Operation & Maintenance senna Manual GDS00A-n GDg00A-n MOTOR GRADER GD305A-6734 GD355A-5801 SERIAL NUMBERS. id up & warning Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel must read this manual before operating or maintain- ing this machine. This manual should be kept near the machine for reference and periodically reviewed by all personnel who will come into contact with it. NOTICE Komatsu has Operation & Maintenance Manuals written in ‘some other languages. If a foreign language manual is necessary, contact your local distributor for availability1. FOREWORD This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. If this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult Komatsu or your Komatsu distributor for those items you may require. By WARNING: ‘© Improper operation and maintenance of this machine can be hazardous and could resul injury or death. in serious ‘© Operators and maintenance personnel should read this manual thoroughly before beginning operation or maintenance. ‘© Some actions involved in operation and maintenance of the machine can cause a serious accident, if they are not done in a manner described in this manual. ‘© The procedures and precautions given in this manual apply only to intended uses of the mac! Hf you use your machine for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in prohibited uses or actions as described in this manual. ‘© Komatsu delivers mact country to which it has es that comply with all applicable regulations and standards of the n shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine © The descr 11. of safety is given in SAFETY INFORMATION on page 0-2 and in SAFETY from page CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. o42. SAFETY INFORMATION Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. To identify safety messages in this manual and on machine labels, the following signal words are used. Apancer This word is used on safety messages and safety labels where there is a high probability of serious injury or death if the hazard is not avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the machine. AAWARNING - This word is used on safety messages and safety labels where there is 2 potentially dangerous situation which could result in serious injury or death if the hazard is not avoided. These safety messages or labels usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the mac! This word is used on safety messages and safety labels for hazards which could result in minor or moderate injury if the hazard is not avoided. This word might also be word for hazards where the only result could be damage to the machine. Acaution NOTICE ns which This word is used for precautions that must be taken to avoid at could shorten the life of the machi Safety precautions are described in SAFETY from page 1-1 Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine. If you are unsure about the safety of some procedures, contact Komatsu or a Komatsu distributor. 023. INTRODUCTION 3.1 INTENDED USE This equipment can be used for the following work. Leveling operations Repair and maintenance of gravel roads Ditch digging Cutting slope faces Mixed operations Spreading operations Front wheel offset operations eecccee For details of operating procedures, see “12.11 WORK POSSIBLE USING MOTOR GRADER” in the operating section. 3.2 FEATURES ¢ Wide visibility and superior suspension seat for grading work High working speed and arrangement of levers matched to the operator's movements Powerful engine with low fuel consumption 3.3 BREAKING IN THE MACHINE Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life. Be sure to break in the machine for the initial 100 hours (as indicated by the service meter.) During breaking in: ‘© Idle the engine for 5 minutes after starting it up. ‘© Avoid operation with heavy loads or at high speeds. '* Avoid sudden starts, sudden acceleration, sudden steering and sudden stops except in cases of emergency. The precautions given in this manual for operating, maintenance, and safety procedures are only those that apply when this product is used for the specified purpose. If the machine is used for a purpose that is not listed in this manual, Komatsu cannot bear any responsibility for safety. All consideration of safety in such operations is the responsibility of the user. Operations that are prohibited in this manual must never be carried out under any circumstances. 034. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 4.1 MACHINE SERIAL NO. PLATE POSITION At the center of the frame on the left side of the machine body. 4.2 ENGINE SERIAL NO. PLATE POSITION At the top of the right side of the engine cylinder head, viewed from the fan side. 4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR Machine serial No.: Engine serial No.: Distributor name: Address: Phone: Service personnel for your machine: REMARKS: o45. CONTENTS 1. Foreword 2. Safety information .. 3. Introduction... 03 3.1 Intended use 03 3.2 Features, 0-3 3.3 Breaking in the machine 03 4, Location of plates, table to enter serial no. and distributor o4 4.1. Machine serial no. plate position . o4 4.2 Engine serial no. plate position ... o4 4.3 Table to enter serial no. and distributor o4 SAFETY 6. General precautions 2 7. Precautions during op VT 7.1 Before starting engine = i 7.2 Operating machine .. +9 7.3 Transportation 113 7.4 Battery 114 75 Towing .. 115 8. Precautions for maintenance 81 Before maintenance 82 During maintenance 83 Tires. 9. Position for sticking safety labels 9.1 Position for sticking safety labels .. os5. CONTENTS: OPERATION 10. General view : 22 10.1 General view of machine 22 10.2 General view of controls and gauges.. 23 11. Explanation of components 11.1. Meter, lamps .. 11.2. Switches. 11.3 Control levers and pedals... 11.4 Dust indicator .. 11.8 Articulate lock pin 11.6 Fuse box 11.7 Storage pocket behind seat back 12. Operation 247 12.1. Checks before starting engine 247 12.2. Starting en: _ 2:30 12.3. Operations and checks after starting engine. 2:33 12.4 Traveling posture for machine... 2:34 12.5 Moving machine 126 Shifting gear...... 12.7 Shifting between forward and reverse. 237 128 Stopping machine. 2-38 129. Turning machine... 2-40 12.10 Operating work equipment 2-42 12.11 Work which can be carried out using a motor grader ... 2-44 12.12 Precautions for operation oe 261 12.13 Adjusting work equipment posture .. 2-63 12.14 Parking machine 2-66 12.15 Check after finishing work 267 12.16 Stopping engine. 2-68 12.17 Check after stopping engine 2.68 12.18 Handling the tires 13. Transportation : 2-70 13.1 Loading, unloading work ... 2-10 13.2. Precautions for loading 2n 13.3. Lifting machine .. 2n 13.4 Precautions for transportation. 213 14. Cold weather operati 276 14.1 Precautions for low temperature .. 274 14.2 Cautions after completion of work... 2-76 14.3. After cold weather 276 15. Long-term storage. 21 15.1 Before storage 277 16.2 During storage 271 15.3. After storage... 277 16. Troubleshooting, es 278 16.1 After running out of fuel. 278 16.2 When leaning piping is damaged. 278 16.3. Towing the machine 279 16.4 If battery is discharged .. 281 16.5 Other trouble 2-85 065. CONTENTS MAINTENANCE 17. Guides to maintenance 18. Outlines of servic 48:1 Outline of oil, fuel, coolant. 18.2 Relating to electric system... 19. Wear parts list ... 20. Use of fuel, coolant and lubricants according to ambient temperature 21. Standard tightening torques for bolts and nuts 21.1 Introduction of necessary tools 21.2 Torque list 22. Periodic replacement of critical parts . 23. Maintenance schedule chat.. 23.1. Maintenance schedule chat e procedure Initial 20 hours service When required . Check before starting Every 50 hours service Every 250 hours service Every 500 hours service Every 1000 hours service Every 2000 hours service .. Every 4000 hours service . SPECIFICATIONS 25. Specifications OPTIONS, ATTACHMENTS 26. Air conditioner 26.1 General locations and function of control panel ... 26.2 Method of operation. 26.3 Precautions when using air conditioner 26.4 Maintenance .. ORENK 07SAFETY A WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death. This safety section also contains precautions for optional equip- ment and attachments. 11WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS ow ese safety precauons -{_SAFETY RULES © ONLY trained and authorized personnel can operate and maintain the machine. ¢ Follow all safety rules, precautions and instructions when operating or performing maintenance fon the machine. ‘© Do not operate the machine if you are not feeling well, or if you are taking medicine which will make you sleepy, or if you have been drinking. Operating in such a condition will adversely affect your judgement and may lead to an accident. ‘© When working with another operator or @ person on worl understand all hand signals that are to be used, traffic duty, be sure all personnel -_SAFETY FEATURES © Be sure all guards and covers are in their proper position. Have guards and covers repaired if damaged. Proper position + See “12.1.1 WALK-AROUND CHECK”. © Use safety features such as safety locks and seat belts properly. ‘© NEVER remove any safety features. ALWAYS keep them in good operating condition. Safety lever + See "12.14 PARKING MACHINE”. Seat belts + See “12.1.4 ADJUSTMENTS BEFORE OPERATION”. ¢ Improper use of safety features could result in serious bodily injury of death ({_CLOTHING AND PERSONAL PROTECTIVE ITEMS © Avoid loose clothing, jewelry, and loose long hair. They can catch on controls or in moving parts and cause serious injury or death. Also, do not wear oily clothes because they are flammable. © Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine. Always wear safety goggles, hard hat and heavy gloves if your job involves causes metal chips or minute materials to fly - this is so particularly when driving pins with a hammer and when cleaning the air cleaner element with compressed air, Check also that there is no one near the machine. © Check that all protective equipment functions properly before using. Cleaning of air cleaner element — See “24.2 WHEN REQUIRED”. «ap b i~ede 908 12A.WARNING: Failure to follow these safety precautions may lead 10 a serious accident. 