gd555-3c_keam038100t.pdf
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FOREWORDFOREWORD
FOREWORDThis manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard whenperforming operation and maintenance.
WARNINGOperators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand them fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have all personnel read it
periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications that are necessary for use in your country. If there is any question about whether your productcomplies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.
Storage location for the Operation and Maintenance Manual:
Pocket at rear of operator's seat
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FOREWORD FOREWORD
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATIONTo enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNINGTo avoid hitting unlocked operation levers, lower equipment to ground and
move SAFETY LOCK LEVER to LOCK position before starting up fromoperator's seat.
Sudden and unwanted machine movement can cause serious injury or
death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shortenthe life of the machine.
This word is used for information that is useful to know.
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FOREWORDSAFETY INFORMATION
Safety labels
Safety labels areaffixed to the machine to inform the operator or maintenanceworker on the spot when carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictogramsshow the type of hazardous condition at the top
or left side, and the method of avoiding the hazardous condition at
the bottomor right side.In addition,the type ofhazardouscondition
is displayed inside a triangle and the method of avoiding the
hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions.
If anyproceduresor actions not specificallyrecommended or allowed in this manualareused, it is your responsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example:1 -> (1))
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FOREWORD INTENDED USE
INTENDED USEThis Komatsu machine is designed to be used mainly for the following work:
Smoothing
Repair and maintenance of gravel roads
Snow-clearing operationsDitch digging
Cutting slope faces
Excavating operations
Mixed operations
Spreading operations
Front wheel offset operations
See the section "WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER (PAGE 3-68)" for further
details.
DIRECTIONS OF MACHINE
In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
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FOREWORDLOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. ANDDISTRIBUTORWhen requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NO. PLATE POSITIONThis is at the front of the rear frame on the left side of the machine.
ENGINE SERIAL NO. PLATE POSITIONThis is at the top of the right side of the engine cylinder head as seen from the fan.
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FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
SERVICE METER POSITIONThe meter is installed to the left side of the steering wheel column.
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORDCONTENTS
CONTENTSFOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTENDED USE 1- 7 DIRECTIONS OF MACHINE 1- 7
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 8
MACHINE SERIAL NO. PLATE POSITION 1- 8
ENGINE SERIAL NO. PLATE POSITION 1- 8
SERVICE METER POSITION 1- 9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9
SAFETY 2- 1
SAFETY INFORMATION 2- 2
SAFETY LABELS 2- 4
POSITION FOR ATTACHING SAFETY LABELS 2- 5
SAFETY LABELS 2- 6 GENERAL PRECAUTIONS 2- 11
PRECAUTIONS DURING OPERATION 2- 19
STARTING ENGINE 2- 19
OPERATION 2- 21
TRANSPORTATION 2- 25
BATTERY 2- 26
TOWING 2- 28
PRECAUTIONS FOR MAINTENANCE 2- 29
PRECAUTIONS WITH TIRES 2- 35
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 6
METERS AND LAMPS 3- 6
SWITCHES 3- 13
CONTROL LEVERS, PEDALS 3- 24
DUST INDICATOR 3- 33
ARTICULATE LOCK PIN 3- 33
FUSE BOX 3- 33
OPERATION 3- 35 CHECK BEFORE STARTING ENGINE 3- 35
STARTING ENGINE 3- 47
OPERATIONS, CHECKS AFTER STARTING ENGINE 3- 51
STOPPING ENGINE 3- 53
CHECK AFTER STOPPING ENGINE 3- 53
TRAVELING POSTURE FOR MACHINE 3- 54
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING 3- 55
TURNING MACHINE 3- 59
OPERATING WORK EQUIPMENT 3- 62
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER 3- 68
PRECAUTIONS WHEN OPERATION 3- 89
ADJUSTING WORK EQUIPMENT POSTURE 3- 93
PARKING MACHINE 3-104
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FOREWORD CONTENTS
CHECKS AFTER COMPLETION OF OPERATION 3-105
LOCKING 3-106
HANDLING THE TIRES 3-106
TRANSPORTATION 3-107
LOADING, UNLOADING WORK 3-107 PRECAUTIONS FOR LOADING 3-108
COLD WEATHER OPERATION 3-109
PRECAUTIONS FOR LOW TEMPERATURE 3-109
CAUTIONS AFTER COMPLETION OF WORK 3-110
AFTER COLD WEATHER 3-110
LONG-TERM STORAGE 3-111
BEFORE STORAGE 3-111
DURING STORAGE 3-111
AFTER STORAGE 3-111
TROUBLESHOOTING 3-112
AFTER RUNNING OUT OF FUEL 3-112 WHEN LEANING PIPING IS DAMAGED 3-113
TOWING THE MACHINE 3-114
IF BATTERY IS DISCHARGED 3-116
OTHER TROUBLE 3-119
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 4
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 4
RELATING TO ELECTRIC SYSTEM 4- 6
WEAR PARTS 4- 7
WEAR PARTS LIST 4- 7
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 8
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 12
TORQUE LIST 4- 12
PERIODIC REPLACEMENT OF CRITICAL PARTS 4- 14
CRITICAL PARTS 4- 14
MAINTENANCE SCHEDULE CHART 4- 15
MAINTENANCE SCHEDULE CHART 4- 15
SERVICE PROCEDURE 4- 17
INITIAL 250 HOURS SERVICE (only after the first 250 hours) 4- 17
WHEN REQUIRED 4- 18 CHECK BEFORE STARTING 4- 30
EVERY 50 HOURS SERVICE 4- 31
EVERY 250 HOURS SERVICE 4- 32
EVERY 500 HOURS SERVICE 4- 47
EVERY 1000 HOURS SERVICE 4- 53
EVERY 2000 HOURS SERVICE 4- 59
EVERY 4000 HOURS SERVICE 4- 64
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
HANDLING BLADE ACCUMULATOR 6- 2
FEATURES OF BLADE ACCUMULATOR 6- 2
METHOD OF OPERATING BLADE ACCUMULATOR 6- 3
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SAFETYSAFETY INFORMATION
SAFETY INFORMATION
SAFETY LABELS 2- 4
POSITION FOR ATTACHING SAFETY LABELS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS 2- 11
SAFETY RULES 2- 11
IF ABNORMALITIES ARE FOUND 2- 11
CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 11
FIRE EXTINGUISHER AND FIRST AID KIT 2- 11
SAFETY FEATURES 2- 11
KEEP MACHINE CLEAN 2- 12
INSIDE OPERATOR'S COMPARTMENT 2- 12
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 12
HANDRAILS AND STEPS 2- 13 MOUNTING AND DISMOUNTIN 2- 13
DO NOT GET CAUGHT IN ARTICULATED PORTION 2- 13
PREVENTION OF BURNS 2- 14
FIRE PREVENTION 2- 14
ACTION IF FIRE OCCURS 2- 15
WINDOW WASHER LIQUID 2- 15
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 15
PRECAUTIONS FOR ATTACHMENTS 2- 16
UNAUTHORIZED MODIFICATION 2- 16
SAFETY AT WORKSITE 2- 16
WORKING ON LOOSE GROUND 2- 16
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 17
ENSURE GOOD VISIBILITY 2- 17
VENTILATION FOR ENCLOSED AREAS 2- 17
CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 18
EMERGENCY ESCAPE FROM OPERATOR'S CAB 2- 18
ASBESTOS DUST HAZARD PREVENTION 2- 18
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SAFETY SAFETY INFORMATION
PRECAUTIONS DURING OPERATION 2- 19
STARTING ENGINE 2- 19
CHECKS BEFORE STARTING ENGINE, ADJUST 2- 19
PRECAUTIONS WHEN STARTING 2- 19
PRECAUTIONS IN COLD AREAS 2- 20 OPERATION 2- 21
CHECKS BEFORE STARTING OPERATION 2- 21
PRECAUTIONS BEFORE MOVING OFF 2- 21
PRECAUTIONS WHEN TRAVELING 2- 21
PRECAUTIONS WHEN TRAVELING ON SLOPES 2- 22
PRECAUTIONS WHEN OPERATIONS ON SLOPES 2- 23
PROHIBITED OPERATIONS 2- 23
PRECAUTIONS WHEN OPERATING 2- 23
OPERATE CAREFULLY ON SNOW 2- 23
PARKING MACHINE 2- 24
TRANSPORTATION 2- 25 LOADING AND UNLOADING 2- 25
SHIPPING 2- 25
BATTERY 2- 26
BATTERY HAZARD PREVENTION 2- 26
STARTING WITH BOOSTER CABLES 2- 27
TOWING 2- 28
WHEN TOWING 2- 28
PRECAUTIONS FOR MAINTENANCE 2- 29
WARNING TAG 2- 29
KEEP WORK PLACE CLEAN AND TIDY 2- 29
APPOINT LEADER WHEN WORKING WITH OTHERS 2- 29
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE 2- 30
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING 2- 31
PROPER TOOLS 2- 31
ACCUMULATOR 2- 32
PERSONNEL 2- 32
ATTACHMENTS 2- 32
WORK UNDER THE MACHINE 2- 32
NOISE 2- 32
PRECAUTIONS WHEN USIN HAMMER 2- 33 REPAIR WELDING 2- 33
REMOVING BATTERY TERMINAL 2- 33
PRECAUTIONS WITH HIGH-PRESSURE OIL 2- 33
HANDLING HIGH-PRESSURE HOSES 2- 34
WASTE MATERIALS 2- 34
MAINTENANCE OF AIR CONDITIONER 2- 34
COMPRESSED AIR 2- 34
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS 2- 34
PRECAUTIONS WITH TIRES 2- 35
HANDLING TIRES 2- 35
PRECAUTIONS WHEN STORING TIRE OPERATION 2- 35
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SAFETYSAFETY LABELS
SAFETY LABELSThe following warning signes and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels topeel off.
