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MOTORGRADER

PEN00178-01

GD555 -3A

SERIAL NUMBERS 11001 and up

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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 in the storage location for the operation and maintenance manual given below, and have all personnel read it

periodically.

If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu

or your Komatsu distributor.

If you sell the machine, be sure to give this manual to the new owners together with the machine.

Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has been shipped.

If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety

devices and specifications that are necessary for use in your country. If there is any question about whether your 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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FOREWORDFOREWORD

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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

WARNINGWhen standing up from the operator's seat, always place the lock lever in the LOCK position.

If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.

Other signal words

In addition to the above, the following signal words are used to indicate precautions that should be followed to

protect the machine or to give information that is useful to know.

This word is used for precautions that must be taken to avoid actions which could shorten

the life of the machine.

This word is used for information that is useful to know.

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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 pictograms show 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:1J (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 3-69)" 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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FOREWORD CONTENTS

CHECKS AFTER COMPLETION OF OPERATION 3-106

LOCKING 3-107

HANDLING THE TIRES 3-107

TRANSPORTATION 3-108

LOADING, UNLOADING WORK 3-108PRECAUTIONS FOR LOADING 3-109

COLD WEATHER OPERATION 3-110

PRECAUTIONS FOR LOW TEMPERATURE 3-110

CAUTIONS AFTER COMPLETION OF WORK 3-111

AFTER COLD WEATHER 3-111

LONG-TERM STORAGE 3-112

BEFORE STORAGE 3-112

DURING STORAGE 3-112

AFTER STORAGE 3-112

TROUBLESHOOTING 3-113

AFTER RUNNING OUT OF FUEL 3-113WHEN LEANING PIPING IS DAMAGED 3-114

TOWING THE MACHINE 3-115

IF BATTERY IS DISCHARGED 3-117

OTHER TROUBLE 3-120

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- 7

WEAR PARTS 4- 8

WEAR PARTS LIST 4- 8

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 9

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 13

TORQUE LIST 4- 13

PERIODIC REPLACEMENT OF CRITICAL PARTS 4- 15

CRITICAL PARTS 4- 15

MAINTENANCE SCHEDULE CHART 4- 16

MAINTENANCE SCHEDULE CHART 4- 16

SERVICE PROCEDURE 4- 18

INITIAL 250 HOURS SERVICE (only after the first 250 hours) 4- 18

WHEN REQUIRED 4- 19CHECK BEFORE STARTING 4- 32

EVERY 50 HOURS SERVICE 4- 33






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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FOREWORDCONTENTS

