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Komatsu GD825A-2 Motor Grader Operation & Maintenance Manual SN 12116 and up – PDF DOWNLOAD
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Komatsu GD825A-2 Motor Grader Operation & Maintenance Manual
Book Code : TEN00012-00
MACHINE MODEL SERIAL NUMBER
GD825A-2 12116 and up
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Description
Komatsu GD825A-2 Motor Grader Operation & Maintenance Manual
FILE DETAILS:
Komatsu GD825A-2 Motor Grader Operation & Maintenance Manual
Size : 5.14 MB
Format : PDF
Language : English
Number of Pages : 267 Pages
Brand: Komatsu
Type of machine: Motor Grader
Type of document: Operation & Maintenance Manual
Model: GD825-2
Serial: 12116 and up
KOMATSU GD825A-2 MOTOR GRADER OPERATION & MAINTENANCE MANUAL SN 12116 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu GD825A-2 Motor Grader Operation & Maintenance Manual
FOREWORD:
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 forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu GD825A-2 Motor Grader Operation & Maintenance Manual
MAIN MENU................................................................................. 0 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..................................... 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...................... 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................................................................... 25 SAFETY RULES...................................................................... 25 IF ABNORMALITIES ARE FOUND........................................................ 25 CLOTHING AND PERSONAL PROTECTIVE ITEMS............................................ 25 FIRE EXTINGUISHER AND FIRST AID KIT............................................... 25 SAFETY FEATURES................................................................... 25 KEEP MACHINE CLEAN................................................................ 26 INSIDE OPERATOR'S COMPARTMENT..................................................... 26 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.................................... 26 HANDRAILS AND STEPS............................................................... 27 MOUNTING AND DISMOUNTING.......................................................... 27 DO NOT GET CAUGHT IN ARTICULATED PORTION.......................................... 28 PREVENTION OF BURNS............................................................... 28 FIRE PREVENTION................................................................... 29 ACTION IF FIRE OCCURS............................................................. 29 WINDOW WASHER LIQUID.............................................................. 30 PRECAUTIONS WHEN USING ROPS (Roll Over Protective Structure)...................... 30 PRECAUTIONS FOR ATTACHMENTS....................................................... 30 UNAUTHORIZED MODIFICATION......................................................... 30 SAFETY AT WORKSITE................................................................ 31 WORKING ON LOOSE GROUND........................................................... 31 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES............................................ 31 ENSURE GOOD VISIBILITY............................................................ 32 VENTILATION FOR ENCLOSED AREAS.................................................... 32 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 PROHIBITED TO DISASSEMBLE BANK CONTROL LOCK PIN................................... 47 PRECAUTIONS WITH HIGH-PRESSURE OIL................................................ 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 OPERATIONS................................................................................ 50 GENERAL VIEW.......................................................................... 51 GENERAL VIEW OF MACHINE........................................................... 51 GENERAL VIEW OF CONTROLS AND GAUGES............................................... 52 EXPLANATION OF COMPONENTS............................................................. 55 MONITOR PANEL..................................................................... 55 METERS AND LAMPS.................................................................. 68 SWITCHES.......................................................................... 69 CONTROL LEVERS, PEDALS............................................................ 78 DUST INDICATOR.................................................................... 87 ARTICULATE LOCK PIN............................................................... 87 FUSE BOX.......................................................................... 88 OPERATOR'S CAB LIFT MECHANISM..................................................... 89 BACKUP ALARM...................................................................... 89 FRONT GLASS....................................................................... 90 TOOL BAG.......................................................................... 91 STORAGE BOX....................................................................... 91 QUICK-FILL FUEL FILLER............................................................ 91 OPERATION............................................................................. 92 CHECK BEFORE STARTING ENGINE...................................................... 92 STARTING ENGINE...................................................................107 OPERATIONS, CHECKS AFTER STARTING ENGINE..........................................110 STOPPING ENGINE...................................................................112 CHECK AFTER STOPPING ENGINE.......................................................112 TRAVELING POSTURE FOR MACHINE.....................................................113 MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING....................114 TURNING MACHINE...................................................................120 OPERATING WORK EQUIPMENT..........................................................122 WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER................................127 PRECAUTIONS WHEN OPERATION........................................................155 ADJUSTING WORK EQUIPMENT POSTURE..................................................159 PARKING MACHINE...................................................................160 CHECKS AFTER COMPLETION OF OPERATION..............................................162 LOCKING...........................................................................162 HANDLING THE TIRES................................................................163 HANDLING BLADE ACCUMULATOR........................................................164 HANDLING BLADE FLOAT..............................................................166 TRANSPORTATION........................................................................168 LOADING, UNLOADING WORK...........................................................168 PRECAUTIONS FOR LOADING...........................................................169 COLD WEATHER OPERATION................................................................170 PRECAUTIONS FOR LOW TEMPERATURE...................................................170 CAUTIONS AFTER COMPLETION OF WORK.................................................171 AFTER COLD WEATHER................................................................171 LONG-TERM STORAGE.....................................................................172 BEFORE STORAGE....................................................................172 DURING STORAGE....................................................................172 AFTER STORAGE.....................................................................172 TROUBLESHOOTING.......................................................................173 AFTER RUNNING OUT OF FUEL.........................................................173 WHEN LEANING PIPING IS DAMAGED....................................................173 TOWING THE MACHINE................................................................174 IF BATTERY IS DISCHARGED..........................................................177 OTHER TROUBLE.....................................................................180 TRANSMISSION CONTROLLER...........................................................185 MAINTENANCE...............................................................................190 GUIDES TO MAINTENANCE.................................................................191 OUTLINES