Operation & Maintenance ecenestits Manual a COSTA GDG21A- GD523)- MOTOR GRADER GD511A-10243 SERIAL NUMBERS GD521A-10075 and up GD523A-30099 KOMATSUFOREWORD This manual deveribes procedures for operation, handling, lubrication, maintenance, checking, and adjustment it will help the operator or anyone realize peek performance through effective, economical and safe machine operation and maintenance. '» Meese read this manual earofully BEFORE operating the machina ‘® Please continue studying this manual until proper operation is completely reinforced into peraonal hebit. © This manual describes the basic techniques. Skill is performed as the ‘operator of enyone get the correct knowledge and performance of the machine. ‘© Operation, inspection, and maintenance should be carefully carried out, and the safety must be given the first priority. Safety precautions are in- dicated with ). marke and technical procautione with + marks in this ‘manual. The safety information contained in this manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations. ‘® Some photogrephs end illustration pioturee are different from your m chine as technical improvement is continuously reflected on it Revision to up-to-date manusl’s content is performed in lator editions. © This operation & maintenance manual may contain attachments and op- tional equipment thet are not available in your ares. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are aubject to change without notice. FOREWORD[BREAKING IN YOUR NEW MACHINE, BREAKING IN YOUR NEW MACHINE Each machine ts carefully adjusted and teste before shi tent. However, a new machine requires careful operation during the first 100 hours to break in the various parts. fa machine is subjected to unreasonably hard use at the i ial operation stage, the potential of pertormance will prematurely Usieriviels aid the service life wil particularly with regard to the following items. '* After starting, let the engine idle @ Ifthe machine is delivered without for 5 minutes to allow proper en- any cooling water in the radiator, gine warm-up prior to actual op- _flush the cooling system with arm eration. pleclean watertocieanthesystem, ‘© Avoid operation with heavy loads _then fill the radiator with cooling or at high speeds. water. Sudden starting or acceleration, unnecessarily abrupt braking and sharp turning should be avoided. be reduced. A new machine must be operated with c & When replacing oil fiter elements (cartridges), check their interiors for dirt and dust. If heavily cot lected, check for possible cause before starting operation. % Hours of operation are indicated by the service meter.CONTENTS OPERATION SAFETY HINTS = + A ae GENERAL LOCATIONS AND SPECIFICATIONS .. 16 INSTRUMENTS AND CONTROLS 18 CHECK DEORE STARTING 31 OPERATING YOUR MACHINE 39 OPERATING OF WORK EQUIPMENT REVERSING AND REPLACEMENT OF ‘CUTTING EDGE AND END BIT CHANGING TIRES . DRIVING ALONG ROAD TOWING . TRANSPORTATION HANDLING OF BATTERY COLD WEATHER OPERATION 47 MAINTENANCE PERIODIC MAINTENANCE . PRECAUTIONS FOR MAINTENANCE - MAINTENANCE TABLE . OIL FILLER AND LEVEL GAUGE POSITIONS . EVERY 50 HOURS SERVICE . EVERY 250 HOURS SERVICE .. EVERY 500 HOURS SERVICE... EVERY 1000 HOURS SERVICE EVERY 2000 HOURS SERVICE EVERY 4000 HOURS SERVICE . WHEN REQUIRED ....... ADJUSTMENT . ‘TROUBLE SHOOTING Gt ‘STORAGE... ‘SERVICE METER MACHINE AND ENGINE SERIAL NUMBERS FUEL, COOLANT AND LUBRICANTS ... n 72 79 83 85 99 + 103 14 116 ME a7! 124 128 128 130 131 132SAFETYHINTS - - - & OPERATION GENERAL ‘© Wear proper clothes Loose clothes, ornaments or other things that may Possibly contact the control lever or other machina arts must not be worn. Do not let you clothes get caught on protruding parts of the machine. Do not wear oily clothes since they may catch fire. ¢ Wear welling helmet, safety shoes and working clothes. ifthe nature of the work requires safety, wear Protective goggles or mask. thick gloves, ear plugs ar other protection. ‘© Accidents or injuries are liable to occur when the operator is careless or slack. It is most important to bear safe operation in mind at ll times. ‘© Take care of your health. Do not drive when tired, or after drinking, ‘# Learn the prohibitions, cautions and rules about work proceduras in the work When there is a leader, fix standard signals and always follow these signale when operating. @ Ifthere should be an accident or fire or any other such ‘unexpected mishap, deal with it quickly, using the nearest apparatus, Learn beforehand the locatione of the ist aid boxes and fire extinguishers and how to use them. Itis also important to know the emergenay contact system. # Learn about the safety devices on your own machine ‘and about how to use them. Confirm that they ore correctly attached in the prescribed position. Such safety devices include: Guards + Canopi * Protective Devices + Roll-Over Protective Structures > Seat Bolts etc.© Take care not to get caught by protruding parts of the machine. Do not wear oil-stained clothing be- ‘cause itis likely to catch fire. @ Keep fire away from stored fuel, lubricants and anti-freeze. Exhaust gas is dangerous. When running the engine for long periods in a poorly ventilated area, there is 2 danger of gas poisoning, so open the windows or doors to ensure a good supply of fresh air. cose ‘@ Read the Operation and Maintenance Manual care- fully.Leam how to use the control devices, geuges and warning devices. Bre sure you understand the meaning of the Caution plates. Remember the check points and checking method for engine oil, fuel, cooling water and hydraulic olf levels. © When working on a road, pay attention to the safety of passing vehicles and pedestrians. If neces- sary, assign a signalman or provide temporary barricades. ‘© Before starting the machine, perform all necessary checks as stated in the Operation and Maintenance ManualBEFORE STARTING OPERATION © Examine the lay of the land and the kind of soil at the ‘work site to determine the dangerous points and the best method of operation. Proceed with the work only after making safety ar- rangements about the dangerous points. ‘© Inspect leakages from the fuel. lubricating and hy- Thetypeoflubricantused depends on the ambient temperature. Se- lect according to the table “FUEL, COOLANT AND LUBRICANTS”, ‘% When checking the oil level, park the machine on a level surface, stop the engine and wait for 15 minutes before checking. -32-{. CHECK AND REFILL FUEL TANK 1. Use of dipstick (@) to check the fuel level. ‘* A clogged cap breather nole (1) may stop the fuel flow to the 2. Top up the tank through the fil engine. ) after the day’s workis over. Check it from time to time and clean, Fuel capacity: 2272 ® When adding fuel, never let the fuel overflow. This may cause a tire, oa (CHECK BEFORE STARTING 9. DRAIN WATER AND ‘SEDIMENT IN FUEL TANK, (For GD511A)(CHECK BEFORE STARTING b. CHECK AND REFILL BRAKE FLUID (For GD521A, GD523A) % Keep the brake oil always at the MAX level. 1. Check the fiuid level of the brake * Use caution to prevent the Loosen fuel tank drain valve (1) aud supply tank in the opera- mixing of the mineral oll with the ‘and drain sediment and water accu- _tor's compartment. brake fluid when refilling, as this mulated at the bottom, together 2. Add brake fluid through the filler 3@ the rubber part of the with fuel ©), ifnecessary. line to perish, le If the brake fluid has to be defective brake operation. The topped up every frequently, an oil special vessel must be used only leak is indicated. Check the pip- for refilling the brake fluid. ings for the leak. * When refilling with brake fluid, be careful not to eplach fluid about on the painted surfaces. Brake fluid, if splashed, will affect the painted surfaces. -34-CHECK AND ADJUST STEERING WHEEL 3 Ld 33 ~ 20m When checking steering wheel play, start engine and raise front wheels off ground. The standard steering whee! play is 10 to 12 mm. if the play is beyond standard or steer- ingisabnormal,contact your Komatsu distributor. j. CHECK AND ADJUST TRAVEL OF BRAKE PEDAL ‘The standard pedal play is § mm. “The standard height (H) from the floor {is 200 to 210 mm, and the standard depressing height (S) is more than 75 mm with a force of 30 kg. & If the travel is excessive, adjust it using the procedure given in EVERY 250 HOURS SERVICE. =35- ‘uitcx Berone STARTING. k. CHECK AND ADJUST BRAKING ABILITY ‘The braking ability is enough ifthe braking distance is 14m or below at 1 braking ability, = fer to EVERY 250 HOURS SERVICE (WHEEL BRAKE).(CHECK BEFORE STARTING 1. CHECK PARKING BRAKE FOR NORMAL LEVER TRAVEL \\aniy ww ‘The lever travel is found normal if the brake is normally applied when the lever grip is pulled until two or ‘three ratchet clicks are felt. If six or ‘more clicks are counted before the parking brake comes into effect, refer to the EVERY 250 HOURS. ‘SERVICE for inspection and adjust- ‘ment procedures. m.CHECK AND ADJUST TIRE PRESSURE Standard pressure (13,00-24—8PR) Front wheel 1.8 ka/em? Rear wheel 1.8 kg/em* Make sure that tire and rim is free from wear and damage, and that hub nuts are not loose. % If the machine is started in travel with the parking brake lever left in pulled position, brake fining will bbe burnt and braking effect will be areately deteriorated. Mostiy. this will be accompanied with dis- coloration of the brake drum. % If @ brake lining is once but, normal braking effect will not recover unless very thin, burnt layer on the lining surface is polished with sandpaper. —36-n, CHECK DUST INDICATOR (For GDST1A) (For GD521A, GD523A) When air cleaner element 1s clogged, the red piston of dust in- dicator (1) reaches service level and gets locked, In that case, clean element reter- ring to the section “WHEN REQUIRED”. Ater cleaning element, push ‘button to return red piston. eye (CHECK BEFORE STARTING 0. CHECK LAMPS FOR SWITCHING, DIRT AND DAMAGE. p. CHECK HORN. q. IS THE COLOR OF EXHAUST GAS NORMAL? F. DOTHE INSTRUMENTS FUNCTION NORMALLY? ‘s. HAVE ANY DEFECTS WHICH ‘WERE FOUND DURING THE PREVIOUS DAY'S OPERATION BEEN CORRECTED? {. CHECK THE DOOR LOCK FOR NORMAL FUNCTION. (MOTOR GRADER WITH CAB) u, CHECK THE WINDSHIELD ‘WIPER, WINDOW WASHER AND DEFROSTER FOR NORMAL FUNCTION. CHECK FOR SUFFICIENT WASHER FLUID LEVEL. (MOTOR GRADER WITH CAB)‘CHECK BEFORE STARTING v. CHECK FOR SEDIMENT AND WATER IN THE WATER, ‘SEPARATOR ‘The water separator separates ‘water mixed in the fuel. float (2)is at or above red line (1), drain the water. For the draining procedure, see sec- tion "WHEN REQUIRED'. % Even if a water separator is in- stalled, be sure to check the fuel tank to remove water and sedi- ment in the fuel. an(OPERATING YOUR MACHINE OPERATING YOUR MACHINE BEFORE STARTING THE EN- GINE 1. Before starting the engine, check 3. Is gear shift lever (2) in the NEU- the position of all levers. TRAL position and locked? Aiitthecontrotieversaretouchedby —* Carryoutan intial inspection. (For Enginewill notstartunless gear accident, the work equipment may details of the inspection see CHECK shift lever is in NEUTRAL. ‘move suddenly. Whenleaving the BEFORE STARTING.) operator's compartment, always 2. Is parking brake lever (1) in lock ‘set the lock lever securely to the position? LOCK position. \ an A. Before starting the engine, use a &. Ips © ‘damp cloth to wipe off the dust | re eh toe ae a “ accumulated on the top surface of esi) ai the battery. \ | 4. Is work equipment control levers (3) at the neutral (HOLD) position? sg‘OPERATING YOUR MACHINE ‘TO START THE ENGINE 1, To start the engine, put the key (2) to the START position and turn over the starting motor. < OFF ys OF era * Put the fuel control lever (1) in the low idling position. 