inhibitor, antifoam agent, etc.) meeting the standard require-
ments as shown below. With permanent antifreeze, no change of
coolant is required for a year. If it is doubtful that an available
antifreeze meets the standard requirements, ask the supplier of that
antifreeze for information.
Standard requirements for permanent antifreeze.
‡ SAE ......................................................................................... J1034
‡ FEDERAL STANDARD ..................................................... O-A-548D
2-107
14.1.3 BATTERY
 WARNING
‡ To avoid gas explosions, do not bring fire or sparks near the
battery.
‡ Battery electrolyte is dangerous. If it gets in your eyes or on
your skin, wash it off with large amounts of water, and
consult a doctor.
When the ambient temperature drops, the capacity of the battery

will also drop. If the battery charge ratio is low, the battery electro-
lyte may freeze. Maintain the battery charge as close as possible to
100%, and insulate it against cold temperature so
that the machine can be started easily the next morning.
Measure the specific gravity and calculate the rate of charge

from the following conversion table.
Temp.
of fluid
20°C 0°C –10°C –20°C
Rate of
charge
100% 1.28 1.29 1.30 1.31

90% 1.26 1.27 1.28 1.29
80% 1.24 1.25 1.26 1.27
75% 1.23 1.24 1.25 1.26
2-108
14.2 CAUTIONS AFTER COMPLETION OF WORK

To prevent mud, water, or the undercarriage from freezing and
making it impossible for the machine to move on the following
morning, always observe the following precautions.
‡ Mud and water on the machine body should be completely

removed. This is to prevent damage to the seal caused by mud
or dirt getting inside the seal with drops of water.
‡ Park the machine on concrete or hard ground. If this is impos-

sible, park the machine on wooden boards.
‡ Open the drain valve and drain any water collected in the fuel
system to prevent it from freezing.
‡ As the battery capacity drops markedly in low temperatures,

cover the battery or remove it from the machine, keep it in a
warm place, and install it again the next morning.
14.3 AFTER COLD WEATHER

When season changes and the weather becomes warmer, do as
follows.
‡ Replace the fuel and oil for all parts with oil of the viscosity
specified.
For details, see “20. USE OF FUEL, COOLANT AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE”.
‡ If for any reason permanent antifreeze cannot be used, and an

ethyl glycol base antifreeze (winter, one season type) is used
instead, or if no antifreeze is used, drain the cooling system
completely, then clean out the inside of the cooling system
thoroughly, and fill with fresh water.
2-109
15. LONG-TERM STORAGE
15.1 BEFORE STORAGE

When putting the machine in storage for more than one month,
do as follows.
‡ After every part is washed and dried, house the machine in a dry
building. Never leave it outdoors.
In case it is indispensable to leave it outdoors, park the machine
on the flat ground and cover it with canvas etc.
‡ Completely fill the fuel tank, lubricate and change the oil before
storage.
‡ Apply a thin coat of grease to metal surface of the hydraulic

piston rods and the idler adjusting rods.
‡ Disconnect the negative terminals of the battery and cover it, or

remove it from the machine and store it separately.
‡ If the ambient temperature is expected to drop below 0°C,

always add antifreeze to the cooling water.
‡ Place gear shift levers at the neutral position, operate the safety
lock lever to the LOCK position. Pull the parking brake lever to
apply the parking brake.
‡ Fit a block under the center of the front wheel and the tandem
case, jack up the tires from the ground, then put a block under
the blade and lower it on top of the block.
15.2 DURING STORAGE

 WARNING
If it is unavoidably necessary to carry out the rust-preventive
operation while the machine is indoors, open the doors and
windows to improve ventilation and prevent gas poisoning.
‡ Operate the engine and move the machine for a short distance
once a month so that a new film of oil will be coated over
movable parts and component surfaces. At the same time, also
charge the battery.
‡ Before operating the work equipment, wipe off the grease on the
hydraulic piston rod.
15.3 AFTER STORAGE

NOTICE
If the machine is stored without carrying out the monthly rust
prevention operation, request your Komatsu distributor for service.
Carry out the following procedure when taking the machine out
of long-term storage.
‡ Wipe off the grease from the hydraulic cylinder rods.
‡ Add oil and grease to all places.
2-110
16. TROUBLESHOOTING
16.1 AFTER RUNNING OUT OF FUEL

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

1. Loosen air bleed plug 1.
2. Loosen the knob of feed pump 2 and move it up and down to

let the fuel flow out of air bleed plug 1 until bubbles do not
comes out any more.
3. Tighten air bleed plug 1, and push in and tighten the knob of
feed pump 2.
16.2 WHEN LEANING PIPING IS DAMAGED

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

repair.
16.2.1 HOW TO USE LEANING STOPPER

Fix the leaning rod 2 to the front axle using the bolts 1 provided
in the tool box.
2-111
16. TROUBLESHOOTING
16.3 TOWING THE MACHINE

 WARNING
‡ If the machine is towed in the wrong way, it may lead to
personal injury or death.
‡ If there is a failure in the air circuit, the brakes cannot be used,
so be extremely careful when towing.
NOTICE
‡ Towing is for moving the machine to a place where inspection
and maintenance can be carried out, and not for moving it long
distances.
The machine must not be towed for long distances.
‡ For details of the procedure for towing a machine when it has
broken down, please contact your Komatsu distributor.
16.3.1 WHEN ENGINE CAN BE USED

‡ Always keep the engine running when towing the machine, so
that the steering and braking can be used.
16.3.2 WHEN ENGINE CANNOT BE USED

‡ When towing a disabled machine the distance should be within
600 m (2 ft) at a speed of 8 km/h (5.0 MPH) or less.
‡ If the distance is more than the above mentioned, or if more than
one day has elapsed since the engine trouble, be sure to use a
trailer for transportation.
NOTICE
If the machine is towed without the engine running, no lubrica-
tion oil will be supplied to the transmission. The gears and bearings
are rotated, so this may cause them to be damaged.
Tow the machine properly according to the instructions given

below.
The explanation given here is only to be used for a machine that

has failed and is to be moved to a safe place for repairs. It must be
moved a maximum of 600 m (2 ft) and at a maximum speed of 8 km/h
(5.0 MPH). This procedure is only for emergency purposes. If the
machine must be moved a long distance, use a transporter.
To protect the operator if the towing rope or bar should break,

install a protector plate to the machine being towed.
If it is impossible to use the steering or brakes on the machine

being towed, do not have anyone sitting in the operator’s seat.
2-112
16. TROUBLESHOOTING
Before towing, check that the tow rope or bar are in good
condition, and that they have ample strength for the towing opera-
tion. If the machine being towed may get stuck in mud or may have
to be towed uphill, the tow rope or bar must be of a strength of at
least 1.5 times greater than the weight of the machine being towed.
Keep the angle of the towing line to the minimum. Operate the
machine so that the angle does not become greater than 30° from
the straight line.
If the machine is moved suddenly, the tow rope or bar will be

subjected to an excessive load, and it may break. Start the machine
gradually and travel at a constant speed.
Normally, use a towing machine of about the same capacity as

the machine being towed. The towing machine must have ample
brake capacity, weight, and rimpull. Check that both machines can
be controlled on slopes and on the tow road.
When moving a failed machine on a downhill slope, a larger

towing machine must be used to ensure ample control and braking
power. Another method is to use a second towing machine at the
rear of the failed machine. In this way, it is possible to prevent the
failed machine from going out of control and turning over.
It is impossible to determine the drawbar pull needed for various

conditions. The minimum drawbar pull may be sufficient on horizon-
tal, 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.
2-113
16. TROUBLESHOOTING
16.3.3 RELEASING PARKING BRAKE

 WARNING
Stop the machine on a flat surface when releasing the parking
brake, and check that the surroundings are safe. In emergencies
or when the parking brake must be released on a hill, block the
tires carefully before releasing the brake.
If the pressure in the air tank drops below 2.4 kg/cm2, the parking
brake is applied automatically. Therefore, when towing the machine,
release the parking brake as follows.
‡ Turn bolt 1 and the parking brake will be released.
Towing machine without emergency steering

 WARNING
When the engine is stopped, it is impossible to steer the
machine, and this may lead to personal injury. If the engine
should stop during operations, immediately apply the service
brake and stop the machine.
The standard steering works only when the engine is running.
Towing machines with emergency steering

 WARNING
Never operate the electrical motor for the emergency steering
for more than 30 seconds.
If the machine battery cells are not functioning, the emergency
steering cannot display its capacity.
This mechanism works to prevent steering failure caused by a

breakdown of the engine or hydraulic pump while the machine is
being operated.
If the oil pressure in the steering hydraulic circuit drops below
(0.69 MPa (7 kgf/cm2, 99.4 PSI), the hydraulic switch is turned on, and
the electrical motor is actuated to turn the hydraulic pump and
enable steering to be carried out.
If the machine is traveling at a speed of less than 1 km/h, or if

the machine is stopped, the emergency steering device automati-
cally stops.
2-114
16. TROUBLESHOOTING
REMARK
If it is necessary to release the parking brake, use the procedure
given in “RELEASING PARKING BRAKE”.
Use the emergency steering only to correct the steering.
Keep the AUTO/MANUAL selector switch at the MANUAL posi-

tion.
After correcting the steering, release the switch. The switch will
return to the AUTO position.
2-115
16. TROUBLESHOOTING
16.4 IF BATTERY IS DISCHARGED When removing, disconnect

the cable from the ground
 WARNING terminal first.
‡ When checking or handling the battery, stop the engine and
turn the starting key to the OFF position before starting. q w
‡ Before starting the engine, use a damp cloth to wipe off the
dust accumulated on the top surface of the battery or on the
starting motor and the alternator.
‡ The battery generates hydrogen gas, so there is danger of

AE072980
explosion. Do not bring lighted cigarettes near the battery, or
do anything that will cause sparks.
‡ Battery electrolyte is dilute sulphuric acid, and it will attack

your clothes and skin. If it gets on your clothes or on your When installing, connect
the cable to the positive
skin, wash it immediately off with large amounts of water. + terminal first.
If it gets in your eyes, wash it out with fresh water, and
consult a doctor.
w q
‡ When handling battery, always wear protective goggles and
rubber gloves.
‡ When removing the battery, first disconnect the cable from

the ground (normally, from the negative . terminal). When
installing, install the positive + terminal first. AE072981
If a tool touches the cable connecting the positive terminal
and the chassis, there is danger that it will cause sparks.
‡ If the terminals are loose, there is danger that the defective

contact may generate sparks that will cause an explosion.
When installing the terminals, install them tightly.
‡ When removing or installing, check which is the positive +

terminal and negative . terminal.
16.4.1 REMOVAL AND INSTALLATION OF BATTERY

When starting the engine with a booster cable, do as follows:
‡ When removing battery, first disconnect the cable from the

ground (normally, from the negative . terminal). If a tool
touches a cable connecting the positive terminal and the chassis,
there is danger of sparks being emitted.
‡ When installing battery, the ground cable should be connected

to the ground terminal as the last step.
2-116
16. TROUBLESHOOTING
16.4.2 PRECAUTIONS FOR CHARGING BATTERY

CHARGING BATTERY WHEN MOUNTED ON MACHINE
‡ Before charging, disconnect the cable from the negative .
terminal of the battery. Otherwise, an unusually high voltage will
damage the alternator.
‡ While charging the battery, remove all battery plugs for satisfac-
tory ventilation.
To avoid gas explosions, do not bring fire or sparks near the
battery.
‡ If the electrolyte temperature exceeds 45°C, stop charging for a

while.
‡ Turn off the charger as soon as the battery is charged.

Overcharging the battery may cause the following:
1) Overheating the battery
2) Decreasing the quantity of electrolyte.
3) Damaging the electrode plate.
‡ Do not mix the cables (positive + to negative . or negative .

to positive +), as it will damage the alternator.
‡ When performing any service to the battery besides checking the

electrolyte level or measuring the specific gravity, disconnect
cables from the battery.
2-117
16. TROUBLESHOOTING
16.4.3 STARTING ENGINE WITH BOOSTER CABLE

When starting the engine with a booster cable, do as follows:
PRECAUTIONS WHEN CONNECTING AND DISCONNECTING

BOOSTER CABLE
 WARNING
INCORRECT
‡ When connecting the cables, never connect the position +
and negative . terminals.
‡ When starting the engine with a booster cable, always wear
safety glasses.
‡ Be careful not to let the normal machine and problem ma-
chine contact each other. This prevents sparks from generat-
ing near the battery which could ignite the hydrogen gas A0067322
given off by the battery. If hydrogen gas explodes, it could
cause serious injury.
‡ Make sure that there is no mistake in the booster cable
connections. The final connection is to the engine block of the
problem machine, but sparks will be generated when this
done, so connect to a place as far as possible from the
battery.
‡ Use care when removing the cables from the machine that
has been started. Do not allow the cable ends to contact each
other or the machine, to avoid hydrogen explosion.
NOTICE
‡ The size of the booster cable and clip should be suitable for the
battery size.
‡ The battery of the normal machine must be the same capacity
as that of the engine to be started.
‡ Check the cables and clips for damage or corrosion.
‡ Make sure that the cables and clips are firmly connected.
There are two batteries at the rear of the machine, but the battery
to be grounded is on the right side of the machine.
2-118
16. TROUBLESHOOTING
CONNECTING THE BOOSTER CABLES

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

of the problem machine.
3. Connect the other clip of booster cable A to the positive +

terminal of the normal machine.
4. Connect one clip of booster cable B to the negative - terminal

of the normal machine.
5. Connect the other clip of booster cable B to the engine block of

the problem machine.
STARTING THE ENGINE

1. Make sure the clips are firmly connected to the battery terminals.
2. Turn the starting switch of the problem machine to the START

position and start the engine. If the engine doesn’t start at first,
wait for at least 2 minutes before trying again.
DISCONNECTING THE BOOSTER CABLES

