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
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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.
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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
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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.
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• 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.
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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.
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• 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.
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• 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.
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• 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.
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