2. As soon as the engine starts. re- lease the starting switch key (2) to allow it to return automatically to ON position. ee aie + Donotieave key in START for more than 20 seconds. % If engine will not start, repeat the starting procedure after about 2 minutes. + To start engine in cold weather, refer to COLD WEATHER OPERA- TION. ‘Special starting ‘When starting after running out of, fuel, fill with fuel , then fill the fuel filter cartridge with fuel and bleed the air from the fuel system before start- ry Referto FUEL FILTER in EVERY 500 HOURS SERIVCE.CHECKS AFTER STARTING After starting the engine, do not operate the machine immediately. First carry out the following opera- tions and checks. 1. Pull fuel contro! lever (1) and run the engine at medium speed for ‘about 5 minutes with no load. r 2. Run engine with light load until engine water temperature gauge tor (2) moves into green range. 3. Afterwarm-uprun,checkall gauges and warning lamps for proper operation. ate OPERATING YOUR MACHINE 4. Check for normal coloration of exhaust, any abnormal sound or vibration. + Do not run the engine at low idling ‘or high idling for more than 20 minutes. Ifitisnecessarytorunthe engine at idling, apply @ load from time to time or raise the engine ‘speed to a midrange speed.OPERATING YOUR MACHINE ‘TO MOVE THE MACHINE OFF 2. Free parking brake lever (3) and check that parking brake pilot lamp goes off. \ 3. Release inching pedal (1), dep- ress accelerator pedal (4), and : the machine will start. * When starting the machine, check that the parking brake pilot lamp goes out. 1. Depress inching pedal (1) and set ear shift lever (2) to 1st. 2nd and 3rd speed. ‘% Do not start with the gear shift lever in 4th speed or above. -42- CHANGING GEAR SPEED ‘Acceleration Partially release accelerator pedal (1) and shift gear shift lever (2) to the next stepped-up position.Deceleration Release accelerator pedal (1) to decrease traveling speed and shift gear shift lever (2) to the ext stepped-down positon. a * * % When shifting gear, aways shift one speed at a time. © Speedometer range White ranges on the speedome- ter are for the 6th speed, 5th speed and 4th speed from the right to the left. They are mainly used for guessing the time at which stepped-down shifting is to be made. 5, at: On deceleration, watch the speedometer pointer. When the pointer reaches the right end of @ white range corresponding to the gear speed next the current gear speed, move the gear shift lever to the stepped-down position. %* When losing speed going uphill, etc, follow this method, but when changing down on downhill slopes, shift gear just before the idicator reaches the right end of the white ra * When traveling downhill, use the ‘engine brake or wheel broke to keep the indicator within the white range for that speed. -43- (OPERATING YOUR MACHNE FORWARD-REVERSE SHIFTING Always stop the machine when switching between FORWARD end REVERSE. 1. Depress (1) to feduce the travel speed, then depress inching pedal (2) to stop the machine. brake pedal(OPERATING YOUR MACHINE 2. Set gear shift lever (3) to the ‘desired position. then depress ac- celerator pedal while slowly releasing inching nedal (2) to start the machine. na TURNING The grader turns to the desired side by turning the steering wheel (1) to that side. TO STOP THE MACHINE 1. Release accelerator pedal (1) 2. Depress brake pedal (2). Before the machine come to a stop, dep- ress inching pedal (3) % Leaning to the turning side will minimize the turning 1 Im case the grader turns while reversing, leaning to the opposite of the turning side will minimize the turning radius. % In case the leaning was used for turning, return the steering whee! after the leaning was returned.3. Set gear snif lever (4) to neutrat QQ Emergency brake postion, then pull parking brake lever (5) to apply heparking brake. Ai s:0p the machine on hardandeven round to peevert Irom fasing down or slipping. Aiwinen the machine isto be ltt stopped fora while, lave the en Gine in low idling or stp the en- Sine. Apply the gear shit ever lock and the parking brake. (OPERATING YOUR MACHINE ‘TO STOP THE ENGINE If an emergency stop has to be made when the machine is ‘traveling, use the parking brake ‘Togetner wrtn tne wee! brat When the emergency brake has beenused, check the parking brake lining, then replace the lining. 1. Idle the engine at low speed for about 5 minutes to cool it. 2. Turn the key of starting switch (1) to the OFF position to stop the gine, and remove the key.‘OPERATING YOUR MACHINE + Do not attempt to stop a hot en- gine immediately unless itis nec- essary. Such unreasonable opera~ on will couse remathable shortage of life of the various engine parts. ‘& Specially when stopping an over- heated engine, be sure to coo! the engine gradually by idling it at © middle idling speed. CAUTIONS FOR OPERATING Drive the machine straight during uphill or downhill traveling. ‘Specially, turning the machine on the gravelly or olayey alent will cause the machine to slip easily. H the engine stope, depress the brake pedal immediately with full force, and at the 2ame time, pull the parking brake lever to stop the machine. Then place the gear shift lever in N (neutral) and start the engine again. Do not attempt to shift the gear shiftlever tothe noutral posi depress inching pedal during downhill traveling. ‘Whentires get stuck while working in ewamp or mud, travel with re sated articulation to simplify get- ting out of the poor ground. ~ 46 — ‘© This machine has two brake con- trol eyetome. if one braskee down the other is still effective. However becouee braking capacity fe re duced drive slowly when traveling. ‘© Operating the articulation system when traveling at high speed may ‘cause the machine to overturn. Always perform this operation ata ‘peed below 10 km/h. (with articu lated) @ Uso the parking brake 2¢ neces- sary to compensate insufficient effect of the wheel brake. Ait the engine etope, the brake booster will not work, so the pedal «will booome heavier and the brak- ing effect will drop evenifthebrake ie depressed with the same force‘OPERATING OF WORK EQUIPMENT OPERATING OF WORK EQUIPMENT OPERATION METHOD OF THE WORK EQUIPMENT + When operating the work equip- CONTROL LEVER ment control lever, sufficient ot- There are provided nine work tention is required for the move- equipment control levers, which ore ment of the work equipment and operated as are indicated in the fol- its movement range must be lowing figures. limited, 28 the work equipment or the hydraulic cylinder possibly hit inst perts, damaging them. Left side Control Lever Bade iting Blade horizontal (ont shifting Powertit Blade rotation (deo oak, 1S ey(OPERATING OF WORK EQUIPMENT CAUTIONS IN OPERATION OF WORK EQUIPMENT © When the work equinment is operated, special attention should be given to contacts at the following parts. Front wheei and blade Blade and step ADJUSTMENT IN SHIFTING OF WORK ATTACHMENT It is essential to shift the work at- ‘tachment to an optimum position for each work. to allow hiah iob efficiency. BLADE PROJECTION ‘The degree of projection is con- trollable by the control lever during operation. If further projection is needed, stop the grader for a while ‘and change the installing position of ‘the blade horizontal shifting cylinder piston rod, as follows. @ Projection toleft. Position (1)PROPULSION ANGLE OF BLADE ‘Angle of biade and body center line is: called the blade propulsion angle. re ur 1 sereping work, set the angle at 60°, more or less. Set at a lesser angle when the scraping resistance is great, or when the soil is hard, or when the soll In front of the blade is difficult to carry or throw to the side. ADJUSTMENT OF BLADE CUTTING ANGLE In hard soll cutting, it is advisable to lean the blade forward. As the soil becomes softer, ean the blade more backward. 1nis operation wit improve job efficiency. It fs essential to adjust the blade cutting angle, depending on the soil conattion. The range through which the blade cutting angle can be adjusted is 26.5° to 75.5°. This range is step- 4ess, s0 any angle within the range ccan be chosen freely. 785° 265° ag ae (OPERATING OF WORK EQUIPMENT Agjustment 160590) 1. Tur the blade so as not to touch ‘the grader body and set the blade in the same direction to the body. Then, place the blade on the ground, 2. Using an accessory tool, loosen nut (1) until lock plate (2) does not lock and is loose. Release the lock plate on the opposite side, too. The adjuster cannot be rotated unless. both lock plates are relieved from locking.‘OPERATING OF WORK EQUIPMENT 3. Operate simultaneously both * instalation of this power tit 3. If the biade is operated with the right and left lift cylinders and blade give the following ——_—ihydraule tip control, the distance lock when the blade has the re- advantages. between the cutting edge and ‘quired angle. 1. Optimum blade cutting angle ean _—tho oxeavatian eurface changer. be obtained by operating the ‘This means that fine adjustment conrol lever for soil quality of the excavation surface is possibl Large ie a Soilqualiy: Herd Soil quay: Sof Exeavaton surface 2. Since the cutting edge can be set 4. In the low-banking position when to the desirable angle, a powerful raising the dirt and enow, the op- breaking is available to cut the _timum blade cutting angle can be frozen ourface during now —_—eelected to incresce operating removal efficiency. ‘small Frozen surface Soft snow 50SAFETY DEVICE OF BLADE (For GD511A) A shear pin (1) is provided on tne CIRCLE to prevent the blade from unexpected failure, because of ab- normal impact load placed on the ‘blade ecige during operation. if te shear pin is broken during operation, remove bolt (2) and lock plate and ull out the shear pin to replace by a OPERATING OF WORK EQUIPMENT BANK-CUTTING POSTURE (RIGHT SIDE) 1. Fully protrude the blade and the ‘rawbar to the right so that the blade angle shown in the figure can be obtained, 2. Depress lifter lock pin pedal (1) fon operator's compartment to remove pin (2). * If the pin cannot be removed be- ‘cause of interference with lifter (3), operate the blade lift eylin- ders as necessary.‘OPERATING OF WORK EQUIPMENT + When bringing the blade into hankecut posture on the left-side fof the machine, change every E “aft-hand” and “right-hand” in the above mentioned description with each other % Relocating the blade cylinder piston rod ee sition to the right (when right- hand bank cutting is mada) or to mn the left (when left-hand bank cut- 3. Rotate liter (3) by protruding the 4, Retract the right-hand lfteylinder ting is. made) will improve hank right-hand blade ft cylinder and protrude the left-hand cyin- cutting efficiency. piston rod and retracting the laft- der. Repeat this several imes so (Sea side-shifting ofthe Blada) hand blade litt cylinder piston that the circle ie rotated with the rod. When top hola (A) in lifter lade raised on the rightshand Ah,Do not attempt to depress the approaches pin (2), release lifter side, and desired bank-cut pos- bank control lock pin removing lack pin pedal (1) and slowly _turecan be attained Pedal unless the blade is rested rotate the lifter until pin (2) * When bringing the blade into on the ground. If the pin is re- sntars hale (A) bank-cut posture, be careful not moved with the blade raised to clash the blade agsinst various _—_ off the ground, dangerous fall- protions of the machine. ing of the blade with rotation of the circle may result. -52- oie‘SHOULDER REACH POSTURE (RIGHT SIDE) 1, Rotate lifter (1) ina similar manner 10 the bank cutting posture, and lock it using bank control lock pin Q). 