After the engine has started, disconnect the booster cables in the
reverse of the order in which they were connected.
1. Remove one clip of booster cable B from the engine block of the
problem machine.
2. Remove the other clip of booster cable B from the negative -

terminal of the normal machine.
3. Remove one clip of booster cable A from the positive + terminal

of the normal machine.
4. Remove the other clip of booster cable A from the positive +

terminal of the problem machine.
2-119
16. TROUBLESHOOTING
16.5 OTHER TROUBLE

16.5.1 ELECTRICAL SYSTEM
‡ ( ): Always contact your Komatsu distributor when dealing with these items.
‡ In cases of abnormalities or causes which are not listed below, please contact your Komatsu
distributor for repairs.
Problem Main causes Remedy
Lamp does not glow brightly even ‡ Defective wiring (‡ Check, repair loose terminals,
when the engine runs at high speed disconnections)
Lamp flickers while engine is running ‡ Defective adjustment of fan belt ‡ Adjust fan belt tension
tension For details, see EVERY 250 HOURS
SERVICE
Machine monitor and charge lamp ‡ Defective alternator (‡ Replace)

do not go out even when engine is ‡ Defective wiring (‡ Check, repair)
running
Abnormal noise is generated from ‡ Defective alternator (‡ Replace)

alternator
Starting motor does not turn when ‡ Defective wiring (‡ Check, repair)
starting switch is turned to ON ‡ Insufficient battery charge ‡ Charge
‡ Safety switch out of adjustment (‡ Adjust safety switch)
Pinion of starting motor keeps ‡ Insufficient battery charge ‡ Charge

going in and out
Starting motor turns engine ‡ Insufficient battery charge ‡ Charge

sluggishly ‡ Defective starting motor (‡ Replace)
Starting motor disengages before ‡ Defective wiring (‡ Check, repair)

engine starts ‡ Insufficient battery charge ‡ Charge
Preheating monitor does not flash ‡ Defective wiring (‡ Check, repair)

‡ Defective heater relay (‡ Replace)
‡ Defective monitor (‡ Replace)
Outside of electrical intake air heater ‡ Defective wiring (‡ Check, repair)

is not warm when touched by hand ‡ Disconnection in electrical intake (‡ Replace)
air heater
‡ Defective operation of heater relay (‡ Check, repair heater relay switch)
switchake air heater
2-120
16. TROUBLESHOOTING
16.5.2 CHASSIS
Engine is running but machine does ‡ Gear shift lever is not shifted (‡ Shift lever properly)
not move properly
‡ Lever linkage is twisted (‡ Inspect, repair)
‡ Transmission pressure does not rise (‡ Inspect, adjust)
‡ Lack of oil in transmission case ‡ Add oil to specified level.
For details, see EVERY 250 HOURS
SERVICE.
‡ When, scuffing of transmission pump (‡ Inspect, replace)
‡ Oil leakage from oil line (‡ Inspect, repair)
‡ Transmission, filter element clogged ‡ Clean, replace.
SERVICE.
‡ Defective operation of transmission, (‡ Inspect, repair)
control valve
Even when engine is run at full ‡ Lack of oil in transmission case ‡ Add oil to specified level.
throttle, machine moves slowly and For details, see EVERY 250 HOURS
lacks power. SERVICE.
‡ Transmission, filter element clogged ‡ Clean, replace.
SERVICE.
More noise than usual is generated ‡ Lack of oil in transmission case, ‡ Add oil to specified level.
from power train tandem case For details, see EVERY 250 HOURS
SERVICE.
Machine monitor, final drive oil ‡ Lack of oil in final drive case ‡ Add oil to specified level.
temperature lamp flash For details, see EVERY 250 HOURS
SERVICE.
‡ Has differential being operated for ‡ Stop operation of differential until
a long time? oil temperature goes down.
Abnormal wear of front tires ‡ Incorrect adjustment of toe-in ‡ Adjust shin

SERVICE
Front wheels wobble when ‡ Incorrect adjustment of toe-in, ‡ Adjust. For details, see EVERY 1000
traveling loose tie rod HOURS SERVICE.
‡ Inflation pressure of left and right ‡ Inflate tires to same air pressure.
tires not same
‡ Wheel not properly installed ‡ Install again. For death, see
HANDLING TIRES.
2-121
16. TROUBLESHOOTING
CHASSIS continued (16.5.2)
Steering wheel is heavy ‡ Improper inflation pressure in ‡ Inflate to specified pressure.

front tires For details, see CHECK BEFORE
STARTING.
‡ Improper greasing of steering, ‡ Add grease.
linkage For details, see EVERY 250 HOURS
SERVICE.
‡ Leakage of oil from steering (‡ Inspect, repair)
piping
Poor braking effect of parking brake ‡ Worn brake pad (‡ Inspect, replace)
Braking effect is poor when brake ‡ Worn disc (‡ Inspect, replace)

pedal is depressed ‡ Leakage of air from brake piping (‡ Inspect, repair)
‡ Seized disc ‡ Inspect, repair
‡ Defective piston seal (‡ Replace)
Blade moves up and down excessively ‡ Play in lift cylinder, ball joint ‡ Adjust shim
during operation For details, see EVERY 250 HOURS
SERVICE.
‡ Excessive clearance between ‡ Adjust shim at circle guide
sliding surface of circle and connector.
drawbar For details, see EVERY 500 HOURS
SERVICE.
‡ Worn blade rail guide (‡ Replace guide)
(‡ Repair blade rail)
Rotation of blade during operation ‡ Excessive clearance in circle in ‡ Adjust position of guide connector.
is excessive radial direction For details, see EVERY 500 HOURS
SERVICE.
Work equipment does not move ‡ Lack of oil ‡ Add oil to specified level.
properly when work equipment For details, see EVERY 250 HOURS
control lever is operated SERVICE.
2-122
16. TROUBLESHOOTING
16.5.3 ENGINE
Machine monitor, engine oil pressure ‡ Engine oil pan oil level is low ‡ Add oil to specified level. For details,
lamp flash when engine is running (sucking in air) see CHECK BEFORE STARTING.
‡ Clogged oil filter cartridge ‡ Replace cartridge. For details, see
EVERY 250 HOURS SERVICE.
‡ Defective tightening of oil pipe (‡ Check, repair)
joint, oil leakage from damaged
part
‡ Defective wiring (‡ Check, repair)
Steam is emitted from to part of ‡ Cooling water level low, water ‡ Add cooling water, repair. For
radiator (pressure valve) leakage details, see WHEN REQUIRED.
‡ Loose fan belt ‡ Adjust fan belt tension. For details,
see EVERY 250 HOURS SERVICE.
‡ Dirt or scale accumulated in ‡ Change cooling water, clean inside
cooling system of cooling system. For details, see
WHEN REQUIRED.
Machine monitor, engine water ‡ Clogged radiator fin or damaged fin ‡ Clean or repair. For details, see
temperature lamp flash in red range EVERY 500 HOURS SERVICE.
‡ Defective thermostat (‡ Replace thermostat)
‡ Loose radiator filler cap (high ‡ Tighten cap or replace packing

altitude operation)
‡ Defective water temperature gauge (‡ Replace water temperature gauge)
Engine does not start when starting ‡ Lack of fuel ‡ Add fuel. For details, see CHECK
motor is turned BEFORE STARTING.
‡ Air in fuel system ‡ Repair place where air is sucked in
‡ Defective fuel injection pump or (‡ Replace pump or nozzle)
nozzle
‡ Starting motor cranks engine ‡ See ELECTRICAL SYSTEM.
sluggishly
‡ Defective monitor ‡ See ELECTRICAL SYSTEM.
‡ Defective compression
fi Defective valve clearance (fi Adjust valve clearance)
2-123
16. TROUBLESHOOTING
ENGINE continued (16.5.3)
Exhaust gas is white or blue ‡ Too much oil in oil pan ‡ Add oil to specified level. For details,
see CHECK BEFORE STARTING.
‡ Lack of fuel ‡ Add fuel. For details, see CHECK
BEFORE STARTING.
‡ Improper fuel ‡ Change to specified fuel.
Exhaust gas occasionally turns black ‡ Clogged air cleaner element ‡ Clean or replace. For details, see
WHEN REQUIRED.
‡ Defective nozzle (‡ Replace nozzle)
‡ Defective compression (‡ Adjust valve clearance)
‡ Defective turbocharger (‡ Clean or replace the turbocharger)
Combustion noise occasionally ‡ Defective nozzle (‡ Replace nozzle)

makes breathing sound
Abnormal noise generated ‡ Low grade fuel being used ‡ Change to specified fuel.
(combustion or mechanical) ‡ Overheating ‡ See item “Machine monitor, engine
oil pressure lamp flash when engine
is running”.
‡ Damage inside muffler (‡ Replace muffler)
‡ Excessive valve clearance (‡ Adjust valve clearance)
2-124
16. TROUBLESHOOTING
16.5.4 TRANSMISSION CONTROLLER

The installation position of transmission controller 1 is inside the engine hood at the rear of the cab.
Open panel 2 and check the LED display from the controller.
CONTENT OF TRANSMISSION CONTROLLER LED DISPLAY

When the starting switch is turned ON, the transmission control-
ler shows the following on the LED display.
1. Display after starting switch is turned ON

1) “88” is displayed for 0.5 seconds to check the LEDs.
2) To distinguish from the next display, ". " is displayed for 0.5
seconds.
3) CHECKSUM is displayed for 3 seconds.
2-125
16. TROUBLESHOOTING
2. Display of past fault history

The failure codes for problems that occurred in the past are
displayed one at a time in turn.
1) To distinguish from the next display, “. ” is displayed for 0.5
seconds.
2) The past failure codes are displayed for 3 seconds.
If these failure codes are reset, they will not be displayed again.
Please ask your Komatsu distributor to reset the codes.
3. Display of existing fault history

The failure codes for problems that still exist are displayed one
at a time in turn. If there are no existing failures, “00” is displayed
for 3 seconds.
1) To distinguish from the next display, “E ” is displayed for 0.5
seconds.
2) The existing failure codes are displayed for 3 seconds.
4. Display of number of records of past abnormal operation

1) To distinguish from the next display, “- ” is displayed for 0.5
seconds.
2) The abnormal operation codes are displayed for 3 seconds.
3) The gearshifting patterns during abnormal operation are dis-
played for 3 seconds. (This is omitted for codes where there is
no record for each transmission clutch.)
4) The number of abnormal operations is displayed for 3 seconds.
5. Display after completion of Display 4

1) If there are any existing failures, Display 3 is shown repeatedly.
If there are no existing failures, “0.0.” is displayed.
2-126
16. TROUBLESHOOTING
WARNING SYSTEM
If any of the mistaken operations in the table below are carried out,
caution lamp 1 or the alarm buzzer are actuated to give a warning.
Abnormal Caution
operation code Content of abnormal operation Record
Lamp Buzzer
When shifting down, or when changing direction between F and R, and shifting N ➞ F
(R) when machine is still traveling, shift-down command is issued according to travel
10 speed.
Caution is issued until it reaches speed range selected by lever position
(from 1 sec after lever operation)
When shifting N ➞ F (R) when machine is traveling at more than 4 km/h
11
Caution issued (for 5 sec after lever operation)
When transmission is shifted to F4 (R4) or above when engine speed is more than 350
12 rpm and travel speed is less than 2 km/h (1.2 MPH)
Caution issued
Inching time Plate calculated temperature
(SEC) Clutch Category (°C)
0 – 10 F 1 200 – 230
2 230 – 260
3 260 – 290
13 4 290 or above
R 1 200 – 230
2 230 – 260
3 260 – 290
4 290 or above
0 – 10 F 0 200 or below
1 200 – 230
2 230 – 260
3 260 – 290
4 290 or above
14
R 0 200 or below
1 200 – 230
2 230 – 260
3 260 – 290
4 290 or above
30 or above F 0 200 or below
1 200 – 230
2 230 – 260
3 260 – 290
15 4 290 or above
R 0 200 or below
1 200 – 230
2 230 – 260
3 260 – 290
4 290 or above
Caution issued when engine is running at high speed
16 • Caution lamp if engine runs at more than 2525 rpm continuously
• Caution buzzer if engine runs at more than 2525 rpm continuously
Acceleration when inching pedal is depressed (exceeding hydraulic control range)
17 Caution lamp if more than max speed for speed range selected by lever position
At above danger speed, shift up and caution buzzer
Time that lubricating oil temperature is above 120°C (248 °F)
18
Caution issued after more than 30 seconds
Time that lever position is at N and travel speed is more than 4 km/h (2.5 MPH) and
19 engine speed is more than 1400 rpm
Recorded as abnormal operation after more than 10 seconds
Lever position at F (R) and inching pedal depressed (exceeding hydraulic control range)
Time that travel speed is more than 4 km/h (2.5 MPH) and engine speed is more than
1A
1400 rpm
Recorded as abnormal operation after more than 10 seconds
2-127
MEMO
2-128
MAINTENANCE
3-1
17. GUIDES TO MAINTENANCE
Do not carry out any inspection and maintenance operation that is not given in this manual.
Perform maintenance work on hard, flat ground.
Check service meter:

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

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

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

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

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

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

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

After oil is changed or filters are replaced, check the oil and filters for metallic particles and foreign
material. If large quantities of metallic particles or foreign materials are found, contact your Komatsu
distributor.
Fuel strainer:
If your machine is equipped with a fuel strainer, do not remove it while fueling.
Oil change:
Check or change oils in a place where there is no dust, and keep dirt and dust away from oils.
Warning tag:
Attach the warning tag to the starting switch or other appropriate control lever to prevent anyone from
starting the engine.
Obey precautions:
During the operation, always obey the precautions on the safety label stuck to the machine.
3-2
17. GUIDES TO MAINTENANCE
Welding instructions:
‡ Turn off the engine starting switch.
‡ Do not apply more than 200 V continuously.
‡ Connect grounding the cable within 1 m from the area to be welded.
‡ Avoid seals or bearings from being between the area to be welded and the position of grounding
point.
Fire prevention:
Use nonflammable cleaner or light oil for cleaning parts. Keep flame or cigarette light away from light
oil.
Clamp faces:
When O-rings or gaskets are removed, clean the clamp faces and replace the O-rings and gaskets with
new ones. Be sure to fit O-rings and gaskets when assembling.
Objects in your pockets:

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

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

Never mix oils of different brands. If you have only oil which is a different brand from the one that is
used in the machine, do not add it but replace all the oil.
Electrical interference:
If there is any external electrical interference, the controller on the machine monitor may work
incorrectly, so consult your Komatsu distributor before installing any radio equipment on the machine.
3-3
18. OUTLINES OF SERVICE
18.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC

18.1.1 OIL
‡ Oil is used in the engine and work equipment under extremely severe conditions (high temperature,
high pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature for use given in the Operation and
Maintenance Manual. Even if the oil is not dirty, always replace the oil after the specified interval.
‡ Oil corresponds to blood in the human body, so always be careful when handling it to prevent any
impurities (water, metal particles, dirt, etc.) from getting in.
The majority of problems with machine are caused by the entry of such impurities.
Take particular care not to let any impurities get in when storing or adding oil.
‡ Never mix oils of different grades or brands.
‡ Always add the specified amount of oil.