CAR RADIO 6- 4

EXPLANATION OF COMPONENTS 6- 4

METHOD OF OPERATION 6- 7

PRECAUTIONS FOR USE 6- 9

AIR CONDITIONER 6- 10LOCATIONS AND FUNCTIONS OF CONTROL PANEL 6- 10

METHOD OF OPERATION 6- 12

PRECAUTIONS WHEN USING 6- 12

TESTING AND MAINTENANCE 6- 12

HANDLING ADJUSTABLE SEAT 6- 13

ADJUST OPERATOR'S SEAT 6- 13

HANDLING AIR-SUSPENSION SEAT 6- 14

ADJUST OPERATOR'S SEAT 6- 14

HANDLING MACHINES EQUIPPED WITH KOMTRAX 6- 16

BASIC PRECAUTIONS 6- 16

INDEX 7- 1

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SAFETYSAFETY INFORMATION

SAFETY INFORMATION

SAFETY LABELS 2- 4

POSITIONS OF SAFETY PICTOGRAMS 2- 4

SAFETY LABELS 2- 5

GENERAL PRECAUTIONS 2- 9

SAFETY RULES 2- 9

IF PROBLEMS ARE FOUND 2- 9

CLOTHING AND PERSONAL PROTECTIVE ITEMS 2- 9

FIRE EXTINGUISHER AND FIRST AID KIT 2- 9

SAFETY FEATURES 2- 9

KEEP MACHINE CLEAN 2- 10

INSIDE OPERATOR'S COMPARTMENT 2- 10

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT 2- 10

HANDRAILS AND STEPS 2- 11MOUNTING AND DISMOUNTIN 2- 11

DO NOT GET CAUGHT IN ARTICULATED PORTION 2- 11

PREVENTION OF BURNS 2- 12

FIRE PREVENTION 2- 13

ACTION IF FIRE OCCURS 2- 13

WINDOW WASHER LIQUID 2- 14

PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure) 2- 14

PRECAUTIONS FOR ATTACHMENTS 2- 14

UNAUTHORIZED MODIFICATION 2- 14

SAFETY AT WORKSITE 2- 15

WORKING ON LOOSE GROUND 2- 15

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES 2- 16

ENSURE GOOD VISIBILITY 2- 16

VENTILATION FOR ENCLOSED AREAS 2- 16

CHECKING SIGNALMAN'S SIGNALS AND SIGNS 2- 17

EMERGENCY ESCAPE FROM OPERATOR'S CAB 2- 17

ASBESTOS DUST HAZARD PREVENTION 2- 17

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SAFETY SAFETY INFORMATION

PRECAUTIONS DURING OPERATION 2- 18

STARTING ENGINE 2- 18

CHECKS BEFORE STARTING ENGINE, ADJUST 2- 18

PRECAUTIONS WHEN STARTING 2- 18

PRECAUTIONS IN COLD AREAS 2- 19OPERATION 2- 20

CHECKS BEFORE STARTING OPERATION 2- 20

PRECAUTIONS BEFORE MOVING OFF 2- 20

PRECAUTIONS WHEN TRAVELING 2- 21

PRECAUTIONS WHEN TRAVELING ON SLOPES 2- 22

PRECAUTIONS WHEN OPERATIONS ON SLOPES 2- 22

PROHIBITED OPERATIONS 2- 22

PRECAUTIONS WHEN OPERATING 2- 22

OPERATE CAREFULLY ON SNOW 2- 23

PARKING MACHINE 2- 24

TRANSPORTATION 2- 25LOADING 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- 33REPAIR 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 2- 35

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SAFETYSAFETY LABELS

SAFETY LABELSThe following warning signs and safety labels are used on this machine.

Be sure that you fully understand the correct position and content of labels.

To ensure that the content of labels can be read properly, be sure that they are in the correct place and always

keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels topeel off.

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

way.

If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part

numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.

POSITION FOR ATTACHING SAFETY LABELS

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SAFETY SAFETY LABELS

SAFETY LABELS(1) Precautions before operating

(09651-A0881)

(2) Precautions for opening hydraulic cap

(09653-A0641)

(3) Precautions when driving in reverse

(09802-43000)

(4) Warning for high voltage (09801-E0881)

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SAFETYSAFETY LABELS

(5) Articulate lock (09161-C0881) (6) Warning for handling accumulator (09659-A057B)

(7) Prohibited to walk (23B-53-31740) (8) Precautions when engine running (09667-A0481)

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SAFETY SAFETY LABELS

(9) Precautions when handling booster cable and

battery cable (09808-A1681)

(10) Prohibited to enter (09162-E0881)

(11) Precautions when startling and traveling

(23B-53-31740)

(12) Exhaust pipe is hot ! (09817-K088B)

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SAFETYSAFETY LABELS

(13) "Do not approach machine" warning (09806-E1201)

(14) Precautions for brake (23B-53-31670)

(15) Precautions when handling battery (16) 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 in this manual when operating or performing maintenance onthe machine.

If you are not feeling well, or if you are under the influence of alcohol or medication, your ability to safely operate

or repair your machine may be severely impaired, putting yourself and everyone else on your job site in danger.

When working with another operator or with the person on the worksite traffic duty, discuss the content of the

operation beforehand and use the determined signals when carrying out the operation.

IF PROBLEMS ARE FOUNDIf you find any problems in the machine during operation or maintenance (noise, vibration, smell, incorrect gauges,

smoke, oil leakage, etc., or any abnormal display on the warning devices or monitor), report to the person in charge

and have the necessary action taken. Do not operate the machine until the problem has been corrected.