2. Rotate the circle to the desired position. % Put the machine in the left hand side shoulder reach posture usi the same procedure as the above. % When increasing the size of the shoulder reach, changethe mount- ing position of the piston rod of the blade horizontal feed cylinder. (See section on BLADE PROJEC- TION.) ‘& The banking performance is im- proved, if the mounting position for the piston rod of the blade hori- zontal feed cylinder is changed as follows: © When banking to right, to a Position where the blade is thrusted left. ‘© When banking to left, toa pos tion where the blade is thrusted to right. =53- (OPERATING OF WORK EQUIPMENT ARTICULATED OPERATIONS When performing operations with the machine articulated, remove the lock link on the left side of the ma- chine. ‘The machine can be articulated, giving a minimum turning radius of 1. Take off lock link (1). 2. Sethe lockliinkto the bracket (2) in the rear.(OPERATING OF WORK EQUIPMENT % When the lock link is removed, the articulation lock pilot lamp on ‘the inctrimant panel will ight up Afor normat traveling ope tions, do not remove the lock ink. PRECAUTIONS WHEN USING ARTICULATION It the machine is articulated when in the travel posture, the blade willinterfere with rear frame. This is dangerous, 60 when using the articulation, lower the blade until it goes under the rear frame, or set the blade to a suitable propulsion angle ADJUSTMENT OF SCARIFIER ADJUSTMENT OF CUTTING ANGLE As the soil becomes harder, a wider exttting angle ineraaees jah efficiency. Adjustment Remove bolt (1) and select a bolt hole sdequate to the cutting angle. The cutting angle is adjustable from 61°, 68° (standard) 74°.OPERATING OF WORK EQUIPMENT b. ADJUSTMENT OF CUTTING PRECAUTIONS FOR SCARIFIER DEPTH OPERATION As the cutting depth is adjustable from tooth, adjust the tooth to job property. Adjustment © When the machine body is raised @ When turning the blade, with it by using the blade as a jack, several cm off the ground, the while the scarifier is left lifted to blade may touch the scarifier. the top position, the drawbar will This may damage the upper part om g come into collision with the scari- of the blade. fier. This will couse damage to Remove the cotter pin, pull the drawber. wedge (1) and change the notch of tooth (2) -55-REVERSING AND REPLACEMENT OF CUTTING EDGE AND END BIT REVERSING AND REPLACEMENT OF CUTTING EDGE AND END BIT Replace cutting edges and end bits before their blade’s end faces wear out (Be sure to replace cutting edges and side edaes before they wear down to ‘a width of less than 10 mm from blade base). When wear is extended to the mountina faces. their repair must be done prior to repl TURNING AND REPLACING 1. Lift the blade to a suitable height 2, Clean the mountina face after + Tiahtenina torque for the mount- and put 2 block underneath the detaching the cutting edge and ingnuts:.— 28.5 + 35 kgm blade rail to preventit fling the end bit % Tighten’ the nuts again after 3. Mount the cutting edges after i several hour's operation. Aco not raise the blade unne- —_verting it, or replacing it with @ ® If both ends of the cutting edge cessarily high. new one. and side edges are worn out. re- Be sure not to put your body un- 4, Mount the end bits after inverting lace them with new ones. derneath the blade when block- and. switching right for left, or ing it replacina with new ones. —56— coreHOW TO CHANGE TIRES: 1. Front wheel 1) Lower the work equipment to the ‘ground, set the gear shift (parking Drake) lever to tne F position to apply the parking brake. 2) Then, atach the socket wrench (accessory machinetool)tathe hub ‘huts anc loosen all the hub nuts by 3/4 to I turn. 3) Depress the littcylinder. tthe front tiresarelifted, lockthe controllever, remove the hub nuts and change all the tires. CHANGING TIRES 4) Ininstallingnewtires, tighten lightly with the tires lifted and tighten the tres to the specified torque in the order shown in the photos, after placing the tires on the ground. ‘ Coatthe threaded part with molyb- denum disulphide grease (NLGI No. 1) before tightening. 4% Tightening torque: 405 kgm Aivneneverthe tronttires are raised ‘off the ground, support the front ‘axle center frame on the block to (CHANGING TIRES 2. Rear wheel 1) Repeat the front wheel change procedures 1) and 2). 2) Depress fully the right and left lift cylinders and the front tires are lifted about 60 em off ground. Re- tract the lift cylinder on the side wherethe treisnotremoved,to lift the rear wheels. 3) Install new tires according to the procedure 4) ofthe frontwheel tire change. + Coatthe threaded partwith molyb- denum disulphide grease (NLGI No. 1) before tightening. % Tightening torque: 405 kgm Awrenever the rear wheels sro 1¢d off the ground, stably sup- Port the tandem on the block to ‘assure safety.(CHANGING TIRES, HOW TO USE LEANING STOPPER AAwinen a front tire punctures, do When the leaning pipe is dam- not attempt to travel the ma- aged, temporarily prevent the front chine by temporarily anplvina a wheels from leaning so that the m pad to the swing stopper. ifit is chine can be successfully self necessary, travel the machine propelled to the nearest repair shop. slowly only within the mini- mum necessary distance. In How to-apply the leaning stopper this case, be sure to securely Fix the leaning rod to the front keep the punctured tire off the axle using the bolts provided in the ground with chains, ete. tool box. Arif the machine is travelled with ing cylinder piston rod fluctuating or the front wheels leaning on one side, because of damaged leaning —_piping, dangerously unstable steering and excessively worn tires will result. Have the faulty leaning pipe repaired by mechanics quickly. ialggiDRIVING ALONG ROAD In addition to strict observance of traffic laws and rules concerned, keep the following in mind: POSITION OF BLADE WHEN PRECAUTIONS WHEN TRAVELING TRAVELING ON ROADS Wher traveling, set the blade at Te relleve operator's fatigue, ‘the minimum propulsion angle and take a rest by 30 minutes — 1 hour ‘aise the blade fully, = 30 minutes mode, every 80 kilometers or every 2 hours of trav- eling (whichever term expires earlier) Be careful to keep a clearance be- ‘tween the blade and front tires. —59- DRIVING ALONG ROADTowns ‘TOWING THE MACHINE This machine must not be towed except in emergencies, When towing the machine, take the follow- ing precautions. ¢ Always keep the engine running when towing the machine, 50 that the steering and braking can be used. ‘When engine cannot be used. © When transporting a disabled machine by towing, the transpor- tation distance should be within 600 m at a speed of 8 km/h or less. (When towing more than {600 m, remove the drive shaft) TOWING + If the distance is more then the ‘above mentioned, or if more than fone day has elapsed since the engine trouble, be sure to use the trailer for transportation. + If the machine is towed without the engine running, no lubrication cil will be supplied to the trans- mission. The gears and bearings are rotated, so this may cause them to be damaged. ‘+ When the engine cannot be used or the steering booster cannot be used, operation of steering whee! is difficult, so run the machine slowly. 60TRANSPORTATION In addition to stict observance MMNever attempt to change the of traffic laws and rules concerned, it fs desirable to provide @ special Platform for loading and unloading Uf the nHGtur yrauer. If itis sreeeary to use a ramp when loading a motor grader on a treiler or unloading it from a trailer, observe the following mtructions to assure safety: 1, Securely brake the trailer ond chock tailer tires. Securely fix the ramp boards in place so that the center of motor grader being loaded coincides with the center fine of the trailer. % Width, length and thickness of ramp buards must farge enough to assure safe loading and un- loading of the motor grader. AFemove the mud from the un- ‘dercarriage to prevent the m chine from slipping to the side onslopes. 2. Slowly travel the motor grader ‘on the ramp straight, direction of travel on the ramp. If it is necessary to change the direction of travel, once return Ue necting Wy Ure urightal Position. 3. Properly load the motor grader (on the trailer at the specified po- sition, To prevent the grader on the trailer from moving back and forth during transportation, apply ‘a chock to front and rear of each Do not wheel and fix the motor grader with chains and wire ropes. Pay special care to prevent the motor grader from slipping sideward. 4, Rest the work equipment on the trailer deck and observe the following, ‘© Pull the parking brake lever. © Place the gear shift lever in the neutral position. © Place work equipment contro! lever in hold position. -61- TRANSPORTATION ‘© Apply safety iocks. @ Pull the starting switch key out, % Determine the optimum transpor- lativn ruts, tehiny width uf wed ‘and permissible overhead clear- nee and weight limitation into consideration. & Lock the articulation lock the same wey as for normal travel, raised off the tr the brade as a jack. The front wheels will fall gradually during transportation. When loading the machine, choose a firm level road surface. Be sure that you are well clea of the road shoulder. ‘* When transporting this machine, check with your Komatsu dis- tributor for advice.HANDUNG OF BATTERY HANDLING OF BATTERY 3. If the electrolyte temperature ex- 6. Do not mix up cables (positive (+) ‘damp cloth to wipe off the dust ceeds 45°C, stop charging fora to negative (-) or negative (-) to accumulatedonthe top surfaceof while. positive (+)), as it will damage the the battery. 4. Tumoffthe chargerassoonasthe _ alternator. battery is charged. 7. When inspecting or servicing a PRECAUTIONS FOR CHARGING Overcharging the battery may _battery, be sure to stop the engine BATTERY cause followings: and turn the starting switch key to 1, Before charging, disconnect the 1) Overheating the battery “OFF" position. cable from the negative (-) termi- 2) Decreasing the quantity ofelec- 8 When performing any service to ral of the battery. Otherwise, an trolyte battery besides checking the elec- unusually high votagewilldamage 3) Damaging the electrode plate trolyte level or measuring the the alternator. 5. Ifthe electrolyte gets on your skin _specific gravity, disconnect cables 2. Whilechargingthebattery, remove or clothes, immediately wash with _from the battery. all battery plugs for satisfactory _plenty of clean water. ventilation. To avoid gas explosions, do not bring ire or sparks nearthe battery. -62-REMOVAL AND INSTALLATION OF BATTERY © When removing bettery, first dis- connect the cable from the ‘ground (normally, from the nega- five 12) terminal) f= tool touches a cable connecting the positive terminal and the chassis, there is danger of sparks being emitted © When installing battery, the ground cable should he connect- 2d to the ground terminal as the last step. conse STARTING ENGINE WITH A. BOOSTER CABLE ‘When starting up the engine with a booster cable, do as followe: 1, Before connecting the booster able 1) Size of booster cable and clip should be suitable for the bat- tery size. 2) Check cables and clipe for breaks, corroded surfaces, etc. 3) Make sure cables and clipe are firmly secured. 4) Keep the starting ewiteh key in OFF position 5) The battery of the running engine must be the same capacity 28 that of engine to be started. -63— HANOUNG OF BATTERY 2. Connect the booster cables in the following manner. 1) Connect one clip of booster cable A to the positive (+) terminal of the engine to be ctorted. 2) Connect the other clip to the positive (+) terminal to the engine which is running. 