Komatsu GD511A-1 Manual

Operation & Maintenance
Manual
GD511A-1
GD521A-1
GD523A-1
SEAMG5110104
MOTOR GRADER
GD511A-10243
SERIAL NUMBERS GD521A-10075
and up
GD523A-30099
KOMAtsU

WW-02595
FOREWORD
This manual describes procedures
for
operation, handling, lubrication,
maintenance, checking, and adjustment
It
will
help the operator or anyone
realize peak performance through effective, economical and safe machine
operation
and
maintenance.
• Please
read
this manual carefully
BEFORE
operating the machine.
• Please continue studying this manual until properoperation is completely
reinforced into personal
habit
• This manual describes the basic techniques. Skill is performed
as
the
operator
or
anyone
get
the correct knowledge and performance
of
the
machine.
• Operation, inspection, and maintenance should
be
carefully carried out,
and the safety must
be
given the
first
priority. Safety precautions are in-
dicated
with
A
marks and technical precautions with
*
marks in this
manual. The safety information contained in this manual is intended only
to supplement safety codes, insurance requirements, local
laws,
rules
and regulations.
• Some photographs and illustration pictures are different from your ma-
chine
as
technical improvement is continuously reflected on
it
Revision
to
up-to-date manual's content
is
performed in latereditions.
• This operation
&
maintenance manual.may contain attachments and op-
tional equipment
that
are not available in your area.
Please
consult your
local Komatsu distributor
for
those itemsyou may require.
Materials and specifications are subject
to
change withoutnotice.
-1-
FOREWORD
Find manuals at https://best-manuals.com

BREAKING
IN
YOUR
NEW
MACHINE
BREAKING
IN YOUR NEW MACHINE
Each
machine is carefully adjusted and tested before shipment. However,
a new machine requires careful operation duringthe first
100
hours
to
break
in the various parts.
If
a machine is subjected
to
unreasonably hard use
at
the initial operation
stage, the potential
of
performance
will
prematurely deteriorate and the
service life
will
be
reduced. A new machine must
be
operated
with
care,
particularly with regard
to
the following items.
• After starting, let the engine idle
for
5 minutes to allow proper en-
gine warm-up prior
to
actual op-
eration.
• Avoid operation with heavy loads
or
at high speeds.
• Sudden starting or acceleration,
unnecessarily abrupt braking and
sharp turning should
be
avoided.
•
If
themachineis deliveredwithout
any cooling
water
in the radiator,
flush the cooling system with am-
pleclean water
to
cleanthesystem,
then fill the radiator with cooling
water.
-2-
*When replacing oil filter elements
(cartridges), check their interiors
for
dirt
and dust.
If
heavily col-
lected, check
for
possible cause
before starting operation.
*Hours
of
operation are indicated
bythe service meter.
Find manuals at https://best-manuals.com