There are also other labels in addition to the warning signes and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
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SAFETY SAFETY LABELS
POSITION FOR ATTACHING SAFETY LABELS
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SAFETYSAFETY LABELS
SAFETY LABELS(1) Precautions before operating (09651-03001) (2) Precautions for opening hydraulic cap
(09653-03001)
(3) Precautions when driving in reverse
(09802-43000)
(4) Danger when approaching (09812-13000)
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SAFETY SAFETY LABELS
(5) Warning for high voltage (09801-43001) (6) Articulate lock (09161-33000)
(7) Warning for handling accumulator
(09659-53000)
(8) Precautions for high temperature cooling water
(09668-03001)
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SAFETYSAFETY LABELS
(9) Roll-over protective structure
(09620-30201)
(10) Prohibited to walk (23B-53-31740)
(11) Precautions when engine running (09667-03001) (12) Precautions when handling booster cable and
battery cable (09808-03000)
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SAFETY SAFETY LABELS
(13) Prohibited to enter (09162-33000) (14) Precautions when startling and traveling
(23B-53-31740)
(15) Exhaust pipe is hot ! (09817-K088B)
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SAFETYSAFETY LABELS
(16) Precautions for brake (23B-53-31670)
(17) Precautions when handling battery (18) Precautions when handling battery
(09664-30082)
(19) Jump start prohibited (09842-A0481)
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SAFETY GENERAL PRECAUTIONS
GENERAL PRECAUTIONS
SAFETY RULESOnly trained and authorized personnel can operate and maintain the machine.
Follow all safety rules, precautions and instructions when operating or performing maintenance on the machine.If you are under the influence of alcohol or medication, your ability to safely operate or repair your machine may
be severly impaired putting yourself and everyone else on your jobsite in danger.
When working with another operator or with a person on worksite traffic duty, be sure that all personnel
understand all hand signals that are to be used.
IF ABNORMALITIES ARE FOUNDIf you find any abnormality in the machine during operation or maintenance (noise, vibration, smell, incorrect
gauges, smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person
in charge and have the necessary action taken. Do not operate the machine until the abnormality has been
corrected.
CLOTHING AND PERSONAL PROTECTIVE ITEMSDo not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other
protruding parts.
If you have long hair and it hangs out from your hard hat, there
is a hazard that it may get caught up in the machine, so tie your
hair up and be careful not to let it get caught.
Always wear a hard hat and safety shoes. If the nature of the
work requires it, wear safety glasses, mask, gloves, ear plugs,
and safety belt when operating or maintaining the machine.
Check that all protective equipment functions properly before
using it.
FIRE EXTINGUISHER AND FIRST AID KITAlways follow the precautions below to prepare for action if any injury or fire should occur.
Be sure that fire extinguishers have been provided and read the
labels to ensure that you know howto use them in emergencies.
Carry out periodic inspection and maintenance to ensure that
the fire extinguisher can always be used.
Provide a first aid kit at the storage point. Carry out periodicchecks and add to the contents if necessary.
SAFETY FEATURESBe sure that all guards and covers are in their proper position. Have guards and covers repaired immediately if
they are damaged.
Understand the method of use of safety features and use them properly.
Never remove any safety features. Always keep them in good operating condition.
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SAFETYGENERAL PRECAUTIONS
KEEP MACHINE CLEANIf water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not
use water or steam to wash the electrical system (sensors, connectors).
If inspection and maintenance is carried out when the machine
is still dirty with mud or oil, there is a hazard that you will slip andfall, or that dirt or mud will get into your eyes. Always keep the
machine clean.
INSIDE OPERATOR'S COMPARTMENT
When entering the operator's compartment, always remove all mud and oil from the soles of your shoes.If you operate the pedal with mud or oil affixed to your shoes, your foot may slip and this may cause a serious
accident.
Do not leave parts or tools lying around the operator's compartment.
Do not stick suction pads to the window glass. Suction pads act as a lens and may cause fire.
Do not use cellular telephones inside the operator's compartment when driving or operating the machine.
Never bring any dangerous objects such as flammable or explosive items into the operator's compartment.
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT
If the work equipmentcontrol levers are touched by mistake, the
machine may move suddenly, and this may lead to a serious
accident.
When leaving the machine, always lower the work equipment
completely to the ground, set gearshift lever (1) to the P
(Parking) position, then stop the engine. Use the key to lock all
the equipment. Always remove the key, take it with you, and
keep it in the specified place.
To ensure that there is enough space to get on or off the
machine, raise the steering column fully when getting off the
machine.
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SAFETY GENERAL PRECAUTIONS
HANDRAILS AND STEPSTo prevent personal injury caused by slipping or falling off the machine, always do as follows.
Use the handrailsand steps markedby arrows in the diagram on
the right when getting on or off the machine.
To ensure safety, always face the machine and maintain
three-point contact (both feet and one hand, or both hands and
onefoot) with the handrailsand steps to ensure that you support
yourself.Do notgrip the control leverswhen getting on or off the machine.
Never climb on the engine hood or covers where there are no
non-slip pads.
Before getting on or off the machine, check the handrails and
steps, and if there is any oil, grease, or mud on them, wipe it off
immediately. In addition, repair any damage and tighten any
loose bolts.
Do notget on or off the machine while holding tools in your hand.
MOUNTING AND DISMOUNTINGNever jump on or off the machine. Never get on or off a moving machine.
If the machine starts to move when there is no operator on the machine, do not jump on to the machine and try
to stop it.
DO NOT GET CAUGHT IN ARTICULATED PORTIONThe clearance in the area around the work equipment changes
according to the movement of the link. If you get caught, it will
lead to serious injury. Do not allow anyone near any of the
rotating or telescoping parts.
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SAFETYGENERAL PRECAUTIONS
PREVENTION OF BURNSHot coolant
To prevent burns from hot water or steam spurting out when
checking or draining the coolant, wait for the water to cool to at
temperature where it is possible to touch the upper tank cap byhand before starting the operation. Even when the coolant has
cooled down, loosen the cap slowly to relieve the pressure inside
the upper tank before removing the cap.