3) Connect one olip of booster cable B to the negative (—) ‘terminal of the engine which running. 4) Connect the other clip to the body of the machine to be started. ‘%* Make sure the clips are firmly connected to battery terminals. Then, start the a)HANDLING OF BATTERY Aiwinen connecting the cabies, ‘never contact the positive (+) and negtive (—) terminals, AAMake sure that the booster ‘cable connections are correct. Connect the booster cable to ‘the body as far as possible from the battery. 3. Starting the engine 1) Turn the starting switch key to START position and start up the engine. 2)If the engine doesn't start at first, try again after 2 minutes oro. After the engine has started, the booster cables should be dis- connected in the reverse order in which they were connected. 1. Disconnecting the booster cables 1) Disconnect the clip of booster cable B from the body of the machine which was started. 2) Disconnect the other clip from the negative (—) terminal of the running engine. Body of the machine vwrich was started ees 3) Disconnect the clip af booster ‘cable A from the positive (+) terminal of the running engine. 4) Disconnect the other clip from the positive (+) terminal of the engine which was started,CcoLD WEATHER OFERATION COLD WEATHER OPERATION PREPARATION FOR LOW TEMPERATURE If the temperature becomes low, it becomes’ difficult to start the engine, dnd the covient mey fieeee, so do as follows. FUEL AND LUBRICANTS Change to fuel and oil with low viscosity for all component For details of the specified viscosity, ‘see the TABLE OF FUEL, COOLANT AND LUBRICANTS. COOLANT ‘After cleaning inside of the cool ing system, add antifreeze to the coolant to prevent the coolant from freezing when the machine is not being used. + For details of the antifreeze ture when changing the coolant, ‘see WHEN REQUIRED. -65— Care in using Antifreeze Use @ Permanent Antifreeze (ethylene glycol mixed with corro- itr, antifoam agent, ote) meeting the stenderd requirements as shown below. With permenent antifreeze, no change of coolant is required for year. If itis doubtful that an available antifreeze meets the standard requirements, ask the supplier of thet antifreeze for information. Standard requirements for perma- nent antirfreeze © SAE - 1034 # FEDERAL STANDARD 0-A-548DCOLD WEATHER OPERATION % Never use methanol, ethanol or propanol based antifreeze. * Where no permanent antifreeze is available. an ethviene alvcol an- tifreeze without corrosion inhibi- tor may be used only for the cold season. In this case, clean the system twice a year spring and autumn). When refil- ing the cooling system, add anti freeze in autumn, but do not add any in spring, ‘® Absolutely avoid using any water leak preventing agent irrespective of whether it is used indepen- dently or mixed with an antifreeze. ‘* Do not mix one antifreeze with a different brand. Mpatitreeze is tammabie, so keep it away from any flam BATTERY As ambient temperature drops, battery capecity will drop, and elec- ‘olvte may sometimes freeze if bat- ‘tery charge is low. Maintain battery at a charge level of approx. 100% and insulate it against cold tempera- ‘ure so that machine can be readily started the next morning. + Measure specific gravity of fluid and obtain rate of charge from the following conversion table: \ ie dg) | oe [eee sox | sae | sa0[ 130 | 131 ox [126 | 127] 1.28 | 129 ox faa | tas| 126 | 127 7% | 123 | 124| 128 | 128 — 66 - ‘* When electrolyte level is low, add distilled water in the morning before work instead of after the day's work. This is to prevent fluid from freezing at night. BT avoid gas explosions, do not bring fire or sparks near the battery. Aiit the electrolyte gets on your ‘skin or clothes, immediately wash with plenty of clean water.STARTING IN COLD WEATHER For attention of engine starting, refer to section “OPERATING YOUR MACHINE”. TO START THE ENGINE 1. Settuelcontroliever(1) atthe HALF OPEN position. 2. Put starting switch (2) in the HEAT position to red-hot heater signal @. eo - ‘% Never put the fuel control lever or ‘the accelerator pedel in the full speed position when starting the engine. -67- ‘COLD WEATHER OPERATION Necessary preheating time is as follows. ‘Ambient emperature | _Prehesttime Above oC a orto 10% 20 exconds eC 20° 30 seconds + If the preheating time is too short (oF too long, the engine will be dif- ficultto start, soalwayskeeptothe(COLD WEATHER OPERATION 3. When heater signal (3) glows 5. Put fuel control lever {1) in LOW — » If the engi does not start up red, turn the key to the START IDLING position despite carrying out the above position to start the engine. operations, leave it for about 2 ~., toe and then ropest the seen / above procedure 2 and 3. RA “+ Once the engine starts up, thor- ' ON i ‘oughly warm up the engine NS ) before putting the machine into Nee zhift lever in the lowest position, t ‘and then gradually apply the loa 4 Release the key of starting switch (2), and the key will return ANever use starting aid fluids as automaticaly ON. + ‘they may cauze explosions. wae‘COLD WEATHER OPERATION CAUTIONS AFTER COMPLE- AFTER COLD WEATHER TION OF WORK When weather becomes warm, 1) Mud and water attached on the perform the following without fail: machine. © Replace lubricating oils for various Mud can easily be removed soon units with the ones specified for afterithasadheredtothemachine. warm-weather use. Dried or frozen mud will not only @ If for any reason permanent anti- becomedifficulttoremove,butalso _—_—‘freeze cannot be used, and an eth- cause various defects. yiglycolbase antifreeze (winter,one Inparticular, water dropscollected season type) is used instead, or if on the surface of the piston rodof -—no antifreeze is used, drain the thehydrauliccylindershallbefully cooling system completely, then wiped out. When water drops is _clean out the inside of the cooling frozen on the surface of the piston _—_system thoroughly, and fill with rod, the seal may be broken. fresh water. 2) When washing the machine, be ‘careful not to throw water on the alternator and breathers. agPERIODIC MAINTENANCE Proper lubrication and maintenance assure trouble-free operation and long machine life. Time and money spent for scheduled periodic mainte- ‘nance will be amply compensated by prolonged macrine operation and ré duced operating cost. All hourly figures given in the following Gescriptions are based on service ‘meter readings. In practice, however, it is recommended to rearrange all of them into nls of days, weeks and months to make the maintenance schedule more convenient. Under rough job site or operating conditions, necessary to somewhat shorten the maintenance intervals stated in this manual. ae PERIODIC MAINTENANCEPRECAUTIONS FOR MAINTENANCE PRECAUTION FOR MAINTENANCE GENERAL © Wear proper clothes Loose clothes, ornaments or other things that may possibly contact the control lever or other machine Parts must not be worn. Do not let you clothes get ‘caught on protruding parts of the machine. Do not wear oily clothes since they may catch fire. © Wear well-ftting helmet, safety shoes and working clothes. When drilling, grinding orhammering, always wear protective goggles. -12- Fue! or oil are dangerous substances. Never handle fuel. cil. grease or oily clathes in places where there is any fire or flame. ‘As preparation in case of fire, always know thi tion and directions for use of fire extinguishers and ‘other fire-fighting equipment Always stop the engine before cleaning the machine or adding fuel.PRECAUTIONS FOR MAINTENANCE ‘© Do not handle electrical equipment while wearing wet gloves, or in wet places, as this can cause elec- ‘@ When working with others, choose @ group leader tric shock. ‘and work according to his instructions. Do not per- ‘® During maintenance do not allow any unauthorized ‘orm any maintenance beyond the agreed work. Person to stand near the machi cna -73-PRECAUTIONS FOR MAINTENANCE ‘© Exhaust gas is dangerous. When working in particularly careful to have good ventilation. Je, be © Unies you have special instructions to the contrary, maintenance should always be carried out with the ‘engine stopped. If maintenance is carried out with the engine running, there must be two men present: ‘one sitting in the operator's seat and the other one performing the maintenance. In such @ case, never touch any moving part. -14— under pressure. When feeding or dr carrying out inspection and maintenance, the pressure first. ‘The procedure for releasing the hydraulic proceure is as follows: lower the blade, scarifier and ripper to ‘the ground, and etop the engine; move the control levers to each position two or three time and then slowly loosen the oil filler cep. Always use Komatsu genuine parts for replacement. Alwaye use the gradee of grease and oil recom- mended by Komatsu. Choose the viscosity specified for the ambient temperature. Always use pure oil or grease, and be sure to use clean containers. When checking or changing the oil, doit in a place free of dust, and prevent any dirt from getting into the oil.DURING MAINTENANCE flat ground. Lower the blade, scarifier and ripper to the ground and stop ‘the engine. Return the gear shift lever to “N {neutral) Position”, apply the brake lock and set each control lever to “LOCK”. When maintenance has to be car- ried out with the blade, scarifier and ripper raised, they must be securely supported by blocks, ‘© Throughly wash the machine. In particular, be care- ful to clean the filler caps greese fittings and tie area around the dipsticks. Be careful not to let any dirt or dust into the system. -75- PRECAUTIONS FOR MAINTENANCE ‘@ Hang 2 caution sign in tne operator's compartment (for example “Do not start” or “Maintenance in progress”) This will prevent anyone from starting or moving the machine by mistake. Flame should never be used instead of lamps. Never use a naked flame to check leaks or the level of oil, ‘uel, anti-freeze or electrotyte. Immediately remove any oil or grease on the floor of the operator's compartment, or on the handrail It is very dangerous if someone slips while on the machine,PRECAUTIONS FOR MAINTENANCE ‘@ When check an open gear case there is a risk of dropping things in. Before removing the covers to inspect such cases, empty everything from your pockets. Be particularly careful to remove wrenches and nuts. ¢- Before draining the oil. warm up itto a temperature of 2010 40°C. © Be particularly careful when removing the radiator cap or the hydraulic oil tank filer cap. if this is done immediately after using the machine, there is a dan- ger that boiling water or oil may spurt out. -76- After replacing oil filter element or strainer, bleed the air from the circuit. When the strainer is located in the oilfiller,the strainer must not be removed while adding ci When adding oil or checking the cil level, check that the oll is at the correct level. When adding oil or fuel, do not let the oil or fuel overfiow. Ifoll or water are spilled, always wipe it up. Spilled oil or water may cause people to slip'spilled oil may cause fire. Hf soil is piled on top of a place where fuel has been spilled, remove the soil, After greasing up. always wipe off the old grease that was forced out. ‘When changing the oil or filter. check the drained oil and filter for any signs of excessive metal particles or other foreign materials. ‘When removing parts containing O-rings, gaskets or seals. clean the mounting surface and repiace with new sealing parts.PRECAUTIONS FOR MAINTENANCE ‘@ When the work equipment is raised for inspection @ Disassembly, repair and assembly of tires require or repair, always place blocks underneath to prevent special equipment and high skill Always consult a