CLOTHING AND PERSONAL PROTECTIVE ITEMS

Do not wear loose clothing and accessories. There is a hazard that they may catch on control levers or other

protruding parts.

If you have long hair and it hangs out from your hard hat, there

is a hazard that it may get caught up in the machine, so tie your

hair up and be careful not to let it get caught.

Always wear a hard hat and safety shoes. If the nature of the

work requires it, wear safety glasses, mask, gloves, ear plugs,

and safety belt when operating or maintaining the machine.

Check that all protective equipment functions properly before

using it.

FIRE EXTINGUISHER AND FIRST AID 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 in the storage point. Carry out periodicchecks and add to the contents if necessary.

SAFETY FEATURESBe sure that all guards, covers and mirrors are in their proper position. Have guards and covers repaired

immediately if they are damaged.

Understand the method of use of safety features and use them properly.

Never remove any safety features. Always keep them in good operating condition.

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SAFETYGENERAL PRECAUTIONS

KEEP MACHINE CLEAN

If water gets into the electrical system, there is a hazard that it will cause malfunctions or misoperation. Do not

use water or steam to wash the electrical system (sensors, connectors).

If inspection and maintenance is carried out when the machine

is still dirty with mud or oil, there is a hazard that you will slip 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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HANDRAILS AND STEPS

To 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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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 a temperature where it

is possible to touch the cap or plug by hand before starting the

operation. Even when the oil has cooled down, loosen the cap

or plug slowly to relieve the internal pressure before removing

the cap or plug.

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FIRE 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.

Fire coming from electric wiring

Short circuits in the electrical system can cause fire.

Always keep electric wiring connections clean and securely tightened.

Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair

or replace any damaged wiring.

Fire coming from hydraulic line

Check that all the hose and tube clamps, guards, and cushions are securely fixed in position.If they are loose, they may vibrate during operation and rub against other parts. This may lead to damage to the

hoses, and cause high-pressure oil to spurt out, leading to fire damage or serious injury.

Explosion caused by lighting equipment

When checking fuel, oil, battery electrolyte, window washer fluid, or coolant, always use lighting with

anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion that may

cause serious injury.

When taking the electrical power for the lighting from the machine itself, follow the instructions in this manual.

ACTION IF FIRE OCCURS

If a fire occurs, escape from the machine as follows.

Turn the start switch OFF to stop the engine.

Use the handrails and steps to get off the machine.

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WINDOW WASHER LIQUID

Use an ethyl alcohol base washer liquid.

Methyl alcohol base washer liquid may irritate your eyes, so do not use it.

PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)Install ROPS when working in places where there is danger of

falling rocks, such as in mines and quarries, or in places where

there is danger of rolling over.

If ROPS is installed, do not remove it when operating the

machine.

ROPS is installed to protect the operator when machine rolls

over. When machine rolls over, ROPS supports its weight and

absorbs its impact energy.

If ROPS is modified, its strength may be reduced. When

modifying, consult your Komatsu distributor.

If ROPS is deformed by falling objects or by rolling over, itsstrength lowers and its design functions cannot be maintained.

In this case,be sure to askyour Komatsu distributoraboutrepair

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.

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, product failures or other property damages resulting from the use of unauthorized

attachments or parts will not be the responsibility of Komatsu.

When installing and using optional attachments, read the instruction manual for the attachment, and the general

information related to attachments in this manual.

UNAUTHORIZED MODIFICATION

Any modification made without authorization from Komatsu can create hazards. Before making a modification,

consult your Komatsu distributor.Komatsu will not be responsible for any injuries, accidents, product failures or other property damages resulting

from modifications made without authorization from Komatsu.

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SAFETY AT WORKSITE

Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous.

Check the terrain and condition of the ground at the worksite, and determine the safest method of operation. Do

not operate where there is a hazard of landslides or falling rocks.