Hot oil
To prevent burns from hot oil spurting out when checking or
draining the oil, wait for the oil to cool to at temperature where
it is possible to touch the cap or plug by handbefore starting the
operation. Even when the oil has cooled down, loosen the cap
or plug slowly to relieve the internal pressure before removing
the cap or plug.
FIRE PREVENTIONFire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly
flammable and can be hazardous. To prevent fire, always
observe the following:
Do not smoke or use any flame near fuel or oil.
Stop the engine before refueling.
Do not leave the machine while adding fuel or oil.
Tighten all fuel and oil caps securely.
Do not spill fuel on overheated surfaces or on parts of the
electrical system.
Use well-ventilated areas for adding or storing oil and fuel.
Keep oil and fuel in the determined place and do not allow
unauthorized persons to enter.
After adding fuel or oil, wipe up any spilled fuel or oil.When carrying out grinding or welding work on the chassis,
move any flammable materials to a safe place before
starting.
When washing parts with oil, use a non-flammable oil. Diesel
oil and gasoline may catch fire, so do not use them.
Put greasy rags and other flammable materials into a safe
container to maintain safety at the work place.
Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
Fire caused by accumulation of flammable material.
Remove any dry leaves, chips, pieces of paper, dust, or any other flammable materials accumulated or affixed
around the engine, exhaust manifold, muffler, or battery, or inside the undercovers.
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SAFETY GENERAL PRECAUTIONS
Fire coming from electric wiring
Short circuits in the electrical system can cause fire.
Always keep electric wiring connections clean and securely tightened.
Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repairor replace any damaged wiring.
Fire coming from hydraulic line
Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the
hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.
Explosion caused by lighting equipment
When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with
anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion that may
cause serious injury.When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.
ACTION IF FIRE OCCURSIf a fire occurs, escape from the machine as follows.
Turn the start switch OFF to stop the engine.
Use the handrails and steps to get off the machine.
WINDOW WASHER LIQUID
Use an ethyl alcohol base washer liquid.
Methyl alcohol base washer liquid may irritate your eyes, so do not use it.
PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)Install ROPS when working in places where there is danger of
falling rocks, such as in mines and quarries, or in places where
there is danger of rolling over.
If ROPS is installed, do not remove it when operating the
machine.
ROPS is installed to protect the operator when machine rolls
over. When machine rolls over, ROPS supports its weight and
absorbs its impact energy.
If ROPS is modified, its strength may be reduced. Whenmodifying, consult your Komatsu distributor.
If ROPS is deformed by falling objects or by rolling over, its
strength lowers and its design functions cannot be maintained.
In this case, be sure to ask your Komatsu distributor about repair
method.
Even if ROPS is installed, always fasten your seat belt properly
when operating the machine. If you do not use your fasten your
seat belt properly, it cannot display its effect.
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SAFETYGENERAL PRECAUTIONS
PRECAUTIONS FOR ATTACHMENTSWhen installing optional parts or attachments, there may be problems with safety or legal restrictions. Therefore
contact your Komatsu distributor for advice.
Any injuries,accidents, or product failures resulting from the use of unauthorized attachments or parts will not be
the responsibility of Komatsu.When installing and using optional attachments, read the instruction manual for the attachment, and the general
information related to attachments in this manual.
UNAUTHORIZED MODIFICATIONAny modification made without authorization from Komatsu can create hazards. Before making a modification,
consult your Komatsu distributor.
Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting
from modifications made without authorization from Komatsu.
SAFETY AT WORKSITE
Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do
not carry out operations at places where there is a hazard of landslides or falling rocks.
If water lines, gas lines, or high-voltage electrical lines may be
buried under the worksite, contact each utility and identify their
locations. Be careful not to sever or damage any of these lines.
Take action to prevent unauthorized people from approaching
the jobsite.
When working on public roads, position flagmen and erect
barriers to ensure the safety of passing traffic and pedestrians.
When traveling or operating in shallow water or on soft ground,
check the shape and condition of the bedrock, and the depth
and speed of flow of the water before starting operations.
In order that travel operations can be carried out safely, always
keep the roads on the jobsite properly maintained.
WORKING ON LOOSE GROUNDAvoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The
ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine,
there is a hazard that the machine may fall or tip over. Remember that the soil after heavy rain or blasting or after
earthquakes is weak in these areas.
When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of themachine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe
and to prevent the machine from rolling over or falling.
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SAFETY GENERAL PRECAUTIONS
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLESDo not travel or operate the machine near electric cables. There is
a hazard of electric shock, which may cause serious injury or
property damage. On jobsites where the machine may go close to
electric cables, always do as follows.Before starting work near electric cables, inform the local power
company of the work to be performed, and ask them to take the
necessary action.
Voltage of Cables Safety Distance
100 V - 200 V Over 2 m (7ft)
6,600 V Over 2 m (7ft)
22,000 V Over 3 m (10 ft)
66,000 V Over 4 m (14 ft)
154,000 V Over 5 m (17 ft)
187,000 V Over 6 m (20 ft)
275,000 V Over 7 m (23 ft)
500,000 V Over 11 m (36 ft)
Even going close to high-voltage cables can cause electric
shock, which may cause serious burns or even death. Always
maintain a safe distance (see the table on the right) between the
machine and the electric cable. Check with the local power
company about safe operating procedure before startingoperations.
To prepare for any possible emergencies, wear rubber shoes
and gloves. Lay a rubbersheet on top of the seat, and be careful
not to touch the chassis with any exposed part of your body.
Use a signalman to give warning if the machine approaches too
close to the electric cables.
When carrying out operations near high voltage cables, do not
let anyone come close to the machine.
If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should
not leave the operator's compartment until it has been confirmed that the electricity has been shut off.
Also, do not let anyone come close to the machine.
ENSURE GOOD VISIBILITYCheck for any persons or obstacles in the area around the machine and check the conditions of the jobsite to
ensure that operations and travel can be carried out safely. Always do as follows.
Position a signalman if there are areas at the rear of the machine where the visibility is not good.
When working in dark places, turn on the working lamp and front lamps installed to the machine, and set up
additional lighting in the work area if necessary.
Stop operations if the visibility is poor, such as in mist, snow, rain, or dust.
VENTILATION FOR ENCLOSED AREASEngine exhaust gas contains substances that may be injurious to
the health or may even cause death. When starting the engine or
operating the machine, do it in a place where there is ample
ventilation.
If it is necessary to start the engine or operate the machine while
the machine is indoors or underground, take steps to remove the
exhaust gas and bring in clean air.
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SAFETYGENERAL PRECAUTIONS
CHECKING SIGNALMAN'S SIGNALS AND SIGNSSet up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if
necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.
Only one signalman should give signals.
Make sure that all workers understand the meaning of all signals and signs before starting work.
EMERGENCY ESCAPE FROM OPERATOR'S CABThe cab installed on this machine has doors on the left and right sides. If the door on one side does not open,
escape through the door on the other side.
ASBESTOS DUST HAZARD PREVENTIONAsbestos dust in the air can causelung cancer if it is inhaled.There
is danger of inhaling asbestos when working on jobsites handling
demolitionwork or work handling industrial waste. Always observe
the following.
Spray water to keep down the dust when cleaning. Do not usecompressed air for cleaning.
If there is danger that there may be asbestos dust in the air,
always operate the machine from an upwind position. All
workers should use an approved respirator.
Do not allow other persons to approach during the operation.
Always observe the rules and regulations for the work site and environmental standards.
This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use
genuine Komatsu parts.
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SAFETYPRECAUTIONS DURING OPERATION
PRECAUTIONS IN COLD AREASCarry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the steering
wheel, control levers, gearshift lever, or brake pedal are operated, the reaction of the machine will be slow or may
suddenly change, and this may lead to an accident. After warming up the engine, operate at low speed and
check the safety while traveling.If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source.