falling specialized tire repair shop. @ When the machine is jacked up, always put chocks inet the wheels on the opposite side. After jack- © Always lock the front and reat fremes before ine ing up, place blocks to prevent the machine from specting and servicing the machine. (In articulate falling, frame model) nangPRECAUTIONS FOR MAINTENANCE © Remove the minus terminal from the battery in maintaining the electrical system. ‘© When carrying out other difficult maintenance works, carrying them out carelessly can cause unexpected occidents. If you consider the maintenance is too difficult, always request the Komatsu distributor to carry it out. '* Special measuring apparatus ie needed for testing hydraulic pressure. Egg asMAINTENANCE TABLE MAINTENANCE TABLE in ay MU senere= MU eae HIN eal nanos ml ease CHECK BEFORE STARTING ° | cme oan 2 | it nd water oak [ cnc [= (2 | torn Check. i | Nas and bts ‘Check andrevonten | 31g | Exhaurt gas color nec a = [een eres pe on lie acres Ges 7 | Cootne Check anawpoty | 31 | Prevauecavedetca | Check 7 © | Engine oit pan Check and suppty | 32 + _| Boor tock Check [2 + | Foe check anduppty | 38“ | Wipe window watherand | Ghecy |» 9 | Feet enh seer ial Taree | tose oat postion | 36 | Brake Ha _ Check and suooiy | 84 L i | Steering whet piay_ Check 35 EVERY 50 HOURS SERVICE 1 | Brake pedal travel [check and adjust | 35 a | Lubricating li a | Broking aby Check endodion_| 38 Gree Labrcae a Parkingbrakelever wovel__| Gheckandaciu | 38 a | uae auide ra Liew a om | Tre premure Check ond oune | 36 | Oust indicator Check a7 i IlMAINTENANCE TABLE Nel rem SERVICE [PAGE No. 17M SERVICE [Page EVERY 250 HOURS SERVICE -7| Front ane centr pin Laveen tint | 86 (The tums marked * ar cried out after the fst 250 nouté ony for new machines) 8] Orawbar bal jine Lubrieste 1 pine | 87 = | Feet finer Replace corvidge | 8 a] Sater pan jm [teers 4 pew | oF a Chana oT and 5 «| Tremmision ase and tter | Grant aens, | 85 0| sewitecevineerin Lorene 2poins | 87 = | Final ave ee Change oi 8 —_-11| lade itteyinder yore Lubricate Soins | 87 —— ‘change ot Boz) lace lift oyingerballjome | obviate pains | 8B > | Tender arve coe Change oi 35a] Berea ee orinder | ooo mime | ee ange OT aE + | Hrdraue tan ona cer | SRapPETES [a5 10| wank conira guice [tebe 3 pois | a8 + | psi vaive clearance Cheek and aclust | 85 15] Ariulation center pin Lubeiete2 Bein | 88 «| tierteing 5 18] Arteuumion eyiingerin | Labvieie@potes | 68 | Leaning einer in Lureate2poine | @8 | Transminion caw | eect ond wo | 60 2| Leaning rod end Lubricate 2 poins | a5 | Engine olf pan and fiter Ghoneesiand™ | 9 ea _| piece carvigge | 8 3 | Tiered Lobriete2 pein | 88 | Firalcrve cams Cheek and supply | ot 2 | ows racket ing [Levemeapoine | ue | Tencemanve caw Check andsupety | 91 5 | Leaning pin Lubricate 2 points 86 t | Circie reverse aear case | Check and cupety. 92 ‘abrite 2 pein ar ene @ | reroute wan ‘heck ana supply | 22 8 | Steering evinder ee eee milee : | (GD523.4) Bi jeeneee ‘Cheek tension J 80 —MAINTENANCE TABLE No rem service [Pace Na rTeM pace i | Ball joint Check clearance 95 © | Final drive case i 108 1 [ Seueryencwowseiewe | cree ee ce Chenge oi 105 [wen nu Cwckandrevanen | 96. | Tandem ave cae Ghanoe oi wor |_| Parking brake ever heck wave 96 | Hyarauictankana ier | Spsegiens. [aor im | Wheet brake Check and adjust: 8 8 |_Orewbar front ball joint | Check tosseness: 108 | 7 | Fem | ereckendaune | 108 EVERY 500 HOURS SERVICE [ 1 |_ Front whee! bearina play Check and adiuse | a40 | Fost titer Replee carrie | 99 || Comoson esior | Reolescarvidoe [191 > | Tranemiion fiver Rouse tment [100 _« | Twostarger ator Check play 12 © | ete wae Grocers [100 “1 | Turpoenarervanoutarenes | Gneckand retanten | #12 | Radiator fin = 102 | EVERY 2000 HOURS SERVICE 2 | rane ee ering Peres ae oh] ae | Enaine bresner “| ctean ne EVERY 1000 HOURS SERVICE ¢ | Aterstorana narang motor | Gheck 16 = [ taorating 103, a | rane vate cierance Cuckand one _| 8 Drive shaft Lubricate 2 points | 103 @ | Vibration damper | cneck 118 Trersmison case a Check and ctn | 115 come -81-MAINTENANCE TABLE te Tew [sevice [roe EVERY #000 HOURS SERVICE 7 [ore Toms te [ WHEN REQUIRED ae oe ey = «| Beer nee wer ve © | Wore error 12 | | ata —82-OIL FILLER AND LEVEL GAUGE POSITIONS OIL FILLER AND LEVEL GAUGE POSITIONS 1. Fuel tank lovel gauge and oil filler 8. Tandem arive case drain plug 2. Hydraulic tank oil filer 9. Tandem drive case level gauge plug 3. Hydraulic tank level gauge 10. Transmission case oi filer 4. Cooling water inlet 11, Transmission case drain plug 5. Final drive case oil filer 12. Circle reverse gear case drain plug 6. Tandem drive case oi filler 13. Circle reverse gear case oil filler 7. Engine oll pan ~83-EVERY 50 HOURS SERVICE EVERY 50 HOURS SERVICE a. LUBRICATING ‘Apply grease to the grease fittings shown by arrows. 1. Circle 2. Blade guide rail ‘Apply grease all around the circle Apply grease all over the guide part rail (For GDB11a) (For GDS11A) (For GDS21A, GD523A) nrgEVERY 250 HOURS SERVICE EVERY 250 HOURS SERVICE > Maintenance for every 50 hours should be carried out at the same time. Carry out the following mainte- a, LUBRICATING. nance only after the first 250 hours. Apply grease to the grease fittings shown by arrows. © FUEL FILTER, REPLACE CAR- 1, Leaning cylinder pin (2points) 2. Leaninarodend —(2 points). TRIDGE (For GD511A, GD521A) TRANSMISSION CASE AND FILTER, CHANGE OIL AND REPLACE ELEMENT © FINAL DRIVE CASE, CHANGE OIL, CIRCLE REVERSE GEAR CASE, CHANGE OIL ¢ TANDEM DRIVE CASE, CHANGE on ‘© HYDRAULIC TANK AND FILTER, (CHANGE OIL AND REPLACE ELEMENT ENGINE VALVE CLEARANCE, CHECK AND ADJUST For details of the method of re- placing or maintaining, see the section ‘on EVERY 500 HOURS, 1000 HOURS ‘AND 2000 HOURS SERVICE. 3. Tie rod (2 points) (For GDB11A, GDS21A)EVERY 250 HOURS SERVICE (For GD523A) 5. Leaning pin {2 points) (For GD523A) (4 points) 4, Knuckle bracket king pin 6, Steering cylinder 7. Front axle center pin (4 points) (For GD511A,GD521A) (2 points) (For GDB11A,GD521A) (1 point!EVERY 250 HOURS SERVICE (For GD523A) 10. Scarifier cylinder pin (2 points) f= 11. Blade lft cylinder yoke 8. Drawbar ball joint (For GD511A, GDS21A) (6 points)evERY 260 HOURE ceRViCE 12. Blade lift cylinder ball joint (2 points) (For GDB21A, GD523A) 16. Articulation canter pin (2 points) 13. Drawbar side shift cylinder ball joint (2 points) (For GD511A) 14, Bank control guide (3 points) (4 points)EVERY 250 HOURS SERVICE b. TRANSMISSION CASE ¢. ENGINE OIL PAN AND FILTER (For GO511A) Check the oil level with oll level gauge (G). If necessary, add oil ‘through filler (F. * Make an oil level check 5 minutes after the engine is stopped. * The type of lubricant used de- pends on the ambient tempera- ture. Select according to the teble “FUEL, COOLANT AND LUBRICANTS”, -89-EVERY 250 HOURS SERVICE |. Loosen drain plug (P) to drain oil After draining, tighten it. . Using a filter wrench. remove car- tridge (1) of the engine oil filter by ‘turning it counterclockwise. If filter cartridge (1) is removed immediately after stopping the engine, oilwill spill. Waitatleast 10 minutes after stopping the engine before replacing the filter cartridge. (For GDB11A) To install cartridge, bring its pack- ing surface into contact with seal- ing surface of fiter base and then tighten cartridge a further 1/2 of a turn. (For GDS21A. GD523A) To install cartridge, bring its pack- ing surface into contact with seal- ing surface of filter base and then tighten cartridge 3/4 to 1 of aturn. -90- a After replacing cartridge, fill with engine oil through oil filler (F). After refilling with oil, start the engine and idle itfor a while. Then, stop the engine and check the oil level Refill capacity: GDS11A: 99 GDS21A, GDSZ3A: 242 ‘Thetype of lubricantused depends on the ambient temperature. Se- lect according to the table “FUEL. COOLANT AND LUBRICANTS”. Replace once every 6 months, regardless of the number of hours operated, Use API category CD classoil. IfCC class oil must be used. change the oil and replace the oil filter at half the usual interval.EVERY 250 HOURS SERVICE d. FINAL DRIVE CASE e. TANDEM DRIVE CASE (For GD511A) Check the oil level with oil level plug (P) 3 minutes after stopping the engine. If necessary, add oll through filler (F), ‘The type of lubricant used de- pends on the ambient tempera- ture. Select according to the table “FUEL, COOLANT AND LUBRICANTS”. eSEVERY 950 HOURS SERVICE {. CIRCLE REVERSE GEAR CASE 9. HYDRAULIC TANK (For GD521A, GD573A) Check the oil level with oil level Remove plug (F}. Check if the oil 1. Set the machine in position as fol- plug(G).Hnecassary.addoilthrough _levalisatthegearupperfaceAddthe ‘lows to check the oil level. filler (F). gear oilthrough fller(F),ifnecessary. © Returntheleaningofthefronttires % Thetypeoflubricantuseddepends Thetypeoflubricantuseddepends tothe upright position and face the: ‘on the ambient tempersture. Se- on the ambient temperature. Se- wheels straight to the front. lect according to the table *FUFL., lect according to the table "FUEL, @ Set the front frame and rear frame COOLANT AND LUBRICANTS". COOLANT AND LUBRICANTS", facing straight (articulated angk © Return the drawbar sidachift and blade sideshift to the center of the ‘set the blade at right angles to the chassis and lower it lightly to the ground © Raise the scarifier fully. 2. Checkthe oil level with sightgauge (G). Add engine oil through filler 16), nareceary machi aeh, FAN BELT (For GDS11A) + Thetype oflubricantused depends fon the ambient temperature. So lect according to the table "FUEL, COOLANT AND LUBRICANTS", Fun pulley sowton | Attrnator eulley Crankshaft pulley J Bivinen oit temperature ie high, do notremovecap. Hotoilsometimes spouts out. When removing the cap, turn it slowly to relieve inner preceure, -93-Every 250 HOURS SERVICE (For GDS21A, GDS29A) Fon pulley i gomeem | ‘Alternator pulley \ Aerantanstepuloy -94- |. The belt toncion chould normally deflect by about 8 mm when proceed with the finger st a point way between the altemator pulley and the fan pulley (approx 6 kg). . To adjust the belt tencion, loosen ott (1) and nut (2) and shift alter- nator (3) elightly. After adjustment, tighten bolt (1) ‘and nut (2) securely. Check for the damage to each pulley, wear of the V groove, and wear of V belt. In particular, check if the V belt contact with the bottom of the V groove. If the belt ie 20 over-extended that no adjustment allowance oxiets, oF if euttings or cracks are found, replace both belts.BALL JOINT (For GDS11) Remove all shims, Tighten the vap in such a manner that the clearances (shown in the picture) on both sides are the same. Measure the clearance with a thickness gauge, and place the shims which are thicker than the measured clearance by one shim, ‘Then, retighten the cap. One shim is equal to 0.2 mm thickness. ‘® Repeat this procedure for each ball =95— EVERY 250 HOURS SERVICE j. BATTERY ELECTROLYTE LEVEL eos the electrolyte level is below the prescribed level of 10t0 12mm above the plate, add distilled water. Should any of the acid be spilt, have it re- plenished by tne nearest battery snop with acid of the correct specific grav- ity. % Clean the air hole of battery cap along with the level check. * Never use metal funnel for elec- rolyte supply.very 2c0 Hours service Aire avoid gas explosions, do not bring fire or eparke near the bat: tery. Aiiithe slectrotyte gets on your skin or clothes, immediately wash with plenty of clean water. k, WHEEL HUB NUT Loose wheel hub nuts(1) willresult in chortened life of tires or troubles. Carefully check loosening of the nuts. % Cootthe threaded part with molyb. denum disulphide grease (NLG! No. 1) before tightening. % Tightening torque: 405 kgm ‘4 Chock all the nute for loosening. ‘Also, check the rim for damage. Ifa hub bettie broken, roplacethe total unit of the wheel stud 4% When checking for loose nuts, ‘always turn the nut in the tighten- ing direction to check. 