KOMATSU GALEO GD655-3A MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:10001 & UP) KOMATSU GD655-3A – PDF DOWNLOAD

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KOMATSU GALEO GD655-3A MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:10001 & UP) KOMATSU GD655-3A

KOMATSU GALEO GD655-3A MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:10001 & UP) KOMATSU GD655-3A – PDF DOWNLOAD:

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KOMATSU GALEO GD655-3A MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:10001 & UP) KOMATSU GD655-3A

• 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, it is your responsibility to take the necessary steps to ensure safety. In no event should you engage in prohibited uses or actions described in this manual.
• The explanations, values, and illustrations in this manual were prepared based on the latest information available at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual.

TABLE OF CONTENTS:

KOMATSU GALEO GD655-3A MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:10001 & UP) KOMATSU GD655-3A

COVER............................................................................  1
FOREWORD.........................................................................  2
	FOREWORD.....................................................................  3
	SAFETY INFORMATION...........................................................  6
	INTENDED USE.................................................................  8
		DIRECTIONS OF MACHINE....................................................  8
	LOCATION OF PLATES,TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR..................  9
		MACHINE SERIAL NO.PLATE POSITION.........................................  9
		ENGINE SERIAL NO.PLATE POSITION..........................................  9
		SERVICE METER POSITION................................................... 10
		TABLE TO ENTER SERIAL NO.AND DISTRIBUTOR................................. 10
CONTENTS......................................................................... 11
SAFETY........................................................................... 14
	SAFETY INFORMATION........................................................... 15
	SAFETY LABELS................................................................ 17
		POSITION FOR ATTACHING SAFETY LABELS..................................... 17
		SAFETY LABELS............................................................ 18
	GENERAL PRECAUTIONS.......................................................... 23
		SAFETY RULES............................................................. 23
		IF ABNORMALITIES ARE FOUND............................................... 23
		CLOTHING AND PERSONAL PROTECTIVE ITEMS................................... 23
		FIRE EXTINGUISHER AND FIRST AID KIT...................................... 23
		SAFETY FEATURES.......................................................... 23
		KEEP MACHINE CLEAN....................................................... 24
		INSIDE OPERATOR'S COMPARTMENT............................................ 24
		ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT........................... 24
		HANDRAILS AND STEPS...................................................... 25
		MOUNTING AND DISMOUNTING................................................. 25
		DO NOT GET CAUGHT IN ARTICULATED PORTION................................. 25
		PREVENTION OF BURNS...................................................... 26
		FIRE PREVENTION.......................................................... 26
		ACTION IF FIRE OCCURS.................................................... 27
		WINDOW WASHER LIQUID..................................................... 27
		PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)............. 27
		PRECAUTIONS FOR ATTACHMENTS.............................................. 28
		UNAUTHORIZED MODIFICATION................................................ 28
		SAFETY AT WORKSITE....................................................... 28
		WORKING ON LOOSE GROUND.................................................. 28
		DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES................................... 29
		ENSURE GOOD VISIBILITY................................................... 29
		VENTILATION FOR ENCLOSED AREAS........................................... 29
		CHECKING SIGNALMAN'S SIGNALS AND SIGNS................................... 30
		EMERGENCY ESCAPE FROM OPERATOR'S CAB..................................... 30
		ASBESTOS DUST HAZARD PREVENTION.......................................... 30
	PRECAUTIONS DURING OPERATION................................................. 31
		STARTING ENGINE.......................................................... 31
			CHECKS BEFORE STARTING ENGINE,ADJUST................................. 31
			PRECAUTIONS WHEN STARTING............................................ 31
			PRECAUTIONS IN COLD AREAS............................................ 32
		OPERATION................................................................ 32
			CHECKS BEFORE STARTING OPERATION..................................... 32
			PRECAUTIONS BEFORE MOVING OFF........................................ 32
			PRECAUTIONS WHEN TRAVELING........................................... 33
			PRECAUTIONS WHEN TRAVELING ON SLOPES................................. 34
			PRECAUTIONS WHEN OPERATIONS ON SLOPES................................ 34
			PROHIBITED OPERATIONS................................................ 34
			PRECAUTIONS WHEN OPERATING........................................... 34
			OPERATE CAREFULLY ON SNOW............................................ 34
			PARKING MACHINE...................................................... 35
		TRANSPORTATION........................................................... 36
			LOADING AND UNLOADING................................................ 36
			SHIPPING............................................................. 36
		BATTERY.................................................................. 37
			BATTERY HAZARD PREVENTION............................................ 37
			STARTING WITH BOOSTER CABLES......................................... 38
		TOWING................................................................... 39
