Komatsu GD511A-1 Manual

Operation

Maintenance

Manual

GD511A-1

GD521A-1

GD523A-1

SEAMG5110104

MOTOR GRADER

GD511A-10243

SERIAL NUMBERS GD521A-10075

and

GD523A-30099

KOMAtsU

WW-02595

FOREWORD

This manual describes procedures

for

operation, handling, lubrication,

maintenance, checking, and adjustment

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

the

operator

anyone

get

the correct knowledge and performance

the

machine.

• Operation, inspection, and maintenance should

carefully carried out,

and the safety must

given the

first

priority. Safety precautions are in-

dicated

with

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

technical improvement is continuously reflected on

Revision

up-to-date manual's content

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

change withoutnotice.

-1-

FOREWORD

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BREAKING

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

break

in the various parts.

a machine is subjected

unreasonably hard use

the initial operation

stage, the potential

performance

will

prematurely deteriorate and the

service life

will

reduced. A new machine must

operated

with

care,

particularly with regard

the following items.

• After starting, let the engine idle

for

5 minutes to allow proper en-

gine warm-up prior

actual op-

eration.

• Avoid operation with heavy loads

at high speeds.

• Sudden starting or acceleration,

unnecessarily abrupt braking and

sharp turning should

avoided.

•

themachineis deliveredwithout

any cooling

water

in the radiator,

flush the cooling system with am-

pleclean water

cleanthesystem,

then fill the radiator with cooling

water.

-2-

*When replacing oil filter elements

(cartridges), check their interiors

for

dirt

and dust.

heavily col-

lected, check

for

possible cause

before starting operation.

*Hours

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 •... •. •. . . . . .•. .. . . .

OPERA

TING

YOUR

MACHINE

.. •.. . . . . . .. . . . . . .

OPERATING

WORK

EQUIPMENT

.••.........

REVERSING

AND

REPLACEMENT

CUTTING

EDGE

AND

END

BIT

.•.•. .. .. .••.•.

CHANGING

TIRES.............................

DRIVING

ALONG

ROAD

.•. •. ... .. . . . . . .. . . . .. .

TOWING

•............•••.....................

TRANSPORTATION . . .. .. . . . . .. . . . . . .. .. . . . . ..

HANDLING

BATTERY . . . . . .. . .•. .. . . . .. . . ..

COLD

WEATHER

OPERATION

. ... . . .. . .. . . . . .. 65

-3-

MAINTENANCE

PERIODIC

MAINTENANCE . ..•. . .. .. . .. .. .••••

PRECAUTIONS

FOR

MAINTENANCE . .. ... ..

MAINTENANCE TABLE . .. . . . .. .. .. . .. .. . ..

OIL

FILLER

AND

LEVEL

GAUGE

POSITIONS

. •. . . .. . . ..•. ... . .. .. .. .. . ..

EVERY

HOURS

SERVICE

••.. •. .. .•. ... .•

EVERY

250

HOURS

SERVICE. . .... ... . .. .. .

EVERY

500

HOURS

SERVICE

. .. .. .•. . ... .. .

EVERY

000

HOURS

SERVICE

. .. .. .. ..•. .• 1

EVERY

2000

HOURS

SERVICE

. .. .. .. . .•.. .

114

EVERY

4000

HOURS

SERVICE

. .. .. .. . ... ..

WHEN

REQUIRED

. . ... . . .. . . ... .. •. . . .. .. .

ADJUSTMENT . . .. . •. . .••. . . .•... .. •.. •.. .. .

124

TROUBLE

SHOOTING

GUIDE

. . . . .. .. .. .. . .. . .. 1

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

other things that may

possibly contact the control lever

other machine

parts must not

worn. Do not let you clothes get

caught on protruding parts

the machine.

not

wear

oily

clothes since they maycatch fire.

• Wear well-fitting helmet, safety shoes and working

clothes.

thenature

the

work

requiressafety,wear

protective goggles

mask,thick gloves, earplugs

other protection.

• Accidents

injuries are liable

occur when the

operator is careless

slack. It is most important

bear

safe

operation

mind

all times.