6. GENERAL PRECAUTIONS [{_UNAUTHORIZED MODIFICATION ithorization from Komatsu can create hazards. ¢ Before making a modific ult your Komatsu distributor. Komatsu will not be responsible for any injury or damage caused by any unauthorized modification. ({_STANDING UP FROM THE SEAT ‘© Before leaving the operator's seat, set the shift lock lever securely to the LOCK position. ifthe gear shift lever is not locked and it is touched by mistake, the machine may move suddenly and cause a serious accident. # When leaving the machine, lower the blade completely to the ground, stop the engine, then turn the key in all locks to the LOCK position and remove the key. Work equipment posture > See “12.14 PARKING MACHINE”. MOUNTING AND DISMOUNTING NEVER jump on or off the machine. NEVER get on or off a moving machine. When mounting and dismounting, face the machine and use the handholds and steps. Do not hold any control levers when getting on of off the machine. Maintain three-point contact to be sure that you do not fall from the machine. Repair any damaged handhold, and tighten any loose bolts. Handholds and steps, must be freq of oil, grease mud and excessive dirt. 13WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions, -[_FIRE PREVENTION FOR FUEL AND OIL Fuel, oil, and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS. © Keep flame away from flammable fluids. ‘® Stop the engine and do not smoke when refueling. © Tighten all fuel and oil caps securely. ‘© Refueling and oiling should be made in well ventilated areas. ‘© Keep oil and fuel in the determined place and do not allow unauthorized persons to enter. (-{_PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURE © Immediately after operations are stopped, the engine oil and hydraulic oil are at high temperature and are still under pressure. Attempting to remove the cap, drain the oil or water, or replace the filters may lead to serious burns. Always wait for the temperature to go down, and follow the specified procedures when carrying out these operations. © Before removing the radiator cap, stop the engine and wait for the water temperature to go down. Then turn the cap slowly to release the internal pressure before removing the cap. ‘© When the cap of the hydraulic tank is removed, oil may spurt out. Turn the cap slowly to release the internal pressure before removing the cap. sislWsshss, Se 4WARNING: Failure to follow these safety precautions may lead to asorious accident. 6. GENERAL PRECAUTIONS -{_ASBESTOS DUST HAZARD PREVENTION Asbestos dust can be HAZARDOUS to your health if it is inhaled. If you handle materials containing asbestos fibers, follow these guidelines as given below: ‘® NEVER use compressed air for cleaning ‘@ Use water for cleaning to keep down the dust. © Operate the machine with the wind to your back, whenever possible. @ Use an approved respirator if necessary. -{_CRUSHING OR CUTTING PREVENTION ‘© Do not enter, or put your hand or arm or any other part of your body between movable parts such ‘as between the work equipment and cylinders, or between the machine and work equipment. If the work equipment is operated, the clearance will change and this may lead to serious damage or personal injury. Rew Va — -_FIRE EXTINGUISHER AND FIRST AID KIT © Be sure fire extinguishers have been provided and know how to use them. ‘© Know where a first aid kit is located. ‘© Know what to do in the event of a fire. ‘@ Be sure you know the phone numbers of persons you should contact in case of an emergency. 15WARNING: For reasons of safety, always 6. GENERAL PRECAUTIONS follow these safety precautions. -{_PRECAUTIONS FOR ROPS © Do not operate machine with ROPS removed if equipped © The ROPS is installed to protect the operator if the machine should overturn. It is designed not only to take the load when the machine overturns, but also to absorb the impact energy. The Komatsu ROPS fulfills all worldwide regulations and standards, but if any unauthorized modification is carried out on it, or if it is damaged when the machine overturns, its strength will be reduced and it will not be able to provide its original capacity. It will be able to provide this, capacity only if modifications and repairs are carried out in the specified way. © When carrying out modification or repairs, always consult your Komatsu distributor first. ‘© Even when the ROPS is installed, if you do not fasten your seat belt securely, it cannot protect you properly. Always fasten your seat belt when operating the machine. Seat belt — See “12.1.4 ADJUSTMENTS BEFORE OPERATION”. [-_PRECAUTIONS FOR ATTACHMENTS ‘© When installing and using an optional attachment, read the instruction manual for the attachment and the information related to attachments in this manual. ‘@ Do not use attachments that are not authorized by Komatsu or your Komatsu distributor. Use of unauthorized attachments could create a safety problem and adversely affect the proper operation and useful life of the machine. ‘© Any injuries, accidents or product failures resulting from the use of unauthorized attachments will not be the responsibility of Komatsu. 167. PRECAUTIONS DURING WARNING: Fatlure to follow these sat! OPERATION 2 Hreauutlons ay los tos svioun aiden” 7.1 BEFORE STARTING ENGINE -{_SAFETY AT WORKSITE ‘© Before starting the engine, thoroughly check the area for any unusual conditions that could be dangerous. Before starting the engine, examine the terrain and soil condi- tions of the worksite. Determine the best and safest method of operation. ¢@ If you need to operate on a street, protect pedestrians and cars, by designating a person for worksite traffic duty or by installing fences around the worksite. ‘© If water lines, gas lines, and high-voltage electrical lines may be buried under the worksite, contact each utility and identify their locations. Be careful not to sever or cut any of these lines. # Check the depth and flow of water before operating in water or crossing a river. NEVER be in water which is in excess of the permissible water depth. aesser0 (_FIRE PREVENTION © Thoroughly remove wood chips, leaves, paper and other flam- mable things accumulated on the engine compartment. They could cause a fire. © Check for leaks from the fuel, lubrication, and hydraulic sys- tems. Repair any leaks and wipe off all the oil and dirt. , Check points + See “12.1.1 WALK-AROUND CHECK”. ‘© Be sure a fire extinguisher is present and working. 055020 -_IN OPERATOR'S CAB ¢ Do not leave tools or spare parts lying around in the operator's compartment. They may damage or break the control levers or switches. Always put them in the tool box. ‘© Keep the cab floor, controls, steps and handholds free of oil, grease, snow, and excess dirt. ‘¢ Check the seat belt, buckle and hardware for damage or wear. Replace any worn or damaged parts. Always use seat belt when operating your machine. Seat belt > See “12.1.4 ADJUSTMENTS BEFORE OPERATION”. WwAWARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION. follow these safety precautions. (_VENTILATION FOR ENCLOSED AREAS © If it is necessary to start the engine within an enclosed area, provide adequate ventilation. Exhaust fumes from the engine can KILL. (-{_PRECAUTIONS FOR MIRRORS, WINDOWS AND LIGHTS © Remove all dirt from the surface of the windows and lights to ensure that you can see well. @ Adjust the side mirrors so that there is a good view from the operator's seat. In addition, wipe the surface clean, and replace the mirror if the glass is broken. ¢ Check that the head lamps and working lamps light up properly. {_CHECK OF MACHINE © Before starting the engine, adjust the operator's seat to the best position for the work. ‘Wrong adjustment of the operator's seat can cause misoperation, fatigue and accidents. ‘¢ Adjust the operator's seat so that you can operate the control levers and pedals easily with your back fitted to the seat back. Adjustment of operator's seat —* See 12.1.4 “ADJUSTMENTS BEFORE OPERATION”. @ Before starting the engine, confirm that the safety lock is at the LOCK position, © Before starting the engine, be sure to perform the “WALK-AROUND CHECK", “CHECK BEFORE STARTING” and “OPERATIONS AND CHECKS BEFORE STARTING ENGINE” Walk-around check 1 WALK-AROUND CHECK”. Check before starting 2 CHECK BEFORE STARTING”. Operations and checks before starting engine = See “12.1.5 OPERATIONS AND CHECKS BEFORE STARTING ENGINE”. = See “12. Perform the above checks and confirm there is no trouble. If the machine has had an accident and it cannot be repaired, be sure to attach a warning tag to the work equipment control levers. | Lock @ 7 18A WARNING: Failure to follow these safety precautions may lead toa serious accident. 7. PRECAUTIONS DURING OPERATION 7.2 OPERATING MACHINE {_WHEN STARTING ENGINE ‘© Walk around your machine again just before mounting it, checking for people and objects that might be in the way. NEVER start the engine if a warning tag has been attached to the control. When starting the engine, sound the horn as an alert. Start and operate the machine only while seated, Do not allow anyone other than the operator to ride in the cab or on the machine body. (Unless an assistant’s seat is installed) For machines equipped with a reverse warning buzzer, check that the warning device operates correctly. (a A DANGER DO NOT operate mon this plate not beng used egp itn tho storage compartment. {_CHECK WHEN DRIVING BACKWARD. Before moving machine or its attachments: @ Sound the horn to alert people nearby. @ Be sure no one is around machine, particularly behind machine. @ Use a spotter if necessary, particularly if you are moving in reverse. ‘@ When operating in areas that may be hazardous or have poor visibility, designate a person to direct worksite traffic. ¢ Prevent people from entering the line of travel of the machine. Follow above even if equipped with back-up alarm and mirrors. sere1980 CHECKING ARTICULATE LOCK PIN Before driving or operating the machine, check that the articulate lock pin has been removed. For general travel operations, leave the lock pin installed. Before operating the machine, confirm that the articulate lock pin has been removed. For travel on roads, keep the articulate lock pin installed to the LOCK position. Lock StorasessS position position ssi 19WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. r-{_PRECAUTIONS WHEN TRAVELING @ Set the machine in the travel posture and travel on a flat road. Travel posture ~ See “12.4 TRAVEL POSTURE FOR MACHINE" « It is dangerous to look around you when operating. Always concentrate on your work. @ It is dangerous to drive too fast, or to start suddenly, stop suddenly, turn sharply, or zigzag. @ If you find any abnormality in the machine during operation (noise, vibration, smell, incorrect gauges, air leakage, oil leakage, etc.), move the machine immediately to a safe place and look for the cause. ‘© When traveling on rough ground, travel at low speed and avoid turning sharply when changing direction. ¢ Ifthe engine stops when the machine is traveling, the steering cannot be operated, so operation is dangerous. Apply the brake immediately and stop the machine. © Operate carefully when the wheels are leaning. It is prohibited to travel on roads with the wheels leaning. ¢ Travel at a maximum speed of 10 km/h (6.2 MPH) when using the articulation. If the articulation is used when traveling at a speed of over 10 km/h (6.2 MPH), there is danger that the machine may overturn. Never use the articulation at speeds of over 10 km/h (6.2 MPH). Keep the machine at a sufficient distance from the other machines during travel and work to avoid contact with those machines. -{_TRAVELING ON SLOPES © Traveling on hills, banks or slopes that are steep could result in the machine tipping over or slipping. # Do not change direction on slopes. Avoid sideways travel whenever possible: rather travel up and down the slopes. ‘* Do not travel up and down on grass, fallen leaves, and wet steel plates. These materials may cause the machine to slip if it is traveling sideways. Keep travel speed very low. ‘© When traveling downhill, drive slowly and use the engine as a brake. « Ifthe engine stops on a slope, immediately apply the brake fully, lower the blade, and apply the parking brake to stop the machine. ‘© When traveling on a slope with the machine body articulated, be sure to place the front wheels on the lower side. If the front wheels are placed on the higher side, the machine may turn over. INCORRECT CORRECT ‘Se oe _. -[_PRECAUTIONS DURING OPERATION ‘© Cars often travel along the part of the road being leveled by the grader, so always pay attention to the area behind the machine when carrying out operations.WARNING: Failure to follow these safety precautions may lead to aserious accident. 