Komatsu GD555-3A Motor Grader Operation & Maintenance Manual (11001 and up) - PEN00178-01

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the GD555-3A Komatsu Motor Grader (SN: 11001 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu GD555-3A Motor Grader
Serial Numbers : 11001 and up


TABLE OF CONTENTS :

- FOREWORD
- CONTENTS
- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- ATTACHMENTS, OPTIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : PEN00178-01
Total Pages : 269


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COVER
FOREWORD
FOREWORD
SAFETY INFORMATION
INTENDED USE
DIRECTIONS OF MACHINE
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
MACHINE SERIAL NO. PLATE POSITION
ENGINE SERIAL NO. PLATE POSITION
SERVICE METER POSITION
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
CONTENTS

SAFETY
SAFETY INFORMATION
SAFETY LABELS
POSITION FOR ATTACHING SAFETY LABELS
SAFETY LABELS
GENERAL PRECAUTIONS
SAFETY RULES
IF PROBLEMS ARE FOUND
CLOTHING AND PERSONAL PROTECTIVE ITEMS
FIRE EXTINGUISHER AND FIRST AID KIT
SAFETY FEATURES
KEEP MACHINE CLEAN
INSIDE OPERATOR'S COMPARTMENT
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT
HANDRAILS AND STEPS
MOUNTING AND DISMOUNTING
DO NOT GET CAUGHT IN ARTICULATED PORTION
PREVENTION OF BURNS
FIRE PREVENTION
ACTION IF FIRE OCCURS
WINDOW WASHER LIQUID
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)
PRECAUTIONS FOR ATTACHMENTS
UNAUTHORIZED MODIFICATION
SAFETY AT WORKSITE
WORKING ON LOOSE GROUND
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES
ENSURE GOOD VISIBILITY
VENTILATION FOR ENCLOSED AREAS
CHECKING SIGNALMAN'S SIGNALS AND SIGNS
EMERGENCY ESCAPE FROM OPERATOR'S CAB
ASBESTOS DUST HAZARD PREVENTION
PRECAUTIONS DURING OPERATION
STARTING ENGINE
CHECKS BEFORE STARTING ENGINE, ADJUST
PRECAUTIONS WHEN STARTING
PRECAUTIONS IN COLD AREAS
OPERATION
CHECKS BEFORE STARTING OPERATION
PRECAUTIONS BEFORE MOVING OFF
PRECAUTIONS WHEN TRAVELING
PRECAUTIONS WHEN TRAVELING ON SLOPES
PRECAUTIONS WHEN OPERATIONS ON SLOPES
PROHIBITED OPERATIONS
PRECAUTIONS WHEN OPERATING
OPERATE CAREFULLY ON SNOW
PARKING MACHINE
TRANSPORTATION
LOADING AND UNLOADING
SHIPPING
BATTERY
BATTERY HAZARD PREVENTION
STARTING WITH BOOSTER CABLES
TOWING
WHEN TOWING
PRECAUTIONS FOR MAINTENANCE
WARNING TAG
KEEP WORK PLACE CLEAN AND TIDY
APPOINT LEADER WHEN WORKING WITH OTHERS
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING
PROPER TOOLS
ACCUMULATOR
PERSONNEL
ATTACHMENTS
WORK UNDER THE MACHINE
NOISE
PRECAUTIONS WHEN USING HAMMER
REPAIR WELDING
REMOVING BATTERY TERMINAL
PRECAUTIONS WITH HIGH-PRESSURE OIL
HANDLING HIGH-PRESSURE HOSES
WASTE MATERIALS
MAINTENANCE OF AIR CONDITIONER
COMPRESSED AIR
PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS
PRECAUTIONS WITH TIRES
HANDLING TIRES
PRECAUTIONS WHEN STORING TIRE

OPERATION
GENERAL VIEW
GENERAL VIEW OF MACHINE
GENERAL VIEW OF CONTROLS AND GAUGES
EXPLANATION OF COMPONENTS
METERS AND LAMPS
SWITCHES
CONTROL LEVERS, PEDALS
DUST INDICATOR
ARTICULATE LOCK PIN
FUSE BOX
OPERATION
CHECK BEFORE STARTING ENGINE
STARTING ENGINE
OPERATIONS, CHECKS AFTER STARTING ENGINE
STOPPING ENGINE
CHECK AFTER STOPPING ENGINE
TRAVELING POSTURE FOR MACHINE
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING
TURNING MACHINE
OPERATING WORK EQUIPMENT
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER
PRECAUTIONS WHEN OPERATION
ADJUSTING WORK EQUIPMENT POSTURE
PARKING MACHINE
CHECKS AFTER COMPLETION OF OPERATION
LOCKING
HANDLING THE TIRES
TRANSPORTATION
LOADING, UNLOADING WORK
PRECAUTIONS FOR LOADING
COLD WEATHER OPERATION
PRECAUTIONS FOR LOW TEMPERATURE
CAUTIONS AFTER COMPLETION OF WORK
AFTER COLD WEATHER
LONG-TERM STORAGE
BEFORE STORAGE
DURING STORAGE
AFTER STORAGE
TROUBLESHOOTING
AFTER RUNNING OUT OF FUEL
WHEN LEANING PIPING IS DAMAGED
TOWING THE MACHINE
IF BATTERY IS DISCHARGED
OTHER TROUBLE