Having too much oil or too little oil are both causes of problems.
‡ If the oil in the work equipment is not clear, there is probably water or air getting into the circuit.
In such cases, please contact your Komatsu distributor.
‡ When changing the oil, always replace the related filters at the same time.
‡ We recommend you to have an analysis made of the oil periodically to check the condition of the
machine.
For those who wish to use this service, please contact your Komatsu distributor.
18.1.2 FUEL
‡ The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work
properly.
‡ Be extremely careful not to let impurities get in when storing or adding fuel.
‡ Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature when it is used (particularly in low temperature
below –15°C), so it is necessary to change to a fuel that matches the temperature.
‡ To prevent the moisture in the air forming water inside the fuel tank, always fill the fuel tank after
completing the day’s work.
‡ Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment
and water from the fuel tank.
‡ If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from
the circuit.
3-4
18.1.3 COOLANT
‡ River water contains large amounts of calcium and other impurities, so if it is used, scale will stick
to the engine and radiator, and this will cause defective heat exchange and overheating.
Do not use water that is not suitable for drinking.
‡ When using anti-freeze, always observe the precautions given in the Operation and Maintenance
Manual.
‡ Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine
is shipped.
This anti-freeze is effective in preventing corrosion of the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as
it is even in hot areas.
‡ Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.
‡ The proportion of anti-freeze to water differs according to the ambient temperature. For details of
the mixing proportions, see “24.2 WHEN REQUIRED”.
‡ If the engine overheats, wait for the engine to cool before adding coolant.
‡ If the coolant level is low, it will cause overheating and will also cause problems with corrosion from
the air in the coolant.
18.1.4 GREASE
‡ Grease is used to prevent twisting and noise at the joints.
‡ The nipples not included in the maintenance section are nipples for overhaul, so they do not need
grease. If any part becomes stiff after being used for a long time, add grease.
‡ Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe
off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating
parts.
3-5
18.1.5 CARRYING OUT KOWA (Komatsu Oil Wear

Analysis)
KOWA is a maintenance service that makes it possible to prevent
machine failures and down-time. With KOWA, the oil is periodically
sampled and analyzed. This enables early detection of wear of the
machine drive parts and other abnormalities.
Periodic use of KOWA makes the following possible:
‡ It enables abnormalities to be detected early, leading to reduc-
tion of repair costs and machine downtime.
‡ It enables repair schedules to be planned, leading to improved
machine availability.
KOWA analysis items

‡ Analysis of metal wear particles
This uses an ICP (Inductively Coupled Plasma) analyzer to meas-
ure the density of metal wear particles in the oil.
‡ Measurement of particle quantity

This uses a PQI (Particle Quantifier Index) measurer to measure
the quantity of large iron particles in the oil.
‡ Others
Measurements are made of items such as the ratio of water or
fuel in the oil, and the dynamic viscosity.
Oil sampling
‡ Sampling interval
250 hours: Engine
500 hours: Other components
‡ Precautions when sampling

• Make sure that the oil is well mixed before sampling.
• Carry out sampling regularly at fixed intervals.
• Do not carry out sampling on rainy or windy days when
water or dust can get into the oil.
For further details of KOWA, please contact your Komatsu dis-

tributor.
3-6
18.1.6 STORING OIL AND FUEL

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

‡ If the wiring gets wet or the insulation is damaged, the electric system leaks and this could result
in hazardous malfunction of the machine.
‡ Services relating to the electric system are (1) check of fan belt tension, (2) check of damage or wear
in the fan belt and (3) check of battery fluid level.
‡ Never remove or disassemble any electric components installed in the machine.
‡ Never install any electric components other than these specified by Komatsu.
‡ Be careful to keep the electric system free of water when washing the machine or when it rains.
‡ When working on the seashore, carefully clean the electric system to prevent corrosion.
‡ Never connect any optional power source to the fuse, starting switch, battery relay, etc.
3-7
19. WEAR PARTS LIST
Wear parts such as the filter element, cutting edge, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits.
The wear parts should be changed correctly in order to use the machine economically.
For part change, Komatsu genuine parts of excellent quality should be used.
The parts in parentheses are to be replaced at the same time.
Replacement
Item Part No. Part Name Q’ty
frequency
Engine oil filter 600-211-1230 Cartridge 1 Every 250 hours
Fuel filter 600-311-7130 Cartridge 1 Every 500 hours

424-16-11140 Element 1
Transmission oil filter Every 500 hours
(07000-13098) (O-ring) (1)
234-60-31330 Return filter element 1
205-60-51450 Suction strainer 1

Hydraulic oil filter Every 1000 hours
235-832-2110 Strainer for emergency 1
steering (if equipped)
(235-60-12580) (O-ring) (1)
6128-81-7042 Element ass'y 1
Air cleaner –
600-181-4400 Outer element ass'y 1
235-70-12320 Edge 2
234-70-32230 Side edge 2
(234-70-32260) (Bolt) (8)
Straight edge
(234-70-32270) (Bolt) (36)
(234-70-32290) (Nut) (44)
(01643-32060) (Washer) (44)
Blade 235-70-12140 Edge 2 –
234-70-32230 Side edge 2
234-70-32240 End bit 2
234-70-32260 (Bolt) (32)
Curved edge
234-70-32270 (Bolt) (10)
234-70-32280 (Bolt) (2)
(234-70-32290) (Nut) (44)
(01643-32060) (Washer) (44)
235-785-1260 Point 3
Ripper –
(09244-02516) (Pin) (3)
235-70-41190 Wear plate 6
Circle guide –
235-70-11431 Wear plate 6
Blade 235-70-42210 Rail guide 4 –
Engine 04121-22565 V-belt 2 –

Air conditioner 04120-21752 V-belt 1 –
Every 1 year or
Air drier 235-44-11790 Desiccant 1
1000 hours
3-8
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING
TO AMBIENT TEMPERATURE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE CAPACITY

KIND OF
RESERVOIR
FLUID –22 –4 14 32 50 68 86 104 122°F
–30 –20 –10 0 10 20 30 40 50°C
Specified Refill
SAE30CD
SAE10WCD 38 ¬ 34 ¬
Engine oil pan 10.0 US gal 9.0 US gal
SAE10W-30CD 8.4 UK gal 7.5 UK gal
SAE 15W-40CD
Engine oil 35 ¬ 25 ¬
Transmission case 9.2 US gal 6.6 US gal
7.7 UK gal 5.5 UK gal
SAE30CD 63 ¬ 57 ¬
Final drive case 16.6 US gal 15.0 US gal
SAE10WCD 13.9 UK gal 12.5 UK gal
120 ¬ 95 ¬
Tandem drive
31.7 US gal 25.0 US gal
case (each)
10 ¬ 8¬
Circle reverse gear
Gear oil SAE90 2.6 US gal 2.1 US gal
case
140 ¬ 80 ¬
Hydraulic system SAE10WCD 37.0 US gal 21.1 US gal
Engine oil
0.9 ¬ 0.9 ¬
Front axle housing SAE30CD 0.2 US gal 0.2 US gal
ASTM D975 No.2 500 ¬

Fuel tank Diesel fuel 132.0 US gal –
ª 110.0 UK gal
58 ¬
Cooling system Water Add antifreeze 15.3 US gal –
12.8 UK gal
ª ASTM D975 No. 1
3-9
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
REMARK
‡ When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.
Change interval of oil in

Fuel sulphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
‡ When starting the engine in an atmospheric temperature of lower than 0˚C, be sure to use engine
oil of SAE10W, SAE10W-30 and SAE15W-40, even though an atmospheric temperature goes up to
10°C more or less in the day time.
‡ Use API classification CD as engine oil and if API classification CC, reduce the engine oil change
interval to half.
‡ There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be
sure to add single grade oil that matches the temperature in the table.
‡ We recommend Komatsu genuine oil which has been specifically formulated and approved for use
in engine and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
3-10
Engine Oil
Anti-freeze
[CD or CE]
Coolant
SAE10W, 30, 40 Gear Oil Grease
No. Supplier [Ethylene Glycol
10W30, 15W40 [GL-4 or GL-5] [Lithium-Base]
Base]
(The 15W40 oil SAE80, 90, 140 NLGI No. 2
Permanent Type
marked * is CE.)
EO10-CD AF-ACL
EO30-CD GO90 G2-LI AF-PTL
1 KOMATSU
EO10-30CD GO140 G2-LI-S AF-PT (Winter, one
EO15-40CD season type)
Diesel sigma S
Super dieselmulti-
2 AGIP Rotra MP GR MU/EP –
grade
*Sigma turbo
Multi-purpose gear RYKON prenium

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

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

Mobilube GX
13 MOBIL *Delvac super Mobilgrease 77 –
Mobilube HD
10W-30, 15W-40 Mobilgrease special
3-11
Engine Oil
Anti-freeze
[CD or CE]
Coolant
SAE10W, 30, 40 Gear Oil Grease
No. Supplier [Ethylene Glycol
10W30, 15W40 [GL-4 or GL-5] [Lithium-Base]
Base]
(The 15W40 oil SAE80, 90, 140 NLGI No. 2
Permanent Type
marked * is CE.)
Multi-purpose white
*Supreme duty Multi-purpose 4092 grease 705 Anti-freeze and
14 PENNZOIL
fleet motor oil Multi-purpose 4140 707L White – bearing summer coolant
grease
FINA potonic N
15 PETROFINA FINA kappa TD FINA marson EPL2 FINA tamidor
FINA potonic NE
Spirax EP
16 SHELL Rimula X Alvania EP grease –
Spirax heavy duty
Sunoco ultra prestige Sunoco antifreeze

Sunoco GL5
17 SUN – 2EP and summer
gear oil
Sun prestige 742 coolant
*Ursa super plus Multifak EP2 Code 2055 startex

18 TEXACO Multigear
Ursa premium Starplex 2 antifreeze coolant
Total EP
Rubia S
19 TOTAL Total transmission Multis EP2 Antigel/antifreeze
*Rubia X
TM
20 UNION *Guardol MP gear lube LS Unoba EP –
*Turbostar Multigear
21 VEEDOL *Diesel star Multigear B – Antifreeze
MDC Multigear C
3-12
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND
NUTS
21.1 INTRODUCTION OF NECESSARY TOOLS

The following tools are needed when carrying out maintenance.
No. Name of tool Part No. Remarks
1 Wrench set 09000-30005 Applicable width across flats (S1–S2)

8mm – 10mm
13mm – 17mm
19mm – 22mm S1
24mm – 27mm S2
AD053370
30mm – 32mm
2 Wrench 09001-07500 Jaw size: 75

3 Wrench 09002-03641 36 mm – 41 mm
4 Wrench 09002-04650 46 mm – 50 mm
5 Socket wrench set 09020-10282 Applicable width across flats
10 mm, 13 mm, 14 mm, 17 mm, 19 mm,
22 mm, 24 mm, 27 mm, 30 mm, 32 mm,
Extension, Handle, Joint, Bar
6 Socket wrench 235-98-11220
7 Screwdriver 09033-00190 Interchangeable flat-head and cross-head
8 Pliers 09036-00150
9 Hammer 09039-00150
10 Feeler gauge 09054-00009
11 Pry bar 09055-10390

12 Tire hose 235-98-11210
13 Tire gauge 09289-10000
14 Filter wrench 09019-08035 For filter cartridges

15 Grease pump 07952-80002 For greasing work
16 Grease cartridge 07950-90403 (Lithium base grease, 400 g)
17 Leaning lock bolt 01011-83040

18 Leaning lock nut 01580-13024
19 Plate 09963-03000 Warning tag
If any of the above tools are broken, please order them from your Komatsu distributor.
3-13
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
21.2 TORQUE LIST

Unless otherwise specified, tighten the metric bolts and nuts to
the torque shown in the table.
The tightening torque is determined by the width across the flats b
b of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a Komatsu
genuine part of the same size as the part that was replaced. a
Nm (newton meter): 1N•m L 0.1 kgf•m AD053380
L 0.74 lbft
Thread diameter Width across

of bolt (mm) flat (mm)
(a) (b) AD054300
N•m kgf•m lbft
6 10 13.2 ± 1.4 1.35 ± 0.15 9.73 ± 1.03

8 13 31.4 ± 2.9 3.2 ± 0.3 23.2 ± 2.1
10 17 65.7 ± 6.8 6.7 ± 0.7 48.5 ± 5.0
12 19 112 ± 9.8 11.5 ± 1.0 82.6 ± 7.2
14 22 177 ± 19 18.0 ± 2.0 131 ± 14
16 24 279 ± 29 28.5 ± 3 206 ± 21

18 27 383 ± 39 39 ± 3 282 ± 29
20 30 549 ± 58 56 ± 6 405 ± 43
22 32 745 ± 78 76 ± 8 549 ± 58
24 36 927 ± 98 94.5 ± 10 684 ± 72
27 41 1320 ± 140 135 ± 15 973 ± 100