CONTENTS
OPERATION
SAFETY
HINTS
• • • A ...............
..
......... 4
GENERAL
LOCATIONS AND
SPECIFICATIONS
. . 16
INSTRUMENTS AND
CONTROLS
. . . . . .. . . .. . . . 18
CHECK
BEFORE
STARTING •... •. •. . . . . .•. .. . . .
31
OPERA
TING
YOUR
MACHINE
.. •.. . . . . . .. . . . . . .
39
OPERATING
OF
WORK
EQUIPMENT
.••.........
47
REVERSING
AND
REPLACEMENT
OF
CUTTING
EDGE
AND
END
BIT
.•.•. .. .. .••.•.
56
CHANGING
TIRES.............................
57
DRIVING
ALONG
ROAD
.•. •. ... .. . . . . . .. . . . .. .
59
TOWING
•............•••.....................
60
TRANSPORTATION . . .. .. . . . . .. . . . . . .. .. . . . . ..
61
HANDLING
OF
BATTERY . . . . . .. . .•. .. . . . .. . . ..
62
COLD
WEATHER
OPERATION
. ... . . .. . .. . . . . .. 65
-3-
MAINTENANCE
PERIODIC
MAINTENANCE . ..•. . .. .. . .. .. .••••
71
PRECAUTIONS
FOR
MAINTENANCE . .. ... ..
72
MAINTENANCE TABLE . .. . . . .. .. .. . .. .. . ..
79
OIL
FILLER
AND
LEVEL
GAUGE
POSITIONS
. •. . . .. . . ..•. ... . .. .. .. .. . ..
83
EVERY
50
HOURS
SERVICE
••.. •. .. .•. ... .•
84
EVERY
250
HOURS
SERVICE. . .... ... . .. .. .
85
EVERY
500
HOURS
SERVICE
. .. .. .•. . ... .. .
99
EVERY
1
000
HOURS
SERVICE
. .. .. .. ..•. .• 1
03
EVERY
2000
HOURS
SERVICE
. .. .. .. . .•.. .
114
EVERY
4000
HOURS
SERVICE
. .. .. .. . ... ..
11
6
WHEN
REQUIRED
. . ... . . .. . . ... .. •. . . .. .. .
11
7
ADJUSTMENT . . .. . •. . .••. . . .•... .. •.. •.. .. .
124
TROUBLE
SHOOTING
GUIDE
. . . . .. .. .. .. . .. . .. 1
25
STORAGE
.•..•..••.........•.•.....•.
•.•.•. ..
128
SERVICE
METER
. •. . . . .. . .. .. .. .. .. .•. . . .••..
130
MACHINE
AND
ENGINE
SERIAL
NUMBERS
.. ... 131
FUEL,
COOLANT AND
LUBRICANTS
. ••. . •. .. ..
132
Find manuals at https://best-manuals.com

SAFETY
HINTS • • • A
OPERATION
GENERAL
• Wear properclothes
Loose clothes, ornaments
or
other things that may
possibly contact the control lever
or
other machine
parts must not
be
worn. Do not let you clothes get
caught on protruding parts
of
the machine.
Do
not
wear
oily
clothes since they maycatch fire.
• Wear well-fitting helmet, safety shoes and working
clothes.
If
thenature
of
the
work
requiressafety,wear
protective goggles
or
mask,thick gloves, earplugs
or
other protection.
• Accidents
or
injuries are liable
to
occur when the
operator is careless
or
slack. It is most important
to
bear
safe
operation
in
mind
at
all times.
•
Take
care
of
your
health.
Do
notdrive when tired,
or
after drinking.
-4-
• Learnthe prohibitions,cautionsandrules about
work
procedures inthe work site.
When there is a leader,
fix
standard signals and
always
follow
these signals when operating.
•
If
thereshould
be
an
accident
or
fire
or
anyothersuch
unexpected mishap, deal
with
it
quickly, using the
nearest apparatus.
Learn beforehand the locations
of
the firstaid boxes
and fire extinguishers and
how
to
use them.
It
isalso
important
to
knowthe emergency contact system.
• Learn aboutthesafety devices
on
your
own machine
and about
how
to use them. Confirm that they are
correctly attached in the prescribed position.
Such safety devices include:
*Guards
*
canopies
*
Protective Devices
*Roll-:Over Protective Structures
*
Seat Belts,
etc.
Find manuals at https://best-manuals.com

• Take care
not
to
get caught by protruding parts
of
the machine. Do
not
wear oil-stained clothing be-
cause
it
is
likely
to
catch fire.
• Keep fire away
from
stored fuel, lubricants
and
anti-freeze.
• Exhaust gas is dangerous. When running the engine
for
long periods in a poorly ventilated
area,
there
is
a danger
of
gas poisoning, so open the windows or
doors
to
ensure a good supply
of
fresh air.
G-01243
-5-
•
Read
the Operation and Maintenance Manual care-
fully.Learn
how
to
use the control devices, gauges
and
warning devices.
Bre
sure you understand the
meaning
of
the Caution plates. Remember the
check points and checking method
for
engine oil,
fuel, cooling water
and
hydraulic oil levels.
• When working
on
a road, pay attention to the
safety
of
passing vehicles and pedestrians. If neces-
sary, assign a signalman
or
provide temporary
barricades.
• Before starting the machine, perform all necessary
checks
as
stated
in
the Operation and Maintenance
Manual.
Find manuals at https://best-manuals.com