96 iat PARKING BRAKE LEVER TRAVEL Check Hf the normal braking grip is effec tive by pulling the brake lever 2 to 3 ratchets from the brake release posi n, the brake lever travel ‘ered normal. If six or more ratchets are counted before the parking brake comes into effect, perform the following adjust- ment. consid- Adjustment _1. Move the machine as necessary until adjustment hole (1) is locat- ed to approx. 15 mm right side from the center bottom of the brake drum. The brake drum ro- tates one complete tum with every 29 cm of movement of the machine. 2. Insert the screwdriver into the ad- Juctment hole, Using the driver blade, rotate the adjusting screw in the “shoe expending” direction lower the screwdriver grip) to bring the shoe into close contact with the drum. Then, back the ad- justment screw eight clicks. {0.23 mm of shoe clearance will rooult) conn 3. * Then, adjust the yoke nut on ‘each end of the cable until proper lever travel (135 mm) can be obtain. After adjustment, try traveling the machine for about 500 meters and confirm that the brake dium is free from waling. (if some traling exists, the brake drum will become hotter than the drive shaft next to the drum) Wear of parking brake, if any, is caused by failure of releasing of the perking brake lever. Most of ‘wear will be accompanied with burning of the lining and discolo- ration of the drum. As burnt brake lining causes deterioration of braking effect, remove the drum end clean the burnt fining surface with sandpaper. amet * * EVERY 250 HOURS SERVICE Keep the lining surface free from ‘ll anc grease. It soiled with oil or grease, wipe off it and polish the surface with sandpaper. To check the parking brake for ‘normal function, pull the parking brake and start the engine. Dep- ress the inching pedal, place the gear shift lever in the forward 31d position, and run the engine at full speed. ‘The effect of the parking brake ‘can be considered normal if the ‘engine Is stopped when the pedal is gradually released. In this case, it should not be regarded as ab- ‘normal if the machine is moved slightiy. Do not attempt to repeat the above-mentioned parking brake test unnecessarily, as this test gives undue stress to the various parts in the power train.m.WHEEL BRAKE Check Adjustment if the height from the figor (H) is 1. Turn the adjusting gear, with the + Ifdeterioration of braking efficiency not within renge of 200t0 210 mm —_acrowdriver inzorted into the hole pected, check it ae follows: with the foot brake pedal fully de- on the lower side of back plate, 1) While the machine travels at Pressed, and the depressing height until the brake lining comes into about 20 km/h of traveling (S) is more than 80 mm, or if the _close contact with the brake drum. ‘speed, try lightly braking the braking effect is poor, adjust e2 fol 2. Backtheadjusting gear 4to Gelicke. machine (so as not to cause lows. 3, Fita 0.6 mm gauge in one side of ‘whee! locking) three times. the ingpection window on the left 2) Touch each brake drum by hand and right and check that the clear- tose whetherheating of drums ance on the other side is lees than folt or not 0.4mm. 3) Cold drums, if any, may be as- 4. After adjusting, cheok that the di cumed ineffective. pressing height of the brake pedal Brake lining with blocksurface due ia within 80 mm. to burning oF lining eolled with oil causes insufficient braking effect. Polish such alining with eandpaper. + After adjusting, travel the machine about 600 metore and confirm that four brake drums are free from overheating caused by trailing. -98—EVERY 500 HOURS SERVICE EVERY 500 HOURS SERVICE ‘* Maintenance for every 50 and 250 hours should be carried out at the same time. a. FUELFILTER (For GO511A} 1. Close the fuel vaive of the fueltank. 2. Using a filter wrench, remove car- {ge(1) by turning itcounterciock- wise. the filter base. If there is any old ‘there will be a gap when the new. gasket is installed and this will cause oil leakag 3. Fill he new cartridge with fuel and refit it after applying a dab of oil to the gasket face. To refit the cartridge, place the gasket face in contact with the seal face of the filter stand, then screw up the cartridge about 2/3 of aturn. . After replacing filter cartridge (1), ‘open fuel valve of the fuel tank. -99-EVERY 800 HOURS SERVICE 5. Loosen alr bleed plug (2) of the fuel filter. ©. Loosen feed pump knob (3) and move the pump up and down to draw’ off fuel until ait ceases to ‘come out of vent plug (2). 7. Tighten air vent plug (2). 8. Push in feed pump knob (3) and tighten ® After replacing the cartridge, start up the engine and check the filter seal face possible oil leakage. * Be sure to use a genuine Komatsu cartridge. b. TRANSMISSION FILTER 1, Remove bolts (1) (4 bolts on the outside) fastening the filter case (2); remove case. 2. Remove the element and discara. ‘Thoroughly clean the case interi- of and removed parts. install a new element. % Use genuine Komatsu element. = 100 — 4. CIRCLE GUIDE ‘Checking With the blade raised from the ‘ground, check the circle guide clear- ances at the portions (P) and (Ql, using tne teeler gauge. Standard clearance at portion (P) is 1.5 £05 mm. ‘Standard clearance at portion (@: {lr = 0 and (Q)a = 2.5 mm or (QiF (average clearance when rotat- ing circle) = (QR = 1mm F: Front R: RearSection A-A {Two places on the front side) Section B-B {Two places on the rear side) Adjustment 1 - To adjust the cles Rest the blade on the ground. ince at portion {), loosen bolt (1) and (3) and adjust thickness of shims for the circle guide (2) and (4). Two kinds of shims different in thick- ness (1 mm and 0.5 mm) are provided. . To adjust the clearance at portion, (Q), first loosen bolt (1), push circle guide (2) rearward to make ance (Q)F zero, and tem tighten bolt (1). (Slightly ‘move the machine forward, with the blade rested on the ground, to make the clearance (Q)F zero) Then, loosen the bolt (3). Loosen locknut (5) fastening bolt (6) and turn in the bolt to push circle ‘guide (4) until the clearance (Q)R becomes zero. Be sure to equally tighten right and left bolts (6)). 101 EVERY 500 HOURS SERVICE With the clearance (IR kept in zero, back bolt (6) half rotation, and tighten locknut (6). Back circle guide (4) until it comes into contact with bolt (6) and tighten bott (3). ‘When either of the following con- ditions arises, replace the circle guide. Clearance at portion (R) has de- creased to zero. Clearance between the circle tooth top ands circle reverse pin gear tooth bottom land has de- creased to zero or clearance be- tween the circle tooth bottom land and the circle reverse pin gear tooth top has decreased to zeF0.EVERY 600 HOURS SERVICE 4. RADIATOR FIN Dust, mud, or leaves sticking to, ‘and blocking, the radiator are to be blown off by compressed air. Stoam ‘or water may be used instead of the ‘compressed air, + Be careful not to bend the fin. + Check the rubber hose also. If any broken, or defective fixtures, or deteriorated parte are found, replace with new one. Check that the hose clamp is tight = 102 — comeEVERY 1000 HOURS SERVICE EVERY 1000 HOURS SERVICE * Maintenance for every 50, 250 and 500 hours: should be carried out at same time. a. LUBRICATING b. TRANSMISSION CASE Apply grease to the grease fie (For @DS11A) 4 eh fas ate 1. Drive shaft (2 points) +83 if (For GD521A, GD523A) = 103 =EVERY 1000 HOURS SERVICE Remove drain plug (P). After raining oil, tighten drain plug. Remove bolt (1). (2) and cover @). Take out strainer and wash out dust with diesel fuel, . After cleaning it, install strainer. Refill engine oll in specified amount throuah filler (F). For refilling procedure see the section EVERY 250 HOURS SERVICE. The type of lubricant used de- pends on the ambient tempera- ture. Select according to the table "FUEL, COOLANT AND LUBRICANTS”. Refill capacity: 34% = 104 = c. FINAL DRIVE CASE (For GD511a)(For GD521A, GD523A) 1, Remove drain plug (P) to drain oil (F) up to the prescribed level. 3. Forthe refilling procedure, see the item “EVERY 250 HOURS SERV- Ice", ‘& Thetype oflubricantused depends on the ambient temperature. Se- lect according to the table “FUEL, COOLANT AND LUBRICANTS”. % Refill capacity: GDSIIA: 122 GDS21A, GD523A: 242 = 105 — [EVERY 1000 HOURS SERVICE d. CIRCLE REVERSE GEAR CASE awe 1, Remove drain plug (P) to drain oil After draining, tighten it. 2. Refi the gear oll through filler (F) up to the predetermined level 2. For the refilling procedure, see the item “EVERY 250 HOURS SERV- Ice”.EVERY 1000 HOURS SERVICE ‘TANDEM DRIVE CASE (For GD5214, GDS73A) + Thetypeoflubricantuseddepands (For GD511A) 2. Ramoveoil level piug (G).then add ‘on the ambient temperature. Se- . engine oil through oi filler (F) until lact according to the table “FUEL, oil comes aut from level plug (Gi. COOLANT AND LUBRICANTS”. 3. Forthe refilling procedure, see the + Refill capacity: 42 ita “EVERY 250 HOURS SERV- Ice’. ‘ Refill capacity: 342 (each side) ‘ Thetypeof lubricant used depends fon the ambient temperature. Se- lect according to the table “FUEL, COOLANT AND LUBRICANTS”. 1. Remove drain plug (P) to drain oil. After draining, tighten it. — 106 —f. HYDRAULIC TANK AND FILTER (For GD511A) 1. Setthe machine in position as fol- lows to check the oil level. © Returnthe leaning of the fronttires to the upright position and face the wheels straight to the front. © Return the drawbar sideshift and blade sideshift to the center of the machine, set the blade at right angles to the chassis and lower it lightly to the ground. © Raise the scarifer fully. — 107 - EVERY 1000 HOURS SERVICE 2. Stop the engine and remove the rain plug. After draining oil, tighten drain plug. 3 Remove bolts(1)(4eacn) andcover (2) and take out element. “Then, clean the inside of the titer housing together with the other removed parts and repiace with a new element. 4, Refillenginecilinspecified amount through fille () 5. Forrefiling procedure, seethestem “EVERY 250 HOURS SERVICE”. Thetype of ubricantused depends ‘on the ambient temperature. Se- lect according to the table “FUEL, COOLANT AND LUBRICANTS". % Refill capacity: 30¥ % Use genuine Komatsu elements.EVERY 1000 HOURS SERVICE 9g. DRAWBAR FRONT BALL JOINT (For GD511A, GD521A) Check ball joint connecting nuts (1) at the front of the drawbar for loosening. if the connecting portions loose. retighten them. — 108 - h. TOE-IN Check toe-in and adjust it so that no side slip is caused. When no side slip tester is available, use the fol lowing procedure. How to measure toe-in: 1. Park the grader on @ level around without steering and leaning the wheels. Be sure to drive straight at least a few meters before parking. 2. Measure the height from the ‘around to the center of the front wheel axe.EVERY 1000 HOURS SERVICE 3. Mark on the front tire surfaces 4 Measure the distance between with the same measure taken by the two marks on the right and the above procedure. loft tires. This distance in named oa cms — 109 — 5. Drive the grader at a low speed and shift backward the mark on the tire. Stop the grader when ‘the mark's height from the ground curface hac become equal to the same value mea- sured in the procedure 2 6. Measure the distance between ‘the two marks, This distance is named “B”.EVERY 1000 HOURS SERVICE How to Adjust Toe-in: ‘When toe-in (8 — A) is adjusted to —5 = 1 mm of standard range side slip ie decreased to zero. If any value other than the standard range is measured, adjust tos-in using the following procedure: 1. Loosen nut (1). Turn the tie rad with a wrench put on square por- tion (2). Then, tighten the locknuts. Toe-in increases when tho wrench is tured in the direction shown by the arrow. and vice versa. The value of toe-in varies, by 6 mm when the tie rods are turned 1/3 rotation in the oppo- site direction to each other. Keep the front axle horizontally without any leaning. = 110 = FRONT WHEEL BEARING PLAY Raise the front wheels off the ground, using the blade or scarifier as a jack. Check hub turning torque with @ spring balance hooked to a hub bot. 1. The bearing play is normal if the front wheel is rotated smoothly with 8 to 12 ka of pulling force. 