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KOMATSU GD555-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:50001 & UP) KOMATSU GD555-3C – PDF DOWNLOAD
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- KOMATSU GD555-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:50001 & UP
- PUBLICATION NUMBER:SEAM038102T
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KOMATSU GD555-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:50001 & UP) KOMATSU GD555-3C
KOMATSU GD555-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:50001 & UP) KOMATSU GD555-3C – PDF DOWNLOAD:
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KOMATSU GD555-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:50001 & UP) KOMATSU GD555-3C
- Operators and maintenance personnel must always do as follows before beginning operation or maintenance. Always be sure to read and understand this manual thoroughly before performing operation and maintenance. Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully.
- Keep this manual at the storage location for the Operation and Maintenance Manual given below, and have all personnel read it periodically. If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu or your Komatsu distributor. If you sell the machine, be sure to give this manual to the new owners together with the machine.
- Komatsu delivers machines that comply with all applicable regulations and standards ofthe country to which it has been shipped. If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before operating the machine.
TABLE OF CONTENTS:
KOMATSU GD555-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:50001 & UP) KOMATSU GD555-3C
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..................................... 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................................................................ 33 CHECKS BEFORE STARTING OPERATION..................................... 33 PRECAUTIONS BEFORE MOVING OFF........................................ 33 PRECAUTIONS WHEN TRAVELING........................................... 33 PRECAUTIONS WHEN TRAVELING ON SLOPES................................. 34 PRECAUTIONS WHEN OPERATIONS ON SLOPES................................ 35 PROHIBITED OPERATIONS................................................ 35 PRECAUTIONS WHEN OPERATING........................................... 35 OPERATE CAREFULLY ON SNOW............................................ 35 PARKING MACHINE...................................................... 36 TRANSPORTATION........................................................... 37 LOADING AND UNLOADING................................................ 37 SHIPPING............................................................. 37 BATTERY.................................................................. 38 BATTERY HAZARD PREVENTION............................................ 38 STARTING WITH BOOSTER CABLES......................................... 39 TOWING................................................................... 40 WHEN TOWING.......................................................... 40 PRECAUTIONS FOR MAINTENENCE.................................................. 41 WARNING TAG.............................................................. 41 KEEP WORK PLACE CLEAN AND TIDY........................................... 41 APPOINT LEADER WHEN WORKING WITH OTHERS.................................. 41 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE............... 42 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING....................... 43 PROPER TOOLS............................................................. 43 ACCUMULATOR.............................................................. 44 PERSONNEL................................................................ 44 ATTACHMENTS.............................................................. 44 WORK UNDER THE MACHINE................................................... 44 NOISE.................................................................... 44 PRECAUTIONS WHEN USING HAMMER............................................ 45 REPAIR WELDING........................................................... 45 REMOVING BATTERY TERMINAL................................................ 45 PRECAUTIONS WITH HIGH-PRESSURE OIL....................................... 45 HANDLING HIGH-PRESSURE HOSES............................................. 46 WASTE MATERIALS.......................................................... 46 MAINTENANCE OF AIR CONDITIONER........................................... 46 COMPRESSED AIR........................................................... 46 PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS............................ 46 PRECAUTIONS WITH TIRES....................................................... 47 HANDLING TIRES........................................................... 47 PRECAUTIONS WHEN STORING TIRE............................................ 47 OPERATION........................................................................ 48 GENERAL VIEW................................................................. 49 GENERAL VIEW OF MACHINE.................................................. 49 GENERAL VIEW OF CONTROLS AND GAUGES...................................... 50 EXPLANATION OF COMPONENTS.................................................... 52 METERS AND LAMPS......................................................... 52 SWITCHES................................................................. 59 CONTROL LEVERS,PEDALS.................................................... 68 DUST INDICATOR........................................................... 77 ARTICULATE LOCK PIN...................................................... 77 FUSE BOX................................................................. 77 CAR STEREO............................................................... 79 AIR CONDITIONER.......................................................... 88 OPERATION.................................................................... 91 CHECK BEFORE STARTING ENGINE............................................. 91 STARTING ENGINE..........................................................104 OPERATIONS,CHECKS AFTER STARTING ENGINE..................................107 STOPPING ENGINE..........................................................109 CHECK AFTER STOPPING ENGINE..............................................109 TRAVELING POSTURE FOR MACHINE............................................110 MOVING MACHINE OFF (FORWARD,REVERSE,SHIFTING GEAR),STOPPING..............111 TURNING MACHINE..........................................................115 OPERATING WORK EQUIPMENT.................................................118 WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER.......................124 PRECAUTIONS WHEN OPERATION...............................................145 ADJUSTING WORK EQUIPMENT POSTURE.........................................149 PARKING MACHINE..........................................................160 CHECKS AFTER COMPLETION OF OPERATION.....................................161 LOCKING..................................................................162 HANDLING THE TIRES.......................................................162 