BEFORE
STARTING
OPERATION
• Examine the lay
of
the land and
the
kind
of
soil atthe
work
site
to
determinethe dangerous points and
the
best method
of
operation.
Proceed
vyith
the
work
only after making safety ar-
rangements about the dangerous points.
• Inspect leakages
from
the fuel, lubricating and hy-
draulic systems. Repair any fuel or oil leakage, and
wipe
off
all dirtyoil. Check
that
tire inflation pressure
is standard, that hub nuts are
not
loose, and
that
no
other parts are damaged
or
missing. Machines hav-
ing such failures should
not
be operated.
• When getting
on
or
off
the machine, use the handrail
and step provided. Do not
jump
up
or
down
from
the
machine.
-6-
•
Do
not
leave parts
or
tools lyingaround in thevicinity
of
or
on the
floor
of
the
operator's compartment.
Keep everything in
its
proper place.
• Wipe
off
throughly
anygrease, oil
or
mud onthestep,
handrail,
floor
or
control levers. Failure
to
do
this
may
cause you
to
slip.
• Check the level
of
the fuel, lubricants and cooling
water. Extinguish cigarettes before checking
or
re-
plenishing. Check
that
the
radiator cap and each
oil
filler caps
or
plugs are
firmly
tightened.
• Adjustthe operator's seat until
it
is in the mostcom-
fortable position
for
operating.
Find manuals at https://best-manuals.com

• If a seat belt is provided, always use it. If the belt is
damaged or worn, replace
it with a new one.
• To ensure the safety
of workers near the machine,
always sound the horn
to warn them before starting
the engine and moving the machine.
Be particularly
careful to check that the rear is clear before backing
the machine.
• Combustible objects such
as pieces of wood, dead
leaves,and pieces
of papermaycause fire, soinspect
the inside
of the engine room and remove them.
• Before starting the engine, confirm that all control
levers are in "NEUTRAL' or "HOLD" position.
-7-
AFTER STARTING ENGINE
• Confirm that all gauges and warning devices are
functioning correctly,and
that the gauge readingsare
within the prescribed range.
• Check the play and travel
of each lever and pedal.
• Operatethe blade
to confirmthattheyarefunctioning
normally.
Find manuals at https://best-manuals.com

• Move the machine slowly and listen carefully to the
engine
or gears to co_nfirm that they are not making
any unusual noises.
• Operate the gear shift lever
to confirm that the
travel speeds for forward and reverse
are function-
ing normally. Also carry out a brake test at each
travel speed. )
.,
✓- ...
{/_J ,~10-1111111.-::
1/..._
• Choosing a safe place, tum the machine to the left
and right to confirm that the steering devices are
functioning normally.
•
If these tests reveal anything wrong, however slight
it may be, contact the man in charge of the machine
and operate the machine only after obtaining his
permission.
-8-
DURING OPERATION
• Always concentrate. It is extremely dangerous to
allow yourself to be distracted or to think of other
things when operating amachine.
In dangerous places, or where there is restricted
visibility,
it is important to get down from the ma-
chine and confirm whether
it is safe before continu-
ing work.
• The
work area should be made as flat as possible. If
the work area is flat, operation is made much easier
and this reduces operatorfatigue.
Find manuals at https://best-manuals.com

• The machine should always be operated
at
a speed
where
it
can be correctly controlled. Never
do
the
following:
* Speeding
*
Sudden starting, sudden braking, sudden
turning.
* Snaking
* Coasting rJ""'li
,
(c
ti'\.:·:.
.
~
·.
<.__,:
•
Be
careful
of
those around you, and always confirm
that
there
is
no person
or
obstacle in the way
beforedriving
or
turning the machine.
•
Always
operate slowly in crowded places.
On
haul
roads
or
in
narrow places, give way
to
loaded
vehicles.
-9-
• Raise each
work
piece
of
equipment
as
high
as
possible and keep the blade within the machine
width
while traveling. Maintain the specified travel-
ing posture.
• Do not control the vehicle speed by pressing the
brake
as
it will overheatthe brake disc.
• Do not allow unauthorized persons into the work
area.
Find manuals at https://best-manuals.com