1. PRECAUTIONS DURING OPERATION -_visiBiLity ‘© Turn ON the working lamps and head lamp when working at night or at dark sites. Provide additional lights for the worksite if necessary. @ If visibility is diminished by fog, snow or rain, stop operations. Wait until there is adequate visibility for safe operation. [{_WORKING ON SNOWY SITES © Snow-covered and frozen ground may cause the machine to slip sideways, even if the grade is not steep. Slow down the machine when traveling on such ground. Avoid rapid starts, stops, and steering. In snow, removal work, pay special attention to the edge of the road and to objects under the snow. ‘¢ When traveling on snow-covered roads, always fit tire chains. ‘© When traveling on snow-covered slopes, never use the brakes to stop the machine suddenly. ‘© The load differs greatly according to the quality of the snow, so be careful not to slip when adjusting the load, -{_D0 NOT HIT THE WORK EQUIPMENT ‘© Be extremely careful when moving the machine in places where there are height limits, such as when working in tunnels, under bridges or electric wires, or when parking the machine indoors. ‘© When operating the blade, be careful not to let the blade hit the tires. (-{_METHOD OF USING BRAKES @ If the brake pedal is depressed lightly to control the machine speed, the brakes will overheat and this may lead to a serious accident. -{_WORKING ON LOOSE GROUND ¢ Avoid operating your machine too close to the edge of cliffs, overhangs, and deep ditches. If these areas collapse, your machine could fall or tip over and result in serious injury or death. Remember that the soil after heavy rain or blasting is weakened in these areas. ¢ Earth laid on the ground and the soil near ditches are loose. They can collapse under the weight or vibration of your machine, ¢ Install the HEAD GUARD if working in areas where there is danger of falling rocks and dirt. ‘@ When working in places where there is danger of falling rocks or danger of the machine turning over, install ROPS and a seat belt.WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION follow these safety precautions. PARKING THE MACHINE © Park the machine on @ level “which is free from falling rock, CORRECT landslide and flooding”, then lower the work equipment to the ground. If you must park the machine on a slope, secure the Wheels with chocks and thrust the edge of the blade in to the ground. Block ‘¢ When parking on public roads, set the safety lock lever to the Thrust the LOCK position, apply the parking brake, and provide fences and blade signs, such as flags or lights, to indicate the position of the Block ssii68 machine to passing vehicles. Be sure that the machine, flags, fences or lights do not obstruct the traffic Parking procedure — See “12.14 PARKING MACHINE”. Before leaving the machine, lower the work equipment to the ground, move the safety lock lever to the LOCK position, stop the engine, and lock all the doors, windows, and covers and remove the keyis). Work equipment posture + See “12.14 PARKING MACHINE”.A WARNING: Failure to follow these safety precautions may lead toa serious accident. 7. PRECAUTIONS DURING OPERATION 7.3 TRANSPORTATION -{_LOADING AND UNLOADING ‘© Loading and unloading the machine always involves potential hazards. EXTREME CAUTION SHOULD BE USED. ‘* Perform loading and unloading on firm, level ground only. Mi of a road. in a safe distance from the edge @ Use sufficiently strong ramps. Confirm that they have sufficient width, length and thickness for safe loading and unloading. If they are deflected remarkably, reinforce them with blocks, etc. ¢ Remove oil, grease and other foreign matter from the surfaces of the ramps so that the machine will not slip sideways. Remove dirt from the undercarriage. ‘@ NEVER correct your steering on the ramps. If necessary, drive esos away from the ramps and climb again. @ After loading, block the wheels and secure the machine with tie- downs. Loading and unloading ~* See “13. TRANSPORTATION”. Tie-downs — See “13. TRANSPORTATION”. -{_ SHIPPING ‘© When shipping the machine on a hauling vehicle, obey all state and local laws governing the weight, width, and length of a load. Also, obey all applicable traffic regulations. ‘© Determine the shipping route while taking into account the width, height and weight of the load. 1-13(WARNING: For reasons of safety, always 7. PRECAUTIONS DURING OPERATION, follow these safety precautions. 7.4 BATTERY -{_BATTERY HAZARD PREVENTION © Battery electrolyte contains sulfuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water. © Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor at once. @ If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or poison prevention center immediately. When working with batteries, ALWAYS wear safety glasses or goggles. Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with 2 small spark or flame. © Before working with batteries, stop the engine and turn the starting switch to the OFF position. @ Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across the terminals. @ Tighten the battery terminals securely. Loosened terminals can generate sparks and lead to an explosion. STARTING WITH BOOSTER CABLES ‘® ALWAYS wear safety glasses or goggles when starting the machine with booster cables. ‘® When starting from another machine, do not allow the two machines to touch. ‘@ Be sure to connect the positive @ cable first when installing the booster cables. Disconnect the ground or negative © cable first when removing them. # Connect the batteries in parallel: positive to positive and negative to negative. ‘When connecting the ground cable to the frame of the machine to be started, be sure to connect, it as far as possible from the battery. Starting with booster cables ~+ See “16.4 IF BATTERY IS DISCHARGED”. INCORRECT we i onesA.WARNING: Failure to follow these safety precautions may lead to a serious accident. 7. PRECAUTIONS DURING OPERATION 7.5 TOWING WHEN TOWING THE MACHINE © Injury or death could result if a disabled machine is towed incorrectly. ‘© If your machine is towed by another machine, ALWAYS use a wire rope with ample towing capacity. ‘¢ NEVER allow a disabled machine to be towed on a slope. ‘¢ Always fix the towing rope to the left and right hooks on the front weight. ‘® Do not use a kinked or frayed wire rope. # Do not straddle the towing cable or wire rope. ‘@ When connecting up a towing machine, do not let anyone enter the area between the towing machine and the equipment being towed. '® Set the towing machine and the towing connection of the ‘equipment being towed in a straight line when connecting it. ‘Towing + See "16. TROUBLESHOOTING”. cress8. PRECAUTIONS FOR MAINTENANCE B Eiowiveorstetyecmuens A 8.1 BEFORE MAINTENANCE -{_WARNING TAG © ifothers start the engine or operate the controls while you are performing service or lubrication, you could suffer serious injury or death @ ALWAYS attach the WARNING TAG to the control lever in the operator's cab to alert others that you are working on the machine. Attach additional warning tags around the machine, if necessary. © These tags are available from your Komatsu distributor. (Part No. 09963-03000) (ca) A DANGER DO NOT operate when this plat isnot being used eep tin the storage compartment -{_PROPER TOOLS © Use only tools suited to the task. Using damaged, low quality, faulty, or makeshift tools can cause personal injury. Tools + See “21.1 INTRODUCTION OF NECESSARY TOOLS”. {PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ‘© Replace the following fire-related components periodically: Fuel system : Fuel hose, spilling hose, and fuel tube cap Hydraulic system: Pump outlet hose, and front and rear pump branch hoses ‘© Replace these components periodically with new ones, regardless of whether or not they appear to be defective. These components deteriorate over time. ‘© Replace or repair any such components if any defect is found, even though they have not reached the time specified. Replacement of safety critical components + See “22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS”.A WARNING: Failure to follow these safety precautions may lead toa serious accident. 8, PRECAUTIONS FOR MAINTENANCE -{_STOP THE ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE © When inspecting or maintaining the machine, be sure to park iton low, “level and rigid place” which is “free from falling rock, landslide and flooding”, then lower the work equipment to the ground and lock the safety lock lever and stop the engine. Be sure to stop the engine before starting inspection and mainte- nance. ¢ If it is necessary to run the engine when carrying out mainte- nance, such as when cleaning the inside of the radiator, place the safety lock lever at the LOCK position and carry out the ‘operation with two workers. ‘© One worker should sit in the operator's seat so that he can stop the engine immediately if necessary. He should also be ex- tremely careful not to touch any lever by mistake. Touch the levers only when they have to be operated. ‘@ The worker carrying out the maintenance should be extremely careful not to touch or get caught in the moving parts. ‘@ Lock the front and rear frames with the articulate lock pin. When. opening the inspection cover to carry out maintenance, always fit the lock bar to the inspection cover. Lav {RULES TO FOLLOW WHEN ADDING FUEL OR OIL Keep the engine stopped while fuel is being added. ‘Always tighten the cap of the fuel and oil fillers securely Never use fuel for washing any parts. Always add fuel and oil in a well-ventilated place. eocee Spilled fuel and oil may cause you to slip, so always wipe it up immediately.WARNING: For reasons of safety, always 8, PRECAUTIONS FOR MAINTENANCE follow these safety precautions. (_RADIATOR WATER LEVEL ‘© When checking the water level, stop the engine and wait for the engine and radiator to cool down first. gs # Slowly loosen the caps to relieve pressure before removing the caps. ~ Te ({_USE OF LIGHTING ¢ When checking fuel, oil, coolant, or battery electrolyte, always use lighting with anti-explosion specifications. If such lighting equipment is not used, there is danger of explosion, --{_DO NOT STEP ON ENGINE HOOD © The top of the engine hood is slippery and dangerous. Never step on it. {_PREVENTION OF FIRE There is danger of the fuel and battery gas catching fire during maintenance, so always follow the precautions below when carrying out maintenance. © Store fuel, oil, grease, and other flammable materials away from flame. @ Use non-flammable materials as the flushing oil for cleaning parts. Do not use diesel oil or gasoline. There is danger that they will catch fire. © When checking fuel, oil, or battery electrolyte, always use lighting with anti-explosion speci tions. Never use lighters or matches as a light source. ‘ is ‘© Be sure that a fire extinguisher is present at the inspection and 4 maintenance point. 