There is a hazard that this will ignite the battery.
Before charging or starting the engine with a different power source, melt the battery electrolyte and check for
frost and leakage of battery electrolyte before starting.
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SAFETY PRECAUTIONS DURING OPERATION
OPERATION
CHECKS BEFORE STARTING OPERATIONWhen carrying out the checks, move the machine to a wide area where there are no obstructions, and operate
slowly. Do not allow anyone near the machine.Always fasten your seat belt.
Check the operation of travel, steering and brake systems, and
work equipment control system.
Check for any abnormality in the sound of the machine,
vibration, heat, smell, or gauges; check also that there is no
leakage of oil or fuel.
If any abnormality is found, carry out repairs immediately.
If the operation requires use of the articulation, removearticulate lock pin (1).
Before traveling on roads, check that articulate lock pin (1) is at
the LOCK position.
PRECAUTIONS BEFORE MOVING OFFBefore travelling, check again that there is no one in the surrounding area, and that there are no obstacles.
Before travelling, sound the horn to warn people in the area.
Always operate the machine only when seated.
Do not allow anyone apart from the operator to ride on the machine.
Check that the back-up alarm (alarm buzzer when machine
travels in reverse) works properly.
Fix the operator's compartment doors and windows in position
securely.
If there is an area to the rear of the machine which cannot be
seen, position a signal person.Take special care not to hit othermachines or people when turning or swinging the machine.
Always be sure to carry out the above precautions even when the machine is equipped with mirrors.
PRECAUTIONS WHEN TRAVELINGNever turn the key in the starting switch to the OFF position.It is dangerous if the engine stopswhen the machine
is traveling, because the steering becomes heavy. If the engine stops, depress the brake pedal immediately to
stop the machine.
When traveling on rough ground, travel at low speed and do not operate the steering suddenly. There is danger
that the machine may turn over. The work equipmentmay hit the ground surface and cause the machine to lose
its balance, or may damage the machine or structures in the area.
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SAFETYPRECAUTIONS DURING OPERATION SAFETYPRECAUTIONS DURING OPERATION
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).
When traveling or carrying out operations, always keep a safe distance from people, structures, or other
machines to avoid coming into contact with them.
When passing over bridges or structures, check first that the structure is strong enough to support the mass of
the machine.
When operating in tunnels, underbridges, under electric wires,or other placeswhere theheight is limited,operate
slowly and be extremely careful not to let the work equipment hit anything.
If youdrive the machine at high speed continuously for a long time, the tires will overheat andthe internal pressure
will become abnormally high. This may cause the tires to burst. If a tire bursts, it produces an extremely large
destructive force, and this may cause serious injury. When traveling continuously, travel for 2 hours or 80 km,
then rest for 30 minutes. Next, travel for 2 hours, then rest for 1 hour, or contact your Komatsu distributor. If you
are going to travel continuously, please consult your Komatsu distributor.
PRECAUTIONS WHEN TRAVELING ON SLOPESTo prevent the machine from tipping over or slipping to the side,
always do as follows.
Always travel straight up or down a slope. Traveling at an angle
or across the slope is extremely dangerous.Do not turn on slopes or travel across slopes. Always go down
to a flat place to change the position of the machine, then travel
on to the slope again.
Travel on grass, fallen leaves, or wet steel plates with low
speed. Even with slight slopes there is a hazard that the
machine may slip.
If the engine stops, depress the brake pedal immediately, lower
the blade, set the gearshift lever to the P (Parking) position, and
stop the machine.
When traveling downhill, never shift gear or place the transmission at neutral. It is dangerous not to use the
braking force of the engine. Always place the transmission in a low gear before starting to travel downhill.
When traveling downhill, travel slowly. If necessary, use the braking force of the engine together with the brake
pedal to control the travel speed.
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SAFETY PRECAUTIONS DURING OPERATION
PRECAUTIONS WHEN OPERATIONS ON SLOPESDo not articulate the machine fully on steep slops. There is danger that the machine may tip over.
When working on slopes, control the machine speed with the accelerator pedal.
PROHIBITED OPERATIONSWhen operating at the bottom of a cliff, there is danger that the soil may collapse or that rocks may fall. Never
operate in such places.
The edge of cliffs or road shoulders may easily collapse, and there is danger of falling. Do not go close to such
places.
Avoid sudden starts, sudden stops, and sudden steering.
PRECAUTIONS WHEN OPERATINGWhen operating in tunnels, under bridges, under electric wires, or other places where the height is limited, be
extremely careful not to let the work equipment hit anything.
To prevent accidents caused by hitting other objects, always operate the machine at a speed which is safe for
operation, particular in confined spaces, indoors, and in places where there are other machines.Check that there is no person other than the operator within the range of flying objects caused by the operation.
OPERATE CAREFULLY ON SNOWSnow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine,
and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly
careful when working on slopes.
With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause the
machine to tip over.
If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful
not to leave the road shoulder or to get trapped in a snow drift.
When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be
seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations
carefully.
When traveling on snow-covered roads, always fit tire chains.
When travelingon snow-coveredslopes, never apply thebrakes suddenly. Reduce thespeed anduse the engine
as a brake while appling the foot brake intermittently (depress the brake intermittently several times). If
necessary, lower the blade to the ground to stop the machine.
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SAFETYPRECAUTIONS DURING OPERATION
PARKING MACHINEPark the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground.
When leaving the machine, set gearshift lever (1) to the P
(Parking) position, then stop the engine.
Always close the operator'scab door, and use the key to lock all
the equipment in orderto prevent any unauthorizedperson from
moving the machine. Always remove the key, take it with you,and leave it in the specified place.
If it is necessary to park the machine on a slope, set blocks
under the wheels to prevent the machine from moving.
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SAFETY PRECAUTIONS DURING OPERATION
TRANSPORTATION
LOADING AND UNLOADINGWhen loading or unloading the machine, mistaken operation may
bring the hazard of the machine tipping over or falling, so particularcare is necessary. Always do as follows.
Perform loading and unloading on firm, level ground only.
Maintain a safe distance from the edge of the road or cliff.
Always use ramps of adequate strength. Be sure that the ramps
are wide, long, andthick enough to provide a safe loading slope.
Take suitable steps to prevent the ramps from moving out of
position or coming off.
Be sure the rampsurface is clean and free of grease, oil, ice and
loose materials. Remove dirt from machine-tracks. On a rainy
day, in particular, be extremely careful since the ramp surface is
slippery.Run the engine at low speed and travel slowly.
Never correct your steering on the ramps. If necessary, drive off the ramps, correct the direction, then enter the
ramps again.
When loading or unloading to an embankment or platform, make sure that it has suitable width, strength, and
grade.
For machines equipped with a cab, always lock the door after boarding the machine. If this is not done, the door
may suddenly open during transportation.
Refer to "TRANSPORTATION (PAGE 3-107)".
SHIPPINGWhen shipping the machine on a trailer, do as follows.
The weight, transportation height, and overall length of the machine differ according to the work equipment, so
be sure to confirm the dimensions.
When passing over bridges or structures on private land, check first that the structure is strong enough to support
the weight of the machine. When traveling on public roads, check first with the relevant authoritiesand follow their
instructions.
Lock the frame with the articulate lock pin to prevent the machine from articulating.
For details of the shipping procedure, see "TRANSPORTATION (PAGE 3-107)" in the OPERATION section.
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SAFETYPRECAUTIONS DURING OPERATION
BATTERY
BATTERY HAZARD PREVENTIONBattery electrolyte contains sulphuric acid, and batteries generate flammable hydrogen gas, which may explode.
Mistaken handling can lead to serious injury or fire. For this reason, always observe the following precautions.Do not use or charge the battery if the battery electrolyte level is below the LOWER LEVEL line. This may cause
an explosion.Always check the battery electrolyte level periodicallyand adddistilledwater to bring the electrolyte
level to the UPPER LEVEL line.
When working with batteries, always wear safety glasses and rubber gloves.
