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KOMATSU GALEO GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:51001 & up) KOMATSU GD655-3C – PDF DOWNLOAD
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- KOMATSU GALEO GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:51001 & up
- PUBLICATION NUMBER:TEN00095-01
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Description
KOMATSU GALEO GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:51001 & up) KOMATSU GD655-3C
KOMATSU GALEO GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:51001 & UP) KOMATSU GD655-3C – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GALEO GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:51001 & up) KOMATSU GD655-3C
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation and maintenance.
TABLE OF CONTENTS:
KOMATSU GALEO GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:51001 & up) KOMATSU GD655-3C
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....................................... 18 SAFETY LABELS.............................................................. 19 GENERAL PRECAUTIONS............................................................ 24 SAFETY RULES............................................................... 24 IF PROBLEMS ARE FOUND...................................................... 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS..................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT........................................ 24 SAFETY FEATURES............................................................ 24 KEEP MACHINE CLEAN......................................................... 25 INSIDE OPERATOR'S COMPARTMENT.............................................. 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT............................. 25 HANDRAILS AND STEPS........................................................ 26 MOUNTING AND DISMOUNTING................................................... 26 DO NOT GET CAUGHT IN ARTICULATED PORTION................................... 26 PREVENTION OF BURNS........................................................ 27 FIRE PREVENTION............................................................ 28 ACTION IF FIRE OCCURS...................................................... 28 WINDOW WASHER LIQUID....................................................... 29 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)............... 29 PRECAUTIONS FOR ATTACHMENTS................................................ 29 UNAUTHORIZED MODIFICATION.................................................. 29 SAFETY AT WORKSITE......................................................... 30 WORKING ON LOOSE GROUND.................................................... 30 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES..................................... 31 ENSURE GOOD VISIBILITY..................................................... 31 VENTILATION FOR ENCLOSED AREAS............................................. 31 CHECKING SIGNALMAN'S SIGNALS AND SIGNS..................................... 32 EMERGENCY ESCAPE FROM OPERATOR'S CAB....................................... 32 ASBESTOS DUST HAZARD PREVENTION............................................ 32 PRECAUTIONS DURING OPERATION................................................... 33 STARTING ENGINE............................................................ 33 CHECKS BEFORE STARTING ENGINE, ADJUST.................................. 33 PRECAUTIONS WHEN STARTING.............................................. 33 PRECAUTIONS IN COLD AREAS.............................................. 34 OPERATION.................................................................. 35 CHECKS BEFORE STARTING OPERATION....................................... 35 PRECAUTIONS BEFORE MOVING OFF.......................................... 35 PRECAUTIONS WHEN TRAVELING............................................. 36 PRECAUTIONS WHEN TRAVELING ON SLOPES................................... 37 PRECAUTIONS WHEN OPERATIONS ON SLOPES.................................. 37 PROHIBITED OPERATIONS.................................................. 37 PRECAUTIONS WHEN OPERATING............................................. 37 OPERATE CAREFULLY ON SNOW.............................................. 38 PARKING MACHINE........................................................ 38 TRANSPORTATION............................................................. 39 LOADING AND UNLOADING.................................................. 39 SHIPPING............................................................... 39 BATTERY.................................................................... 40 BATTERY HAZARD PREVENTION.............................................. 40 STARTING WITH BOOSTER CABLES........................................... 41 TOWING..................................................................... 42 WHEN TOWING............................................................ 42 PRECAUTIONS FOR MAINTENANCE.................................................... 43 WARNING TAG................................................................ 43 KEEP WORK PLACE CLEAN AND TIDY............................................. 43 APPOINT LEADER WHEN WORKING WITH OTHERS.................................... 43 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE................. 44 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING......................... 45 PROPER TOOLS............................................................... 45 ACCUMULATOR................................................................ 46 PERSONNEL.................................................................. 46 ATTACHMENTS................................................................ 46 WORK UNDER THE MACHINE..................................................... 46 NOISE...................................................................... 46 PRECAUTIONS WHEN USING HAMMER.............................................. 47 REPAIR WELDING............................................................. 