If water lines, gas lines, or high-voltage electrical lines may beburied 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 the

machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe

and to prevent the machine from rolling over or falling.

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DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES

Do not travel or operate the machine near electric cables. There is

a hazard of electric shock, which may cause serious personal

injury or death. On jobsites where the machine may go close to

electric cables, always do as follows.Before starting work near electric cables, inform the local power

company of the work to be performed, and ask them to take the

necessary action.

Voltage of Cables Safety Distance

100 V - 200 V Over 2 m (7 ft)

6,600 V Over 2 m (7 ft)

22,000 V Over 3 m (10 ft)

66,000 V Over 4 m (14 ft)

154,000 V Over 5 m (17 ft)

187,000 V Over 6 m (20 ft)

275,000 V Over 7 m (23 ft)

500,000 V Over 11 m (36 ft)

Even going close to high-voltage cables can cause electric

shock, which may cause serious burns or even death. Always

maintaina 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 rubbersheeton top of the seat, and be careful

not to touch the chassis with any exposed part of your body.

Use a signalman to give warning if the machine approaches too

close to the electric cables.

When carrying out operations near high voltage cables, do not

let anyone near the machine.

If the machine should come too close or touch the electric cable, to prevent electric shock, the operator should

not leave the operator's compartment until it has been confirmed that the electricity has been shut off.

Also, do not let anyone near the machine.

ENSURE GOOD 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 AREASThe engine exhaust gas contains substances that may damage

your health or even cause death. Start or operate the engine in a

place where there is good ventilation. If the engine or machine

must be operated inside a building or under ground, where the

ventilation is poor, take steps to ensure that the engine exhaust

gas is removed and that ample fresh air is brought in.

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CHECKING SIGNALMAN'S SIGNALS AND SIGNS

Set up signs to inform of road shoulders and soft ground. If the visibility is not good, position a signalman if

necessary. Operators should pay careful attention to the signs and follow the instructions from the signalman.

Only one signalman should give signals.

Make sure that all workers understand the meaning of all signals and signs before starting work.

EMERGENCY ESCAPE FROM OPERATOR'S 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 cause lungcancer if it is inhaled.There

is danger of inhaling asbestos when working on jobsites handling

demolition work or work handling industrial waste. Always observe

the following.

Spray water to keep down the dust when cleaning. Do not 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 notuse 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 DURING OPERATION

STARTING ENGINEIf thereis a warningtag hangingfromgearshift lever, do notstart

the engine or touch the levers.

CHECKS BEFORE STARTING ENGINE, ADJUSTCarry out the following checks before starting the engine at the beginning of the day's work.

Remove all dirt from the surface of the window glass to ensure a good view.

Remove all dirt from the surface of the lens of the front lamps, working lamps, and rear combination lamp, and

check that they light up correctly.

Check the coolant level, fuel level, and oil level in engine oil pan, check for clogging of the air cleaner, and check

for damage to the electric wiring.

Check that thereis nomud or dust accumulated aroundthe movable parts of the acceleratorpedalor brakepedal,

and check that the pedals work properly.

Adjust the operator'sseat to a position where it is easy to carry out operations, andcheck that there is no damage

or wear to the seat belt or mounting clamps.

Check the operation of the instruments and gauges, check the angle of the mirror, and check that the control

levers are all at the Neutral position.Before starting the engine, check that the gearshift lever is at the P (Parking) position.

Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat.

Refer to "WALK-AROUND CHECK (PAGE 3-35)".

Check that there are no persons or obstacles above, below, or in the area around the machine.

PRECAUTIONS WHEN STARTINGStart and operate the machine only while seated.

Do not attempt to start the engine by short-circuiting the engine starting circuit. Such an act may cause a serious

bodily injury or fire.

When starting the engine, sound the horn as a warning.

Do not allow anyone apart from the operator to ride on the machine.

For machines equipped with a back-up alarm, check that the alarm works properly.