1, ‘© Never smoke when carrying out inspection or maintenance. Smoke only in the prescribed place. ots 118A WARNING: Failure to follow these safety precautions may lead to a serious accident 8, PRECAUTIONS FOR MAINTENANCE 8.2 DURING MAINTENANCE (-|_PERSONNEL ‘© Only authorized personnel can service and repair the machine. Extra precaution should be used when grinding, welding, and using a sledge-hammer. ATTACHMENTS ‘¢ Place attachment that have been removed from the machine in a safe place so that they do not fall. If they fall on you or others, serious injury could result. -|_WORK UNDER THE MACHINE © Always lower all movable work equipment to the ground or to their lowest position before performing service repairs under za the machine. 1 Always block the wheels securely. @ Never work under the machine if the machine is poorly sup- "40088140 ported. (-_KEEP THE MACHINE CLEAN © Spilled oil or grease, or scattered tools or broken pieces are dangerous because they may cause you to slip or trip. Always keep your machine clean and tidy. ‘© If water gets into the electrical system, there is danger that the machine may not move or may move unexpectedly. Do not use water or steam to clean the sensors, connectors, or the inside of the operator's ‘compartment.WARNING: For reasons of safety, always 8, PRECAUTIONS FOR MAINTENANCE follow these safety precautions. PRECAUTIONS WITH BATTERY ‘© When repairing the electrical system or when carrying out electrical wel © terminal of the battery to stop the flow of current. Using of battery + See “16.4 IF BATTERY IS DISCHARGED” \g, remove the negative --{_HANDLING HIGH-PRESSURE HOSES ‘© Do not bend high-pressure hoses or hit them with hard objects. Do not use any bent or cracked piping, tubes or hoses. They may burst during use. ‘© Always repair any loose or broken fuel hoses or oil hoses. If fuel or oil leaks, it may cause a fire. (-[_PRECAUTIONS WITH HIGH PRESSURE OIL © Do not forget that the work equipment circuits are always under pressure, ‘© Do not add oil, drain oil, or carry out maintenance or inspection before completely releasing the internal pressure. © If oil is leaking under high pressure from small holes, it is dangerous if the jet of high-pressure oil hits your skin or enters your eyes. Always wear safety glasses and thick gloves, and use a piece of cardboard or a sheet of wood to check for oil leakage. © If you are hit by a jet of high-pressure oil, consult a doctor immediately for medical attention. ye C= PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE ‘© Immediately after stopping operations, the engine cooling water and oil at all parts are at high temperature and under high pressure. In this condition, if the cap is removed, or the oil or water are drained, or the filters are replaced, this may result in burns or other injury. Wait for the temperature to go down, then carry out the inspection and maintenance in accordance with the procedures given in this manual. Clean inside of cooling system, check lubricating oil level, add oil + ‘See “24.2 WHEN REQUIRED”. Check cooling water level, level of oil in engi "24.3 CHECK BEFORE STARTING”. oil level in hydraulic tank, add oil + “24.5 PERIODIC MAINTENANCE”. 19 oil, replacing filters + ‘See “24.6-7 PERIODIC MAINTENANCE”. oil pan, add oil or water -+ psslish tis, xX 1-20A WARNING: Failure to follow these safety precautions may lead to a serious accident. 8, PRECAUTIONS FOR MAINTENANCE -_ROTATING FAN AND BELT ‘© Keep away from rotating parts and be careful not to let anything VY get caught in them. « if your body or tools touch the fan blades or fan belt, they may e be cut off or sent flying, so never touch any rotating parts. ey x -|_WHEN CARRYING OUT OPERATIONS WITH THE CHASSIS RAISED ‘© When carrying out operations with the work equipment or chassis raised, always set the control lever to the HOLD position and use blocks to support the part that is being raised. ‘¢ Block the wheels on the opposite side before jacking up the machine. Fit blocks under the machine after jacking it up. {_TIRE MAINTENANCE Disassembly, repair, and assembly of tires requires special equipment and skill, so please ask a specialist tire repair shop to carry out these operations. -_WASTE MATERIALS. ‘@ Never dump waste oil in a sewer system, rivers, etc. Always put oil drained from our machine in containers. Never drain oil directly on the ground. @ Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, batteries, and others. INCORRECT 121WARNING: For reasons of safety, always ‘8. PRECAUTIONS FOR MAINTENANCE follow these safety precautions. 8.3 TIRES -{_HANDLING TIRES: If the tires are not used under the specified conditions, they may overheat and burst, or may be cut and burst by sharp rocks when traveling on road surfaces that have not been properly maintained. If the tires burst, this may lead to serious injury. To ensure safety, always observe the following. © Use the specified tire inflation pressure. In particular, low tire pressures may lead to abnormal overheating. Properly tire inflation pressure + “24.3 CHECK BEFORE STARTING”. ¢ Use the specified tires. The tire inflation pressures and permissible travel speed given in this manual are general values. The actual values depend on the type of tires and the conditions under which the tires are used, so check with your Komatsu distributor or tire manufacturer for details. If tires become hot, flammable gases are generated, and these may ignite. It is particularly dangerous if the tires become hot when they are under internal pressure. If the gas generated inside the tire ignites, the internal pressure may rise suddenly, causing the tire to explode, leading to serious personal injury. Such explosions differ from the situation when a tire is punctured and bursts, because there is a high destructive force produced, so the following operations are prohibited if the tire is under internal pressure. ‘© Carrying out welding operations on the rim ‘* Carrying out welding operations or building fires near the wheel or tire If the procedure for replacing the wheel or tire is not properly understood and a mistaken method is used, the wheel or tire may burst and cause injury or damage. When carrying out this operation, please consult your Komatsu distributor or tire manufacturer. 1-22AWARNING: Failure to follow these safety precautions may lead to a serious accident, ‘8, PRECAUTIONS FOR MAINTENANCE ‘STORING TIRES AFTER REMOVAL « As a basic rule, store the tires in a warehouse where unauthorized persons cannot enter. If the tires are stored outside, always surround the tires with a fence and make it clear even to young children that they should not go inside the fence. @ Stand the tire on horizontal ground, block it securely, and take steps to prevent the tire from rolling or falling over. © Ifthe tire should start to fall over, get out of the way immediately. Tires for construction equipment are extremely heavy, so trying to support them with human power may lead to a serious accident. _ a” 1-239. POSITION FOR STICKING SAFETY LABELS Always keep these labels clean. If they are lost or damage, stick them back again or replace them with a new label. There are other labels in addition to the safety labels listed as follows, so handle them in the same way. Safety labels may be available in languages other than English. To find out what labels are available, contact your Komatsu distributor. 9.1 POSITION FOR STICKING SAFETY LABELS View Z estar 1:261. Precautions before starting (09651-13001) 7 MCI Nc} Improper operation and maintenance ‘can cause serious injury or death, Read manual and labels before operation and maintenance. Follow instructions and warnings in manual and in labels on machine. Keep manual in machine cab near operator. Contact Komatsu distributor for a replacement manual. 09651-13001 2. Warning for opening radiator cap (09668-13001) A warnine Hot water hazard. To prevent hot water from spurting out: * Tum engine off + Allow water to coo} * Slowly loosen cap to relieve pressure before removing 09668-13001 9. POSITION FOR ATTACHING SAFETY LABELS 3. Precautions for opening hydraulic tank cap (09653-13001) 7 OG} Hot oil hazard. To prevent hot oll from spurting out: * Tum engine off. Allow oil to coo * Slowly loosen cap to relieve pressure before removing 09653-13001 4. Warning for leaving operator's seat, starting engine, and driving (09164-13000) Awarnine 1. MAKE SURE OF TAKING THE FOLLOW. ING MEASURES WHEN LEAVING THE OPERATOR SEAT. (1) SET THE GEARSHIFT LEVER IN NEUTRAL (2) APPLY THE PARKING BRAKE. (3) LOWER THE WORK EQUIPMENT ON, THE GROUND AND ATTACH THE LOCK PLATE OVER THE LEVER (4) STOP THE ENGINE. MAKE SURE THAT THE INSTRUCTIONS (1) THROUGH (3) ABOVE ARE OBSERV- [ED PRIOR TO STARTING THE ENGINE. 2. WHEN DRIVING THE GRADER ON THE ROAD. D0 NOT USE GOVERNOR CON. TROL LEVER, MAKE SURE OF SETTING THE GEAR. SHIFT LEVER IN A POSITION OTHER THAN NEUTRAL ON A DOWNWARD SLOPE WITH THE CLUTH ENGAGED. 09164-13000 1-259. POSITION FOR ATTACHING SAFETY LABELS. 5. Articulate lock (09161-33000) A WARNING If safety pin is unlocked, machine can jackknite unexpectedly when it is traveling, being transported or hoisted. Jackknifing can cause serious injury or death to the operator or bystanders. + Always lock safety pin when machine is traveling, being transported or hoisted. * If necessary, lock safety pin during servicing or maintenance. 9161-33000 6. Do not enter (09162-33000) A DANGER Crush Hazard. Can cause severe injury or death, When machine is being operated, never place yourself in articulated area of machine, 09162-33000 1-26 7. Prohibition of operating with the engine cover open (09667-10000) yes ceo EFL ARPUADT LEFT SEEM, LAME UTE, 2Ipy BU DrLAW NSD eect. WHILE ENGINE IS RUNNING: 1. DO NOT OPEN COVER, 2. KEEP AWAY FROM FAN AND FAN-BELT. 09867-100009. POSITION FOR ATTACHING SAFETY LABELS 8. Warning for general driving (23B-53-12240) A @1885.E WARNING MELE. PF 4 FAL bAF PULTE LEUTC ES Et, ROBT -F 1 aL hAF PUL IER SID IUTEALTS EE WS PaF 4 Fa bAFP YL INDY ELE MD IL— MICRA S. WHEN DRIVING THE MACHINE ON THE ROAD, DO NOT USE ARTICULATE FRAME STEERING. AND LOCK ARTICULATE FRAME STEERING AS FOLLOWING. FIX THE LOCK PIN BETWEEN FRONT FRAME AND REAR FRAME. 208-59.12240 9. Precautions for use of brake (23B-53-12250) ACAUTION BECAUSE THIS MACHINE USES THE HYDRAULIC SERVO TYPE BRAKE DURING THE ENGINE STOPS, THE PRESSING FORCE OF PEDAL BECOMES HEAVY. WHEN THE ENGINE STOPS ON THE SLOPE, PRESS PROMPTLY THE BRAKE PEDAL STRONGLY AND AT THE SAME TIME BY PULLING THE PARKING BRAKE LEVER STOP THE MACHINE THEN, START THE ENGINE AGAIN. 