30 46 1720 ± 190 175 ± 20 1270 ± 140
33 50 2210 ± 240 225 ± 25 1630 ± 180
36 55 2750 ± 290 280 ± 30 2030 ± 210
39 60 3280 ± 340 335 ± 35 2420 ± 250
NOTICE
When tightening panels or other parts having tightening fix-
tures made of plastic, be careful not to use excessive tightening
torque: doing so will damage the plastic parts.
3-14
22. PERIODIC REPLACEMENT OF CRITICAL PARTS
To ensure safety at all times when operating or driving the machine, the user of the machine must
always carry out periodic maintenance. In addition, to further improve safety, the user should also carry
out periodic replacement of the parts given in the table. These parts are particularly closely connected
to safety and fire prevention.
With these parts, the material changes as time passed, or they easily wear or deteriorate. However,
it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always
be replaced after a fixed time has passed,
regardless of their condition. This is necessary to ensure that they always maintain their function
completely.
However, if these parts show any abnormality before the replacement interval has passed, they
should be repaired or replaced immediately.
If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at
the same as the hoses.
When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same
time.
Ask your Komatsu distributor to replace the critical parts.
3-15
CRITICAL PARTS
No. Safety critical parts for periodic replacement Q’ty Replacement interval
1 Fuel hose (fuel tank – injection pump) 1
2 Fuel hose (injection pump – fuel filter) 2
3 Fuel return hose (Injection pump – fuel tank) 1

4 Fuel spill hose (between nozzle) 2
5 Fuel spill hose (nozzle – fuel tank) 1
6 Turbocharger lubricating hose 1

Every 2 years or
7 O-ring for brake disc piston 8 every 4000 hours,
whichever comes
8 O-ring for steering valve 8 sooner.
9 Steering circuit hose 14
10 Rubber parts for brake valve 16
11 Rubber hose for leaning cylinder 2
12 Brake hose 12
13 O-ring for steering cylinder 7
14 Seat belt 1 Replace every 3 years
3-16
3-17
23. MAINTENANCE SCHEDULE CHART
23.1 MAINTENANCE SCHEDULE CHART

SERVICE ITEM PAGE
INITIAL 250 HOURS SERVICE (only after the first 250 hours)
Replace fuel filter cartridge 3-58
Check circle guide clearance, adjust 3-61
Checking, adjust slip load of clutch for circle reverse gear 3-65
Change oil in transmission case 3-68
Change oil in final drive case, clean strainer 3-70
Replace return filter element and clean suction strainer in hydraulic tank 3-73
Change oil in tandem drive case 3-79
Change oil in circle reverse gear case 3-80
Check engine valve clearance, adjust 3-83

WHEN REQUIRED
Clean inside of cooling system 3-23
Check, clean and replace air cleaner element 3-27

Check electrical intake air heater 3-29
Clean element of air conditioner fresh filter 3-29

Clean element of air conditioner recirculation air filter 3-30
Checking level of refrigerant (GAS) in air conditioner 3-31
Reverse and replace the end bits and cutting edges 3-32
Replacing ripper point 3-33
Inspecting inching pedal 3-33
Inspection corrosion, wear of wheel rim, lock ring, side ring 3-33
Selection and inspection of tires 3-34
CHECK BEFORE STARTING
Check coolant level, add water 3-36

Check fuel level, add fuel 3-37
Drain water and sediment in fuel tank 3-37
Check oil level in engine oil pan, add oil 3-38

Check dust indicator 3-39
Check electric wiring 3-39
Have any defects which were found during the previous day’s operation been corrected 3-40
Check and refill with window washing fluid 3-40
3-18
SERVICE ITEM PAGE
(CHECK BEFORE STARTING)
Check and adjust steering wheel 3-40
Check for water and sediment in water separator, drain water 3-40
Check that rise in air pressure is normal 3-41
Check that flashing of lamps is normal, check for dirt or damage 3-41
Check that direction of backup mirror is correct, check for dirt or damage 3-41
Check operation of horn 3-41
Check engine exhaust color and sound 3-41
Check operation of gauges 3-41

Check inflation pressure of tires 3-41
EVERY 50 HOURS SERVICE
Lubricating 3-42
Grease blade guide rail 3-42
Inspect wear of blade guide 3-42
Lubricating 3-43
‡ Leaning cylinder pin (1 point) 3-43

‡ Tie rod (2 points) 3-43
‡ Steering linkage (6 points) 3-43
‡ Steering cylinder pin (4 points) 3-43

‡ Drawbar ball joint (1 point) 3-43
‡ Front axle center pin (1 point) 3-43
‡ Front axle king pin (6 points) 3-43

‡ Blade lift cylinder yoke (4 points) 3-44
‡ Blade lift cylinder ball joint (2 points) 3-44
‡ Drawbar side shift cylinder ball joint (2 points) 3-44

‡ Bank control guide (2 points) 3-44
‡ Articulation center pin and articulation cylinder pin (6 points) 3-44
‡ Blad lifter guide (2 points) 3-44

‡ Ripper cylinder (3 points) 3-44
‡ Bank control lock pin (2 points) 3-44
3-19
SERVICE ITEM PAGE
(EVERY 250 HOURS SERVICE)
‡ Ripper rod (8 points) 3-44
‡ Power tilt cylinder (2 points) 3-44

Check oil level in transmission case, add oil 3-45
Check oil level in final drive case, add oil 3-46
Check oil level in tandem drive case, add oil 3-47

Check oil level in circle reverse gear case, add oil 3-48
Check oil level in hydraulic tank, add oil 3-49
Change oil in engine oil pan, replace engine oil filter cartridge 3-50
Check fan belt tension, adjust 3-51
Check alternator belt tension, adjust 3-52
Check air conditioner belt tension, adjust 3-53

Check level of battery electrolyte 3-54
Check ball joint clearance, adjust 3-56
Check and tighten wheel hub nut 3-56

Check wheel brake adjust 3-57
Replace fuel filter cartridge 3-58

Clean, check radiator fins 3-60
Check circle guide clearance, adjust 3-61
Check parking brake level stroke, adjust 3-64

Checking, adjust slip load of clutch for circle reverse 3-65
Grease drive shaft (2 points) 3-67

Change oil in transmission case, clean strainer 3-68
Replace transmission oil filter element 3-69
Change oil in final drive case, clean strainer 3-70

Change oil in hydraulic tank 3-71
Replace return filter element and clean suction strainer in hydraulic tank 3-73
Check looseness in drawbar front ball joint 3-74

Check toe-in, adjust 3-75
3-20
SERVICE ITEM PAGE
(EVERY 1000 HOURS SERVICE)
Check front wheel bearing play, adjust 3-76
Check for loose ropes mount bolts 3-76

Replacing air dryer desiccant 3-77
Replace corrosion resistor cartridge 3-77

Change oil in front wheel bearing 3-78
Change oil in tandem drive case 3-79
Change oil in circle reverse gear case 3-80

Clean engine breather element 3-81
Clean breather 3-82
Check all tightening parts of turbocharger 3-82

Check play of turbocharger rotor 3-82
Clean, check turbocharger 3-82
Check alternator, starting motor 3-83

Check engine valve clearance, adjust 3-83
Clean and inspect inching potentiometer sensor 3-83

Check water pump 3-84
Check vibration damper 3-84
Check fan pulley and tension pulley 3-84
3-21
24. SERVICE PROCEDURE
24.1 INITIAL 250 HOURS SERVICE

Carry out the following maintenance only after the first 250
hours.
‡ REPLACE FUEL FILTER CARTRIDGE

‡ CHECK CIRCLE GUIDE CLEARANCE, ADJUST
‡ CHECKING, ADJUST SLIP LOAD OF CLUTCH FOR REVERSE
GEAR
‡ CHANGE OIL IN TRANSMISSION CASE
‡ CHANGE OIL IN FINAL DRIVE CASE
‡ REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION
STRAINER IN HYDRAULIC TANK
‡ CHANGE OIL IN TANDEM DRIVE CASE
‡ CHANGE OIL IN CIRCLE REVERSE GEAR CASE
‡ CHECK ENGINE VALVE CLEARANCE, ADJUST
For details of the method of replacing or maintaining, see the

section on EVERY 500 HOURS, 1000 HOURS AND 2000 HOURS
SERVICE.
3-22
24.2 WHEN REQUIRED

24.2.1 CLEAN INSIDE OF COOLING SYSTEM
 WARNING
‡ When the engine has been stopped, the coolant is hot and
can cause personal injury. Allow the engine to cool before
draining water.
‡ Never go under the machine with the engine running. To
avoid serious injury, always stop the engine before going
under the machine to open the drain valve.
‡ Never remove the radiator cap when the engine is at operat-
ing temperature. At operating temperature, the coolant is
under pressure. Steam blowing up from the radiator could
cause personal injury. Allow the engine to cool until the
radiator filler cap is cool enough to touch with your hand.
Remove the filler cap slowly to relieve pressure.
‡ When removing the drain plug, avoid pouring coolant on
yourself.
‡ Antifreeze is flammable, so keep it away from any flame.
‡ Stop the machine on level ground when cleaning or changing

the coolant.
‡ Clean the inside of the cooling system, change the coolant and
replace the corrosion resistor according to the table below.
Cleaning inside of Replacing corrosion

Kind of coolant cooling system and
changing coolant resistor
Permanent type antifreeze Every year (autumn) or

(All season type) every 2000 hours,
whichever comes first
Every 1000 hours and
Non-permanent type Every 6 months (spring, when cleaning the in-
antifreeze containing autumn) side of the cooling
ethylene glycol (Winter, (Drain antifreeze in spring, system and when
one season type) add antifreeze in autumn) changing coolant.
Every 6 months or every
When not using antifreeze 1000 hours, whichever
comes first
3-23
‡ Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent type
antifreeze, use an antifreeze containing ethylene glycol.
‡ When deciding the ratio of antifreeze to water, check the lowest

temperature in the past, and decide from the mixing rate table
given below.
It is actually before to estimate a temperature about 10°C lower
when deciding the mixing rate.
Mixing rate of water and antifreeze
Min. °C –5 –10 –15 –20 –25

atmospheric
temperature °F 23 14 5 –4 –13
¬ 13.4 17.5 21.00 27 29.00

Amount of
US gal 3.54 4.62 5.54 7.13 7.66
antifreeze
UK gal 2.95 3.85 4.62 5.94 6.38
¬ 44.6 40.5 37.00 31 29.00

Amount of
US gal 11.77 10.69 9.77 8.18 7.66
water
UK gal 9.81 8.91 8.14 6.82 6.38
‡ We recommend use of an antifreeze density gauge to control the

mixing proportions.
‡ Use city water for the cooling water.

If river water, well water or the such water supply must be used,
3-24
1. Stop the engine and turn radiator cap 1 slowly to remove it.
Tighten corrosion resistor cartridge 2 of valve 3.
2. Set a container to catch the coolant under drain valve 4 and drain
plug 5. Open drain valve 4 at the bottom of the radiator and
drain plug 5 on the side face of the cylinder block to drain the
water.
3. After draining the water, close drain valve 4 and drain plug 5,
and fill with city water.
4. Open drain valve 4 and drain plug 5, run the engine at low
idling, and flush water through the system for 10 minutes. When
doing this, adjust the speed of filling and draining the water so
that the radiator is always full.
While flushing water through the system, watch carefully that
the water inlet hose does not come out of the radiator water
filler.
5. After flushing, stop the engine, open drain valve 4 and drain
plug 5, then close it again after all the water has drained out.
6. After draining the water, clean with a flushing agent.

When washing, follow the instructions given with the detergent.
7. After flushing, open drain valve 4 and drain plug 5, completely

drain all the water, then close the drain valve and drain plug, and
fill with city water up to near the filler port.
8. When the tank is filled to near the water filler port, open drain
valve 4 and drain plug 5, start the engine, run at low idling, and
continue the flushing operation until clean water comes out.
Adjust the amount of water flowing in and out to ensure that the
radiator is always full during the flushing operation.
9. When clean water comes out, stop the engine, and close drain
valve 4 and drain plug 5.
10. Replace corrosion resistor cartridge 2 and open corrosion resis-

tor valve 3.
For details of replacement of the corrosion resistor, see “24.7
11. Add city water until the water overflows from the water filler
port.
12. To remove the air in the cooling water, run for five minutes at
low idling, then for another five minutes at high idling. (When
doing this, leave the radiator cap off.)
13. Drain the cooling water inside sub-tank 6, clean the inside of the
sub-tank, then fill again with cooling water to a point midway
between the FULL and LOW marks.
3-25
14. Stop the engine, wait for 3 minutes, add city water until the water
level reaches near the water filler port, then tighten the cap.
3-26
24.2.2 CHECK, CLEAN AND REPLACE AIR CLEANER

ELEMENT
 WARNING
‡ Never clean or replace the air cleaner element with the engine
running.
‡ When using pressure air to clean the element wear safety
glasses or goggles to protect the eyes.
CHECKING
Whenever the red piston in dust indicator 1 appears, clean the
air cleaner element.
CLEANING OR REPLACING OUTER ELEMENT

1. Loosen wing bolt 2, remove cover 3 and the outer element.
2. Clean the air cleaner body interior and the cover.
3. Direct dry compressed air (less than 0.69 MPa (7 kgf/cm2, 50.6
lbft)) to the element from inside along its folds, then direct it
from outside along its folds and again from inside.
(1) Remove one seal from the outer element. The number of
times the outer element has been cleaned can be seen by the
number of removed seals.
AE063670
(2) Replace the outer element which has been cleaned 6 times
repeatedly or used throughout a year. Replace the inner
element at the same time.
(3) Replace the element when the air cleaner clogged warning
lamp lights up soon after installing the cleaned element even
though it has not been cleaned 6 times.
(4) Check inner element mounting nuts for looseness and, if

necessary, retighten.
(5) Replace seal washer 4 or wing nut 2 with new parts if they
are broken.
AE063681
3-27
NOTICE
If small holes or thinner parts are found on the element when
it is checked with an electric bulb after cleaning and drying, replace
the element.
Do not use an element whose folds or gasket or seal are
damaged.
When cleaning the element, do not hit it or beat it against some-
thing.
AE063690
4. Set the cleaned element.
5. Push dust indicator 1 reset button to return the red piston to the
original position.
REPLACING INNER ELEMENT