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SAFETY PRECAUTIONS DURING OPERATION

PRECAUTIONS IN COLD AREAS

Carry out the warming-up operation thoroughly. If the machine is not thoroughly warmed up before the steering

wheel, controllevers, gearshift lever, or brakepedalare 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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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 problem in the sound of the machine, vibration,

heat, smell, or gauges; check also that there is no leakage of oil

or fuel.

If any problem is found, carry out repairs immediately.

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 backup alarm (alarm buzzer when machine

travels in reverse) works properly.

Fix the operator's compartment doors and windows in the

closed position securely.

If there is an area to the rear of the machine which cannot be

seen,position a signal person. Take special care not to hit 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.

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PRECAUTIONS WHEN TRAVELING

Never 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 dangerthat the machine may turn over. The work equipment may hit the ground surface and cause the machine to lose

its balance, or may damage the machine or structures in the area.

Operate carefully when the wheels are leaning. It is prohibited to

travel on roads with the wheels leaning.

Travel at a maximum speed of 10 km/h (6.2 MPH) when using

the articulation. If the articulation is used when traveling at a

speed of over 10 km/h (6.2 MPH), there is danger that the

machine may overturn. Never use the articulation at speeds of

over 10 km/h (6.2 MPH).

When traveling or carrying out operations, always keep a safe distance from people, structures, or other

machines to avoid coming into contact with them.

When passing over bridges or structures, check first that the structure is strong enough to support the mass of

the machine.

When operating in tunnels, under bridges, underelectric wires,or other placeswhere theheight is limited,operate

slowly and be extremely careful not to let the machine body or work equipment hit anything.

If you drive the machine at high speedcontinuously for a long time, the tires will overheat and the internalpressure

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 youare going to travel continuously, please consult your Komatsu distributor.

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PRECAUTIONS WHEN TRAVELING ON SLOPES

To prevent the machine from tipping over or slipping to the side,

always do as follows.

Always travel straight up or down a slope. Traveling at an angle

or across the slope is extremely dangerous.Do not turn on slopes or travel across slopes. Always go down

to a flat place to change the position of the machine, then travel

on to the slope again.

Travel on grass, fallen leaves, or wet steel plates with low

speed. Even with slight slopes there is a hazard that the

machine may slip.

If the engine stops, depress the brake pedal immediately, lower

the blade, set the gearshift lever to the P (Parking) position, and

stop the machine.

When traveling downhill, never shift gear or place the transmission at neutral. It is dangerous not to use the

braking force of the engine. Always place the transmission in a low gear before starting to travel downhill.When traveling downhill, travel slowly. If necessary, use the braking force of the engine together with the brake

pedal to control the travel speed.

PRECAUTIONS WHEN OPERATIONS ON 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 OPERATIONS

When operating at the bottom of a cliff, there is danger that the soil may collapse or that rocks may fall. Never

operate in such places.

The edge of cliffs or road shoulders may easily collapse, and there is danger of falling. Do not go close to such

places.

Avoid sudden starts, sudden stops, and sudden steering.

PRECAUTIONS WHEN OPERATINGWhen operating in tunnels, under bridges, under electric wires, or other places where the height is limited, be

extremely careful not to let the machine body or work equipment hit anything.

To prevent accidents caused by hitting other objects, always operate the machine at a speed which is safe for

operation, particular in confined spaces, indoors, and in places where there are other machines.

Check that there is no person other than the operator within the range of flying objects caused by the operation.

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OPERATE CAREFULLY ON SNOW

Snow-covered or frozen surfaces are slippery, so be extremely careful when traveling or operating the machine,

and do not operate the levers suddenly. Even a slight slope may cause the machine to slip, so be particularly

careful when working on slopes.

With frozen ground surfaces, the ground becomes soft when the temperature rises, and this may cause themachine to tip over or make it impossible for the machine to escape.

If the machine enters deep snow, there is a hazard that it may tip over or become buried in the snow. Be careful

not to leave the road shoulder or to get trapped in a snow drift.

When clearing snow, the road shoulder and objects placed beside the road are buried in the snow and cannot be

seen. There is a hazard of the machine tipping over or hitting covered objects, so always carry out operations

carefully.