47 REMOVING BATTERY TERMINAL.................................................. 47 PRECAUTIONS WITH HIGH-PRESSURE OIL......................................... 47 PRECAUTIONS WITH HIGH-PRESSURE FUEL........................................ 47 HANDLING HIGH-PRESSURE HOSES............................................... 48 WASTE MATERIALS............................................................ 48 MAINTENANCE OF AIR CONDITIONER............................................. 48 COMPRESSED AIR............................................................. 48 PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS.............................. 48 PRECAUTIONS WITH TIRES......................................................... 49 HANDLING TIRES............................................................. 49 PRECAUTIONS WHEN STORING TIRE.............................................. 49 OPERATION.......................................................................... 50 GENERAL VIEW................................................................... 51 GENERAL VIEW OF MACHINE.................................................... 51 GENERAL VIEW OF CONTROLS AND GAUGES........................................ 52 EXPLANATION OF COMPONENTS...................................................... 55 METERS AND LAMPS........................................................... 55 SWITCHES................................................................... 62 CONTROL LEVERS, PEDALS..................................................... 73 DUST INDICATOR............................................................. 82 ARTICULATE LOCK PIN........................................................ 82 FUSE BOX................................................................... 82 OPERATION...................................................................... 84 CHECK BEFORE STARTING ENGINE............................................... 84 STARTING ENGINE............................................................ 96 OPERATIONS, CHECKS AFTER STARTING ENGINE...................................100 STOPPING ENGINE............................................................102 CHECK AFTER STOPPING ENGINE................................................102 TRAVELING POSTURE FOR MACHINE..............................................103 MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING.............104 TURNING MACHINE............................................................108 OPERATING WORK EQUIPMENT...................................................111 WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER.........................117 PRECAUTIONS WHEN OPERATION.................................................138 ADJUSTING WORK EQUIPMENT POSTURE...........................................142 PARKING MACHINE............................................................152 CHECKS AFTER COMPLETION OF OPERATION.......................................153 LOCKING....................................................................154 HANDLING THE TIRES.........................................................154 TRANSPORTATION.................................................................155 LOADING, UNLOADING WORK....................................................155 PRECAUTIONS FOR LOADING....................................................156 COLD WEATHER OPERATION.........................................................157 PRECAUTIONS FOR LOW TEMPERATURE............................................157 CAUTIONS AFTER COMPLETION OF WORK..........................................158 AFTER COLD WEATHER.........................................................158 LONG-TERM STORAGE..............................................................159 BEFORE STORAGE.............................................................159 DURING STORAGE.............................................................159 AFTER STORAGE..............................................................159 TROUBLESHOOTING................................................................160 AFTER RUNNING OUT OF FUEL..................................................160 WHEN LEANING PIPING IS DAMAGED.............................................161 TOWING THE MACHINE.........................................................162 IF BATTERY IS DISCHARGED...................................................164 OTHER TROUBLE..............................................................167 MAINTENANCE........................................................................174 GUIDES TO MAINTENANCE..........................................................175 OUTLINES OF SERVICE............................................................177 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.....................177 RELATING TO ELECTRIC SYSTEM................................................180 WEAR PARTS.....................................................................181 WEAR PARTS LIST............................................................181 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...........182 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.................................186 TORQUE LIST................................................................186 PERIODIC REPLACEMENT OF CRITICAL PARTS.........................................188 CRITICAL PARTS.............................................................188 MAINTENANCE SCHEDULE CHART.....................................................189 MAINTENANCE SCHEDULE CHART.................................................189 SERVICE PROCEDURE..............................................................191 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS).................191 WHEN REQUIRED..............................................................192 CLEAN INSIDE OF COOLING SYSTEM.........................................192 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...........................195 CLEAN, CHECK WATER SEPARATOR...........................................199 CHECK ELECTRICAL INTAKE AIR HEATER.....................................200 REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT.................200 