28-59-1250 127OPERATION10. GENERAL VIEW. 10.1 GENERAL VIEW OF MACHINE If directions are indicated in this section, they refer to the directions shown by the arrows in the diagram below. Rear Leaning cylinder | Left Rear whee! Articulate cylinder te Blade Front Scarifier Front whee! Scarifier lift cylinger This illustration is the general view of GD305A-1A. 2210. GENERAL VIEW 10.2 GENERAL VIEW OF CONTROLS AND GAUGES Dinmer ewitch Steering wheel Steering vost Tilt lever Work equipment control lever Work eavipment control lever Blade raise/lower Blade raise/loner speed adjustment bolt (for left brade lift eine Brake pedal Accelerator Inching pedal a3 Fuel control lever Parking brake lever Gear shift lever Safety lock lever (or sear shift lever) Front panel Right panel meter Heater sional Yellow rotary lam awiten (it eaui eed) serv Engine oil pressure Working pilot caution lamp Foo Jano Chere tam (iT eayi nes) Engine cooling mater tempgrature Speed neter Fuel gauee Hieh bean Parkine brake Starting Working lamo | pilot lame pilot lame switch switch | Head lane Emersency flasher | switch switch Used as parking lamp Switch. oO) sesiseie 2311. EXPLANATION OF COMPONENTS The following is an explanation of the devices needed for operating the machine. To carry out suitable operations correctly and safely, it is impor- tant to understand fully the methods of operating the equipment and the meanings of the displays. 11.1METER, LAMPS ENGINE WATER TEMPERATURE GAUGE This indicates the temperature of the engine cooling water. The pointer is in the green range, if normal, during operation. if the pointer enters the red range during operation, stop the machine and run the engine at a medium speed with no load applied until the pointer enters the green range again. After starting the engine, warm it up until the pointer enters the green range. 2. SPEEDOMETER This indicates the travel speed of the machine. An integrated odometer is installed under this meter. 243. FUEL GAUGE This indicates the fuel level in the fuel tank. “G" denotes Empty, and “F” denote Full. 4. SERVICE METER This indicates the integrated operating hours of the mach Set the interval of the periodic inspections according the cated operating hours. The service meter advances as long as the engine is running, even if the machine is not traveling or working. While the engine is running, operation indicator (D at the bottom in the meter rotates to show that the meter is advancing. Meter @ advances by 1 each time the engine runs for 1 hour, regardless of the engine speed, 5. HEATER SIGNAL This shows the heating condition of the electric heater. This is held at the preheat position. If the starting switch key is released, it returns to the OFF position and the signal goes off. 6, HIGH BEAM OF FRONT LAMP This lamp lights up when the beam of the front lamp is set high is heated red 20 - 30 seconds after the starting switch key | 11, EXPLANATION OF COMPONENTS aonss190 acs 7. ENGINE OIL PRESSURE CAUTION LAMP. This indicates dropping of the engine oil pressure. This lamp lights up when the starting switch is turned on, and goes off after the engine is started, if normal. | Ifthe engine oil pressure drops during operation, this lamp lights up. In this case, stop the engine immediately and check according to “16.5 OTHER TROUBLE”. 2511. EXPLANATION OF COMPONENTS 8. CHARGE LAMP This indicates trouble with the alternator. This lamp lights up when the starting switch is turned ON, and goes off as the engine speed rises, if normal. If this lamp lights up during operation, stop the engine and check the V-belt for looseness. If there is another trouble, check according to "16.5 OTHER TROUBLE”. 9. PARKING BRAKE PILOT LAMP This lamp lights up when the parking brake is applied. 10. WORKING LAMP PILOT LAMP This lamp lights up when the working lamp is turned ON. 2611. EXPLANATION OF COMPONENTS 11.2. SWITCHES estsa90 1. STARTING SWITCH This switch is used to start the engine. OFF position: At this position, the starting switch key can be inserted or removed. When the switch is turned to this position, the electrical circuits are switched off, and the engine stops. ON position: In this position, electric current flows in the charging and lamp. circuits. START position: This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately after the engine has been started. The key will return to ON position when released. HEAT position: If the key is set to this position in cold weather, the air taken in the engine is heated so that the engine can start easily. If the key is released it will return to the OFF position, so turn it immediately to the START position to start the engine. 271. EXPLANATION OF COMPONENTS. 2. FRONT LAMP SWITCH This switch is used to turn on and off the front lamp, clearance lamp, tail lamp and panel lamp. | | Position @: OFF | oO Position @:Clearance lamp, tail lamp and panel lamp light up. | Position @:Front lamp, as well as lamps in @, light up. | 3. WORKING LAMP SWITCH [eae This switch is used to turn on and off the front working lamp and rear working lamp (if equipped) Position @: Front working lamp lights up. Position © Rear working lamp (if equipped), as well as lami | Position @: OFF | | | ight up. | 4. FOG LAMP SWITCH (IF EQUIPPED) This switch is used to turn the fog lamp on and off. Each time this switch is pressed, the fog lamp lights up and goes off alternately i | Oo 5. YELLOW ROTARY LAMP SWITCH (IF EQUIPPED) This switch is used to turn the yellow rotary lamp on and off. Each time this switch is pressed, the yellow rotary lamp lights up 6 and goes off alternately. REMARK I Use the yellow rotary lamp during work according to the direc- tions of the manager. 6. EMERGENCY FLASHER SWITCH & Warninc —o Never use the flasher except in emergencies. If it is used while traveling when there is no abnormality, it may cause misunder- «K —orr standing for drivers of other vehicles. = Use this switch only in emergencies, such as when the machine has to be stopped on the road because of a failure. ON: All the turn signal lamps flash. PARKING LAMP This lamp warns the other machines when machine is parked at night. Turning switch to right: Front and rear parking lamp light up. 2811. EXPLANATION OF COMPONENTS 7. DIMMER SWITCH This switches the head lamp between high beam and low beam. @: High beam @: Low beam 8 HORN BUTTON —momouo When the button in the center of the steering wheel is pressed, the horn will sound. | 9, TURN SIGNAL LEVER This lever operates the turn signal lamps. @ LEFT TURN: Push lever up. @ RIGHT TURN: Pull lever down. When the lever is operated, the turn signal pilot lamp will also light up. The turn signal is not canceled when the steering wheel is returned. Return the lever by hand. — = 10. BLADE RAISE / LOWER SPEED ADJUSTMENT BOLTS ‘These bolts are used to adjust the raising and lowering speed of ® ‘ the blade. Logammat}on [Lowmea Hh Bolt @: For left-hand blade lift cylinder Oe oO Bolt @: For right-hand blade lift cylinder Turning to right (clockwise): Speed is heightened, Turning to left (counterclockwise): Speed is lowered, Set the speed as follows. High speed: Bank cutting, rough fin Low speed: Finishing 2911, EXPLANATION OF COMPONENTS. 11.3, CONTROL LEVERS AND PEDALS 1. LEFT BLADE LIFT CYLINDER CONTROL LEVER, This lever operates the left blade lift cylinder. @ LOWER : The left side of the blade goes down. @HOLD : The blade stops and is held in the same position. @ RAISE: The left side of the blade goes up. 2.10 Lower snesta0e11, EXPLANATION OF COMPONENTS 2. BLADE ROTATION CONTROL LEVER This lever rotates the blade. @ RIGHT ROTATION : The blade is rotated to the right. ® HOLD : The blade stops and is held in the same position. @ LEFT ROTATION : The blade is rotated to the left. NOTICE To prevent damage to the tires, be careful not to let the blade hit the tires when rotating the blade. Richt Left rotation rotation L 3, SCARIFIER CONTROL LEVER This lever is used to control the scarifier. @ LOWER: Scarifier is lowered. @ HOLD : Scarifier is held at current position. © RAISE : Scarifier is raised. 4, ARTICULATE CONTROL LEVER Ay WARNING Operate this lever only when traveling at a speed of below 10 km/h (6.2 MPH). If the articulation is operated at a speed of over 10 km/h (6.2 MPH), there is danger that the machine may overturn. This lever is used to operate the articulation. @ RIGHT TURN : ®@ HOLD : The articulation is kept in the same condition. @ LEFT TURN NOTICE To prevent damage to the tires, be careful not to let the blade hit the tires when articulating the machine.u eo eS @ @ @ e890 EXPLANATION OF COMPONENTS BLADE SIDE SHIFT CONTROL LEVER This lever shifts the blade to the side. LEFT SHIFT : The blade is shifted to the left position. HOLD : The blade stops and is held in the same position. | RIGHT SHIFT: The blade is shifted to the right. LEANING CONTROL LEVER RIGHT TURN : HOLD : The articulation is kept in the same condition. LEFT TURN 5 anu | . oe ® ae? od \ Left turn Right turn WK BT RIGHT BLADE LIFT CYLINDER CONTROL LEVER This lever operates the right blade lift cylinder. LOWER : The right side of the blade goes down. HOLD. : The blade stops and is held in the same position. RAISE. : The right side of the blade goes up. 2428 PARKING BRAKE LEVER My WARNING When parking or leaving the machi parking brake. be sure to apply the This lever is used to apply the parking brake. Pull this lever to the end, and the parking brake is applied. 8. INCHING PEDAL This pedal connects and disconnects the motive force from the engine and is used when stopping or starting the machine, or when switching between FORWARD and REVERSE. When the pedal is depressed, the motive force is cut off. In ‘1st, 2nd, and 3rd speeds, fine control of the machine is possible using this pedal. NOTICE Continuous use of the ir clutch condition should be ing pedal to give a partially engaged ted to 10 seconds. 10. BRAKE PEDAL By WARNING Do not put your foot on this pedal unnecessarily. This applies the wheel brakes. 11, ACCELERATOR PEDAL This pedal is used to control the engine speed and output. This is interconnected with the fuel control lever, and can be operated freely between the speed set by the fuel control lever and the full speed position. 11. EXPLANATION OF COMPONENTS111, EXPLANATION OF COMPONENTS. 12. GEAR SHIFT LEVER This lever is used to change the transmission gear. There are 6 gears forward and 5 gears reverse. Any gear can be selected by simply changing the gear shift lever to the position corresponding to that gear. REMARK If the gear shift lever is not at the N (Neutral) position, the engine does not start, 13. FUEL CONTROL LEVER This lever is used to control the engine speed and output. @ Low idling position: Push the lever forward fully. ® ing position: Pull the lever fully back from the low idling | position, REMARK ‘© Use the fuel control lever only for working. Use the accelerator |___— pedal for general travel. © If the transmission lever is set to the 6 gear forward, it is interlocked with the fuel control lever so that the engine speed will not be raised to the maximum. 