Never smoke or use any flame near the battery.
If you spill acid on your clothes or skin, immediately flush the
area with large amount of water.
If acid gets into your eyes, flush them immediately with large
amount of water and seek medical attention.
Beforeworking with batteries, turn the starting switch to the OFF
position.
As there is a hazard that sparks will be generated, always do as follows.
Do not let tools or othermetal objects make any contactbetween the battery terminals.Do not leavetools or other
metal objects lying around near the battery.
Always disconnect the negative (-) terminal (ground side) first when removing the battery; when installing the
battery, connect the positive (+) terminal first, andconnect thegroundlast. Tighten thebattery terminalssecurely.
Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take
it to a well-ventilated place, and remove the battery caps before charging it.Tighten the battery caps securely.
Install the battery securely to the determined place.
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SAFETY PRECAUTIONS DURING OPERATION
STARTING WITH BOOSTER CABLESIf any mistake is made in the method of connecting the booster
cables, it may cause the battery to explode, so always do as
follows.
When starting with a booster cable, carry out the startingoperation with two workers (one worker sitting in the operator's
seat and the other working with the battery).
When starting from another machine, do not allow the two
machines to touch.
When connecting the booster cables, turn the starting switch
OFF for both the normal machine and problem machine. There
is a hazard that the machine will move when the power is
connected.
Be sure to connect the positive (+) cable first when installing the
booster cables. Disconnect the negative (-) cable (ground side)
first when removing them.When removing the booster cables, be careful not to let the
booster cable clips touch each other or to let the clips touch the
machine.
Always wear safety goggles and rubber gloves when starting
the engine with booster cables.
When connecting a normal machine to a problem machine with
booster cables, always use a normal machine with the same
battery voltage as the problem machine.
For details of the starting procedure when using booster cables,
see "STARTING ENGINE WITH BOOSTER CABLE (PAGE
3-117)" in the OPERATION section.
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SAFETYPRECAUTIONS DURING OPERATION
TOWING
WHEN TOWINGSerious injury or death could result if a disabled machine is towed incorrectly or if there is a mistake in the selection
or inspection of the wire rope.For towing, see "TOWING THE MACHINE (PAGE 3-114)".
Always wear leather gloves when handling wire rope.
During the towing operation, never stand between the towing
machine and the machine being towed.
Never tow a machine on a slope.
Never use a wire rope which has cut strands (A), reduced
diameter (B), or kinks (C). There is danger that the rope may
break during the towing operation.
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SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR MAINTENANCE
WARNING TAGAlways attach the "DO NOT OPERATE" warning tag to gear
shift lever in the operator's cab to alert others that you areperforming service of maintenance on the machine. Attach
additional warning tags around the machine if necessary.
Warning tag Part No.09963-03001
Keep this warning tag in the tool box while it is not used. If there
is no tool box, keep the tag in the operation manual pocket.
If others start the engine, or touch or operate the work
equipment control lever while you are performing service or
maintenance, you could suffer serious injury or property
damage.
KEEP WORK PLACE CLEAN AND TIDYDo not leave hammers or other tools lying around in the work place. Wipe up all grease, oil, or other substances
that will cause you to slip. Always keep the work place clean the tidy to enable you to carry out operations safely.
If the work place is not kept claen and tidy, there is the danger that you will trip, slip, or fall over and injure yourself.
APPOINT LEADER WHEN WORKING WITH OTHERSWhen repairing the machine or when removing and installing the work equipment, appoint a leader and follow his
instructions during the operation.
When working with others, misunderstandings between workers can lead to serious accidents.
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SAFETYPRECAUTIONS FOR MAINTENANCE
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCEStop the machine on firm, level ground.
Select a place where there is no hazard of falling rocks or
landslides, or of flooding if the land is low.
Lower the work equipment completely to the ground and stopthe engine.
After stopping the engine, operate the left and right blade lift
cylinder control levers fully to the RAISE and LOWER positions
2 or 3 times to release the pressure remaining in the hydraulic
circuit, then set gearshift lever (1) to the P (Parking) position.
Put blocks under the front and rear of the tires.
Lock the frame with articulate lock pin (1) to prevent the machine
from articulating.
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SAFETY PRECAUTIONS FOR MAINTENANCE
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNINGTo prevent injury, do not carry out maintenance with the engine running. If maintenance must be carried out with
the engine running, carry out the operation with at least two workers and do as follows.
One worker must always sit in the operator's seat and be ready to stop the engine at any time. All workers must
maintain contact with the other workers.Set gearshift lever (1) to the P (Parking) position and take action
to prevent the work equipment from moving.
When carrying out operations near the fan, fan belt, or other
rotating parts, there is a hazard of being caught in the parts, so
be careful not to come close.
Do not touch any control levers. If any control lever must be
operated, give a signal to the other workers to warn them to
move to a safe place.
Never dropor insert tools or other objects into the fan or fan belt.Parts may break or be sent flying.
PROPER TOOLSUse only tools suited to the task and be sure to use the tools
correctly. Using damaged, low quality, faulty, makeshift tools or
improper use of the tools could cause serious personal injury.
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SAFETYPRECAUTIONS FOR MAINTENANCE
ACCUMULATORThe accumulator is charged with high-pressure nitrogen gas.
When handling the accumulator, careless procedure may cause
an explosion which could lead to serious injury or property
damage. For this reason, always observe the followingprecautions.
Do not disassemble the accumulator.
Do not bring it near flame or dispose of it in fire.
Do not make holes in it, weld it, or use a cutting torch.
Do not hit or roll the accumulator, or subject it to any impact.
When disposing of the accumulator, the gas must be released.
Please contact your Komatsu distributor to have this work
performed.
PERSONNEL
Only authorized personnel can service and repair the machine. Do not allow unauthorizedpersonnel into the area.If necessary, employ an observer.
ATTACHMENTSAppoint a leader before starting removal or installation
operations for attachments.
Place attachments that have been removed from the machine in
a stable condition so that they do not fall. And take steps to
prevent unauthorized persons from entering the storage area.
WORK UNDER THE MACHINEIf it is necessary to go under the work equipment or the machine
to carry out service and maintenance, support the work
equipment and machine securely with blocks and stands strong
enough to support the weight of the work equipment and
machine.
NOISEIf the noise from the machine is too loud, it may cause temporary or permanent hearing problems. When carrying
out maintenance of the engine and you are exposed to noise for long periods of time, wear ear covers or ear plugs
while working.
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SAFETYPRECAUTIONS FOR MAINTENANCE
HANDLING HIGH-PRESSURE HOSESIf oil or fuel leaks from high-pressure hoses, there is danger that it may cause fire or defective operation, which may
lead toserious injuryor fire. If thereare any loose hosesor piping,or anyleakage of oil or fuel fromthe hose or piping
mount, stop operation and tighten to the specified torque.
If any hoses or pipes are damaged or deformed, please contact your Komatsu distributor.Replace the hose if any of the following problems are found.
Damaged or leaking hydraulic fitting.
Frayed or cut covering or exposed reinforcement wire layer.
Covering swollen in places.
Twisted or crushed movable portion.
Foreign material embedded in covering.
WASTE MATERIALSTo prevent pollution, pay careful attention to the method of disposing of waste materials.
Always put oil drained from your machine in containers. Never
drain oil directly onto the ground or dump into the sewagesystem, rivers, the sea, or lakes.
Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
MAINTENANCE OF AIR CONDITIONERIf air conditioner refrigerant gets intoyour eyes, it may cause blindness; if it touches your skin, it may cause frostbite.
Never touch refrigerant.
COMPRESSED AIRWhen carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.
When using compressed air to clean elements or the radiator, always wear safety goggles, dust mask, gloves,
and other protective equipment.
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS
In order for the machine to be operated safely for a long time, it is necessary to add oil and to carry out service
and maintenance at periodic intervals. In order to further increase safety, components with a strong relationshipto safety, such as hoses and seat belts, must be replaced at periodic intervals.