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

When 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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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 3-108)".

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 3-108)" in the OPERATION section.

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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. Check the battery electrolyte level periodically and add distilled water to bring the electrolyte level

to the UPPER LEVEL line.

When working with batteries, always wear safety glasses and rubber gloves.

Never smoke or use any flame near the battery.

If you spill acid on your clothes or skin, immediately flush the

area with large amount of water.

If acid gets into your eyes, flush them immediately with large

amount of water and seek medical attention.

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 contactbetweenthe 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 terminals securely.

Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take

it to a well-ventilated place, and remove the battery caps before charging it.Tighten the battery caps securely.

Install the battery securely to the determined place.

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STARTING WITH BOOSTER CABLES

If any mistake is made in the method of connecting the booster

cables, it may cause the battery to explode, so always do as

follows.

When starting with a booster cable, carry out the 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 position for both the normal machine and problem

machine.There is a hazard that the machine will move when the

power is connected.

Be sure to connect the positive (+) cable first when installing the

booster cables. Disconnect the negative (-) cable (ground side)

first when removing them.When removing the booster cables, be careful not to let the

booster cable clips touch each other or to let the clips touch the

machine.

Always wear safety glasses andrubbergloveswhen 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

3-118)" in the OPERATION section.

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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 3-115)".

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 OTHERS

When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his

instructions during the operation.

When working with others, misunderstandings between workers can lead to serious accidents.

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SAFETYPRECAUTIONS FOR MAINTENANCE

STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE

Stop the machine on firm, level ground.

Select a place where there is no hazard of landslides, falling

rocks, or flooding.

Lower the work equipment completely to the ground and 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 RUNNING

To prevent personal injury, do not carry out maintenance with the engine running. If maintenance must be carried

out with the engine running, carry out the operation with at least two workers and do as follows.

One worker must always sit in the operator's seat and be ready to stop the engine at any time. All workers must

maintain contact with the other workers.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 TOOLS

Use only tools suited to the task and be sure to use the tools

correctly. Using damaged, low quality, faulty, makeshift tools or

improper use of the tools could cause serious personal injury.

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ACCUMULATOR

The accumulator is charged with high-pressure nitrogen gas.

When handling the accumulator, careless procedure may cause

an explosion which could lead to serious injury or property

damage. For this reason, always observe the 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

Do not allow any unauthorized personnel into the area when servicing the machine. If necessary, employ a guard.

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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HANDLING HIGH-PRESSURE HOSES

If oil or fuel leaks from high-pressure hoses, there is danger that it may cause fire or defective operation, which may

lead 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 AIR

When carrying out cleaning with compressed air, there is a hazard of serious injury caused by flying particles.

When using compressed air to clean elements or the radiator, always wear safety glasses, dust mask, gloves,

and other protective equipment.

PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS

In order for the machine to be operated 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 4-15)".

Thematerial of these components naturally 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 specified

replacement time.

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OPERATIONGENERAL VIEW

GENERAL VIEW

GENERAL VIEW OF MACHINE

The drawing shows the machine with the cab (if equipped) installed(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

The drawing shows the machine with the cab (if equipped) installed

(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 (if equipped)

(27) Lift arm lock switch

(28) Front wiper switch (top) (if equipped)

(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 devices needed for operating the machine.

To perform suitable operations correctly and safely, it is important to completely understand methods of operating

the equipment, and the meanings of the displays.

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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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 3-120)",and

contact your Komatsu distributor for repairs.

BATTERY CHARGEThis lamp (6) warns of any problem in the charging system when

the engine is running.

If it flashes, check the charging circuit. Stop the engine, and check

for any looseness of the V-belt. If any problem is found, see

"OTHER TROUBLE (PAGE 3-120)".

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 problem. For details, see "OTHER TROUBLE

(PAGE 3-120)".

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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 gearshifting 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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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 noproblem, set the differential to UNLOCK and wait for the lampto 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/float switch is

turned ON.

This protects the operator and work equipment when carrying out

leveling work on road surfaces where there are many rocks.