14. SAFETY LOCK LEVER Ay WARNING ‘© When leaving the operator's seat, always be sure to lock the safety lock lever securely. If it is not locked, and anyone touches the gear shift lever by mistake, it may lead to a serious accident. If the safety lock lever is not placed securely in the LOCK position, the shift lever may not be locked. This locks the gear shift lever. Set the gear shift lever to N (Neutral) and lower this lever, and the gear shift lever is locked. | Be —11, EXPLANATION OF COMPONENTS: 11.4 DUST INDICATOR This device indicates clogging of the air cleaner element. When red piston © appears in the transparent part of this indicator, the element is clogged. Immediately clean the element. After cleaning, push indicator button @ to return the red piston to the original po: 11.5 ARTICULATE LOCK PIN A warning ‘© When servicing or transporting the machine always use this lock pin, ® For normal travel, always use the lock pin, This pin is used to lock the front frame and rear frame to prevent the machine from bending during normal travel or when servicing ‘_— or transporting the machine. Align the holes in the front frame and rear frame, then insert the lock pin. ‘When not using the lock, always insert the lock pin in the storage position. 215111, EXPLANATION OF COMPONENTS. 11.6 FUSE BOX hy WARNING If the fuse blows again immediately after it is replaced, please contact your Komatsu distributor. NOTICE Before replacing a fuse, be sure to turn off the starting switch. The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse is loose in the fuse holder, replace the fuse. Remove the bolt, open cover (®, and replace the fuse. Replace a fuse with another of the same capacity. 11.6.1 FUSE CAPACITY AND CIRCUIT NAME Fuse capacity 20A_| Head lamp, side clearance lamp, main lamp circuit 15A_| Turn signal lamp 15A_| Working lamp 15A_| Brake lamp Circuit name 15A_| Gauge 20A__| Spare 20A_| Spare 20a _| Spare 20A_| Car heater 16A_| Caution lamp 20A_| Heat glass 20A_ | Wiper 20A_| Wiper 20a _| Wiper - 20A_| Battery relay 11.7: STORAGE POCKET BEHIND SEAT BACK ‘A storage pocket is installed on the rear side of the operator's seat back. Keep the operation manual in this pocket so that the operator can read it at any time. 2.16 BOSSSOOOOSOBSO BBUNDEUCHNSEURG)12. OPERATION 12.1 CHECKS BEFORE STARTING ENGINE 12.1.1 WALK-AROUND CHECK Ay WARNING Leakage of oil or fuel, or accumulation of flammable material around high temperature parts, such as the engine muffler may cause fire. Check carefully, and if any abnormality is found, always repair it or contact your Komatsu distributor. Before starting the engine, look around the machine and under the machine to check for loose nut or bolts, or leakage of cil, fuel, ‘or coolant, and check the condition of the work equipment and hydraulic system. Check also for loose wiring, play, and collection of dust at places which reach high temperatures. Carry out the checks in this section before starting the engine each day. cwssz0 24712. OPERATION 1. Check for damage, wear, play in work equipment, cylinders, linkage, hoses Check that there are no cracks, excessive wear, or play in the work equipment, cylinders, linkage, or hoses. If any abnormality is found, repair it. 2. Remove dirt and dust from around engine, battery, radiator Check if there is any dirt or dust accumulated around the engine or radiator. Check also if there is any flammable material (dead leaves, twigs, grass, etc.) accumulated around the battery or high temperature engine parts, such as the engine muffler or turbo- charger. Remove all such dirt or flammable material. 3. Check for leakage of water or oil around engine Check that there is no leakage of oil from the engine or leakage cof water from the cooling system. If any abnormality is found, repair it 4. Check for oil leakage of oil from transmission case, final drive case, tandem drive case, hydraulic tank, circle reverse gear case, hose, joints. Check that there is no oil leakage. If any abnormality is found, repair the place where the oil is leaking. 5. Check for leakage of air or oil from brake line Check that there is no leakage of air or oil. If any abnormality is found, repair the place where the air or oil is leaking. 6. Check for wear or damage to tires, loose mounting bolts Check that there are no cracks or pealing of the tires. Tighten any loose wheel nuts. If any abnormality is found, repair or replace. 7. Check for damage to handrail, steps, loose bolts Repair any damage and tighten any loose bolts. 8 Check for damage to gauges, lamps on instrument panel, loose bolts Check that there is no damage to the panel, gauges and lamps. If any abnormality is found replace the parts. Clean off any dirt on the surface. Tighten any loose bolts. 9. Check for damaged mirror, reflector, loose mounting bolts Check that there is no damage to the mirror or reflectors, and replace if there is any abnormality. Tighten any loose bolts. Clean all dirt from the surface of the mirror and reflector. 21810. Check seat belt and clamps Ay WARNING Even if no abnormality can be seen in the seat belt, replace the seat belt every 3 years. REMARK The date of manufacture of the seat belt is printed on the label shown by the arrow in the diagram on the right. Check that there are no loose bolts in the damps and holder installing the seat belt to the machine. Tighten any loose bolts. Tightening torque: 24.5 + 4.9 Nem (2.5 + 0.5 kgfem, 18.1 + 3.6 Ibft) If the belt is damaged or has become fluffy, or if the clamps or holders are damaged or deformed, replace the seat belt with a new part. 11. Is door lock normal? {machine equipped with cab) Check that there is no damage to the cab door lock. Repair or replace if any abnormality is found. 12. Clean cab window (machine equipped with cab) To ensure a good view during operations, always keep the cab windows clean. 12. OPERATION 21912, OPERATION 12.1.2 CHECK BEFORE STARTING Carry out the items in this section before starting the engine each day. CHECK COOLANT LEVEL, ADD WATER BA WARNING. Do not remove the cap while cooling water is hot. Hot water ‘may spout out. When removing the radiator cap, lift the lever tor internal pressure. ve the 1. Remove radiator cap @ at the rear of the machine and check that the coolant is above the hatched portion marked in the diagram on the right. If the coolant level is low, add more water. 2. After adding water, tighten the cap securely. NOTICE If the volume of coolant added is more than usual, check for possible water leakage. Confirm that there is no oil in the coolant. 2:2012. OPERATION (CHECK FUEL LEVEL, ADD FUEL “By WARNING When adding fuel, never let the fuel overflow. This may cause a fire. If you spill any fuel, thoroughly clean up all the spillage. 1. Tum the engine starting switch to the ON position and check the fuel level with fuel level gauge ©. After checking, turn the switch back to the OFF position. 2. After completing work, fill the fuel tank through oil filler port ©. [ For details of the oil to use, see “20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. 3. After adding fuel, tighten the cap securely. Fuel capacity: 210 £ (55.4 US gal, 46.2 UK gal) NOTICE If breather hole @ in the cap becomes clogged, the pressure inside the tank will go down and the fuel may not flow, so clean the breather hole from time to time. DRAIN WATER AND SEDIMENT IN FUEL TANK Loosen fuel tank drain valve @ and drain the sediment and water, accumulated at the bottom, together with fuel. 22112, OPERATION CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL 1. Open the side cover on the right side at the rear of the chassis. 2. Remove dipstick © and wipe the oil off with a cloth. 3. Insert dipstick @ fully in the oil filler pipe, then take it out again. 4, The oil level should be between the H and L marks on dipstick If the oil level is below the L mark, add engine oil through oil filler ©. For details of the oil to use, see "20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE”. 5. If the oil is above the H mark, drain the excess engine oil from drain plug ®, and check the oil level again. 6. If the oil level is correct, tighten the oil filler cap securely and close the engine side cover. REMARK When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before check- ing. If the machine is at an angle, make it horizontal before checking. CHECK DUST INDICATOR 1. Check that the red piston has not appeared in the transparent portion of dust indicator @. 2. If the red piston has appeared, clean or replace the element immediately. For details of the method of cleaning the element, see "24.2 WHEN REQUIRED”. After checking, cleaning, and replacing, press the knob of dust indicator @ to return the red piston to its original position. 22212. OPERATION CHECK AND ADJUST TIRE PRESSURE Standard pressure © GD305A Front wheel 0.27 MPa (2.8 kgf/om?, 39.76 PSI) Rear wheel 0.26 MPa (2.6 kgf/cm?, 36.92 PSI) © GD355A Front and rear wheel 0.32 MPa (3.25 kgf/cm’, 46.15 PSI) ‘Make sure that tire and rim are free from wear and damage, and that hub nuts are not loose. CHECK AND ADJUST STEERING WHEEL Start the engine and check the steering wheel play. Standard: 10 - 12 mm (0.4 ~ 0.5 in) maximum If the steering wheel play is out of the standard range or the steering wheel waves normally or is abnormally heavy, ask your Komatsu distributor for repairs, CHECK AND REFILL BRAKE FLUID NOTICE When refilling the brake fluid, make sure that mineral oil is not mixed with it. Even a small quantity of mineral oil (such as engine oil) can deteriorate the rubber parts of the brake oil line, and that will cause a malfunction of the brake. Accordingly, use a special container to refill the brake fluid. Check the fluid level in the brake fluid tank in the operator's compartment, and add new brake fluid through fluid filler © if necessary. If the brake fluid is consumed abnormally, check the brake oil piping for leakage. REMARK Keep the brake fluid at the MAX level. ‘¢ When refilling the brake fluid, take care that it will not stick to a painted surface, since it can deteriorate the paint. © Check the cylinder cup, piping and joints for breakage and looseness that can cause leakage of brake fluid. If any defect is found, ask your Komatsu distributor for repairs. 2:2312. OPERATION CHECK ELECTRIC WIRING A warnine © If fuses are frequently blown or if there are traces of short circuit on the electrical wiring, locate the cause and carry out repair. © Accumulation of flammable material (dead leaves, twigs, grass, etc.) around the battery may cause fires, so always, check and remove such material. ¢ Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with dirt or dust, wash the battery cap to clear the breather hole. Check for damage and wrong capacity of the fuse and any sign of disconnection or short circuit in the electric wiring. Check also for loose terminals and tighten and loose parts. Check the wiring of the “battery”, “starting motor” and “alter- nator” carefully, in particular. ‘When carrying out walk-around checks or checks before starting, always check if there is any accumulation of flammable material around the battery, and remove such flammable material. Please contact your Komatsu distributor for investigation and correction of the cause. CHECK STROKE OF BRAKE PEDAL The standard play of the pedal is 5 mm (0.197 in). The standard height above the floor (H) is 200 - 210 mm (7.9 - 8.3 in), and the pressing distance of the pedal (S) is 75 mm (3.0 in) or longer (when the pressing force is 294N (30 kgf)). If the stroke is increased and needs to be adjusted, see “24.5.13 CHECK FOOT BRAKE, ADJUST” CHECK BRAKING EFFICIENCY When the initial speed is 20 km/h (12.4 MPH), if the stopping distance is 5m (16 ft 5 in) or shorter, the braking efficiency is normal. If the braking efficiency is low, see “24.5.13 CHECK FOOT BRAKE, ADJUST”. 