Replacement of safety-critical parts: See "PERIODIC REPLACEMENT OF CRITICAL PARTS (PAGE 4-14)".
Thematerial of these componentsnaturally changes over time, andrepeated usecausesdeterioration,wear,and
fatigue. As a result, there is a hazard that these components may fail and cause serious injury or death. It is
difficult to judge the remaining life of these components from external inspection or the feeling when operating,
so always replace them at the specified interval.
Replace or repair safety-critical parts if any defect is found, even when they have not reached the time specified
interval.
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SAFETY PRECAUTIONS WITH TIRES
PRECAUTIONS WITH TIRES
HANDLING TIRESIf tires or rims are handled mistakenly, there is danger that the tire
may explode or be damaged, or that the rim may fly off and causeserious injury or death.
To maintain safety, always do as follows.
Maintenance, disassembly, repair, and assembly of the tires
and rims requires special equipment and special technology,so
always ask your Komatsu distributor to carry out these
operations.
Always use the tires specified by Komatsu and maintain the
specified inflation pressure.
Suitable tire inflation pressure: see "CHECK OF INFLATION
PRESSURE OF TIRES AND INFLATION OF THEM (PAGE
4-29)"When pumping up the tires, check that no other person is
standing near the tire, and install an air chuck with a clip that can
be secured to the air valve.
To prevent the tire inflation pressure from becoming too high,
measure the pressure from time to time with an air gauge while
pumping up the tire.
If the tire pressure goes down abnormallyor the rim parts do not
fit the tire, there is a problem with the tire or rim parts. Always
contact your Komatsu distributor for repairs.
If the rim parts are not fitted properly when the tire is being
pumped up, there is danger that the rim parts may fly off, so set
up a protective fence around the tire, and do not stand directly
in front of the rim. Stand beside the tread when pumping up the
tire.
Do not adjust the tire inflation pressure immediately after traveling at high speed or carrying out operations under
heavy load.
Never carry out welding or light a fire near the tire.
PRECAUTIONS WHEN STORING TIRE
Tires forconstructionequipmentareextremelyheavy, so they may
cause serious personal injury.As a basic rule, store the tires in a warehouse which
unauthorized persons cannot enter.
If the tires must be stored outside, always erect a fence and put
up "No Entry" signs.
Stand the tire on level ground, and block it securely so that it
cannot roll or fall over if any person should touch it.
Do not lay the tire on its side. This will deform the tire and cause
it to deteriorate.
If the tire should fall over, do not attempt to stop it. Get out of the
way quickly.
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OPERATIONGENERAL VIEW
GENERAL VIEW
GENERAL VIEW OF MACHINE
(1) Front wheel(2) Blade lift cylinder
(3) Rear wheel
(4) Head lamp (if equipped)(5) Blade
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OPERATION GENERAL VIEW
GENERAL VIEW OF CONTROLS AND GAUGES
(1) Inching pedal
(2) Steering wheel
(3) Horn button
(4) Work equipment control lever
(5) Starting aid switch
(6) Dimmer switch
(7) Machine monitor
(8) Differential lock switch (if equipped)
(9) Turn signal lever
(10) Accelerator pedal
(11) Gearshift lever
(12) Fuel control lever
(13) Right side panel
(14) Decelerator pedal
(15) Brake pedal
(16) Steering console tilt pedal
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OPERATIONGENERAL VIEW
Machine monitor Right panel
(1) Engine water temperature gauge
(2) Speedometer (if equipped)
(3) Turn signal pilot lamp (if equipped)
(4) Fuel gauge
(5) Message center
(6) Battery charge
(7) Engine oil pressure
(8) Brake oil pressure
(9) Transmission system electric circuit monitor
(10) Lift arm lock
(11) Torque converter oil temperature
(12) Differential oil temperature (if equipped)(13) Differential control (if equipped)
(14) Blade accumulator (if equipped)
(15) Working lamp (if equipped)
(16) Blade float (if equipped)
(17) Preheating lamp
(18) High beam of front lamp (if equipped)
(19) Parking brake
(20) Articulation gauge
(21) Torque converter oil temperature gauge
(22) Starting switch
(23) Hazard lamp switch (if equipped)
(24) Working lamp switch (if equipped)
(25) Blade accumulator/float switch (if equipped)
(26) Cigarette lighter
(27) Lift arm lock switch
(28) Front wiper switch (top)
(29) Front lamp switch (if equipped)
(30) Transmission mode selector switch
(31) Car heater switch (if equipped)
(32) Additional car heater switch (if equipped)
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OPERATION GENERAL VIEW
Top left inside cab
(1) Front wiper switch (bottom) (if equipped)
(2) Rear wiper switch (if equipped)
(3) Yellow rotating lamp switch (if equipped)
(4) Front defroster fan switch (if equipped)
(5) Rear defroster fan switch (if equipped)
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OPERATIONEXPLANATION OF COMPONENTS
EXPLANATION OF COMPONENTSThe following is an explanation of the devices needed for operating the machine.
To carry out suitable operations correctly and safely, it is important to understand fully the methods of operating the
equipment and the meanings of the displays.
METERS AND LAMPS
(1) Engine water temperature gauge
(2) Speedometer (if equipped)
(3) Turn signal pilot lamp (if equipped)
(4) Fuel gauge
(5) Message center
(6) Battery charge
(7) Engine oil pressure lamp(8) Brake oil pressure lamp
(9) Transmission system electric circuit monitor
(10) Lift arm lock
(11) Torque converter oil temperature
(12) Differential oil temperature (if equipped)
(13) Differential control (if equipped)
(14) Blade accumulator (if equipped)
(15) Working lamp (if equipped)
(16) Blade float (if equipped)
(17) Preheating lamp
(18) High beam of front lamp (if equipped)
(19) Parking brake(20) Articulation gauge
(21) Torque converter oil temperature gauge
(22) Service meter (to the left side of the steering
wheel column)
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OPERATION EXPLANATION OF COMPONENTS
ENGINE WATER TEMPERATURE GAUGEThis meter (1) displays the engine cooling water temperature.
During normal operation, the gauge should be in the white range.
If the gauge goes into the red range during operation, stop the
machine, run the engine at a mid-range speed under no load, andwait for the temperature to go down to the white range. After
starting the engine, carry out the warming-up operation until the
indicator enters the white range.
SPEEDOMETER(If equipped)
This meter (2) displays the travel speed of the machine.
There is an odometer at the bottom of the meter.
TURN SIGNAL PILOT LAMP(If equipped)
This lamp (3) flashes at the same time as the turn signal lamp.
REMARKIf there is a disconnection in the turn signal lamp, the flashing
interval becomes shorter.
FUEL GAUGEThis gauge (4) indicates the amount of fuel in the fuel tank.
E: Little fuel remaining
F: Full tank
If the gauge comes close to the E mark, add fuel.
Fuel tank capacity: 340 liters (89.76 US gal)
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OPERATIONEXPLANATION OF COMPONENTS
MESSAGE CENTERThis meter (5) indicates the engine speed, transmission range,
error code, and machine travel speed.
When the "MODE" button is pressed, the display changes asfollows:
AUTO -> engine speed -> transmission range -> error code ->
monitor brightness adjustment -> version of software -> machine
travel speed (mph display) -> machine travel speed (km/h display).
REMARKAUTO always shows the engine speed, but when changing to the transmission range, the transmission range
is displayed for 3 seconds, and then the display returns to the engine speed display. If any failure occurs in the
transmission control, the error code is displayed.
When adjusting the brightness of the monitor, press the SCROLL button to change the brightness of themessage center as follows: 100% -> 25% -> 50% -> 100%.
Theerrorcodealwaysdisplays [E--0]. If anyother display appears, see"OTHERTROUBLE (PAGE 3-119)",and
contact your Komatsu distributor for repairs.
BATTERY CHARGEThis lamp (6) warns of any abnormality in the charging system
when the engine is running.