TRANSPORTATION...............................................................163 LOADING, UNLOADING WORK..................................................163 PRECAUTIONS FOR LOADING..................................................163 COLD WEATHER OPERATION.......................................................164 PRECAUTIONS FOR LOW TEMPERATURE..........................................164 CAUTIONS AFTER COMPLETION OF WORK........................................165 AFTER COLD WEATHER.......................................................165 LONG-TERM STORAGE............................................................166 BEFORE STORAGE...........................................................166 DURING STORAGE...........................................................166 AFTER STORAGE............................................................166 TROUBLESHOOTING..............................................................167 AFTER RUNNING OUT OF FUEL................................................167 WHEN LEANING PIPING IS DAMAGED...........................................167 TOWING THE MACHINE.......................................................168 IF BATTERY IS DISCHARGED.................................................170 OTHER TROUBLE............................................................173 MAINTENANCE......................................................................180 GUIDE TO MAINTENANCE.........................................................181 OUTLINES OF SERVICE..........................................................183 HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC......................183 RELATING TO ELECTRIC SYSTEM..............................................185 WEAR PARTS...................................................................186 WEAR PARTS LIST..........................................................186 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........187 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................191 TORQUE LIST..............................................................191 PERIODIC REPLACEMENT OF CRITICAL PARTS.......................................192 CRITICAL PARTS...........................................................192 MAINTENANCE SCHEDULE CHART...................................................193 MAINTENANCE SCHEDULE CHART...............................................193 SERVICE PROCEDURE............................................................195 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)...............195 WHEN REQUIRED............................................................196 CLEAN INSIDE OF COOLING SYSTEM.......................................196 CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT..........................199 DRAIN WATER,SEDIMENT FROM WATER SEPARATOR............................201 CHECK ELECTRICAL INTAKE AIR HEATER...................................201 REPLACE THE CUTTING EDGES,REVERSE AND REPLACE END BIT................201 CHECK INCHING PEDAL..................................................201 CLEAN AIR CONDITIONER AIR FILTER.....................................202 CHECK REFRIGERANT (GAS) LEVEL........................................203 CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT.....................203 SELECTION AND INSPECTION OF TIRES....................................204 CHECK BEFORE STARTING....................................................206 EVERY 50 HOURS SERVICE...................................................207 LUBRICATING..........................................................207 EVERY 250 HOURS SERVICE..................................................208 LUBRICATING..........................................................208 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....214 CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL........................215 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.........................216 CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL........................217 CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE,ADD OIL..................217 CHECK OIL LEVEL IN HYDRAULIC TANK,ADD OIL............................218 CHECK LEVEL OF BATTERY ELECTROLYTE...................................219 CHECK BALL JOINT CLEARANCE,ADJUST....................................221 CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT.........................221 CHECKING WHEEL RIM,LOCK RING AND SIDE RING FOR CORROSION AND WEAR....221 CHECK FAN BELT TENSION,ADJUST........................................222 EVERY 500 HOURS SERVICE..................................................223 REPLACE FUEL FILTER/WATER SEPARATOR CARTRIDGE........................223 CLEAN,CHECK RADIATOR FINS............................................224 CHECK CIRCLE GUIDE CLEARANCE,ADJUST..................................224 EVERY 1000 HOURS SERVICE.................................................227 GREASE DRIVE SHAFT...................................................227 REPLACE TRANSMISSION OIL FILTER CARTRIDGE............................227 CHANGE OIL IN TRANSMISSION CASE,CLEAN STRAINER.......................228 CHANGE OIL IN FINAL DRIVE CASE.......................................229 REPLACE HYDRAULIC TANK FILTER ELEMENT................................229 CHECK LOOSENESS,PLAY OF BALL JOINT AT FRONT OF DRAWBAR...............230 CHECK TOE-IN,ADJUST..................................................230 CHECK FRONT WHEEL BEARING PLAY,ADJUST................................231 EVERY 2000 HOURS SERVICE.................................................232 CHANGE OIL IN HYDRAULIC TANK.........................................232 CHANGE OIL IN CIRCLE REVERSE GEAR CASE...............................233 CHANGE OIL IN TANDEM DRIVE CASE......................................234 CHECK DISC BRAKE.....................................................235 CHECK ALTERNATOR,STARTING MOTOR......................................236 CHECK ENGINE VALVE CLEARANCE,ADJUST..................................236 CHECK VIBRATION DAMPER...............................................236 CLEAN,CHECK TURBOCHARGER.............................................236 CHECK ACCUMULATOR GAS PRESSURE.......................................236 CHANGE GREASE IN FRONT WHEEL BEARING.................................236 EVERY 4000 HOURS SERVICE.................................................237 CHECK WATER PUMP.....................................................237 CHECK AND ADJUST AIR COMPRESSOR......................................237 CHECK FAN PULLEY.....................................................237 SPECIFICATIONS...................................................................238 SPECIFICATIONS...............................................................239 ATTACHMENTS,OPTIONS..............................................................241 HANDLING BLADE ACCUMULATOR...................................................242 FEATURES OF BLADE ACCUMULATOR............................................242 METHOD OF OPERATING BLADE ACCUMULATOR....................................243 INDEX............................................................................244
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