2.2412. OPERATION CHECK STROKE OF PARKING BRAKE LEVER ‘When the parking brake lever is pulled by 3 or 4 clicks, if the machine is braked securely, the lever stroke is normal. If the lever is pulled to the 6 clicks, see “24.5.1 CHECK PARKING BRAKE LEVER / STROKE, ADJUST". NS \ ine travels with the parking brake lever pulled, the ing will burn and the braking efficiency will be lowered. The “S| drum is generally discolored in such cases. ‘© Once the lining is burnt and the braking efficiency is lowered, braking effici ‘ored unless the burnt thin layer of sandpaper. CHECK THAT FLASHING OF LAMPS IS NORMAL, CHECK FOR DIRT OR DAMAGE CHECK THAT DIRECTION OF BACKUP MIRROR IS CORRECT, CHECK FOR DIRT OR DAMAGE (CHECK REFLECTORS AND NUMBER PLATE FOR DIRT OR DAMAGE CHECK OPERATION OF HORN CHECK ENGINE EXHAUST COLOR AND SOUND CHECK OPERATION OF GAUGES CHECK THAT ABNORMALITIES FROM PREVIOUS DAY HAVE BEEN REPAIRED CHECK CONDITION OF SEAT BELT CHECK DOOR LOCK (Machine equipped with cab) CHECK OPERATION OF WINDSHIELD WIPER, WINDOW WASHER AND DEFROSTER, AND CHECK DETERGENT LEVEL (Macl equipped with cab) CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER ‘The water separator separates water mixed in the fuel. If float @ is at or above red line (D, drain the water according to the following procedure: 1. Loosen drain plug @ and drain the accumulated water until the float reaches the bottom, 2. Tighten drain plug @. 3. If the air is sucked into fuel line when draining the water, be sure to bleed air in the same manner as for the fuel filter. See “24.6 EVERY 500 HOURS SERVICE”. 2.2512, OPERATION 12.1.3 REMOVAL OF ARTICULAR LOCK PIN A warning For general travel, maintenance, and transportation, always keep the articulate lock pin installe Ifthe articulation is to be used during travel operations, remove the articulate lock pin and keep it in the place shown by the arrow. 12.1.4 ADJUSTMENTS BEFORE OPERATION ADJUST OPERATOR'S SEAT Ay WARNING 1e machine in a safe place and stop the engine when istment of the operator's seat. ¢ Adjust the seat position at the beginning of each shift or when operators change. ‘¢ Adjust the seat so that the brake pedal can be depressed all the way with the operator's back against the backrest. @ Seat height adjustment Pull up lever @. When the seat is set to a desired height, release the lever. The height adjustment range is 165mm (6.5 in). @ Forward-backward adjustment of seat Pull up lever @ and set the seat to a desired position, then release the lever. The forward-backward adjustment range is 140 mm (6.5 in) (7 steps). 2.26 LL XS oes position sesiir positionADJUSTING POSITION OF STEERING POST, WORK EQUIPMENT CONTROL LEVERS A warning Do not carry out adjustments while traveling. ull up lever @. When the steering post is set to a desired position, release the lever. ‘Adjust to a position that matches your physique and operating posture. ADJUST CONTROL LEVER SHAFT ANGLE A WARNING When adjusting the control lever shaft, be sure to stop the engine. 1. Remove bolt (, then remove cover ®. 2. Loosen nut @. Adjust the angle of control lever shaft ® so that control lever @ will be at a position for easier operation. 3, After setting control lever @ to the desired position, secure control lever shaft © with nut ©. 4, Install cover @, then tighten bolt ©. 12. OPERATION SO 2.2712, OPERATION USING SEAT BELT When operating a machine equipped with ROPS, be sure to use the seat belt. A WARNING ‘© Before fastening the seat belt, inspect the securing brackets and belt for abnormal conditions. Replace any worn or damaged seat belt or the securing brackets. ‘© Adjust and fasten the seat belt before operating the machine. ‘© Always use seat belt when operating the machine. ‘© Do not use seat belt with either half of the belt twisted. Fasten the belt and remove it in the following manner Install the belts so that it fits you exactly without being too tight. 1. Adjust the seat so that the brake pedal can be depressed all the way with the operator's back against the backrest. 2. Sit in the seat. Hold buckle @ with your left hand and tongue @ ith your right hand, and put tongue @ into buckle (D. Pull the belt to check that the belt has locked, 3. When removing the belt, raise the tip of the lever of buckle ® to release it. Fasten the belt along your body without twisting it. Adjust the lengths of the belt on both the buckle and the tongue sides so that, the buckle is located at the mid-point of the front of your body. Adjust the belt length in the following manner To shorten the belt: Pull the free end of the belt on either the buckle body or tongue side. To lengthen the belt: Pull the belt while holding it at a right angle to the buckle or tongue. 2:28 SN12.1.5 OPERATIONS AND CHECKS BEFORE STARTING ENGINE Ay WARNING ‘ If the control levers are touched by accident, the work equip- ment may move suddenly. When leaving the operator’s com- partment, always set the safety lever securely to the LOCK position. starting the engine, use a damp cloth to wipe off the dust accumulated on the top surface of the battery or on tl starting motor and alternator. 1. Check that parking brake lever (@ is at the LOCK position. 2. Check that gear shift lever @) is at the N (Neutral) position and locked with safety lock lever @. If gear shift lever @ is not at the N (Neutral) position, the engine | will not start. 3. Check that work equipment control lever @ is at the N (Holding) position. 12. OPERATION csitoue 2.2912. OPERATION 12.2 STARTING ENGINE 12.2.1 NORMAL STARTING Ay WARNING Check that there are no people or obstacles in the surrounding area, then sound the horn and start the engine. NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds. Hf the engine will not star trying to start the engine again. Do not start the engine with the fuel control lever at the FULL | OPEN position. | wait for at least 2 minutes before | 1. Set fuel control lever @ at the LOW IDLING position. Low idling a 7 2. Insert the key into starting switch @ and turn the key to the START position. The engine will start. 3. When the engine starts, release the key in starting switch @. The key will return automatically to the ON position 2.30 navi12.2.2 STARTING IN COLD WEATHER A WarnNinc ‘© Check that there are no people or obstacles in the surround- 19 area, then sound the horn and start the engi ‘© Never use starting aid fluids as they may cause explosions. 12, OPERATION NOTICE Do not keep the starting motor rotating continuously for more than 20 second: If the engine fails to start, repeat steps 1 ~ 3 after waiting for about 2 minutes. When starting is low temperatures, do as follows. 1. Set fuel control lever @ at the HALF OPEN position. 2. Hold starting key @ at the HEAT position until heater signal @ is heated red. If the preheating time is too short or too long, the engine will be difficult to start, so always keep to the correct preheating time. The preheating time is as follows. Ambient emperature ‘Above 0°C OFC to -10°C 10°C to -20°C Preheating time ‘Approx. 20 sec Approx. 30 sec Low 3. When heater signal @ is heated red, turn starting key @ to the START position to start the engine. alt oven al we oF | ~ a ye 2:3112. OPERATION 4, After the engine starts, release starting switch @, and it returns to the ON position. 5. Set fuel contro! lever @ at the LOW IDLING position. 2.32 Low idling Half open12. OPERATION 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE After starting the engine, do not immediately start operations. First, carry out the following operations and checks. NOTICE Avoid abrupt acceleration until the warm-up run is completed. Do not run the engine at low idling or high idling for more than ites. If it is necessary to run the engine at at a medium speed from time to time. 20 ing, apply a load or run 1. Pull fuel control lever @ and run the engine at medium speed for about § minutes with no load. Medium speed 2. After the warm-up run is completed, check gauges and caution lamps for proper operation. If any abnormality is found, repair it. Continue to run the engine at light load until engine water temperature gauge indicator (2 falls within the green range. | 3. Check that there is no abnormal exhaust gas color, noise, or | vibration, If any abnormality is found, repair it esse 2.3312. OPERATION 12.4 TRAVELING POSTURE FOR MACHINE A. WaRNING © For general travel, always lock the front frame and r with the articulate lock pin. © Before moving any work equipment control lever, check the distance between the blade and tires. 1. For general travel, raise the blade fully as shown in the diagram on the right, and set so that the blade does not extend outside = the machine. frame NOTICE Be sure to maintain a clearance between the blade and inside tire. If the machine is articulated with the blade at an angle, the step | may be bent by the blade. 2:3412. OPERATION 12.5 MOVING MACHINE Ay WARNING ‘© When moving off, check that the area around the machine is safe, and sound the horn before moving. Clear all personnel from the machine and the area. Use extreme care when reversing the machine. Note there is a blind spot behind the machine. ‘© Before starting operations, check that the seat belt is properly installed. 1. Set the blade and scarifier to the traveling position. sooo 2. Set safety lock lever ® of gear shift lever (7) to the FREE position. | Lock scsiase 3. Depress inching pedal @ and set gear shift lever (@ to the first, second or third speed. Do not start traveling with the gear shift lever at the fourth or a higher speed position. | 4. Return packing brake lever @ to the FREE position. At this time, = confirm that parking brake lamp © has gone off. De 3 Lock ccoeth an 2:3512, OPERATION 5. Depress accelerator pedal @ while releasing inching pedal @, and move the machine off. NOTICE When starting travel, check the following items. @ Check that the parking brake lamp is turned off. ‘@ When the braking force is lowered because of rainwater, wash- ing water, etc., apply the brake lightly several times to dry up the lining with frictional heat. 12.6 SHIFTING GEAR Ay WARNING Do not shift gear suddenly when traveling at high speed. Before shifting gear, apply the brake to reduce the travel speed. NOTICE When shifting gear, always shift one speed at a time. Shift gear as follows, 12.6.1 ACCELERATION Partially release the accelerator pedal and shift the gear shift lever @ up to the next position. 12.6.2 DECELERATION Release accelerator pedal ( to decrease traveling speed and gear shift lever @ down to the next position. 2:36 esi at12.7 SHIFTING BETWEEN FORWARD AND REVERSE 2 WARNING ‘© When shifting between forward and reverse, always check that it is safe to travel in the new directior Use extreme care when reversing the machi an blind spot behind the machine. © Do not shift between forward and reverse when traveling at Note there is 12, OPERATION high speed. Always stop the machine when switching between FORWARD and REVERSE. 1. Depress brake pedal (@) to reduce the travel speed, then depress inching pedal @ to stop the machine. 