•

Take

care

your

health.

notdrive when tired,

after drinking.

-4-

• Learnthe prohibitions,cautionsandrules about

work

procedures inthe work site.

When there is a leader,

fix

standard signals and

always

these signals when operating.

•

thereshould

accident

fire

anyothersuch

unexpected mishap, deal

with

quickly, using the

nearest apparatus.

Learn beforehand the locations

the firstaid boxes

and fire extinguishers and

how

use them.

isalso

important

knowthe emergency contact system.

• Learn aboutthesafety devices

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

get caught by protruding parts

the machine. Do

not

wear oil-stained clothing be-

cause

likely

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

a danger

gas poisoning, so open the windows or

doors

ensure a good supply

fresh air.

G-01243

-5-

•

Read

the Operation and Maintenance Manual care-

fully.Learn

how

use the control devices, gauges

and

warning devices.

Bre

sure you understand the

meaning

the Caution plates. Remember the

check points and checking method

for

engine oil,

fuel, cooling water

and

hydraulic oil levels.

• When working

a road, pay attention to the

safety

passing vehicles and pedestrians. If neces-

sary, assign a signalman

provide temporary

barricades.

• Before starting the machine, perform all necessary

checks

stated

the Operation and Maintenance

Manual.

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BEFORE

STARTING

OPERATION

• Examine the lay

the land and

the

kind

soil atthe

work

site

determinethe dangerous points and

the

best method

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

other parts are damaged

missing. Machines hav-

ing such failures should

not

be operated.

• When getting

off

the machine, use the handrail

and step provided. Do not

jump

down

from

the

machine.

-6-

•

not

leave parts

tools lyingaround in thevicinity

on the

floor

the

operator's compartment.

Keep everything in

its

proper place.

• Wipe

off

throughly

anygrease, oil

mud onthestep,

handrail,

floor

control levers. Failure

this

may

cause you

slip.

• Check the level

the fuel, lubricants and cooling

water. Extinguish cigarettes before checking

re-

plenishing. Check

that

the

radiator cap and each

oil

filler caps

plugs are

firmly

tightened.

• Adjustthe operator's seat until

is in the mostcom-

fortable position

for

operating.

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•

a seat belt

provided, always use it.

the belt is

damaged or worn, replace

with a new one.

• To ensure the safety

workers near the machine,

always sound the horn

warn them before starting

the engine and moving the machine.

particularly

careful

check that the rear is clear before backing

the machine.

• Combustible objects such

pieces

wood, dead

leaves,and pieces

papermaycause fire, soinspect

the inside

the engine room and remove them.

• Before starting the engine, confirm that all control

levers

are

in "NEUTRAL'

"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

each

lever and pedal.

• Operatethe blade

confirmthattheyarefunctioning

normally.

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• Move the machine slowly and listen carefully

the

engine

gears

co_nfirm

that they

are

not making

any unusual noises.

• Operate the gear shift lever

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

confirm

that

the steering devices are

functioning normally.

•

these tests reveal anything wrong, however slight

may

be,

contact the man in charge

the machine

and operate the machine only after obtaining his

permission.

-8-

DURING OPERATION

• Always concentrate. It is extremely dangerous

allow yourself

distracted

to think of other

things when operating amachine.

dangerous places, or where there is restricted

visibility,

is important

get

down from the ma-

chine and confirm whether

is safe before continu-

ing work.

• The

work

area

should

made

flat

possible.

the

work

area

is flat, operation is made much easier

and this reduces operatorfatigue.

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• The machine should always be operated

a speed

where

can be correctly controlled. Never

the

following:

* Speeding

Sudden starting, sudden braking, sudden

turning.

* Snaking

* Coasting rJ""'li

ti'\.:·:.

·.

<.__,:

•

careful

those around you, and always confirm

that

there

no person

obstacle in the way

beforedriving

turning the machine.

•

Always

operate slowly in crowded places.

haul

roads

narrow places, give way

loaded

vehicles.

-9-

• Raise each

work

piece

equipment

high

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

it will overheatthe brake disc.

• Do not allow unauthorized persons into the work

area.

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