If it flashes, check the charging circuit. Stop the engine, and check
for any looseness of the V-belt. If any abnormality is found, see
"OTHER TROUBLE (PAGE 3-119)".
ENGINE OIL PRESSUREThis lamp (7) lights up to warn that the engine lubricating oil
pressure has dropped. It lights up when the starting switch is
turned ON, and goes out after the engine stops.
If it lights up during operation, stop the engine immediately, andcheck for any abnormality. For details, see "OTHER TROUBLE
(PAGE 3-119)".
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OPERATION EXPLANATION OF COMPONENTS
BRAKE OIL PRESSUREThis lamp (8) lights up to warn that the oil pressure in the brake
circuit has dropped.
If it lights up, stop the engine immediately, and check for leakage
of oil from the brake circuit.
TRANSMISSION SYSTEM ELECTRIC CIRCUIT MONITORThis lamp (9) lights up when there is any failure, disconnection, or
short circuit in the electrical equipment and it has become
impossible to carry out the normal gear- shifting function of thetransmission. Read the error code displayed on the controller and
contact your Komatsu distributor for repairs.
LIFT ARM LOCKThis lamp (10) lights up when the lift arm is not locked.
TORQUE CONVERTER OIL TEMPERATUREThis lamp (11) lights up to warn that the torque converter oil
temperature has risen.
If it lights up, stop the machine, run the engine at a midrange speed
under no load, and wait for the lamp to go out.
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OPERATIONEXPLANATION OF COMPONENTS
DIFFERENTIAL OIL TEMPERATURE(If equipped)
This lamp (12) lights up to warn that the differential oil temperature
has risen.
If it lights up, check the oil level in the final drive case. If there is noabnormality, set the differential to UNLOCK and wait for the lamp
to go out.
DIFFERENTIAL CONTROL(If equipped)
This lamp (13) lights up when the differential is locked.
BLADE ACCUMULATOR(If equipped)
This lamp (14) lights up when the blade accumulator switch is
turned ON.
This protects the operator and work equipment when carrying out
leveling work on road surfaces where there are many rocks.
WORKING LAMP(If equipped)
This lamp (15) lights up when the working lamp switch is turned
ON.
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OPERATION EXPLANATION OF COMPONENTS
BLADE FLOAT(If equipped)
This lamp (16) lights up when the blade accumulator/float switch
switch is turned ON.
This is effective for snow-clearing operations.
PREHEATING LAMPThis lamp (17) displays the preheating time when starting the
engine at temperatures of 5°C (41°F) or below.
When the starting switch is turned to the HEAT position, the lamplights up for approx. 20 seconds.
When it goes out, it shows that the preheating has been
completed.
HIGH BEAM OF FRONT LAMP(If equipped)This lamp (18) lights up to indicate that the head lamps are at
BEAM.
PARKING BRAKEThis lamp (19) lights up to indicate that the gearshift lever is at the
P (Parking) position.
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OPERATIONEXPLANATION OF COMPONENTS
ARTICULATION GAUGEThis gauge (20) indicates the angle between the front frame and
rear frame.
When the key is at the OFF position, the gauge indicator is at the
left side, and when the switch is at the ON position, it shows theangle of the machine body.
TORQUE CONVERTER OIL TEMPERATURE GAUGEThis gauge (21) indicates the torque converter oil temperature.
When the pointer of the temperature gauge shows the green
range, the oil temperature is normal.When the pointer enters the red range, stop the machine
immediately, and run the engine at 1900 rpm with the gear shift
lever in neutral until the oil temperature drops to the normal value.
SERVICE METERThis meter (22) displays the accumulated hoursof operation of the
machine.
The service meter reading advances by 1 for every hour that the
engine is running, regardless of the engine speed.
The service meter will advance while the engine is running even if
the machine is not moving.
The meter is installed to the left side of the steering wheel column.
REMARKWhen the engine is running, the operation display at the top of the
meter rotates to indicate that the meter is advancing.
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OPERATION EXPLANATION OF COMPONENTS
SWITCHES
(1) Starting switch
(2) Starting aid switch
(3) Front lamp switch (if equipped)(4) Working lamp switch (if equipped)
(5) Blade accumulator/float switch (if equipped)
(6) Cigarette lighter
(7) Lift arm lock switch
(8) Front wiper switch (top)
(9) Hazard lamp switch (if equipped)
(10) Transmission mode selector switch
(11) Dimmer switch (if equipped)
(12) Differential lock switch (if equipped)(13) Turn signal lever (if equipped)
(14) Horn button
(15) Car heater switch (if equipped)
(16) Additional car heater switch (if equipped)
(17) Fresh/recirc selector switch (if equipped)
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OPERATIONEXPLANATION OF COMPONENTS
Top right inside cab Top left inside cab
(18) Room lamp switch (19) Front wiper switch (bottom) (if equipped)
(20) Rear wiper switch (if equipped)
(21) Yellow rotating lamp switch (if equipped)
(22) Front defroster fan switch (if equipped)
(23) Rear defroster fan switch (if equipped)
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OPERATION EXPLANATION OF COMPONENTS
STARTING SWITCHThis switch (1) is used to start or stop the engine.
OFF
The starting key can be inserted and removed at this position.When the key is turned to this position, the electric circuit is turned
off and the engine stops.
ON
Electricity flows to the charging circuit and lamp circuit.
START
This is the position for starting the engine. Keep the key at this
position while cranking the engine. When the engine starts,
release the key immediately.
The key returns automatically to the ON position.
HEAT position
Set to this position when starting the engine in cold weather.
If the key is held at the HEAT position, the electrical heater will be heated and the preheat monitor will light up.
When the preheating is completed, the preheating monitor will go out.
When the preheating monitor goes out, release the key immediately.
If the key is released, it will return to the OFF position. Stop the engine with the key at the OFF position, then turn
the key to the START position to start the engine.
REMARKWhen the preheating lamp goes out in cold weather, continue preheating for a further 10 seconds before releasing
the key.
STARTING AID SWITCHUse this switch (2) when starting the engine in cold weather (-21°
C (-5.8°F) or below).
If this switch (2) is pressed when the engine is being started, the
load on the hydraulic pump will be reduced and this will make it
easier for the engine to start. When the engine starts and the
engine speed rises to a stable condition, release the switch.
Position (a) (when pressed): ON
Position (b) (when released): OFF
This switch functions only when the gearshift lever is at the P
(Parking) position.
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OPERATIONEXPLANATION OF COMPONENTS
FRONT LAMP SWITCH(If equipped)
This switch (3) is used to light up the front lamps, side clearance
lamps, tail lamps, and instrument panel.
Position (a) (pushed back): OFFPosition (b): Side clearance lamps, tail lamps, and instrument
panel light up
Position (c) (pushed forward): Front lamps light up in addition to
lamps at position (b).
WORKING LAMP SWITCH(If equipped)
This switch (4) is used to light up the working lamp.
Position (a) (pushed back): OFFPosition (b) (pushed forward): Working lamp lights up
BLADE ACCUMULATOR/FLOAT SWITCH(If equipped)
This switch (5) is used to actuate the blade accumulator and float.
Position (a) (neutral): OFF
Position (b) (pushed forward): Blade float ON
Position (c) (pushed back): Blade accumulator ON
REMARKThe blade accumulator is effective in leveling road surfaces on
jobsites where there are many rocks or when clearing
compressed snow.
The blade float is effective when clearing fresh snow.
CIGARETTE LIGHTERThis switch (6) is used to remove or insert the lifter lock pin.
This switch is used when setting the blade to the bank cut posture
or shoulder reach posture. Press the switch to remove the pin;
press the switch again to return the switch and insert the pin.
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OPERATION EXPLANATION OF COMPONENTS
LIFT ARM LOCK SWITCH
WARNINGLower the blade to the ground before removing the bank control lock pin. Do not remove it at any other position. There is danger
that it will rotate and the blade will fall.
This switch (7) is used to remove or insert the lifter lock pin.