2.If the inspection shows that there is plav. or that the rotating force is small, adjust as follows.. Remove cover (1). Select proper shims (2) and set them tempo- rary. Tighten bolt (3) and rotate the shaft by more than 3 revolu- tions each for clockwise and counterclockwise directions. Loosen bolt (3). Reduce the umber of shims (rake out at = 0.1 or t = 0.3 shim), and decide the thickness of shims property 80 that the pulling force of the spring balance becomes to 8 to 12kg. This measurement of tne pulling force should be done after shaft (4) has been rotated by more ‘than 3 turns and ater the bearing has ceased rotati ‘Also wait until the bearing gets down to normal room tempera- ture for adjustment. <= EVERY 1000 HOURS SERVICE J, CORROSION RESISTOR (For GDBTTA) 1. Close valves (1). 2. Using the fiiter wrench provided, remove cartridge (2) by turning it counterclockwise. 3. Fit a new cartridge after applying @ dab of engine oil to the seal face.(For QD521A, GD523A) % To fit the cartridge, put the seal foce in contact with heed, then screw it up about 2/8 of atu. 4. Afterreplacement, open valves(1). “x Be sure to use a genuine Komatsu cartridge. Be careful not to screw in more then required. k. TURBOCHARGER ROTOR PLAY Have the turbocharger inspected by Komatsu to check it by yourself Using the following procedure: Remove the inteke and exhaust pipes and hoses from the turbo- charger. 1. Play in the axial direction Move the rotor and check for rotor play in the axial direction. Standard axial play: 0.025 - 0.100 mm tion in pa your hends on beth endo and ‘measure radial play. Standard radial ploy: 10.075 0.180 mm + If necessary play cannot be ob: tained, have the turbocharger re- peired by Komatou distributor. & If the rotor is excessively soiled ‘with dust or earben oF if any leakage caused by turbocharger ‘trouble ie noted, have the turbo- charger repaired by Komatsu dis- =112- 1, TURBOCHARGER VARIOUS FASTENERS ‘The performance of turbocharger «will be deteriorated when sir or gae leakage exists at the joint section of inteke and exhauet pipinge. Further, when leakage exists at oil food piping, ‘or prosoure may drop and bearings may be selzed. Poriodically inepect all joints for loosenessand, ifnecessary, retighten. Hany faultis detected, askKomatsu distributor to disassemble and repair or replace.‘¢ Turbine housing mounting bolt Tightening torque. 1.84 — 2.19 kgm ‘© Blower housing mounting bolt Tightening torque: 1.15 — 1.50 kgm ¢ Turbocharger mounting bolt (for securing the exhaust manifold and turbine housing together) Tightening torque. 60-75 kgm ‘© Turbocharger ol feed pipe {inlet line} Tightening torque: 2.8 -3.5kgm @ Turbocharger oil feed pipe (outlet ine) Tightening torque, GDBI1A: 28 — 3.5 kgm GD521A, GDS23A: 6.0 —7.5kgm =113- EVERY 1000 HOURS SERVICEEVERY 2000 HOURS SERVICE EVERY 2000 HOURS SERVICE ‘* Maintenance for every 50, 250, 500 and 1000 hours should be carried out at the same time. 2, FRONT WHEEL BEARING 3. Clean the axle and bearing, and —_b. ENGINE BREATHER GREASE (ON BOTH RIGHT clean out oll the old grease from (For GDE21A, GDE22A) AND LEFT SIDES) inside the hub. Fill the grease pan 1. Support the front axle ons block —_about half fullwith new grease. to raise the front wheel off the 4. Replace the hub seal and spacer ‘ground. Remove the wheels with new parts, + When raising the front wheels, * Coat the lip surface of the hub ‘securely apply the parking broke seal and the surface of oliding ‘and rest the biade and scarifier _parts with grease, fill the spacer fon the ground ‘between the lip with grease, then 2. Take off cover (1), remove lock assemble. (2) and holder (2), then remove Fill with groage 90 that grooze is hhub shaft (4), pushed between the axle and bearing. Make oure that groaco 1. Remove breather (1) from the also comes up around the bearing _ cylinder head. {alzo the outside bearing) befor 2. Rinse the whole breather in installing the hub shaft. diesel oil or flushing oil, dry with 5. After inotolling the hub chaft, compressed air, then install again ‘adjust the rotating force. For —_inthecylinder block. details, cee Inspecting and Ad- * Before taking the breather out of justing Play of Front wheel place, wipe the dust off the sur- Bearing. rounding area, When carrying out this mainte- * When restoring the element to its nance, please contact your original position, be sure to coat Komatsu distributor. the new O-ring with engine oil -114- cons¢. ALTERNATOR AND STARTING —‘f. TURBOCHARGER moron Excessive carbon or vil sludge ad- 4. Rotetetheimpeller by hand atleast The brush may be worn, or the hering to turbocharger blower _one turn at speed to check that beering may have run out of grease, impeller may lead to deterioration of there is contact noise of catching so please contact your Komatsu dis- normal charger performance, and _inside. tributor for inspection or repair. possible damage. Have turbocherge: _—iif the impeller does not turn + Ifthe engine is started frequently, cleaned by Komatsu distributor. smoothly, contact your Komatsu carry out inspection every 1000 1. Remove the turbocharger vil filer distributor for repair or veplace- hours. pipe and drain pipe, then remove _ment. the intake air pipe connector and 5. If thete is no abnormality, dry off d. ENGINE VALVE CLEARANCE blower housing so that the blower the light oil with compressed air ‘Ask Komatsu distributor to check _ impeller can be seen. after inspection, then add engine engine valve clearance because spe- 2. Using light oil asacleaning agent, oil. cial tools should be used. remove the carbon, sludge and ‘other dirt fromthe blowerimpeller. VIBRATION DAMPER. Do ot i i'l abnormality, contact your Komatsu 3. Pour in light oil through the tur- distributor for repaires. bucharger oil filler and rotate the blower impeller several times to wait out the sludge, -115—[EVERY 4000 HOURS SERVICE EVERY 4000 HOURS SERVICE + Maintenance for every 50, 250, 500, 1000 and 7000 hours should be carried out at the same time. ‘a. WATER PUMP Cheok that there io ne play in the pulley, grease leakage, waterleakage, or clogging of the drain hole. If any abnormality is found, please contact your Komateu dietributor for dieae- sembly and repair or replacement. ~116-WHEN REQUIRED WHEN REQUIRED a. CLEAN INSIDE OF COOLING ‘SYSTEM system, change the coolant andre.” Yesistorcartdge. When decicing the rato of ont EASE it onencr een ns cy ase tom Soong es ineacn tar ces Oe ore ‘to the table. ‘ter. temperature in the past, and decide * Swope machine onlvel ground Welver water, well wate or other —_‘from the mining re table glen when cleaning or changing the such water supply must be used, below. coolant Tomact your Korat dictaor, els toualy Heuaevo emdmeme a s Unve permanenttype ofanttreze. temperature about 10°C lower N.forsomereason,itisimpossible 4 Antifreezets flammable, sokeepit ing rate, to use permanent type antifreeze, away from any flame. Mixing rate of water and antifreeze vse ar antec contain eth stmospheric | 5 | -19/ -15|~z0| -28| -30 Coe a acogenacts a i setter ance weir sated | of vv] ule] 7 ee wt ft : Croce, | ery tor hiner “ger | as] ae a] 20/10] 7 Steer sonata aun ee | nate nee ne cz Wie. econimend, Use) et, aan ‘ethylene glycol (Drain antifreeze in spring, cooling system and when freeze density gauge to control the ees eee auil|Hcaessemmn coon ttawreemen Hisepdobod dering aes ee tee Setoeeenees ae =17-(WHEN REQUIRED Corrosion resistor (For GD511A) (For GD521A, GD523A) Water filler oe i, = :- = sr i i and tighten up 5. When the water reaches the 7. After draining water, use a flush- corrosion resistor valve (1). Vicinity of the water fille. put the ing agent to clean. 2. Tum cap (2) slowly untilit comes engine at low idling, open drain * We recommend the use of off. valve (3) and plug (4). then pass Komatsu genuine goods as the 3. Open drain valve (3) at the water through the cooling —_—flushing agent. Follow the in- bottom of the radiator and plug _ system for 10 minutes. structions on the label of the (4) on the side of cylinder block * When doing this, adjust the flushing agent to clean the to drain off the cooling water. inflow and outfiow of water so system 4. Drain off all the water, then close _that the radiators always full, 8. After washing the cooling up drain valve (3), plug (4), and 6. After flushing with water. stop system. drain off all tha water, pour in soft water (ex: city water) _—the engine. Close drain valve (3) __then close up drain valve (3) and up to the vicinity of the water and drain plug (4) after draining plug (4), and pour in soft water filler. water, (ex: city water) up to the vicinity of tha water filler =118-Drain valve (bottom of radiator) 10. ‘When the water reaches the vi- Cinity of the water filler, put the engine at low idling, open drain valve (3) and plug (4), then pass water through the cooling sys- tem until clean water comes out from drain valve (3) and plug (4). When doing this, adjust th flow and outflow of water so that the radiator is always full. When the water becomes com- Pletely clean, stop the engine, close drain valve (3) and plug (4. Drain plug (cylinder block) (For GD511A) 12. 13, Replace the corrosion resistor cartridge and open corrosion resistorvalve (1) (See EVERY 1000 HOURS SERVICE). ‘Supply water up to the vicinity of the water filler. Run the engine for § minutes at lowidling to eliminateairtrapped inthecooling system, andrunthe engineforSminutesathigh idling (leave water filler cap (2) off dur- ing this operation.) WHEN REQUIRED (For GD521A, GD523A) 14. Stop the engine and 3 minutes later supply water again up to Vicinity of the water filler and tighten water filler cap (2). Bio rot remove the cap while cooling water is hot. Hot water mar spout ut When removing radiator cap, lift the lever to relieve inner pres- plb. CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT Checking Cleaning oF replacing outer element (For GD511A) (For GDE11A) Whenever the red piston in dust indicator (1) appears, clean the air cleaner outer element. Stop the en- ine when cleaning the element. 120 -When ReauiReD Loosen wing nut (2),remove cover Replace both inner and outer ele- (8) and outer element. ‘ments when the dust indicator red . Clean the air cleaner body interior _—_ piston appears soon after install- and the removed cover. ingthecleaned outer elementeven . Cleanandinspecttheelement.(See though it has not been cleaned 6 the item “Cleaning outerelement” times. forcleaning procedure.) Installthe & Remove one seal from the outer cleaned element. ‘element. The number of times the Push the dust indicator reset but- outer element has been cleaned ton to retum the red piston tothe can be seen by the number of original position removed seals. + Replace seal washer (4) orwingnut Replace the outer element which (2)if they are broken. has been cleaned 6 times repeat- ‘* When inspecting or cleaning the edly ur used throughout a year. aircleaner, removeevacuatorvalve Replace the inner element at the (6) and clean with compressed air. same tine. -121-‘wun neauinen Replacing the inner element 1. After removing the cover and outer clement, remove the inner element. 