1. First remove the cover and the outer element, and then remove
AE073060
the inner element.
2. To prevent dust from getting in, use a clean cloth or tape to cover
the air connector (outlet side).
3. Clean the air cleaner body interior, then remove the cover
installed in Step 2.
4. Fit a new inner element to the connector and tighten it with nuts.
Do not clean and reinstall the inner element.
5. Install the outer element and the cover.
6. After replacing the element, return the red piston in the dust
indicator to its original position.
3-28
24.2.3 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.
24.2.4 CLEAN ELEMENT OF AIR CONDITIONER FRESH

AIR FILTER
 WARNING
When using pressure air to clean the element wear safety
glasses or goggles to protect your eyes.
If the air conditioner is being used, clean the air filter element.
1. Stop the air conditioner.
2. Loosen bolt 1, then remove cover 2.
3. Loosen bolt 3, then remove plate 4.
4. Loosen bolt 5, then take out element 7 and clean it.
5. Install the cleaned filter element.
Method of cleaning filter

Direct dry compressed air (less than 0.69 MPa (7 kgf/cm2, 99.4
PSI)) to the element from inside along its folds, then direct it from
outside along its folds and again from inside.
3-29
24.2.5 CLEAN ELEMENT OF AIR CONDITIONER

RECIRCULATION AIR FILTER
 WARNING
When using pressure air to clean the element wear safety
glasses or goggles to protect your eyes.
NOTICE
When bracket 4 is removed using bolt 3, the balance of unit
5 will be lost. Be careful not to let unit 5 fall off or cause damage
to the wiring.
1. Loosen bolt 1 and remove cover 2.
2. Loosen bolt 3 and pull out bracket 4.
3. Loosen bolt 6 and remove air conditioner unit 5.
5. Pull filter 9 out to the side and filter 0 out to the top.
6. Clean the filter with compressed air in the same way as the fresh
air filter.
If the filter is extremely dirty, rinse it in water. After rinsing it in
water, dry it thoroughly before assembling again.
Method of cleaning filter

Direct dry compressed air (less than 0.69 MPa (7 kgf/cm2, 99.4
PSI)) to the element from inside along its folds, then direct it from
outside along its folds and again from inside.
3-30
24.2.6 CHECKING LEVEL OF REFRIGERANT (GAS) IN AIR

CONDITIONER
WARNING
The refrigerant used in the cooler is colorless and odorless, and
is harmless when released into the atmosphere. However if it
gets in the eyes or on the hands, it will cause burns or loss of
sight, so never loosen any part of the refrigerant circuit.
Check the refrigerant level twice a year in spring and autumn.
Operate the cooler of the air conditioner, and after 5 – 10

minutes, touch the high pressure and low pressure parts (or the
connector of the high pressure hose and low pressure hose) by
hand. In this condition, observe the flow of the refrigerant gas
(R134a) through the sight glass in receiver 1 to check the gas level.
Ask your Komatsu distributor to carry out the inspection.
Condition of cooler No abnormality Abnormal
Temperature of high, High pressure pipe is hot, High pressure pipe is warm, Almost no difference in
low pressure low pressure pipe is cold, low pressure pipe is cool, temperature can be felt
pipe obvious difference in little difference in temperature. between high pressure pipe
temperature. and low pressure pipe.
Condition of sight Almost transparent, some Bubbles are always seen Misty flow is seen.
glass bubbles can be seen, but flowing.
become transparent when Sometimes transparent or
engine speed is raised and white bubbles
lowered.
Condition of pipe No abnormality Traces of oil leakage Extremely dirty with oil in
connector places
In this condition of There is no lack of refrigerant, There is probably a leak some- Almost all refrigerant has
the cooler and no other abnormality. where. leaked out.
The equipment can be used Please contact your Komatsu Contact your Komatsu distributor
as it is. distributor for inspection. immediately for inspection.
3-31
24.2.7 REVERSE AND REPLACE THE END BITS AND

CUTTING EDGES
 WARNING
Do not raise the blade unnecessarily high. Be sure not to put any
part of your body underneath the blade when blocking it.
Reverse or replace the end bits and cutting edges before it is

worn out to the blade end.
If it has been worn out up to the mounting surface, repair the
fitting surface.
1. Lift the blade to a suitable height and put a block underneath the
blade rail to prevent it from falling.
2. Remove bolts and nuts 1, then remove the cutting edge 2.
3. Clean the mounting face for the cutting edge 2.
4. Turn cutting edge 2, and install it to the blade. When turning the
cutting edge, interchange the left and right cutting edges.
If the cutting edge and the end bit on both sides are worn out,
replace with new one.
If it has been worn out up to the mounting surface, repair the
fitting surface and then reverse or replace.
5. Tighten bolts and nuts 1 uniformly so that there is no clearance

between the blade and cutting edge.
Tightening torque for mounting run: 260 ± 34.3 N•m (26.5 ± 3.5
kgf•m, 191.7 ± 25.3 lbft)
6. After several hours of running, retighten the nuts.
Guide for blade replacement interval

If the distance from the blade holder to the ground surface
reaches 10 mm when the cutting angle is the minimum and the
blade is lowered to the ground, replace the edge.
3-32
24.2.8 REPLACING RIPPER POINT

 WARNING
It is dangerous if the work equipment is moved by accident
during the replacement operation.
Set the work equipment in stable position and stop the engine.
‡ If the pin is knocked out, the pin may fly out and injure people
in the surrounding area. Check that there is no one near the
machine before removing the pin.
‡ If the pin is hit with a hammer and pieces of metal fly, there
is danger that they will get in your eyes and cause serious
injury.
When carrying out this operation, always wear goggles,
helmet, gloves, and other protective equipment.
1. Raise the ripper to suitable height, and put a block under the
beam to prevent the ripper from coming down.
2. Using a hammer and bar, remove the pin, then remove the point.
3. Install a new point, and insert the pin.

Dimension of point
New part: 377 mm (14.9 in)
ervice limit: 170 mm (6.7 in)
24.2.9 INSPECTING INCHING PEDAL

If the following problems occur, please contact your Komatsu
distributor for inspection and adjustment.
‡ The machine does not stop when the inching pedal is depressed.
‡ The machine does not move or lacks power when the inching
pedal is released.
24.2.10 INSPECTING CORROSION, WEAR OF WHEEL

RIM, LOCK RING, SIDE RING
If there is marked corrosion of the wheel rim, lock ring, or side
ring, please contact your Komatsu distributor or the tire maker for
inspection.
3-33
24.2.11 SELECTION AND INSPECTION OF TIRES

WARNING
If a tire or a rim is handled wrongly, the tire may burst or may
be damaged and the rim may be broken and scattered, and that
can cause serious injury and death.
‡ Since maintenance, disassembly, repair and assembly of the

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

not make a fire near the tire.
SELECTION OF TIRES
WARNING
Select the tires according to the conditions of use and attach-
ments on the machine. Use only specified tires and inflate them
to the specified pressure.
Select the tires according to the conditions of use and attach-

ments of the machine. Use the following table. Since the indicated
speed varies with the tire size, consult your Komatsu distributor
when using optional tires.
Inflation pressure
Tire size Remarks
MPa (kgf/cm2, PSI)
Type 2 for
0.16 MPa
23.50–25–12PR construction
(1.6 kgf/cm2, 22.72 PSI)
equipment
3-34
CHECK OF INFLATION OF PRESSURE OF TIRES AND INFLATION OF

THEM
WARNING
‡ When inflating a tire, check that no one will enter the working
area and use an air chuck which has a clip and which can be
fixed to the air valve.
While inflating the tire, check the inflation pressure occasion-
ally so that it will not rise too high.
If the rim is not fitted normally, it may be broken and
scattered while the tire is inflated. To ensure safety, place a
guard around the tire and do not work in front of the rim but
work on the tread side of the tire.
‡ Abnormal drop of inflation pressure and abnormal fitting of

the rim indicate a trouble in the tire or rim. In this case, be
sure to ask a tire repair shop to carry out repairs.
‡ Be sure to observe the specified inflation pressure.
‡ Do not adjust the inflation pressure of the tires just after high-
speed travel or heavy-duty work.
Check
Inflation of tires
Adjust the inflation pressure properly.
When inflating a tire, use an air chuck which can be fixed to the
air valve of the tire as shown in the figure. Do not work in front of
the rim but work on the tread side of the tire.
Standard tire inflation pressure (front and rear wheels)
Tire size Inflation pressure MPa (kgf/cm2, PSI)

23.50–25–12PR 0.16 MPa (1.6 kgf/cm2, 22.72 PSI)
3-35
24.3 CHECK BEFORE STARTING

Always carry out the checks in this section before starting the
engine each day.
24.3.1 CHECK COOLANT LEVEL, ADD WATER

 WARNING
Normally, do not open the radiator cap. When checking the
cooling water level, check the sub-tank when the engine is cold.
1. Check that the cooling water is between the FULL and LOW
marks on sub-tank 1. If the water level is low, add water to the
FULL level through the water filler port in sub-tank 1.
2. After adding water, tighten the cap securely.
3. If the sub-tank is empty, check for leakage of water and confirm

that the radiator main tank is full, then add water to the radiator
sub-tank.
NOTICE
If the volume of coolant added is more than usual, check for
possible water leakage.
Confirm that there is no oil in the coolant.
REMARK
In summer, the coolant may overflow from the sub-tank drain
hose. This is no problem. It occurs because too much coolant has
been added.
3-36
24.3.2 CHECK FUEL LEVEL, ADD FUEL

 WARNING
When adding fuel, never let the fuel overflow. This may cause
a fire. If you spill any fuel, thoroughly clean up all the spillage.
1. Turn the engine starting switch to the ON position and check the
fuel level with fuel level gauge G.
After checking, turn the switch back to the OFF position.
2. After completing work, fill the fuel tank through oil filler port F.
3. After adding fuel, tighten the cap securely.
Fuel capacity: 500 ¬ (132.0 US gal, 110.0 UK gal)
NOTICE
If breather hole 1 in the cap becomes clogged, the pressure
inside the tank will go down and the fuel may not flow, so clean the
breather hole from time to time.
AD054210
24.3.3 DRAIN WATER AND SEDIMENT IN FUEL TANK

Loosen fuel tank drain valve 1 and drain the sediment and
water, accumulated at the bottom, together with fuel.
REMARK
The fuel will not be drained if it is not above the installation
position of drain valve 1 on the tank.
3-37
24.3.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL

1. Open the side cover on the right side at the rear of the chassis.
2. Remove dipstick G and wipe the oil off with a cloth.

G.
If the oil level is below the L mark, and engine oil through oil filler
F.
H
5. If the oil is above the H mark, drain the excess engine oil from L
drain plug P, and check the oil level again. AD052340
6. If the oil level is correct, tighten the oil filler cap securely and
close the engine side cover.
REMARK
When checking the oil level after the engine has been operated,
wait for at least 15 minutes after stopping the engine before check-
ing. If the machine is at an angle, make it horizontal before checking.
3-38
24.3.5 CHECK DUST INDICATOR

1. Check that the red piston has not appeared in the transparent
portion of dust indicator 1.
2. If the red piston has appeared, clean or replace the element

immediately.
For details of the method of cleaning the element, see “24.2

WHEN REQUIRED”.
3. After checking, cleaning, and replacing, press the knob of dust

indicator 1 to return the red piston to its original position.
AE073060
24.3.6 CHECK ELECTRIC WIRING

 WARNING
‡ If fuses are frequently blown or if there are traces of short
circuit on the electrical wiring, locate the cause and carry out
repair.
‡ Accumulation of flammable material (dead leaves, twigs,
grass, etc.) around the battery may cause fires, so always,
check and remove such material.
‡ Keep the top surface of the battery clean and check the
breather hole in the battery cap. If it is clogged with dirt or
dust, wash the battery cap to clear the breather hole.
Check for damage and wrong capacity of the fuse and any sign
of disconnection or short circuit in the electric wiring. Check also for
loose terminals and tighten any loose parts.
Check the wiring of the “battery”, “starting motor” and “alter-
nator” carefully, in particular.
When carrying out walk-around checks or checks before starting,

always check if there is any accumulation of flammable material
around the battery, and remove such flammable material.
Please contact your Komatsu distributor for investigation and
correction of the cause.
3-39
24.3.7 HAVE ANY DEFECTS WHICH WERE FOUND

DURING THE PREVIOUS DAY’S OPERATION BEEN
CORRECTED?
24.3.8 CHECK AND REFILL WITH WINDOW WASHING

FLUID
If the washer fluid level is low, and fluid through cap 1.
24.3.9 CHECK AND ADJUST STEERING WHEEL

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

WATER SEPARATOR, DRAIN WATER
The water separator separates water mixed in the fuel. If float 2
is at or above red line 1, drain the water according to the following
procedure:
1. Loosen drain plug 3 and drain the accumulated water until the
float reaches the bottom.
AE082240
2. Tighten drain plug 3.
3. If the air is sucked into fuel line when draining the water, be sure
to bleed air in the same manner as for the fuel filter. See “24.6
3-40
24.3.11 CHECK THAT RISE IN AIR PRESSURE IS

NORMAL
If the pressure inside the air tank is 0, it should be possible to
charge the tank with air to raise the indicator of the air pressure
gauge to the green range under the following conditions.
By running the engine at low idling for approx. 2 minutes, or by
running it at full throttle for less than 1.5 minutes.
24.3.12 CHECK THAT FLASHING OF LAMPS IS

NORMAL, CHECK FOR DIRT OR DAMAGE
24.3.13 CHECK THAT DIRECTION OF BACKUP MIRROR

IS CORRECT, CHECK FOR DIRT OR DAMAGE
24.3.14 CHECK OPERATION OF HORN
24.3.15 CHECK ENGINE EXHAUST COLOR AND

SOUND
24.3.16 CHECK OPERATION OF GAUGES
24.3.17 CHECK INFLATION PRESSURE OF TIRES

Check for damage or wear to the tires and the rims.
Check for loose wheel hub nuts (bolts).
Tire size Inflation pressure MPa (kgf/cm2, PSI)