• Always be aware
of
the operating capacity
of
the
machine. Using the machine to
do
work beyond its
capacity will notonly damage the machine. but may
even cause unexpected accidents.
• The machine condition can be judged from many
factors. Changes in the gauges, sound, vibration,
exhaust gas color
or
response
of
the control levers
can indicate the occurrence
of
some disorder.
If
any
disorder occurs, park the machine immediately
in
a
safe
place
and
take appropriate action.
Be
especially
careful in the case
of
a fuel leak as there is danger
of
fire.
-10-
•
If
the machine breaks
down
and needs
to
be
towed,
first confirm
that
the brakes are working properly,
and then
tow,
using awire rope
or
any othersuitable
towing equipment
• When parking the machine after discontinuing
work, put the gear
shift
lever into "NEUTRAL",
apply the brake lock, lower the blade. scarifier and
ripper to the ground, and put all safety levers into
the "LOCK" position. Never leave the operator's
seat
without
switching the engine
off.

• When continuing operations
after
rain, remember
that
conditions
will
have
changed from those
beforethe rain started, so proceed
with
caution.
Be
particularly careful when approaching the shoul-
der
of
the road
or
cliffs,
as
they may have been
loosened by the rain.
•.
Check the load limits
of
bridges beforecrossing.
G-01249
-11 -
•
When
operating on uneven ground, drive
at
as
low
a speed
as
possible
and
avoid sudden changes in
direction.
• When operating at the edge
of
a
cliff
or
on
the
shoulder
of
aroad, remember the following points:
o When operating in a place where there is danger
of
the machine falling over the side.
be
doubly
careful. Do
not
approach the edge
of
the
cliff
or
road shoulder by mistake.

o When working on river embankments
or
other
places
made
of
piled soil, there
is
the dangerthat
the weight or vibration
of
the machine may
cause the machine to sink into the piled soil,
so
be
extremely careful when operating
in
such
places.
• When operating on slopes, remember the following
points:
c When driving
on
a slope, always drive directly up
or down it. Never drive horizontally or diagonally
across the slope,
as
this may cause the machine
to roll over or slip
sideways.
-
12
-
c When going
down
a slope, use the engine
as
a
brake.
If
this is
not
enough
to
control the speed
of
the machine, usethewheel brake
as
well.
Never coast
down
a slope with the gear
shift
leverin "NEUTRAL"
or
with
clutch disengaged.
c As
far
as
possible, avoid turning the machine on
a slope.
It
may cause the machine to roll over
or
slip sideways.
G-01250

c Before going up or down a slope, select a travel
speed most suited
to
the slope. Do
not
change
gearon the slope.
c
If
the
engine stalls on a slope,
first
use
the brake
to
stop the machine, then return the gear
shift
lever
to
"NEUTRAL" before starting the engine
again.
• When using the articulation system,
be
particularly
careful
not
to
letthe blade damage the rear tires.
(In
articulateframe model)
• Operating the articulation system when traveling
at
high speed may cause the machine
to
overturn.
Always perform this operation
at
a speed below 10
km/h.
(In
articulate frame
modeO
·
-13 -
• Always observe the
traffic
regulations and leave
margin
for
emergencies.
• When operating in a city area,
be
sure
to
locate un-
derground pipes and cables before starting the ma-
chine
to
prevent them from being broken.
• When operating inside a building always
be
sure
of
the clearances
of
the ceiling, entrances, aisles, etc.
and the load limit
of
the
floor. ·
• Never allow other person than the operator
to
ride
on
themachine during operation.