This switch is used when setting the blade to the bank cut posture
or shoulder reach posture. Press the switch to remove the pin;
press the switch again to return the switch and insert the pin.
FRONT WIPER SWITCH (TOP)This switch (8) is used to operate the wiper at the top of the front
glass.
Position (a): Washer liquid is sprayed out
Position (b): Wiper is operated
Position (c): Wiper is operate and washer liquid is sprayed out
HAZARD LAMP SWITCH(If equipped)
WARNINGNever use the hazard lamp except in emergencies. If it is used while traveling when there is no abnormality, it may cause
misunderstanding for drivers of other vehicles.
The emergency lamp is used only in emergencies. This switch (9)
is used to make the emergency lamp flash when there is a failure
or when the machine has to be parked on the road.
Position (a) (pushed back): OFF
Position (b) (pushed forward): All turn signal lamps flash
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OPERATIONEXPLANATION OF COMPONENTS
TRANSMISSION MODE SELECTOR SWITCHThis switch (10) switches the gearshifting pattern of the transmission.
Position (b) (push forward): Mode 1
When carrying out work with the same operating feeling as theconventional direct power shift (hydroshift), select Mode 1.
Use Mode 1 in the following cases:
When carrying out work with production efficiency raised to the
maximum.
When carrying out snow clearing or other work with the
gearshift range fixed.
Position (a) (push back): Mode 2
When carrying out work in the torque converter drive with easy-to-operate automatic gearshifting, select Mode 2.
When traveling in a high-gear speed range at a speed of 10 km/h (6.2 MPH) or above, this automatically shifts tothe lock-up with its more efficient power transmission.
Use Mode 2 in the following cases:
When carrying out work with big variation in load, where the engine is likely to stall (F1 - F4)
When carrying out snow-clearing work in high-gear speed range at a speed of 10 km/h (6.2 MPH) or above
When traveling under own power.
: Manual gearshifting uses the torque converter lock-up from the beginning
With automatic gearshifting, when the travel speed rises and the torque converter slippage is reduced, the
transmission is automatically locked up.
: Remains in torque converter drive (torque converter drive is held, regardless of travel speed or engine speed)
Manual gearshifting: Transmission is held in same gear range as position of gearshift lever
Automatic gearshifting: Transmission is automatically shifted according to travel speed within maximum range set
by position of gearshift lever
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OPERATION EXPLANATION OF COMPONENTS
REMARKWhen Mode 1 is selected, the engine may stall because of the use of direct power shift.
When Mode 2 is selected and work is carried out in F1 with the engine at low idling, it becomes easier to perform
light load operations, such as finishing work at low travel speed (approx. 1 km/h (0.6 MPH)).
When Mode 2 is selected and the gear speed range is set between F5 and F8, the transmission is shiftedautomatically. With automatic transmission, the transmission starts in F4 torque converter drive, and shifts up
automatically as necessary through the gear speeds to the set gear speed range.
Even if the gearshift lever is shifted, if there is danger of overrun, the overrun inhibitor is actuated to prevent
gearshifting. When the travel speed drops to a speed where there is no danger of overrun, the transmission
starts to shift again.
DIMMER SWITCH(If equipped)
This switch (11) is used to switch the head lamps between high
beam and low beam.
(a) High beam(b) Low beam
DIFFERENTIAL LOCK SWITCH(If equipped)
This switch (12) is used to actuate the differential lock.
Position (a) (pushed back): Differential lock actuated
Position (b) (pushed forward): OFF
TURN SIGNAL LEVER(If equipped)
This lever (13) is used to operate the turn signal lamps.
(a)Left turn: Operate the lever up
(b)Right turn: Operate the lever down
The lever does not return to its original position when the steering
lever is returned to the straight position. Return the lever by hand.
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OPERATIONEXPLANATION OF COMPONENTS
HORN BUTTONWhen horn button (14) in the center of the steering wheel is
pressed, the horn will sound.
CAR HEATER SWITCH(if equipped)
Use this switch (15) to turn the heater ON/OFF and to regulate the
air flow (3 levels).Position (a): OFF
Position (b): ON, low air flow
Position (c): ON, medium air flow
Position (d): ON, high air flow
ADDITIONAL CAR HEATER SWITCH(if equipped)
Use this switch (16) to increase the heater capacity.
Position (a): OFF
Position (b): ON, low air flow
Position (c): ON, medium air flow
Position (d): ON, high air flow
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OPERATION EXPLANATION OF COMPONENTS
FRESH/RECIRC SELECTOR SWITCH(if equipped)
This switch (17) is used to choose introduction of fresh air from outside or recirculation of the air inside the cab.
Pull the switch to position (a) to take in outside air; push the switch
to position (b) to circulate the air inside the cab.
ROOM LAMP SWITCH
This switch (18) is used to light up the room lamp.ON position: Lamp lights up
OFF position: Lamp goes out
FRONT WIPER SWITCH (BOTTOM)(If equipped)
This switch (19)actuates the wiper for the bottom of the front glass.
Position (a): OFF
Position (b): Wiper actuated
Position (c): Washer fluid sprayed out
REAR WIPER SWITCH(If equipped)
This switch (20) actuates the wiper for the rear glass.
Position (a): OFF
Position (b): Wiper actuated
Position (c): Washer fluid sprayed out
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OPERATIONEXPLANATION OF COMPONENTS
YELLOW ROTATING LAMP SWITCH(If equipped)
This switch (21) is used to light up and rotate the rotating lamp.
Position (a): OFF
Position (b): Rotating lamp lights up
REMARKThe yellow rotating lamp is used when carrying out operations, but
follow the guidance of the supervisor.
FRONT DEFROSTER FAN SWITCH(If equipped)
This switch (22) is used to actuate the front defroster fan.Position (a) (pushed back): OFF
Position (b) (pushed forward): Front defroster fan actuated
This is the switch installed to the defroster and can be used to stop
or start operation of the defroster.
REAR DEFROSTER FAN SWITCH
(If equipped)This switch (23) is used to actuate the rear defroster fan.
Position (a) (pushed back): OFF
Position (b) (pushed forward): Rear defroster fan actuated
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OPERATIONEXPLANATION OF COMPONENTS
CONTROL LEVERS, PEDALS
(1) Left blade lift cylinder control lever
(2) Ripper/Scarifier control lever (if equipped)
(3) Blade side shift control lever
(4) Power tilt control lever
(5) Blade rotation control lever
(6) Articulate control lever
(7) Front attachment control lever
(8) Drawbar side shift control lever
(9) Leaning control lever
(10) Right blade lift cylinder control lever
(11) Inching pedal
(12) Steering console tilt pedal
(13) Brake pedal
(14) Accelerator pedal
(15) Decelerator pedal
(16) Gearshift lever
(17) Fuel control lever
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OPERATION EXPLANATION OF COMPONENTS
LEFT BLADE LIFT CYLINDER CONTROL LEVERThis lever (1) operates the left blade lift cylinder.
(a) LOWER: The left side of the blade goes down.
(b) HOLD: The blade stops and is held in the same position.
(c) RAISE: The left side of the blade goes up.
RIPPER/SCARIFIER CONTROL LEVER(If equipped)
This lever (2) is used to operate the ripper or scarifier.
When the machine is equipped with a ripper
(a) LOWER: The ripper is lowered.
(b) HOLD: The ripper is stopped and held in position.
(c) RAISE: The ripper is raised.
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OPERATIONEXPLANATION OF COMPONENTS OPERATIONEXPLANATION OF COMPONENTS
When the machine is equipped with a scarifier
(a) LOWER: The scarifier is lowered.
(b) HOLD: The scarifier is stopped and held in position.
(c) RAISE: The scarifier is raised.
BLADE SIDE SHIFT CONTROL LEVERThis lever (3) shifts the blade to the side.
(a) LEFT SHIFT: The blade is shifted to the left position.
(b) HOLD: The blade stops and is held in the same