23.50–25–12PR 0.16 MPa (1.6 kgf/cm2, 22.72 PSI)
3-41
24.4 EVERY 50 HOURS SERVICE

24.4.1 GREASE BLADE GUIDE RAIL
 WARNING
‡ Apply the parking brake, and secure the front and rear frame
‡ Set the work equipment in a stable condition, and stop the
engine.
Apply grease all over the guide rail.
24.4.2 INSPECT WEAR OF BLADE GUIDE

 WARNING
‡ Apply the parking brake and secure the front and rear frames
with the articulation lock pin.
‡ Set the work equipment in a stable condition and stop the
engine.
1. Check if distances (wear tolerances) a1, a2 and a3 between the

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

replaced.
3-42

Maintenance for the 50 hours service should be carried out at
the same time.
24.5.1 LUBRICATING
 WARNING
engine.
 CAUTION
Do not insert your finger into any of the holes at the 15 greasing
points.
1. Using a grease pump, pump in grease through the grease

fittings shown by arrows.
2. After greasing, wipe off any old grease that was pushed out.
1. Leaning cylinder pin (1 point)

2. Tie rod (2 points)
3. Steering linkage (6 points)
4. Steering cylinder pin (4 points)
5. Drawbar ball joint (1 point)
6. Front axle center pin (1 point)
7. Front axle king pin (6 points)
3-43
8. Blade lift cylinder yoke (4 points)

9. Blade lift cylinder ball joint (2 points)
10. Drawbar side shift cylinder ball joint (2 points)
11. Bank control guide (2 points)
12. Articulation center pin and articulation cylinder pin (6 points)
13. Blade lifter guide (2 points)
14. Ripper cylinder (3 points)
15. Bank control lock pin (2 points)
Lower the blade to the ground, set the lifter lock switch to the
RETRACT position, then remove the lock pin, and add grease
to the bushing from the front.
16. Ripper rod (8 points)
17. Power tilt cylinder (2 points)
3-44
24.5.2 CHECK OIL LEVEL IN TRANSMISSION CASE,

ADD OIL
 WARNING
‡ The oil if at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before
starting the operation.
‡ Normally, check the oil level with the engine stopped.
‡ If the oil level is measured with the engine idling, always do
as follows.
fi Before inspecting, place the shift lock lever at the LOCK
position and set all levers at the neutral position to ensure
that the machine does not move.
fi After starting the engine, run until the oil level is stable,
then wait for a further 5 minutes, and measure the oil level
with the RUNNING marks.
1. Stop the engine, remove dipstick G, and leave for at least 5

minutes.
2. Wipe dipstick G with a cloth.
4. Check that the oil level is between the H and L marks for STOP
on dipstick G.
If the oil level is below the L mark, add engine oil through oil filler
F.
NOTICE
The dipstick is marked on one side with the levels for STOP
(engine stopped) and RUNNING (engine idling).
Always check the level using the STOP marks.
5. If the oil is above the H mark, drain the excess engine oil from
drain plug P, and check the oil level again.
6. If the oil level is correct, insert dipstick G in the oil filler tube.
3-45
24.5.3 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

 WARNING
The oil is at high temperature immediately after the machine
has been operated. Wait for the oil to cool down before starting
the operation.
1. Stop the engine, and leave it for 5 minutes.
2. Open the right side cover and lower plate.
3. Remove dipstick G, and wipe the oil off with a cloth

G.
If the oil level is below the L mark, add engine oil through oil filler
F.
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. H
L
AD052340
7. If the oil level is correct insert dipstick G the oil filler pipe.
3-46
24.5.4 CHECK OIL LEVEL IN TANDEM DRIVE CASE,

ADD OIL
 WARNING
the operation.
2. Remove dipstick G, and wipe the oil off with a cloth.

G. If the oil level below the L mark, add engine oil through oil
filler F.
6. If the oil level is correct, insert dipstick G the oil filler pipe.
3-47
24.5.5 CHECK OIL LEVEL IN CIRCLE REVERSE GEAR

CASE, ADD OIL
 WARNING
operation.
2. Remove oil filler plug F, and check that the oil level is up to the
top surface of the gear inside.
3. If the oil level is not up to the top surface of the gear, add engine
oil through the oil filler port.
4. If the oil level is correct, install oil filler plug F.
REMARK
There may be wear particles in the oil, but there is no problem
using the oil as it is.
3-48
24.5.6 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

 WARNING
When removing the oil filler cap, oil may spurt out, so stop the
engine and wait for the oil temperature to go down, then turn
the cap slowly to release the internal pressure before removing
the cap.
NOTICE
Do not add oil if the level is above the H line. This will damage
the hydraulic equipment and cause the oil to spurt out.
1. Set the machine in position as follows to check the oil level.

‡ Return the leaning of the front tires to the upright position
and face the wheels straight to the front.
‡ Set the front frame and rear frame facing straight (articulated
angle = 0°).
‡ Return the drawbar sideshift and blade sideshift to the center
of the machine, set the blade at right angles to the chassis
and lower it lightly to the ground.
‡ Raise the ripper to the maximum height, and put a block
under the ripper.
2. Open the side panel.
3. Stop the engine, wait for 5 minutes, then check that the oil level
is between the H and L marks on sight gauge G.
4. If the oil level is below the L mark, add engine oil through oil filler
F.
3-49
24.5.7 CHANGE OIL IN ENGINE OIL PAN, REPLACE

ENGINE OIL FILTER CARTRIDGE
 WARNING
The oil is at high temperature after the engine has been oper-
ated, so never change the oil immediately after finishing opera-
tions. Wait for the oil to cool down before changing it.
Prepare the followings.

‡ Container to catch drained oil: Min 34¬ capacity
‡ Refill capacity: 34 ¬ (8.98 US gal, 7.48 UK gal)
‡ Filter wrench
1. Open the engine side cover on the right side of the chassis.
2. Open oil filler F.
3. Set a container to catch the oil directly under drain plug P under
the chassis.
4. Loosen drain plug P, and drain the oil.
5. Check the drained oil, and if there are excessive metal particles
or foreign material, please contact your Komatsu distributor.
6. Install drain plug P.
7. Using a filter wrench, turn filter cartridge 1 counterclockwise to

remove it.
In particular, if this operation is carried out immediately after
stopping the engine, a large amount of oil will come out, so wait
for 10 minutes before starting the operation.
8. Clean the filter holder, coat the packing surface of a new filter
cartridge with engine oil (or coat it thinly with grease), then
install it to the filter holder.
9. When installing, tighten until the packing surface contacts the

seal surface of the filter holder, then tighten it up 3/4 to 1 of a
turn.
3-50
10. After replacing the filter cartridge, add engine oil through oil
filler F until the oil level is between the H and L marks on the
dipstick.
AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. H
L
11. Run the engine at idling for a short time, then stop the engine,
AD052340
and check that the oil level is between the H and L marks on the
dipstick. For details, see “24.3 CHECK BEFORE STARTING”.
Even if the machine has not been operated for 250 hours, the oil
and filter cartridge must be replaced when the machine has been
operated for 6 months.
In the same way, even if the machine has not been operated for
6 months, the oil and filter cartridge must be replaced when the
machine has been operated for 250 hours.
24.5.8 CHECK FAN BELT TENSION, ADJUST

Checking
The belt should normally deflect by about 6 mm (0.315 in) when
pressed with the finger (with a force of approx. 58.8 N (6 kgf)) at a
point midway between the fan pulley and tension pulley.
Adjusting
1. Loosen nut 1.
2. Use adjust bolt 2 to move tension pulley 3 so that the deflec-

tion of the belt is approx. 6 mm (0.315 in) (at a pressure of
approx. 58.8 N (6 kgf)).
3. Tighten nut 1 to fix tension pulley 3.
4. Check each pulley for damage, wear of the V-groove, and wear
of the V-belt. In particular, be sure to check that the V-belt is not
touching the bottom of the V-groove.
5. If any belt has stretched and there is no allowance for adjust-

ment, or if there are cuts or cracks on any belt, replace both belts
at the same time.
6. When the new belt is set, readjust it after operation for an hour.
3-51
24.5.9 CHECK ALTERNATOR BELT TENSION, ADJUST

Checking
The belt tension should normally deflect by about 15 mm (0.6 in)
when pressed with the finger at a point midway between the
alternator pulley and the accessory pulley (with a force of approx.
58.8 N (6 kgf)).
Adjusting
1. Loosen the nuts and bolts in the order 1 to 6, then move
alternator 8 to the side to adjust the belt tension. Adjust the
tension of the bolt with nut 7 as follows.
TIGHTEN nut to INCREASE tension
LOOSEN nut to DECREASE tension
2. After adjusting the belt tension, tighten the nuts and bolts in the
order 1 to 6. Finally, tighten nut 7.
4. Tighten the bolts and nuts 2, 3 to fix alternator 1 in position.

at the same time.
REMARK
When adjusting the V-belt, do not push alternator 8 directly with
a bar. Insert a wooden block and push the wooden block with the
bar.
3-52
24.5.10 CHECK AIR CONDITIONER BELT TENSION,

ADJUST
Checking
The belt should normally defect by about 12 mm (0.5 in) when
pressed with the finger (with a force of approx. 58.8 N (6 kgf)) at a
point midway between the compressor pulley and fan pulley.
Adjusting
1. Insert a bar between compressor 1 and the cylinder block, and
hold compressor 1 in position.
When holding compressor 1 in position, put a wooden block
between the bar and compressor 1 to prevent damage to the
compressor.
2. Loosen bolts and nuts 2, 3.
3. Use the bar to move compressor 1 so that the deflection of the

belt is approx. 12 mm (0.5 in) (at a pressure of approx. 58.8 N
(6 kgf)).
4. Tighten the bolts and nuts 2, 3 to fix compressor 1 in position.

at the same time.
7. When the new belt is set, readjust it after operation for an hour.
3-53
24.5.11 CHECK LEVEL OF BATTERY ELECTROLYTE

Carry out this check before operating the machine.
WARNING
‡ Do not use the battery if the battery electrolyte level is below
the LOWER LEVEL line. This will accelerate deterioration of
the inside of the battery and reduce the service life of the
battery. In addition, it may also cause an explosion.
‡ The battery generates flammable gas and there is danger of
explosion, so do not bring fire or sparks near the battery.
‡ Battery electrolyte is dangerous. If it gets in your eyes or on
your skin, wash it off with large amount of water and consult
a doctor.
‡ When adding distilled water to the battery, do not allow the
battery electrolyte to go above the UPPER LEVEL line. If the
electrolyte level is too high, it may leak and cause damage to
the paint surface or corrode other parts.
NOTICE
When adding distilled water in cold weather, add it before
starting operations in the morning to prevent the electrolyte from
freezing.
Inspect the battery electrolyte level at least once a month and

follow the basic safety procedures given below.
WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY

If it is possible to check the electrolyte level from the side of the
battery, check as follows.
1. Open the battery cover.
2. Use a wet cloth to clean the area around the electrolyte level
lines and check that the electrolyte level is between the UPPER
LEVEL (U.L) and LOWER LEVEL (L.L) lines.
If the battery is wiped with a dry cloth, static electricity may
cause a fire or explosion.
3. If the electrolyte level is below the midway point between the U.L
and L.L lines, remove cap 1 and add distilled water to the U.L
line.
4. After adding distilled water, tighten cap 1 securely.
REMARK
If distilled water is added to above the U.L line, use a pipette 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.
3-54
WHEN IT IS IMPOSSIBLE TO CHECK ELECTROLYTE LEVEL FROM

SIDE OF BATTERY
If it is impossible to check the electrolyte level from the side of
the battery, or there is no display of the UPPER LEVEL line on the
side of the battery, check as follows.
1. Open the battery cover.
2. Remove cap 1 at the top of the battery, look through the water
filler port, and check the electrolyte surface. If the electrolyte
does not reach the sleeve, add distilled water so that the level
reaches the bottom of the sleeve (UPPER LEVEL line) without fail.
Use the diagram below for reference, and check if the electrolyte
reaches the bottom of the sleeve.
3. After adding distilled water, tighten cap 1 securely.
REMARK
If distilled water is added to above the bottom of the sleeve, use
a pipette 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 ELECTRO-

LYTE LEVEL
If it is possible to use and indicator to check the electrolyte level,
follow the instructions given.
3-55
24.5.12 CHECK BALL JOINT CLEARANCE, ADJUST

‡ Feeler gauge
There are ball joints at the places shown in the diagram on
the right, so inspect and adjust all of these places.
1. Remove all the shims 1 from the ball joint.
2. Tighten the caps with bolts 2 to make the same clearance on the
left and right.
3. Measure the clearance with a feeler gauge, then insert one shim
more than this dimension, and tighten the cap.
Thickness of one shim: 0.2 mm, 0.5 mm
24.5.13 CHECK AND TIGHTEN WHEEL HUB NUT

Loose wheel hub nuts 1 will result in shortened life of tires or
other troubles.
1. Carefully check for loose nuts.

When checking for loose nuts, always turn the nut in the tight-
ening direction to check.
Tightening torque: 1960 – 2450 N•m

(200 – 250 kgf•m, 1446.6 – 1808.3 lbft)
2. Check all the nuts for loosening. Also, check the rim for damage.
If a hub bolt is broken, replace all the hub bolts.
3-56
24.5.14 CHECK WHEEL BRAKE ADJUST

 WARNING
Since a small amount of oil may come out from inspection plug
hole 2, do not peep through the plug wheel when the brake is
being applied.
1. Remove only one wheel at the front of the tandem on the left or
right side.
If the wheel is not worn much, it is not necessary to inspect the
three remaining wheels. If it is worn, inspect all the wheels.
REMARK
Before installing or removing tires, please contact your Komatsu
distributor.
2. Remove cage 1 inspection plug 2.
3. Depress the brake pedal to keep the brake applied.
4. Carry out inspection as illustrated below.