• When passing through a narrow space, be careful
of
the side and overhead clearances. Take special·
care
not
to touch any obstacles on either side
or
overhead.
If
necessary, have someone outside the
machine call outinstructions.
• When operating
at
night, remember the following
points:
c
Be
sure
to
arrange
an
adequate lighting system.
c
At
night
it
is
very easy
to
make mistakes
in
assuming the distance and height
of
objects and
land.
-14-
•
When
operating
in
fog, mist
or
smoke,
where visibil-
ity
is bad, be especially careful to confirm first
whether operation is safe.
When
visibility drops below safety level, stop work
and
wait
for
the visibility
to
improve.
•
When
operating in snow,
or
cleaning snow, remem-
berthe following points:
c Even slight slopes can cause unexpected side
slipping, so in such places, operate
with
extreme
caution.
c When show is thrown to one side
of
the ma-
chine, take engough caution
to
obstacles cov-
ered underthe snow.

c Never use the wheel brake
to
stop suddenly on
slopes. Lowering
the
working equipment
is
a far
nioreeffective
way
of
stopping.
• During operation, use the seat
belt
-15
-
PARKING
•
When
parking the machine, park
it
in a safe place
outsidethe working area, or
in
the specified
place.
The following factors should
be
considered when
choosing a parking place:
it
should be on
flat
firm
ground where there
is
no danger
of
rockfalls, land-
slides
or
floods.
If
the machine
has
to
be parked on
a slope,
it
should be parked facing
<;lirectly
up
or
down the slope, and chocks should be placed under
the tires.
When
the. machine
is
facing downhill,
lower
the blade so
that
it
cuts slightly into the
ground
to
further
increase the safety.
• When parking
the
machine, return the
gear
shift
lever
to
"NEUTRAL", apply the
brake
lock, lower
the
blade,
scarifier and ripper
to
the ground, and
put
all safety levers
in
the "LOCK" position. Switch
off
theengine and remove the
key.

GENERAL
LOCATIONS
AND
SPECIFICATIONS
GENERAL LOCATIONS AND SPECIFICATIONS
1.
Head lamp
6.
Drawber side shift
2.
Blade
lift
cylinder cylinder
3.
Reartire
7.
Fronttire
MACHINE MODEL
4.
Articulation cylinder
5.
Blade
8.
Scarifier
9.
Leaning cylinder
PERFORMANCE
1.
Travel speeds Forward
(km/h) Reverse
2.
Minimum
turning radius (m)
3.
Gradeability
4.
Stability
OPERATING
WEIGH
(kg)
ENGINE
1.
Model
2.
Flywheel horsepower
(HP)
NOTE:
Specifications are subjectto change without notice.
-
16
-

GENERAL
LOCATIONS
AND
SPECIFICATIONS
GD511A-1 GD521A-1 GD523A-1
44.5 44.6 44.6
54.4 54.4 54.4
6.6 6.6 6.6
24° 24° 24°
30° 30° 30°
10800 10800 10800
Komatsu 56O95L diesel engine Komatsu 560105 diesel engine
135 135
13.5
(at 2900 rpm) (at 2500 rpm) (at 2500 rpm)
-
17
-

INSTRUMENTS
AND
CONTROLS
INSTRUMENTS AND CONTROLS
METERS, GAUGE
AND
PILOT
LAMPS
-
18
-
1. ENGINE COOLING WATER
TEMPERATURE GAUGE
Engine is normal when indicator
is
on green range during operation.
After
starting engine, continue
to
warm
up engine until indicator
points green range.
If
indicator is over green range,
keep engine
in
low idling and
wait
till
temperature drops.
G-<ions

2.
ENGINE
OIL
PRESSURE PILOT
LAMP
This lamp indicates a low engine
oil
pressure.
If
the lamp goes
off,
the engine
oil pressure is normal.
When engine is cool, this lamp
lights
up.
In this case
warm
up
engine untilthis lampgoes
off.
G-00656
3.
BATTERY CHARGING
LAMP
J
·oo®
00
This lamp
is
used
to
indicate the
generating condition
of
the alterna-
tor. Normally, when the start-
ing switch
is
turned ON, the lamp
will light up and then go
out
as
the
engine speed rises.
-
19
-
INSTRUMENTS
AND
CONTROLS
4.
PARKING BRAKE PILOT LAMP
When
the parking brake lever is
pulled,
this
lamp lights
up.
Before
starting the machine, release the
parking brake lever and check
that
the lamp goes out.
5.
SPEEDOMETER
Indicates the running speed
of
the machine.
It
also contains
an
odometer.