			WHEN TOWING.......................................................... 39
	PRECAUTIONS FOR MAINTENANCE.................................................. 40
		WARNING TAG.............................................................. 40
		KEEP WORK PLACE CLEAN AND TIDY........................................... 40
		APPOINT LEADER WHEN WORKING WITH OTHERS.................................. 40
		STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............... 41
		TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................... 42
		PROPER TOOLS............................................................. 42
		ACCUMULATOR.............................................................. 43
		PERSONNEL................................................................ 43
		ATTACHMENTS.............................................................. 43
		WORK UNDER THE MACHINE................................................... 43
		NOISE.................................................................... 43
		PRECAUTIONS WHEN USING HAMMER............................................ 44
		REPAIR WELDING........................................................... 44
		REMOVING BATTERY TERMINAL................................................ 44
		PROHIBITED TO DISASSEMBLE BANK CONTROL LOCK PIN.......................... 44
		PRECAUTIONS WITH HIGH-PRESSURE OIL....................................... 44
		HANDLING HIGH-PRESSURE HOSES............................................. 45
		WASTE MATERIALS.......................................................... 45
		MAINTENANCE OF AIR CONDITIONER........................................... 45
		COMPRESSED AIR........................................................... 45
		PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS............................ 45
	PRECAUTIONS WITH TIRES....................................................... 46
		HANDLING TIRES........................................................... 46
		PRECAUTIONS WHEN STORING TIRE............................................ 46
OPERATION........................................................................ 47
	GENERAL VIEW................................................................. 48
		GENERAL VIEW OF MACHINE.................................................. 48
		GENERAL VIEW OF CONTROLS AND GAUGES...................................... 49
	EXPLANATION OF COMPONENTS.................................................... 51
		METERS AND LAMPS......................................................... 51
		SWITCHES................................................................. 58
		CONTROL LEVERS,PEDALS.................................................... 67
		DUST INDICATOR........................................................... 76
		ARTICULATE LOCK PIN...................................................... 76
		FUSE BOX................................................................. 76
	OPERATION.................................................................... 78
		CHECK BEFORE STARTING ENGINE............................................. 78
		STARTING ENGINE.......................................................... 90
		OPERATIONS,CHECKS AFTER STARTING ENGINE.................................. 93
		STOPPING ENGINE.......................................................... 95
		CHECK AFTER STOPPING ENGINE.............................................. 95
		TRAVELING POSTURE FOR MACHINE............................................ 96
		MOVING MACHINE OFF (FORWARD,REVERSE,SHIFTING GEAR),STOPPING.............. 97
		TURNING MACHINE..........................................................101
		OPERATING WORK EQUIPMENT.................................................104
		WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER.......................110
		PRECAUTIONS WHEN OPERATION...............................................131
		ADJUSTING WORK EQUIPMENT POSTURE.........................................135
		PARKING MACHINE..........................................................145
		CHECKS AFTER COMPLETION OF OPERATION.....................................146
		LOCKING..................................................................147
		HANDLING THE TIRES.......................................................147
	TRANSPORTATION...............................................................148
		LOADING,UNLOADIGN WORK...................................................148
		PRECAUTIONS FOR LOADING..................................................148
	COLD WEATHER OPERATION.......................................................149
		PRECAUTIONS FOR LOW TEMPERATURE..........................................149
		CAUTIONS AFTER COMPLETION OF WORK........................................150
		AFTER COLD WEATHER.......................................................150
	LONG-TERM STORAGE............................................................151
		BEFORE STORAGE...........................................................151
		DURING STORAGE...........................................................151
		AFTER STORAGE............................................................151
	TROUBLESHOOTING..............................................................152
		AFTER RUNNING OUT OF FUEL................................................152
		WHEN LEANING PIPING IS DAMAGED...........................................152
		TOWING THE MACHINE.......................................................153
		IF BATTERY IS DISCHARGED.................................................155
		OTHER TROUBLE............................................................158
MAINTENANCE......................................................................165
	GUIDES TO MAINTENANCE........................................................166
	OUTLINES OF SERVICE..........................................................168
		HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC......................168
		RELATING TO ELECTRIC SYSTEM..............................................170
	WEAR PARTS...................................................................171
		WEAR PARTS LIST..........................................................171
	USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE..........172
	STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................176
		TORQUE LIST..............................................................176
	PERIODIC REPLACEMENT OF CRITICAL PARTS.......................................177
		CRITICAL PARTS...........................................................177
	MAINTENANCE SCHEDULE CHART...................................................178
		MAINTENANCE SCHEDULE CHART...............................................178
	SERVICE PROCEDURE............................................................180
		INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)...............180
		WHEN REQUIRED............................................................181
			CLEAN INSIDE OF COOLING SYSTEM.......................................181
			CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT..........................184
			DRAIN WATER,SEDIMENT FROM WATER SEPARATOR............................187
			CHECK ELECTRICAL INTAKE AIR HEATER...................................187
			REPLACE THE CUTTING EDGES,REVERSE AND REPLACE END BIT................187
			CHECK INCHING PEDAL..................................................187
			CLEAN AIR CONDITIONER AIR FILTER.....................................188
			CHECK REFRIGERANT (GAS) LEVEL........................................189
			CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT.....................189
			SELECTION AND INSPECTION OF TIRES....................................190
		CHECK BEFORE STARTING....................................................192
		EVERY 50 HOURS SERVICE...................................................193
			LUBRICATING..........................................................193
		EVERY 250 HOURS SERVICE..................................................194
			LUBRICATING..........................................................194
			CHANGE OIL IN ENGINE OIL PAN,REPLACE ENGINE OIL FILTER CARTRIDGE.....200
			CHECK OIL LEVEL IN TRANSMISSION CASE,ADD OIL.........................201
			CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL..........................202
			CHECK OIL LEVEL IN TANDEM DRIVE CASE,ADD OIL.........................203
			CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE,ADD OIL..................203
			CHECK OIL LEVEL IN HYDRAULIC TANK,ADD OIL............................204
			CHECK LEVEL OF BATTERY ELECTROLYTE...................................205
			CHECK BALL JOINT CLEARANCE,ADJUST....................................207
			CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT.........................207
			CHECKING WHEEL RIM,LOCK RING AND SIDE RING FOR CORROSION AND WEAR....207
			CHECK FAN BELT TENSION,ADJUST........................................208
			REPLACE CORROSION RESISTOR CARTRIDGE.................................208
		EVERY 500 HOURS SERVICE..................................................209
			REPLACE FUEL FILTER/WATER SEPARATOR CARTRIDGE........................209
			CLEAN,CHECK RADIATOR FINS............................................210
			CHECK CIRCLE GUIDE CLEARANCE,ADJUST..................................210
		EVERY 1000 HOURS SERVICE.................................................213
			GREASE DRIVE SHAFT...................................................213
			REPLACE TRANSMISSION OIL FILTER CARTRIDGE............................213
			CHANGE OIL IN TRANSMISSION CASE,CLEAN STRAINER.......................214
			CHANGE OIL IN FINAL DRIVE CASE.......................................215
			REPLACE HYDRAULIC TANK FILTER ELEMENT................................215
			CHECK LOOSENESS,PLAY OF BALL JOINT AT FRONT OF DRAWBAR...............216
			CHECK TOE-IN,ADJUST..................................................216
			CHECK FRONT WHEEL BEARING PLAY,ADJUST................................217
		EVERY 2000 HOURS SERVICE.................................................218
			CHANGE OIL IN HYDRAULIC TANK.........................................218
			CHANGE OIL IN CIRCLE REVERSE GEAR CASE...............................219
			CHANGE OIL IN TANDEM DRIVE CASE......................................220
			CHECK DISC BRAKE.....................................................221
			CHECK ALTERNATOR,STARTING MOTOR......................................222
			CHECK ENGINE VALVE CLEARANCE,ADJUST..................................222
			CHECK VIBRATION DAMPER...............................................222
			CLEAN,CHECK TURBOCHARGER.............................................222
			CHECK ACCUMULATOR GAS PRESSURE.......................................222
			CHANGE GREASE IN FRONT WHEEL BEARING.................................222
		EVERY 4000 HOURS SERVICE.................................................223
			CHECK WATER PUMP.....................................................223
			CHECK AND ADJUST AIR COMPRESSOR......................................223
			CHECK FAN PULLEY.....................................................223
SPECIFICATIONS...................................................................224
	SPECIFICATIONS...............................................................225
ATTACHMENTS,OPTIONS..............................................................226
	HANDLING BLADE ACCUMULATOR ..................................................227
		FEATURES OF BLADE ACCUMULATOR............................................227
		METHOD OF OPERATING BLADE ACCUMULATOR....................................228
	CAR RADIO....................................................................229
		EXPLANATION OF COMPONENTS................................................229
		METHOD OF OPERATION......................................................232
		PRECAUTIONS FOR USE......................................................234
	AIR CONDITIONER .............................................................235
		LOCATIONS AND FUNCTIONS OF CONTROL PANEL.................................235
		METHOD OF OPERATION......................................................237
		PRECAUTIONS WHEN USING...................................................237
		TESTING AND MAINTENANCE..................................................237
INDEX............................................................................238

PLEASE NOTE:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.