If the gap disappears between the inspection hole edge and
separator plate 3, ask a Komatsu distributor to replace the disc.
5. Remove the drain plug P from the cage 1, and measure the
amount of oil leaking into the piston chamber.
6. If there is no leakage, the seal is functioning properly.
7. If the amount of leakage is more than 0.02¬, please contact your

Komatsu distributor for replacement of the seal.
8. Install cage 1 inspection plug 2 and the drain plug P.
9. Install the tire.
3-57

Maintenance for every 50 and 250 hours should be carried out
at the same time.
24.6.1 REPLACE FUEL FILTER CARTRIDGE

 WARNING
‡ Engine is at high temperature immediately after the machine
has been operated. Wait for engine to cool down before
replacing the filter.
‡ Do not bring fire or sparks near the fuel.
Prepare a filter wrench and a container to catch the fuel.
1. Open the engine side cover on the right side of the chassis.
2. Set the container under the filter cartridge to catch the fuel.
3. Using a filter wrench, turn filter cartridge 1 counterclockwise to

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

seal surface of the filter holder, then tighten it a further 1/2 to 3/4
of a turn.
If the filter cartridge is tightened too far, the packing will be
damaged and this will lead to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing, so
always tighten to the correct amount.
6. After replacing filter cartridge 1, loosen air bleed plug 2.
7. Loosen feed pump knob 3 and move the pump knob up and
down to draw off fuel until air ceases to come out of air bleed
plug 2.
8. Tighten air bleed plug 2.
3-58
9. Tighten up air bleed plug 2. Push in the knob of feed pump 3

and tighten it.
10. After replacing the filter cartridge, start the engine and check that
there is no leakage of fuel from the filter seal surface. If there is
any leakage of fuel, check the tightening of the filter cartridge.
Whenever there is leakage of fuel, follow
Steps 2 and 3 to remove the filter cartridge, then check the
packing surface for damage or foreign material. If any damage
or foreign material is found in the packing, replace the packing
with a new part, then repeat Steps 4 – 9 to install the filter
cartridge.
3-59
24.6.2 CLEAN, CHECK RADIATOR FINS

 WARNING
If compressed air, steam, or water hit your body directly, there
is danger of injury. Always wear protective glasses, mask, and
safety shoes.
When cleaning, use a maximum pressure of less than 0.2 MPa
(2.0 kgf/cm2, 28.4 PSI).
Clean the radiator fins if any mud or dirt is stuck to the radiator.
1. Remove bolts 1 and panel 2.
2. Clean the radiator fins clogged with mud, dust and leaves with
compressed air. Steam or water may be used instead of com-
pressed air.
3. Check the rubber hoses. If the hose is found to have cracks to be

hardened by ageing, replace such hoses with new ones.
3-60
24.6.3 CHECK CIRCLE GUIDE CLEARANCE, ADJUST

 WARNING
Before stating the adjustment, confirm that there are gaps
between the tooth crest of the circle gear and root of the circle
pinion and between the tooth crest of the circle pinion and root
of the circle gear. If there is no gap, replace the guide before
starting the adjustment.
Checking
 WARNING
When raising the blade, do not raise it higher than necessary.
1. Raise the blade from the ground.
2. Measure the clearance at portion P with a feeler gauge.

Standard clearance: 1.5 ± 0.5 mm
1 – 2 mm (0.039 – 0.079 in)
3. Measure the clearances at portions F, C, and R.

Standard value: F = 0, C = 0.7 mm (0.028 in),
R = 1.5 mm (0.059 in)
or F = C = R = 1 mm (0.039 in)
F is the clearance for the guide at the front.

C is the clearance for the guide at the center.
R is the clearance for the guide at the rear.
4. If the clearance for portions P, F, C, and R are not the above

values, adjust as follows.
3-61
Adjustment
1. Raise the blade so that the drawbar is parallel to the ground
surface, then set dimension E between the ground surface and
the end of the blade edge to approx. 30 mm (1.2 in).
2. Loosen bolt 1, put portions F, C, and R of circle 5 and circle

guide 2, 3, and 4 in contact, then adjust shim 6 so that
clearance P between the top face of the circle and bottom face
of the drawbar is 1 – 2 mm (0.039 – 0.079).
3. Loosen locknut 7, then tighten pushing bolt 8 of rear circle

guide 4 to move the whole circle to the rear and adjust to give
dimension H of 35.9 – 56.0 mm (1.4 – 2.2 in) between machined
surface 9 of the case at the bottom of the pinion gear and the
circle and circle guide contact surface 0.
REMARK
When not using circle guide pusher bolt 8 to carry out the
movement, use a lever block.
4. Loosen locknut B, tighten pushing bolt C of front circle guide

2 to maintain clearance H between machined surface 9 of the
case at the bottom of the pinion gear and the circle and circle
guide contact surface 0, then tighten locknut B.
5. Check clearance H between machined surface 9 of the case at

the bottom of pinion gear and the circle and circle guide contact
surface 0 again. Then loosen locknut D, tighten pusher bolt E
of center circle guide 3, set clearance C between center circle
guide 3 and circle 5 to 0.7 mm (0.028 in), then tighten locknut D.
6. Adjust pusher bolt 8 so that clearance R between rear circle

guide 4 and circle 5 is 1.5 mm (0.059 in), then tighten locknut
7.
7. Tighten bolt 1 and locknuts 7, B, and D.
3-62
8. Coat the sliding surface of the circle guide with lubricant (LM-P).
9. Check that it rotates also at the left and right 90° high bank
positions.
NOTICE
If the following condition is reached, replace the wear plate of
the circle guide.
When dimension A of wear plate F or dimensions B or C of wear
plate G become 2 mm.
3-63
24.6.4 CHECK PARKING BRAKE LEVEL STROKE, ADJUST

Checking
1. Place the gear shift lever in “P (Parking)” position, then confirm
that slack adjuster move smoothly.
2. Check that the angle of the slack adjuster and push rod 2 of
brake chamber 1 is slightly more than 90°.
3. When checking the effect of the parking brake, place the gear-
shift lever at the P position (parking brake applied) set the gear
at F8, run the engine at full throttle, then slowly release the
inching pedal and check that the engine stops within 3 seconds
of the power being transmitted.
The parking brake effect test applies a large force to the drive
system, and also applies excessive force to the transmission, so
do not check more than necessary.
Adjustment
Adjust the stroke by turning worm shaft 1 with a wrench. When
doing this, adjust 1 notch at a time so that ball 2 ships into the ball
stop position (hole 3 made to take the ball) of worm shaft 1.
3-64
24.6.5 CHECKING, ADJUST SLIP LOAD OF

CLUTCH FOR CIRCLE REVERSE
 WARNING
When jacking up the front tire, put blocks under the frame at the
center of the front axle for safety.
Checking
2. Push the blade against the ground to prevent the circle from
rotating, and jack up the front wheels or secure the end of the
blade.
‡ Method of jacking up front wheels

1) Lower the work equipment, and place the gear shift lever at
the N position.
2) Lower the blade and raise the front tires from the ground.
3) Put a block under the frame at the center of the front axle.
3. Operate the blade rotation lever and check if the clutch slips.
‡ Method of checking slip

1) If there is slippage, a sliding noise can be heard, and when
the blade turns a little at a time, vertical shaft end holder 4
turns more than the blade. Return the blade rotation control
lever to neutral to stop the slippage. (Check the condition at
the border point between slippage and no slippage.)
2) In this condition, loosen bolt 3, remove holder 4, then take

out 1 shim 5 (0.2 mm (0.008 in)).
4. Install holder 4, tighten bolt 3, then install cover 2 with bolt

1.
3-65
Adjustment
‡ Order for tightening bolts
If clutch does not slip
1. Loosen bolts 3 and remove holder 4, then add one 0.2 mm
(0.008 in) shim 5.
2. Go back to the section on inspection for slippage, repeat the

operation until there is slippage, and align with the slip limit
point.
3. Align with the border point, loosen bolt 3, remove holder 4,

then take out 1 shim 5 (0.2 mm (0.008 in)).
If clutch slips
1. Loosen bolts 3 and remove holder 4, then add one 0.2 mm
(0.008 in) shim 5.
2. Go back to the section on inspection for slippage, and repeat the

operation until there is no slippage.
3. When the slippage stops, loosen bolts 3, then add one 0.2 mm
(0.008 in) shim 2 and align with the slip limit point.
4. Align with the border point, loosen bolt 3, remove holder 4,

then take out 1 shim 5 (0.2 mm (0.008 in)).
REMARK
If a shim is added, the pushing force of the belleville spring is
reduced, so it becomes easier for the clutch to slip.
If a shim is removed, the pushing force of the belleville spring is
increased, so it becomes more difficult for the clutch to slip.
3-66

Maintenance for every 50, 250 and 500 hours should be carried
out at the same time.
24.7.1 GREASE DRIVE SHAFT (2 POINTS)

 WARNING
engine.
1. Using a grease pump, pump in grease through the grease

fittings shown by arrows.
2. After greasing, wipe off any old grease that was pushed out.
3-67
24.7.2 CHANGE OIL IN TRANSMISSION CASE, CLEAN

STRAINER
 WARNING
the operation.
Prepare the following.

‡ Container to catch drained oil: Min 25 ¬ (6.60 US gal 5.50 UK gal)
capacity
‡ Refill capacity: 25 ¬ (6.60 US gal 5.50 UK gal)
1. Remove the under cover and set a container under the transmis-
sion case to catch the oil.
2. To prevent getting oil on yourself, loosen drain plug P and drain

the oil.
To prevent the oil from spurting out, loosen drain plug P, then
gradually remove it.
3. After draining the oil, tighten drain plug P.

Tightening torque: 127 – 177 N·m
(13 – 18 kgf·m, 94.0 – 130.2 lbft)
4. After removing bolts 1, remove tube 2, then remove bolts 4

and cover 3, take out strainer 5, and wash it.
5. Remove all the dirt stuck to strainer 5, then wash it in clean

diesel oil or flushing oil. If strainer 5 is damaged, replace it with
a new part.
6. After washing strainer 5, install it, then install cover 3 with

bolts 4, and install tube 2 with bolts 1.
7. Refill the specified quantity of engine oil through oil filler F.
8. After refilling, check that the oil is at the specified level. For
details, see “24.5 EVERY 250 HOURS SERVICE”.
9. Check that there is no leakage of oil from the transmission case

or oil filter.
3-68
24.7.3 REPLACE TRANSMISSION OIL FILTER ELEMENT

Prepare a container to catch the oil
1. Set a container under the filter case to catch the oil.
2. Remove drain plug 1 at the bottom of the filter case, drain the
oil, then tighten the drain plug again.
3. Hold case 2 and loosen center bolt 3, then remove case 2.
4. Take out the element and wash the inside of the case.
5. Replace the filter gasket and O-ring with new parts. Coat the
gasket and O-ring thinly with clean engine oil before installing.
6. Assemble the new element in the case, then install the case with
center bolt 3.
When installing center bolt 3, install so that chamfered portion
4 of the washer comes on the same side as the hexagonal head
of the center bolt.
Be careful not to tighten center bolt 3 too much.
Tightening torque: 167 – 196 N·m
(17 – 20 kgf·m, 123.0 – 144.7 lbft)
7. Run the engine for a short time at low idling, then stop the
engine and check that the oil is at the specified level. For details,
see “24.5 EVERY 250 HOURS SERVICE”.
3-69
24.7.4 CHANGE OIL IN FINAL DRIVE CASE, CLEAN

STRAINER
 WARNING
the operation.

‡ Container to catch drained oil: Min. 57 ¬ (15.05 US gal, 12.54
UK gal) capacity
1. Remove the under cover and set a container under the final drive
case to catch the oil.

the oil.

Tightening torque: 58.8 – 78.5 N·m
(6 – 8 kgf·m, 43.4 – 57.9 lbft)
4. Remove 4 bolts 1, then remove cover 2 and take out strainer

3.
5. Remove all the dirt stuck to strainer 3, then wash it in clean

diesel oil or flushing oil. If strainer 3 is damaged, replace it with
a new part.
6. After washing strainer 3, install it, then install cover 2 with

bolts 1.
7. Refill the specified quantity of engine oil through oil filler F.
8. After refilling, check that the oil is at the specified level. For
details, see “24.5 EVERY 250 HOURS SERVICE”.
9. Check for oil leakage from the final drive case.
3-70
24.7.5 CHANGE OIL IN HYDRAULIC TANK

 WARNING
has been operated. Wait for the oil to cool down before chang-
ing the oil. When removing the oil filler cap, turn it slowly to
release the internal pressure, then remove it carefully.

‡ Container to catch drained oil: Min. 80 ¬ (21.12 US gal, 17.60 UK
gal) capacity
1. Set the machine in position as follows to check the oil level.

‡ Return the leaning of the front tires to the upright position
and face the wheels straight to the front.
‡ Set the front frame and rear frame facing straight (articulated
angle = 0°).
‡ Return the drawbar sideshift and blade side shift to the
center of the machine, set the blade at right angles to the
chassis and lower it lightly to the ground.
‡ Raise the ripper to the maximum height, and put a block
under the ripper.
2. Loosen oil filler port F slowly to completely release the air inside
the hydraulic tank.
3. Set the container under drain plug P to catch the oil.

the oil.

