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KOMATSU GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:50001 & UP) KOMATSU GD655 3C – PDF DOWNLOAD
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- KOMATSU GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:50001 & UP
- PUBLICATION NUMBER:SEAM037902T
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Description
KOMATSU GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:50001 & UP) KOMATSU GD655 3C
KOMATSU GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:50001 & UP) KOMATSU GD655 3C – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:50001 & UP) KOMATSU GD655 3C
This manual provides mles 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 mles 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 GD655-3C MOTOR GRADER OPERATION & MAINTENANCE MANUAL (SN:50001 & 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..................................... 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 MAINTENENCE.................................................. 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 USIN 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 CAR STEREO............................................................... 78 AIR CONDITIONER.......................................................... 87 OPERATION.................................................................... 90 CHECK BEFORE STARTING ENGINE............................................. 90 STARTING ENGINE..........................................................103 OPERATIONS,CHECKS AFTER STARTING ENGINE..................................106 STOPPING ENGINE..........................................................108 CHECK AFTER STOPPING ENGINE..............................................108 TRAVELING POSTURE FOR MACHINE............................................109 MOVING MACHINE OFF (FORWARD,REVERSE,SHIFTING GEAR),STOPPING..............110 TURNING MACHINE..........................................................114 OPERATING WORK EQUIPMENT.................................................117 WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER.......................123 PRECAUTIONS WHEN OPERATION...............................................144 ADJUSTING WORK EQUIPMENT POSTURE.........................................148 PARKING MACHINE..........................................................158 CHECKS AFTER COMPLETION OF OPERATION.....................................159 LOCKING..................................................................160 HANDLING THE TIRES.......................................................160 TRANSPORTATION...............................................................161 LOADING, UNLOADING WORK..................................................161 PRECAUTIONS FOR LOADING..................................................161 COLD WEATHER OPERATION.......................................................162 PRECAUTIONS FOR LOW TEMPERATURE..........................................162 CAUTIONS AFTER COMPLETION OF WORK........................................163 AFTER COLD WEATHER.......................................................163 LONG-TERM STORAGE............................................................164 BEFORE STORAGE...........................................................164 DURING STORAGE...........................................................164 AFTER STORAGE............................................................164 TROUBLESHOOTING..............................................................165 AFTER RUNNING OUT OF FUEL................................................165 WHEN LEANING PIPING IS DAMAGED...........................................165 TOWING THE MACHINE.......................................................166 IF BATTERY IS DISCHARGED.................................................168 OTHER TROUBLE............................................................171 MAINTENANCE......................................................................178 GUIDE TO MAINTENANCE.........................................................179 OUTLINE OF SERVICE...........................................................181 HANDLING OIL,FUEL,COOLANT,AND PERFORMING OIL CLINIC......................181 RELATING TO ELECTRIC SYSTEM..............................................183 WEAR PARTS...................................................................184 WEAR PARTS LIST..........................................................184 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........185 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...............................189 TORQUE LIST..............................................................189 PERIODIC REPLACEMENT OF CRITICAL PARTS.......................................190 CRITICAL PARTS...........................................................190 MAINTENANCE SCHEDULE CHART...................................................191 MAINTENANCE SCHEDULE CHART...............................................191 SERVICE PROCEDURE............................................................193 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)...............193 WHEN REQUIRED............................................................194 CLEAN INSIDE OF COOLING SYSTEM.......................................194 CHECK,CLEAN AND REPLACE AIR CLEANER ELEMENT..........................197 DRAIN WATER,SEDIMENT FROM WATER SEPARATOR............................199 CHECK ELECTRICAL INTAKE AIR HEATER...................................199 REPLACE THE CUTTING EDGES,REVERSE AND REPLACE END BIT................199 CHECK INCHING PEDAL..................................................199 CLEAN AIR CONDITIONER AIR FILTER.....................................200 CHECK REFRIGERANT (GAS) LEVEL........................................201 CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT.....................201 SELECTION AND INSPECTION OF TIRES....................................202 CHECK BEFORE STARTING....................................................204 EVERY 50 HOURS SERVICE...................................................205 LUBRICATING..........................................................205 EVERY 250 HOURS SERVICE..................................................206 LUBRICATING..........................................................206 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....211 CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL........................212 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.........................213 CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL........................214 CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE,ADD OIL..................214 CHECK OIL LEVEL IN HYDRAULIC TANK,ADD OIL............................215 CHECK LEVEL OF BATTERY ELECTROLYTE...................................216 CHECK BALL JOINT CLEARANCE,ADJUST....................................216 CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT.........................217 CHECKING WHEEL RIM,LOCK RING AND SIDE RING FOR CORROSION AND WEAR....217 CHECK FAN BELT TENSION,ADJUST........................................217 EVERY 500 HOURS SERVICE..................................................218 REPLACE FUEL FILTER/WATER SEPARATOR CARTRIDGE........................218 CLEAN,CHECK RADIATOR FINS............................................219 CHECK CIRCLE GUIDE CLEARANCE,ADJUST..................................219 EVERY 1000 HOURS SERVICE.................................................222 GREASE DRIVE SHAFT...................................................222 REPLACE TRANSMISSION OIL FILTER CARTRIDGE............................222 CHANGE OIL IN TRANSMISSION CASE,CLEAN STRAINER.......................223 CHANGE OIL IN FINAL DRIVE CASE.......................................224 REPLACE HYDRAULIC TANK FILTER ELEMENT................................224 CHECK LOOSENESS,PLAY OF BALL JOINT AT FRONT OF DRAWBAR...............225 CHECK TOE-IN,ADJUST..................................................225 REPLACE CORROSION RESISTOR CARTRIDGE.................................226 CHECK FRONT WHEEL BEARING PLAY,ADJUST................................226 EVERY 2000 HOURS SERVICE.................................................227 CHANGE OIL IN HYDRAULIC TANK.........................................227 CHANGE OIL IN CIRCLE REVERSE GEAR CASE...............................228 CHANGE OIL IN TANDEM DRIVE CASE......................................229 CHECK DISC BRAKE.....................................................230 CHECK ALTERNATOR,STARTING MOTOR......................................231 CHECK ENGINE VALVE CLEARANCE,ADJUST..................................231 CHECK VIBRATION DAMPER...............................................231 CLEAN,CHECK TURBOCHARGER.............................................231 CHECK ACCUMULATOR GAS PRESSURE.......................................231 CHANGE GREASE IN FRONT WHEEL BEARING.................................231 EVERY 4000 HOURS SERVICE.................................................232 CHECK WATER PUMP.....................................................232 CHECK AND ADJUST AIR COMPRESSOR......................................232 CHECK FAN PULLEY.....................................................232 SPECIFICATIONS...................................................................233 SPECIFICATIONS...............................................................234 ATTACHMENTS,OPTIONS..............................................................236 HANDLING BLADE ACCUMULATOR...................................................237 FEATURES OF BLADE ACCUMULATOR............................................237 METHOD OF OPERATING BLADE ACCUMULATOR....................................238 INDEX............................................................................239
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