2. Operate gear shift lever @ to the F (FORWARD) or R (REVERSE) position, and set it at Ist or 2nd speed. 3. Depress accelerator pedal @ while releasing inching pedal ®, and move the machine off. : | eat P 23712. OPERATION 12.8 STOPPING MACHINE Ay WARNING ‘® Avoid stopping suddenly. Give yourself ample room when stopping. ‘¢ When stopping the machine, select flat hard ground and avoid dangerous places. If itis unavoidably necessary to park the machine on a slope, place the safety lock lever in the LOCK position and insert blocks underneath the tires. As an additional safety measure, thrust the blade into the ground. ‘¢ If any control lever is touched by accident, the work equip- ment may move suddenly, and this may lead to a serious accident. Before leaving the operator's seat, always operate the safety lock lever to place it securely at the LOCK position. 1, Release accelerator pedal 2. Depress brake pedal @). Before the machine comes toa stop, [| SS depress inching pedal @. 3. Set gear shift lever @ at the N position and move the safety lock lever to the LOCK position. 2:38 CORRECT | | ps 712. OPERATION 4. Pull parking brake lever @ and set the parking brake to the LOCK position. At this time, the parking brake pilot lamp lights up. 2:3912. OPERATION 12.9 TURNING MACHINE A WARNING @ It is dangerous to turn the machine suddenly at high speed or to turn the machine on steep slopes. ¢ If the engine stops when the machine is traveling, the steer- ing will become heavy, so never stop the engine. is particularly dangerous on slopes, so never allow the ie to stop while traveling on slopes under any circum- stance. If the engine stops, imme stely apply the brake and stop the To turn the machine when traveling, turn steering wheel @ in the direction of the turn, 12.9.1 LEANING OPERATION Operate leaning control lever @ to change the angle of the front tires as follows. Pull BACK to lean to RIGHT. Push FORWARD to lean to LEFT ‘When traveling forward and turning the machine, the radius of the turn becomes smaller if the tires are leaned in the direction of the turn. When traveling in reverse and turning the machine, the radius of the turn becomes smaller if the tires are leaned in the opposite direction to the turn, 2-40 ' Hole a] REM aia o \ Left turn Right turn n aR pe ~12.9.2 ARTICULATING OPERATION A WARNING Do not remove the lock pin for general trave NOTICE When turning with the machine articulated, pay particular at- tention to the clearance between the blade end and the whet To carry out articulation operations, remove the lock pin on the loft side of the chassis. The machine can be articulated up to a maximum of 27° to the left or right, and the turning radius becomes 5.6 m (18 ft 4 in). 1. Stop the machine, remove pin @, and insert it in the storage position. 2. Operate articulate control lever as follows. Pull BACK to articulate to LEFT. Push FORWARD to articulate to RIGHT. 3. When not operating the articulation, set the front frame and rear [— frame straight, align the pin holes, and fix the front and rear frames in the original position with pin ©. 12. OPERATION © Nessa | (f 24112. OPERATION 12.10 OPERATING WORK EQUIPMENT 12.10.1 OPERATING BLADE BLADE LIFT OPERATION Operate left blade contro! lever @) as follows. Pull BACK to RAISE left end of blade Push FORWARD to LOWER left end of blade Operate right blade control lever @ as follows. Pull BACK to RAISE right end of blade Push FORWARD to LOWER right end of blade 2-42 wha a IP Raise A Lower Bi Raise 4 yOPERATING BLADE SIDE SHIFT Operate blade side-shift control lever @ as follows. Pull BACK to shift blade to RIGHT Push FORWARD to shift blade to LEFT OPERATING BLADE ROTATION Operate blade rotation control lever @ as follows. Pull BACK to rotate blade to LEFT Push FORWARD to rotate blade to RIGHT 12.10.2 OPERATING SCARIFIER Operate scarifier control lever @) as follows. Pull BACK to scarifier to RAISE. Push FORWARD to scarifier to LOWER. 12. OPERATION Lett shittag Hold a Riaht shift Rioht rotation ae: oA) Bu sest1078 scsitoee | 2-43,12, OPERATION 12.11 WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER 12.11.1 LEVELING GROUND TO RIGHT 1. Operate the drawbar side shift and move the circle approx. 200 mm (7.9 in) to the left, 2. Set the blade so that the earth is discharged oul wheel. 3. Operate the blade lift cylinder so that the blade is at the desired digging depth, then set it horizontal. 4. Lean the front wheels to the left. REMARK Leaning the wheels to the left prevents the machine from being pushed to the right by the load acting on the left side of the machine. 5. Rotate so that the blade is at the optimum position for the soil. (Be careful not to let the rear left wheel run over the window discharged from the blade.) 6. Operate the power tilt so that the top of the blade is slightly in front of the cutting edge, then start operation. (Only machine ‘equipped with power tilt.) 7. Discharge the soil to the side to prevent any excessive load from bearing on the machine. 244 fanny8. Spread fine crushed loose soil over the ground surface until it is level. REMARK © Generally speaking, carry out operations on flat ground with the frame straight to the blade. Articulate the frame to deal with the force in the side direction caused by the load on the blade. © If the tires start to spin, turn the blade to a greater angle to reduce the digging width, thereby reducing the load on the machine, ‘@ Inleveling operations, discharge the soil outside the rear wheels. This makes it easier to steer with the rear wheels. 12.112 LEVELING GROUND TO LEFT 1. Operate the drawbar side shift and move the circle approx. 200 mm (7.9 in) to the right. 2. Set the blade so that the earth is discharged outside the rear right wheel. 3. Operate the blade lift cylinder so that the blade is at the desired digging depth, then set it horizontal. 4, Lean the front wheels to the right. 5. Carry out the operation in the same way as when leveling to the right. 12, OPERATION 2-4512. OPERATION, 12.113 DIGGING RIGHT V-DITCHES NOTICE Set the frame straight. If the machine is articulated, the side of the tire will be pushed against the slope face, and this will cause damage to the side face of the tires. In addition, mud will be pushed in between the tire and rim, and this will cause problems such as leakage of air. 1. Set the right edge of the blade in line with the outside of the front right wheel. 2. Operate the power tilt so that the top of the blade is slightly in front of the cutting edge. (Only machine equipped with power tilt.) 3. Operate the left blade lift cylinder and raise the left edge of the blade. (The right end of the blade determines the depth of the ditch. The left end of the blade determines the shape of the ditch.) 4, Rotate the blade so that the soil is discharged inside the rear left wheel, then set the blade at an angle. 5. Operate the right blade lift cylinder and set the right end of the blade to a digging depth of 50 ~ 100 mm (2.0 - 3.9 in). 6. Lean the front wheels to the left. 7. Operate the blade lift cylinder to the right to set the right edge of the blade to the desired digging depth. 2-4612, OPERATION Align the front right whee! with the bottom of the ditch and dig a ditch of the desired depth. First, dig to depth of 30 - 50 mm (1.2 - 2.0 in) to determine the line of the dite The chassis is in an unstable posture when digging ditches, so align the front and rear wheels with the bottom of the ditch when carrying out such operations. 2.4712. OPERATION 12.11.4 DIGGING LEFT V-DITCHES ht. If the machine is articulated, the side of the tire will be pushed against the slope face, and this will cause damage to the side face of the ti addition, mud will be pushed in between the tire and rim, and this will cause problems such as leakage of air. 1. Set the left edge of the blade in line with the outside of the front left wheel. 2. Operate the power tilt so that the top of the blade is slightly in 1g edge. (Only machine equipped with power 3. Operate the right blade lift cylinder and raise the right edge of the blade. (The left end of the blade determines the depth of the ditch. The right end of the blade determines the shape of the ditch.) y 4, Rotate the blade so that the soil is discharged inside the rear [~ right wheel, then set the blade at an angle. 5. Operate the left blade lift cylinder and set the right end of the blade to a digging depth of 50 ~ 100 mm (2.0 ~ 3.9 in). 6. Lean the front wheels to the right. 7. Operate the blade lift cylinder to the left to set the left end of the blade to the desired digging depth.Align the front right wheel with the bottom of the ditch and dig a ditch of the desired depth. First, dig to depth of 30 - 50 mm (1.2 - 2.0 in) to determine the line of the ditch. ‘The chassis is in an unstable posture when digging ditches, so align the front and rear wheels with the bottom of the ditch when carrying out the operation. 12. OPERATION 24912. OPERATION 12.11.5 RIGHT DITCH FINISHING 1. Set the right side of the blade behind the front right wheel. 2. Operate the right blade lift cylinder and set the blade to the depth of the ditch. 3. Be careful not to let the rear left wheel run over the window discharged from the blade. Operate the blade lift cylinder and blade rotation to set the blade in position. 4, Lean the front wheels slightly to the left. 6. To push out the soil to the top of the slope face and the road shoulder, a separate pass is needed. Spread the soil, then carry ‘out final finishing with the grader. 2-5012.11.6 LEFT DITCH FINISHING 1. Set the left side of the blade bel 2. Operate the left blade lift cylinder and set the blade to the depth of the ditch. 3. Be careful not to let the rear right wheel run over the windrow discharged from the blade. Operate the blade lift cylinder and blade rotation to set the blade in position. 4, Lean the front wheels slightly to the left. 5. To push out the soil to the top of the slope face and the road shoulder, a separate pass is needed. Spread the soil, then carry out final finishing with the grader. 12. OPERATION 2-5112, OPERATION 12.1.7 FINISHING RIGHT ROAD SHOULDER 1. Set so that the right end of the blade is in line with the outside of the right tire. Set the blade so that the soil is discharged between the two wheels. (The soil can be moved more smoothly if the blade is at a small propulsion angle.) 2. Align the center of the machine with the line of the soil dis- charged when digging the ditch. 3. Operate the left and right blade lift cylinders to keep the blade horizontal and at the desired digging depth. 4. Lean the front wheels slightly to the left. 12.11.8 FINISHING LEFT ROAD SHOULDER 1. Operate the drawbar shift cylinder to set the circle to the left end. 2. Set so that the left end of the blade is in line with the outside of the right tire. Set the blade so that the soil is discharged between the two wheels. (The soil can be moved more smoothly if the blade is at a small propulsion angle.) 3. Align the center of the machine with the line of the soil dis charged when digging the ditch. 4, Operate the left and right blade lift cylinders to keep the blade horizontal and at the desired digging depth. 5. Lean the front wheels slightly to the right.