Tightening torque: 58.8 – 78.5 N·m
(6 – 8 kgf·m, 43.4 – 57.9 lbft)
6. Add the specified quantity of engine oil through oil filler F.
7. Check that the oil is at the specified level.
For details, see “24.5 EVERY 250 HOURS SERVICE”.
8. Install cap F.
9. Run the engine at low idling, and extend and retract each
cylinder 4 – 5 times to a point approx. 100 mm (3.9 in) before the
end of its stroke.
3-71
NOTICE
If the engine is run immediately at high speed or the cylinder is
operated to the end of its stroke, the air inside the cylinder will
damage the piston packing.
10. Next, operate each cylinder 3 – 4 times to the end of its stroke.
3-72
24.7.6 REPLACE RETURN FILTER ELEMENT AND CLEAN

SUCTION STRAINER IN HYDRAULIC TANK
1. Remove bolt 1, then remove hose 2 from filter assembly 3.
2. Remove 4 bolts 4, then remove filter assembly 3 from the

hydraulic tank.
(The other bolts are used to install the filter head and case, so
do not remove them.)
3. Remove 4 bolts 5, then remove filter head cover 6.
4. Remove the filter element, clean the filter case and the removed
parts, then install a new filter element.
5. Install filter head cover 6 with bolts 5.
6. Install filter assembly 3 to the hydraulic tank.
7. Remove bolt 7 of the suction strainer, then remove cover 8.
8. Remove the strainer, wash the strainer and remove parts, then
install them to the hydraulic tank again.
9. Install cover 8 with bolt 7.
3-73
24.7.7 CHECK LOOSENESS IN DRAWBAR FRONT BALL

JOINT AND BALL STUD
Check ball joint connecting nuts 1 and ball stud connecting bolt
2 at the front of the drawbar for loosening. If the connecting portion
are loose, retighten them.
3-74
24.7.8 CHECK TOE-IN, ADJUST

How to measure toe-in:
Check toe-in and adjust it so that no side slip is caused. When
no side slip tester is available, use the following procedure.
1. Park the grader on a level ground without steering and leaning

the wheels.
Be sure to drive straight at least a few meters before parking.
2. Measure the height from the ground to the center of the front
wheel axle.
3. Mark the same dimension as measured in step 2 at about the

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

This distance is called “A”.
5. Next, drive the machine forward slowly to move the marks on

the tire to the rear, and stop the machine when the marks come
to the same position as the height from the ground to the center
of the front axle.
Always travel forward when doing this.
h h
AE157130
6. Measure the distance between the two marks.

This distance is called “B”.
7. When toe-in (B – A) is adjusted to –4 – 6 mm (–0.158 – 0.236 in)

of standard range, side slip is decreased to zero.
If any value other than the standard range is measured, adjust
toe-in using the following procedure.
3-75
How to Adjust Toe-in:

NOTICE
When adjusting, make sure that the front axle is horizontal and
that the front wheels are not leaning.
1. Loosen tightening nut 1, fit a wrench to corner 2 of the tie rod,

then turn the left and right tie rods as shown in the diagram on
the right to adjust as follows.
To INCREASE toe-in, turn in DIRECTION OF ARROW
To DECREASE toe-in, turn in OPPOSITE DIRECTION
Amount of extension for one turn of left or right tie rod in
direction of extension: 9 mm
2. After adjusting, tighten tightening nut 1.
AE157151
24.7.9 CHECK FRONT WHEEL BEARING PLAY, ADJUST

Please ask your Komatsu distributor to carry out this inspection
and adjustment.
24.7.10 CHECK FOR LOOSE ROPS MOUNT BOLTS

Check for loose and damaged bolts. If any loose bolt is found.
If any damaged bolt is found, replace the bolt with a genuine
Komatsu bolt.
3-76
24.7.11 REPLACING AIR DRYER DESICCANT

Loosen bolts 1 of the air dryer, take out the desiccant, and
replace it with new desiccant.
NOTICE
‡ Be careful not to get oil on the desiccant. This will reduce the
ability of the air dryer to absorb water.
‡ After replacing, check the air pressure, then start the machine.
24.7.12 REPLACE CORROSION RESISTOR CARTRIDGE

1. Close valves 2 (2 places) on the upper side of the corrosion
resistor.
2. Using the filter wrench provided, remove cartridge 1 by turn-

ing it counterclockwise.
Fit a new cartridge after applying a dab of engine oil to the
packing face.
3. To fit the cartridge put the packing face in contact with the seal
face of the holder, the screw it up about 2/3 of a turn.
4. After replacement, open the valves.

Be sure to use a genuine Komatsu cartridge.
REMARK
After replacing the cartridge, start the engine and check that
there is no leakage of water from the filter seal surface.
3-77

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

‡ Capacity of container
to catch drained oil: Min. 1.8 ¬ (0.48 US gal, 0.40 UK gal)
‡ Refill oil volume: 0.9 ¬ (0.24 US gal, 0.20 UK gal) (each)
1. Set the front wheels in the normal position, then apply the
parking brake securely
2. Remove plugs 1 from the left and right front axle housings,
drain the oil, then tighten the plugs again.
3. Remove plug 2 and add engine oil through the plug hole to the
specified level.
Front details of the oil to use, see “20. USE OF FUEL, COOLANT
3-78
24.8.2 CHANGE OIL IN TANDEM DRIVE CASE

 WARNING
the operation.

‡ Container to catch drained oil: Min. 190 ¬
(50.16 US gal, 41.80 UK gal)
capacity
‡ Refill capacity: Each 95 ¬ (25.08 US gal, 20.90 UK gal)
2. Remove drain plug P and drain the oil.
3. After draining the oil, clean drain plug P and install it again.
4. Add engine oil to the specified level through the oil filler F.

3-79
24.8.3 CHANGE OIL IN CIRCLE REVERSE GEAR CASE

 WARNING
the operation.
For gear case

‡ Container to catch drained oil:Min. 8 ¬ (2.11 US gal, 1.76 UK gal)
capacity
2. Remove drain plug P and drain the oil.
3. After draining the oil, clean drain plug P and install it again.
4. Remove oil filler plug F and add gear oil to the specified level.
6. Install oil filler plug P.
NOTICE
There may be wear particles in the oil, but there is no problem
using the oil as it is.
3-80
24.8.4 CLEAN ENGINE BREATHER ELEMENT

1. Before removing the breather, wipe off all the dirt around the
breather.
2. Remove breather 1.
3. Wash the whole breather in diesel oil or flushing oil, then blow
it dry with compressed air.
4. Replace the breather O-ring with a new part, coat with engine oil,
and install it.
5. Install breather 1.
3-81
24.8.5 CLEAN BREATHER

Remove the breather and wash out dust remaining inside with
diesel oil and flushing oil.
1. Transmission case breather (1 point)
2. Final drive case breather (1 point)
3. Tanden case breather (2 points)
24.8.6 CHECK ALL TIGHTENING PARTS OF

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

Contact your Komatsu distributor to have the play checked.
24.8.8 CLEAN, CHECK TURBOCHARGER

If there is many carbon or oil sludge stuck to the blower impeller,
the capacity of the turbocharger will drop, or the turbocharger may
damaged, so please contact your Komatsu distributor.
3-82
24.8.9 CHECK ALTERNATOR, STARTING MOTOR

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

Contact your Komatsu distributor for inspection or adjustment.
24.8.11 CLEAN AND INSPECT INCHING

POTENTIOMETER SENSOR
1. Remove bolt 1 of the inching potentiometer sensor, then re-
move cover. 2.
2. Use a brush to remove all the dirt stuck to the top surface of
potentiometer sensor 3.
3. Use a cloth to wipe off all the grease stuck to hatched portion A
of the lever of potentiometer sensor 3, then coat thinly with
fresh grease (LM-G).
3-83

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

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

Check that there are no cracks or peeling in the outside surface
of the rubber.
If any cracks or peeling are found, contact your Komatsu dis-
tributor to have the parts replaced.
24.9.3 CHECK FAN PULLEY AND TENSION PULLEY

Check the pulley to see if there is any leaking grease. If any
abnormality is found, as your Komatsu distributor to repair or
replace it.
3-84
SPECIFICATIONS
4-1
25. SPECIFICATIONS
GD825A-2
WEIGHT
‡ OPERATING WEIGHT (with operator) (75 kg) 29,700 kg (65,489 lb)
PERFORMANCE
‡ Travel speed Forward 1st 4.0 km/h (2.5 MPH)
2nd 5.4 km/h (3.4 MPH)
3rd 8.0 km/h (5.0 MPH)
4th 11.5 km/h (7.1 MPH)
5th 15.8 km/h (9.8 PH)
6th 21.4 km/h (13.3 MPH)
7th 31.3 km/h (19.5 MPH)
8th 44.9 km/h (27.9 MPH)
Reverse 1st 4.3 km/h (2.7 MPH)
2nd 5.8 km/h (3.6 MPH)
3rd 8.5 km/h (5.3 MPH)
4th 12.2 km/h (7.6 MPH)
5th 16.9 km/h (10.5 MPH)
6th 22.8 km/h (14.2 MPH)
7th 33.4 km/h (20.8 MPH)
8th 47.9 km/h (29.8 MPH)
‡ Maximum drawbar pull 14,420 kg (31,796 lb)
‡ Minimum turning radius 7.9 m (25 ft 11 in)
‡ Ground clearance (to bottom of final drive case) 440 mm (17.3 in)
ENGINE
‡ Model Komatsu S6D140 diesel engine
‡ Flywheel horsepower 208.88 kW (280 HP)/2,100 rpm
‡ Starting motor 24 V 7.5 kW
‡ Alternator 24 V 50 V
‡ Battery 12 V 200 Ah x 2 pieces
4-2
25. SPECIFICATIONS
4-3
MEMO
4-4
OPTIONS, ATTACHMENTS
5-1
26. HANDLING EMERGENCY STEERING DEVICE
 WARNING
The emergency steering motor must not be operated continu-
ously for more than 30 seconds.
This system acts to prevent steering failure caused by a break-

down in the engine or hydraulic pump when the machine is being
operated.
If the pressure in the steering hydraulic circuit goes below 0.69
MPa (7 kg/cm2, 99.4 PSI), the pressure switch is turned ON, and the
electric motor
is actuated to turn the hydraulic pump and supply hydraulic pressure
to the steering circuit to make it possible to operate steering.
However, if the machine is traveling at less than 1 km/h (0.62

mph) (including when the machine is stopped), the steering is not
automatically actuated.
26.1 CHECKS
26.1.1 EVERY 500 HOURS SERVICE
 WARNING
When inspecting the emergency steering mechanism, or when
actuating it in an emergency, always keep the oil in the sub-tank
at the FULL level.
1. Check that AUTO/MANUAL selector switch is at the AUTO posi-

tion.
2. Start the engine and raise the front wheels of the ground with
the blade.
Normally keep the AUTO/MANUAL selector switch at the AUTO
position.
3. Stop the engine. Be sure to leave the starting switch at the ON

position.
4. Turn the AUTO/MANUAL selector switch to the “MANU” posi-

tion.
5. When the switch is operated, check that the alarm buzzer sounds
continuously and that the electric pump for the emergency
steering is operated.
6. Turn the steering wheel and check that the steering can be
operated without problem.
NOTICE
When checking items 5 and 6, do not continue the checks more
than 30 seconds.
5-2
26. HANDLING EMERGENCY STEERING DEVICE
7. Turn the AUTO/MANUAL selector switch to the AUTO position

and check that the monitor and warning lamps go out, and that
the electric pump for the emergency steering stops working.
NOTICE
If any abnormality occurs, turn the starting switch to the OFF
position to stop the whole system.
5-3
GD825A-2 MOTOR GRADER
Form No. SEAM021403T
©2002 7
All Rights Reserved

Printed in Japan 10-02 (01-1)

Manual de Operación GD825A-2

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SEAM021403T

Operation & Maintenance

SERIAL NUMBERS GD825A-2 -12107 and up

Copyright 2002 Komatsu

Safety precautions are described in SAFETY from page 1-1.

3.1 INTENDED USE

3.3 BREAKING IN THE MACHINE

During breaking in:

4.1 MACHINE SERIAL NO. PLATE POSITION

4.2 ENGINE SERIAL NO. PLATE POSITION

4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

Machine serial No.:

Engine serial No.:

Service personnel for your machine:

2. Safety information ............................................................................................................................ 0- 4

4. Location of plates, table to enter serial No. and distributor ...................................................... 0- 6

7. Precautions during operation .......................................................................................................... 1- 8

8. Precautions for maintenance ........................................................................................................... 1-21

9. Position for attaching safety labels ................................................................................................ 1-33

11. Explanation of components ............................................................................................................. 2- 5

12. Operation ............................................................................................................................................ 2- 39

13. Transportation ................................................................................................................................... 2-105

14. Cold weather operation ................................................................................................................... 2-107

15. Long-term storage ............................................................................................................................ 2-110

16. Troubleshooting ................................................................................................................................ 2-111

18. Outlines of service ............................................................................................................................ 3- 4

19. Wear parts list ................................................................................................................................... 3- 8

22. Periodic replacement of safety critical parts ................................................................................. 3-15

23. Maintenance schedule chart ............................................................................................................ 3-18

24. Service Procedure ............................................................................................................................. 3-22

This safety section also contains precautions for optional equip-

CLOTHING AND PERSONAL PROTECTIVE ITEMS

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR’S SEAT

MOUNTING AND DISMOUNTING

FIRE PREVENTION FOR FUEL, OIL, AND ANTIFREEZE

PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURE

ASBESTOS DUST HAZARD PREVENTION

INJURY FROM WORK EQUIPMENT

FIRE EXTINGUISHER AND FIRST AID KIT

PRECAUTIONS FOR ROPS

PRECAUTIONS FOR ATTACHMENTS

7.1 BEFORE STARTING ENGINE

CHECKS BEFORE STARTING ENGINE

WHEN STARTING ENGINE

7.2 AFTER STARTING ENGINE

CHECK DIRECTION BEFORE STARTING MACHINE

PRECAUTIONS WHEN SWINGING OR CHANGING

‡ Sound the horn to warn people in the area.

‡ Check that there is no one in the area around the machine.

‡ Ensure that no person can come within the turning radius or

PRECAUTIONS WHEN TRAVELING

INHIBITION OF DANGEROUS WORK

PRECAUTIONS DURING OPERATION

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Voltage Min. safety distance

METHOD OF USING BRAKES

OPERATE CAREFULLY ON SNOW

‡ When traveling on snow-covered roads, always fit tire chains.

WORKING ON LOOSE GROUND

‡ Always close the door of the operator’s compartment.

PRECAUTIONS IN COLD WEATHER

STARTING WITH BOOSTER CABLES

Starting with booster cables ➞ See ”16.4 IF BATTERY IS DISCHARGED”.