WORKING LAMP(If equipped)

This lamp (15) lights up when the working lamp switch is turned

ON.

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BLADE FLOAT(If equipped)

This lamp (16) lights up when the blade accumulator/float switch

switch is turned ON.

This is effective for snow-clearing operations.

PREHEATING LAMPThis lamp (17) displays the preheating time when starting the

engine at temperatures of 5C (41F) or below.

When the starting switch is turned to the HEAT position, the 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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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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STARTING SWITCHThis switch (1) is used to start or stop the engine.

OFF position

The key canbe insertedor with drawn.The switches for the electricsystem are all turned off and the engine is stopped.

ON

Electricity flows to the charging circuit and lamp circuit.

START

This is the position for starting the engine. Keep the key at this

position while cranking the engine. When the engine starts,

release the key immediately.

The key returns automatically to the ON position.

HEAT position

Set to this position when starting the engine in cold weather.

If the key is held at the HEAT position, the electrical heater will be heated and the preheat monitor will light up.

When the preheating is completed, the preheating monitor will go out.

When the preheating monitor goes out, release the key immediately.

If the key is released, it will return to the OFF position. Stop the engine with the key at the OFF position, then turn

the key to the START position to start the engine.

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 (-5.8F) 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): ONPosition (b) (when released): OFF

This switch functions only when the gearshift lever is at the P

(Parking) position.

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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 LIGHTER(If equipped)

This cigarette lighter (6) is used to light cigarettes. When the

cigarette lighter is pushedin, it will returnto itsoriginalposition after

several seconds, so pull it out and use it to light your cigarette.

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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)(If equipped)

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

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HAZARD LAMP SWITCH(If equipped)

WARNING

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

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

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 the

conventional 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 to

the 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.

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z : 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

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 idle, it becomes easier to perform

light load operations, such as finishing work at low travel speed (approx. 1 km/h (0.6 MPH)).

When Mode 2 is selected and the gear speed range is set between F5 and F8, the transmission is shifted

automatically. With automatic transmission, the transmission starts in F4 torque converter drive, and shifts up

automatically as necessary through the gear speeds to the set gear speed range.

Even if the gearshift lever is shifted, if there is danger of overrun, the overrun inhibitor is actuated to prevent

gearshifting. When the travel speed drops to a speed where there is no danger of overrun, the transmission

starts to shift again.

DIMMER SWITCH(If equipped)

This switch (11) is used to switch the head lamps between high

beam and low beam.

(a) High beam(b) Low beam

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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.

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

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ADDITIONAL CAR HEATER SWITCH(If equipped)

Use this switch (16) to increase the heater capacity.

Position (a): OFF

Position (b): ON, low air flowPosition (c): ON, medium air flow

Position (d): ON, high air flow

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 SWITCHThis switch (18) is used to light up the room lamp.

ON position: Lamp lights up

OFF position: Lamp goes out

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FRONT WIPER SWITCH (BOTTOM)(If equipped)

This switch (19)actuates the wiperfor the bottomof the front glass.

Position (a): OFF

Position (b): Wiper actuatedPosition (c): Washer fluid sprayed out

REAR WIPER SWITCH(If equipped)

This switch (20) actuates the wiper for the rear glass.

Position (a): OFFPosition (b): Wiper actuated

Position (c): Washer fluid sprayed out

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.

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CONTROL LEVERS, PEDALS

The drawing shows the machine with the cab (if equipped) installed

(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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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.


(c) RIGHT SHIFT: The blade is shifted to the right.

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POWER TILT CONTROL LEVERThis lever (4) changes the cutting angle of the blade.

(a) Max. cutting angle: This makes the blade cutting angle bigger.

This is effective when operating on hard

ground.(b) HOLD: The blade stops and is held in the same position.

(c) Min. cutting angle: This makes the blade cutting angle smaller.

This is effective when operating on soft

ground.

BLADE ROTATION CONTROL LEVER

NOTICE

To prevent damage to the tires, be careful not to let the blade hit the tires when rotating the blade.