MAINTENANCE
INDEX
GUIDES TO MAINTENANCE
OUTLINES OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
RELATING TO ELECTRIC SYSTEM
WEAR PARTS
WEAR PARTS LIST
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
TORQUE LIST
PERIODIC REPLACEMENT OF CRITICAL PARTS
CRITICAL PARTS
MAINTENANCE SCHEDULE CHART
MAINTENANCE SCHEDULE CHART
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURES)
WHEN REQUIRED
CLEAN INSIDE OF COOLING SYSTEM
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
CLEAN, CHECK WATER SEPARATOR
CHECK ELECTRICAL INTAKE AIR HEATER
REPLACE THE CUTTING EDGES, REVERSE AND REPLACE END BIT
CHECK INCHING PEDAL
CLEAN AIR CONDITIONER AIR FILTER
CHECK REFRIGERANT (GAS) LEVEL
CHECK TENSION OF AIR CONDITIONER COMPRESSOR BELT
SELECTION AND INSPECTION OF TIRES
CHECK BEFORE STARTING
EVERY 50 HOURS SERVICE
LUBRICATING
EVERY 250 HOURS SERVICE
LUBRICATING
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL
CHECK OIL LEVEL IN CIRCLE REVERSE GEAR CASE, ADD OIL
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
CHECK LEVEL OF BATTERY ELECTROLYTE
CHECK BALL JOINT CLEARANCE, ADJUST
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT
CHECKING WHEEL RIM, LOCK RING AND SIDE RING FOR CORROSION AND WEAR
CHECK FAN BELT TENSION, ADJUST
EVERY 500 HOURS SERVICE
REPLACE FUEL FILTER CARTRIDGE
CLEAN, CHECK RADIATOR FINS
CHECK CIRCLE GUIDE CLEARANCE, ADJUST
EVERY 1000 HOURS SERVICE
LUBRICATING
REPLACE TRANSMISSION OIL FILTER CARTRIDGE
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER
CHANGE OIL IN FINAL DRIVE CASE
REPLACE HYDRAULIC TANK FILTER ELEMENT
CHECK LOOSENESS, PLAY OF BALL JOINT AT FRONT OF DRAWBAR
CHECK TOE-IN, ADJUST
CHECK FRONT WHEEL BEARING PLAY, ADJUST
REPLACE CORROSION RESISTOR CARTRIDGE
EVERY 2000 HOURS SERVICE
CHANGE OIL IN HYDRAULIC TANK
CHANGE OIL IN CIRCLE REVERSE GEAR CASE
CHANGE OIL IN TANDEM DRIVE CASE
CHECK DISC BRAKE
CHECK ALTERNATOR, STARTING MOTOR
CHECK ENGINE VALVE CLEARANCE, ADJUST
CHECK VIBRATION DAMPER
CLEAN, CHECK TURBOCHARGER
CHECK ACCUMULATOR GAS PRESSURE
CHANGE GREASE IN FRONT WHEEL BEARING
EVERY 4000 HOURS SERVICE
CHECK WATER PUMP
CHECK AND ADJUST AIR COMPRESSOR
CHECK FAN PULLEY

SPECIFICATIONS
SPECIFICATIONS

ATTACHMENTS, OPTIONS
HANDLING BLADE ACCUMULATOR
FEATURES OF BLADE ACCUMULATOR
METHOD OF OPERATING BLADE ACCUMULATOR
CAR RADIO
EXPLANATION OF COMPONENTS
METHOD OF OPERATION
PRECAUTIONS FOR USE
AIR CONDITIONER
LOCATIONS AND FUNCTIONS OF CONTROL PANEL
METHOD OF OPERATION
PRECAUTIONS WHEN USING
TESTING AND MAINTENANCE
HANDLING ADJUSTABLE SEAT
ADJUST OPERATOR'S SEAT
HANDLING AIR-SUSPENSION SEAT
ADJUST OPERATOR'S SEAT
HANDLING MACHINES EQUIPPED WITH KOMTRAX
BASIC PRECAUTIONS

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