CHECK INCHING PEDAL....................................................200 CLEAN AIR CONDITIONER AIR FILTER.......................................201 CHECK REFRIGERANT (GAS) LEVEL..........................................202 CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT.......................202 SELECTION AND INSPECTION OF TIRES......................................203 CHECK BEFORE STARTING......................................................205 EVERY 50 HOURS SERVICE.....................................................206 LUBRICATING............................................................206 EVERY 250 HOURS SERVICE....................................................207 LUBRICATING............................................................207 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......213 CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL..........................214 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...........................215 CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL..........................216 CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL...................216 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.............................217 CHECK LEVEL OF BATTERY ELECTROLYTE.....................................218 CHECK BALL JOINT CLEARANCE, ADJUST.....................................220 CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT...........................220 CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION AND WEAR.....220 CHECK FAN BELT TENSION, ADJUST.........................................221 EVERY 500 HOURS SERVICE....................................................222 REPLACE FUEL FILTER CARTRIDGE..........................................222 CLEAN, CHECK RADIATOR FINS.............................................224 CHECK CIRCLE GUIDE CLEARANCE, ADJUST...................................225 EVERY 1000 HOURS SERVICE...................................................228 LUBRICATING............................................................228 REPLACE TRANSMISSION OIL FILTER CARTRIDGE..............................229 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER........................230 CHANGE OIL IN FINAL DRIVE CASE.........................................231 REPLACE HYDRAULIC TANK FILTER ELEMENT..................................231 CHECK LOOSENESS, PLAY OF BALL JOINT AT FRONT OF DRAWBAR................232 CHECK TOE-IN, ADJUST...................................................233 CHECK FRONT WHEEL BEARING PLAY, ADJUST.................................234 REPLACE CORROSION RESISTOR CARTRIDGE...................................235 EVERY 2000 HOURS SERVICE...................................................236 CHANGE OIL IN HYDRAULIC TANK...........................................236 CHANGE OIL IN CIRCLE REVERSE GEAR CASE.................................237 CHANGE OIL IN TANDEM DRIVE CASE........................................238 CHECK DISC BRAKE.......................................................239 CHECK ALTERNATOR, STARTING MOTOR.......................................241 CHECK ENGINE VALVE CLEARANCE, ADJUST...................................241 CHECK VIBRATION DAMPER.................................................241 CLEAN, CHECK TURBOCHARGER..............................................241 CHECK ACCUMULATOR GAS PRESSURE.........................................241 CHANGE GREASE IN FRONT WHEEL BEARING...................................241 EVERY 4000 HOURS SERVICE...................................................242 CHECK WATER PUMP.......................................................242 CHECK AND ADJUST AIR COMPRESSOR........................................242 CHECK FAN PULLEY.......................................................242 CHECK INJECTOR.........................................................242 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.....242 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER....243 EVERY 8000 HOURS SERVICE...................................................244 REPLACE INJECTOR NOZZLE TIP............................................244 REPLACE HIGH-PRESSURE PIPING CLAMP.....................................244 REPLACE FUEL SPRAY PREVENTION CAP......................................244 SPECIFICATIONS.....................................................................245 SPECIFICATIONS.................................................................246 ATTACHMENTS, OPTIONS...............................................................248 HANDLING BLADE ACCUMULATOR.....................................................249 FEATURES OF BLADE ACCUMULATOR..............................................249 METHOD OF OPERATING BLADE ACCUMULATOR......................................250 AM/FM RADIO-CASSETTE STEREO....................................................251 EXPLANATION OF COMPONENTS..................................................251 METHOD OF OPERATION........................................................256 PRECAUTIONS WHEN USING.....................................................259 AIR CONDITIONER................................................................260 LOCATIONS AND FUNCTIONS OF CONTROL PANEL...................................260 METHOD OF OPERATION........................................................262 PRECAUTIONS WHEN USING.....................................................262 TESTING AND MAINTENANCE....................................................262 HANDLING AIR-SUSPENSION SEAT...................................................263 ADJUST OPERATOR'S SEAT.....................................................263 HANDLING MACHINES EQUIPPED WITH KOMTRAX........................................265 BASIC PRECAUTIONS..........................................................265 INDEX..............................................................................266
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⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
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