This lever (5) rotates the blade.

(a) RIGHT ROTATION: The blade is rotated to the left.


(c) LEFT ROTATION: The blade is rotated to the right.

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ARTICULATE CONTROL LEVER

WARNINGOperate this lever only when traveling at a speed of below 10 km/h (6.2 MPH). If the articulation is operated at a speed of over 10

km/h (6.2 MPH), there is danger that the machine may overturn.

NOTICE

To prevent damage to the tires, be careful not to let the blade hit the tires when articulating the machine.

This lever (6) is used to operate the articulation.

(a) LEFT TURN: The machine articulates to the left.

(b) HOLD: The articulation is kept in the same condition.

(c) RIGHT TURN: The machine articulates to the right.

FRONT ATTACHMENT LEVERThis lever (7) is used when an optional front attachment is installed.

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DRAWBAR SIDE SHIFT CONTROL LEVERThis lever (8) shifts the drawbar to the side.

(a) LEFT SHIFT: The drawbar is shifted to the left.

(b) HOLD: The drawbar stops and is held in the same position.

(c) RIGHT SHIFT: The drawbar is shifted to the right.

LEANING CONTROL LEVERThis lever (9) is used to operate the leaning.

(a) LEFT TURN: The tires lean to the left.

(b) HOLD: The leaning is kept in the same condition.

(c) RIGHT TURN: The tires lean to the right.

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RIGHT BLADE LIFT CYLINDER CONTROL LEVERThis lever (10) operates the right blade lift cylinder.

(a) LOWER: The right side of the blade goes down.


(c) RAISE: The right side of the blade goes up.

INCHING PEDAL

NOTICE

Do not operate continuously for more than 10 seconds. If the inching operation is used continuously for more than 10 seconds,

it will cause serious damage to the clutch, such as abnormal wear or seizure.

This pedal (11) cuts off the power from the engine.

Use this pedal when stopping the machine, starting the machine

off, or when shifting the direction between forward and reverse.

When the pedal is depressed, the power is cut off.

When the transmission is in F1 - F4 or in R2, operating this pedal

makes it possible to make fine movements of the machine.

STEERING CONSOLE TILT PEDALThis pedal (12) can be used to adjust the angle of the steering

console steplessly.

Depress the tilt pedal, move the steering console to the desired

position, then release the pedal.

REMARKThe steering wheel, instrument panel, and work equipment control

levers also move forward or backward at the same time.

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BRAKE PEDAL

WARNINGDo not place your foot on this pedal unnecessarily.

This pedal (13) is used to apply the wheel brakes.

ACCELERATOR PEDALThis pedal (14) adjusts the engine speed.

It is interconnected with the fuel control lever, and it can be used

freely to operate from the position set by the fuel control lever to thefull speed position.

DECELERATOR PEDALThis pedal (15) is used to adjust the engine speed.

It is interconnected with the fuel control lever; when the fuel control

lever is pulled, the decelerator pedal rises.

When the decelerator pedal has risen and it is depressed, the

engine speed will go down.

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GEARSHIFT LEVER

WARNINGWhen standing up from the operator's seat, always set the gearshift lever

to the P (Parking) position.

This lever (16) is used to select the transmission speed range.

The transmissionhas 8 FORWARD and 4 REVERSE speeds,and

the gear is shifted simply by setting the gearshift lever to the

desired position.

REMARKThe gearshift lever must be placed at the P (Parking) position to

start the engine.

The gearshifting pattern differs according to the position of thetransmission mode selector switch. For details, see

"TRANSMISSION MODESELECTOR SWITCH (PAGE3-18)".

FUEL CONTROL LEVERThis lever (17) is used to adjust the engine speed and output.

(a) Low idling: Lever pushed fully forward

(b) High idling: Lever pulled fully back

REMARKUse the fuel control lever only when starting the engine or

during operations. For general travel, use the accelerator

pedal.

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DUST INDICATORThis device

Documents

GD555-3A PEN00178-01 OPM