OF SERVICE...................................................................193 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC............................193 RELATING TO ELECTRIC SYSTEM.......................................................195 WEAR PARTS............................................................................196 WEAR PARTS LIST...................................................................196 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO......................................197 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS........................................201 TORQUE LIST.......................................................................201 PERIODIC REPLACEMENT OF CRITICAL PARTS................................................202 CRITICAL PARTS....................................................................202 MAINTENANCE SCHEDULE CHART............................................................203 MAINTENANCE SCHEDULE CHART........................................................203 SERVICE PROCEDURE.....................................................................205 INITIAL 250 HOURS SERVICE (only after the first 250 hours)........................205 REPLACE FUEL FILTER CARTRIDGE.................................................230 CHANGE OIL IN TRANSMISSION CASE...............................................240 CHANGE OIL IN FINAL DRIVE CASE................................................241 CHANGE OIL IN CIRCLE REVERSE GEAR CASE........................................247 CHANGE OIL IN HYDRAULIC TANK..................................................243 REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK....242 CHANGE OIL IN TANDEM DRIVE CASE...............................................248 CHECK CIRCLE GUIDE CLEARANCE, ADJUST..........................................232 CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR...........236 CHECK ENGINE VALVE CLEARANCE, ADJUST..........................................250 WHEN REQUIRED.....................................................................206 CLEAN INSIDE OF COOLING SYSTEM................................................206 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT..................................208 CHECK ELECTRICAL INTAKE AIR HEATER............................................210 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES............................210 REPLACING RIPPER POINT........................................................211 CHECK INCHING PEDAL...........................................................211 CLEAN ELEMENT OF AIR CONDITIONER FRESH AIR FILTER.............................211 CLEAN ELEMENT OF AIR CONDITIONER RECIRCULATION AIR FILTER.....................212 CHECK REFRIGERANT (GAS) LEVEL.................................................213 SELECTION AND INSPECTION OF TIRES.............................................213 INSPECTING CORROSION, WEAR OF WHEEL RIM, LOCK RING, SIDE RING.................214 CHECK BEFORE STARTING.............................................................215 EVERY 50 HOURS SERVICE............................................................216 LUBRICATING...................................................................216 INSPECT WEAR OF BLADE GUIDE...................................................216 EVERY 250 HOURS SERVICE...........................................................217 LUBRICATING...................................................................217 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.............219 CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL.................................220 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL..................................221 CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL.................................221 CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL..........................222 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....................................222 CHECK LEVEL OF BATTERY ELECTROLYTE............................................223 CHECK BALL JOINT CLEARANCE, ADJUST............................................225 CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT..................................225 CHECK FAN BELT TENSION, ADJUST................................................226 CHECK ALTERNATOR BELT TENSION, ADJUST.........................................227 CHECK AIR CONDITIONER BELT TENSION, ADJUST....................................228 CHECK, ADJUST FOOT BRAKE......................................................229 EVERY 500 HOURS SERVICE...........................................................230 REPLACE FUEL FILTER CARTRIDGE.................................................230 CLEAN, CHECK RADIATOR FINS....................................................231 CHECK CIRCLE GUIDE CLEARANCE, ADJUST..........................................232 CHECK PARKING BRAKE LEVEL STROKE, ADJUST......................................235 CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR...........236 EVERY 1000 HOURS SERVICE..........................................................238 GREASE DRIVE SHAFT............................................................238 GREASE FAN PULLEY AND TENSION PULLEY..........................................238 REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................239 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...............................240 CHANGE OIL IN FINAL DRIVE CASE, CLEAN STRAINER................................241 REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK....242 CHANGE OIL IN HYDRAULIC TANK..................................................243 CHECK LOOSENESS IN DRAWBAR FRONT BALL JOINT AND BALL STUD.....................244 CHECK TOE-IN, ADJUST..........................................................244 CHECK FRONT WHEEL BEARING PLAY, ADJUST........................................245 REPLACE CORROSION RESISTOR CARTRIDGE..........................................246 CHECK FOR LOOSE ROPS MOUNT BOLTS..............................................246 REPLACING AIR DRYER DESICCANT.................................................246 EVERY 2000 HOURS SERVICE..........................................................247 CHANGE OIL IN FRONT WHEEL BEARING.............................................247 CHANGE OIL IN CIRCLE REVERSE GEAR CASE........................................247 CHANGE OIL IN TANDEM DRIVE CASE...............................................248 CLEAN ENGINE BREATHER ELEMENT.................................................248 CLEAN BREATHER................................................................249 CLEAN AND INSPECT INCHING POTENTIOMETER SENSOR................................250 CHECK ALTERNATOR, STARTING MOTOR..............................................250 CHECK ENGINE VALVE CLEARANCE, ADJUST..........................................250 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER....................................250 CHECK PLAY OF TURBOCHARGER ROTOR..............................................250 CLEAN, CHECK TURBOCHARGER.....................................................250 EVERY 4000 HOURS SERVICE..........................................................251 CHECK WATER PUMP..............................................................251 CHECK VIBRATION DAMPER........................................................251 CHECK FAN PULLEY AND TENSION PULLEY...........................................251 SPECIFICATIONS............................................................................252 SPECIFICATIONS........................................................................253 ATTACHMENTS, OPTIONS......................................................................256 HANDLING EMERGENCY STEERING DEVICE....................................................257 CHECKING..........................................................................257 AIR CONDITIONER.......................................................................258 LOCATIONS AND FUNCTIONS OF CONTROL PANEL..........................................258 METHOD OF OPERATION...............................................................260 PRECAUTIONS WHEN USING............................................................260 HANDLING AIR-SUSPENSION SEAT..........................................................261 ADJUST OPERATOR'S SEAT............................................................261 INDEX.....................................................................................264
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