2. Cover the intake opening. 3. After cleaning inside the body romove the intake opening cover. 4. Fix @ inner new element to the ‘connector and tighten the nut 5.Fix on the outer element and ‘cover and return the dust indica tor red piston to its place. NOTE: Do not attempt to re- inetall a cleaned inner element. Apo not clean oF replace the air cleaner element with the engine running. Cleaning outer element With compressed air Direct dry compressed air (less. than 7 kg/em#) to element from inside along its folds, then direct it from outside slong its folds and again from inside, and check alamant Aiwnen using compressed Wear safety glasses and other things required to maintain safety. = 122 ‘The following methods require spare parts. ‘With water Dash city water (less than 3 kg/em’) on element from inside along folds, then from outside and again from inside. Dry and check it With cleaning agent For removing oils and fats as well ‘as carbon etc. attached on the ele- ment, the element may be cleaned in lukewarm solution of mild deter- ‘gent, then rinsed in clean water and left to drip dry. % Drying can be speeded up by blowing dried compressed air Jess than 7 kg/cm?) from the to the outside of the element. Never attempt element. + Using warm water (about 40°C) instead of soapy water may also be effective. to heat theIf small holes or thinner parts are found on element when it is checked with an electric bulb after cleaning and drying, replace the element. If element is usable, wrap it and store itin dry place. %® Do not use element whose folds of gasket or seal are damaged. * When cleaning element, co not hitit or beatit against something. ©, ELECTRICAL INTAKE AIR HEATER Check electrical intake oir heater once @ year before commencing ‘work in the cold season. Remove electrical inteke air heater from the engine intake con- nection, and check it for possible open-circuits and dirt. ‘When inspecting and replacing electrical intake air heater, replace ‘the gasket with new one, = 123 = WHEN REQUIRED d. WATER SEPARATOR When float (2) is at or above red line (1), drain the water according to ‘the following procedure: 1. Loosen drain plug (3) and drain the accumulated water until the fost reaches the bottom. 2. Tighten drain plug (3). 3.1f the air is sucked into fuel line when drain the water, be sure to bieed air in the same manner as for the fuel fiter. (See Fuel Filter Certridge in EVERY 500 HOURS SERVICE section)ADLUSIMENT ADJUSTMENT ADJUSTMENT OF INCHING PEDAL ‘When any abnormal pedel condi- 1, At fullengine speed, the machine * These abnormal conditions con- tion such as mentioned below in no- moves when the inching pedal cerning inching pedal operation iced, consult your Komatsu dis- (1) is depressed and the gear are sometimes caused by trans- ‘ributor for checking, readjustment shift lever (2) is placed in the for _ mission troubles. Therefore, care- or reper of werd 1st speed position (The ful inepection of faulty conditions system. parking brake. lever (3) is left must be made by your Komatsu released. diewibutor not only about the 2. With parking brake lever (3) ap- _inching pedal control system, but plied, the brake pedal (4) de- algo about the transmission. pressed and the gear shift lever placed in the forward 6th (or reverse 6th) position, the engine does not stop within 2 seconds when the inching pedal is re- leased from the depressed position. etl ae cro"TROUBLE SHOOTING GUIDE TROUBLE SHOOTING GUIDE ‘The pointer of encine oil pressure gauge isin rad range on lott hand side of the gauge when engine speed is raised after com- pletion of warmup. (© Acc tne ow the specrted level (© Replace the ol elernent. 1& Check ailleakage rom the pipe or the joint (© Replace the pressure gauge. ‘Steam is emitted trom the top part of the radiator (the pressure valve! ‘The pointer of the water temperature geuge tein tight hand side ofthe gu ‘Supply the coolina water and check leakage. ‘Adjust fn belt tension, ‘Wash out inside of cooking system, Clean or repair ie raciator hn. Replace the thermostat, Tighten the radiator cap rly or replace the gasket of Replace the water temperature gauge. ‘The pointer of the water temperature gauge is in white range ‘oniefthand side of the gauge. 1 Replace th thormostot. 1 Replace the water temperature gouge, ‘The engine does not start when the starting motor ie tured. ‘A fuel 1 Repair where aris leaking into fuel system. 1¢ Replace the injection pump and the nozzle 1 Cheok the valve clearance '© Check engine compression pressure, ‘© Refer to the section of electrical system, [Exhaust gas is white or blue. (© Adjust specified oil quarticy (© Replace with specified fuel Exhaust gas occasionaly turns black. {© Clean or replace the sir cleaner element. © Replace the nozzle. (© Check engine compression pressure. Combustion noise occasionally changes to breathing sound. © Replace the nozzle. ‘Unusual combustion noise or mechanical noise. (© Repace with species tue © Check over-heatng Replace the muller (© Adjust valve clearance. conse — 125 =‘TROUBLE SHOUTING GUIDE ELECTRICAL SYSTEM CHASSIS Unusual neiae i emitted from the alternator, “Tractve force Is aching. lnaulicient wave speed Replace the alternator 4¢ Refer totam “Engine” (© Inspect and adjust transmission valve, ‘Starting motor dows not tum when starting switch i turned on. 1 Raleate parking brake lever. ‘© Check ane repair wiring. charge the beter. ‘Machine fis vo start xt any gear sift lever poston. © Add cil tothe specified level ‘The pinion ofthe starting matne Hawn gring inant at 1 lnanaet and ae ranemiecion vata © Charge the batey. Loud noise inthe power transmitting system. ‘Starting motor turns the engine sluggishly. 12 Add oi tothe specified level ‘© Charge the battery. + Replace he staring meter Excessive wear of front wheels © Adjust toe. ‘The starting motor dlsengages before the engine starts up. ‘eCheck and ropa wiring. Heat generation at front whee! hub ‘© Charge the batry © Apply grease, ‘The heater signal does not glow red. Front wheels sway while traveling Replace the ester relay. 1 Equalze ire pressure on each sie. ‘© Replace the heater signal © Check whee! instalation. Tighten front wheel bearing nut Cunside theribbon heater andthe collheaterisnot warm when touched, withthe end. = Check and reps wiring Replace the ribbon hestr and the coil heater. Check and repsirehe heater switch. — 126 -Steering wheel eels heavy. (© Ad arto front tire tothe specified preseure (© Apply grease staenng inksge, © Check engagement of ba nut 1 Comeet pining, Parking brake does not operate satisfactorily. © Adjust brake shoes. © Polish te ning with sand paper. 1 Claon the interior of brake drum. Excessive blade swing during wore (© Adjust shims of all joint and circle guide, '© Replace side bushing (= Correct bade ral, Excessive vibration of tha hisda whan rotating during werk, (© Adjust positon of ccle guide ‘Work equioment is siow to move by operating the control lever. © Add otto the specified ieve, ‘Wear of parking brake lining (© Adjust clearance between ring and crum. owns =127- ‘TROUBLE SHOOTING GUIDESTORAGE BEFORE STORAGE To place the machine in storage for an extended period of time, the following measures must be taken to insure that it can be returned to operation with minimum of service. @ After every part is washed and ried, the machine shall be housed in a dry building. Never leave it outdoors. In case itis indispensable to leave it outdoors, lay wood plates on ‘the ground, and park the machine ‘on the wood plates and cover it with canvas ete. © Completely fill fuel tank, lubricate and change oil before storage. © Apply sufficient quantity of ‘grease and oil replacement. STORAGE Lower the air pressure in the tires to about 80% of the standard ‘operating pressure. Give a thin coat of grease to metal surface (hydraulic. piston rods and oil seal) As to batteries, remove the termi- nals and place cover on them. or remove them from the machine and store separately. In case the atmospheric tempera- ture may drop below 0°C. add an- tifreeze in the cooling water. Set the gear shift lever to neutral position, set the fuel control lever to engine stop position. and apply the parking brake. — 128 - DURING STORAGE @ Operate the engine and move the machine for a short distance ‘once a month so that new oil film will be generated and exhaustion of oil film in a long period will be prevented. % Before using work equipment, wipe off the grease from the pressure cylinder rod. Adwinen it is unavoidably neces- sary to carry out rust- preventive operation indoors, ‘open all windows and doors to circulate the air and prevent ‘the accumulation of poisonous gases.AFTER STORAGE After etorage (when it is kept without cover or the rust-preventive eperation once a month is not made), you shall apply the following treatment before operation, @ Loosen the drain plugs on oil pan and other caces ond drain mixed water # You should request Kometsu dis tributor for following servi 9 Remove the cylinder head ‘cover and lubricate sufficiently valve and rocket arms, And inspect the valve operation. Engine with turbocharger only Remove the oil pipe flange on the turbocharger oil inlet, fll with 0.8 to 12 engine oil, and leave the flange lightly loosened. Then, rotate the ‘engine by the starting motor without fuel injection and decompression so that the discharge of oil is con- firmed. Then, tighten the flange and start the engine, — 129 — STORAGE ‘© To bleed the air from the hydrau- Nie cylinders or hydraulic piping, run the engine at low idling and do as follows. 1) Operate each hydraulic cylin- ders 4 to 5 times, stopping 100 mm from stroke end. 2) Next, operate each cylinder 3 tod times to the stroke end, % If the engine is run at nigh speed at first, or if the cylinder is moved to the end of its stroke, the air in the cylinder may damage the piston pack- ing, etc. © After the engine is started, oper- ate it until it is warmed up completely.‘SERVICE METER This meter indicates the in- ‘tegrated work hours. So, use it ac- cording to instructions. the following SERVICE METER ‘@ Record the readings at the start and the end of work, this Is the work record of the machine. fe Ths record will indicate when periodical maintenance is due. fe It also indicates the integrated working hours when machine problems are encountered. = 130 — * How the meter progresses: ‘The service meter progresses by 1 when the engine is operated for fone hour, regardless of the engine speed. Consequently, if the engine is running, the service meter will ad vance even if the machine does not"MACHINE AND ENGINE SERIAL NUMBERS. MACHINE AND ENGINE SERIAL NUMBERS. When calling for service of mechanic or when making repla ment perts order, be sure to give SAWN UO, Tre well as the service meter reading beforementioned. These numbers ‘are found on the plates shown in the photos below. ‘© Location of the machine seriat ‘number mark eal » on the left side of the frame =131— @ Location of the engine serial umber mark (For GD5114) cylinder blockFURL, COOLANT AND LUBRICANTS FUEL, COOLANT AND LUBRICANTS PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS a KIND OF "AMBIENT TEMPERATURE CAPACITY (2) RESERVOIR FLUID Pe a; eK 2 = a 38.3 BE [cocci | tee = SAE SD ‘SAE iow Ee] aa 4 Ensine oi pan EIR ah ea Sat Taso Tanumason ove Engiow ot eso 2 ™ ‘Tender drive cove (ach) 45 20 Final drive cate She 100 wee | 1208) Hydraulic sytem z SE ow e 2 Cirle revere guar cave ‘Gear oi aes: * rane i A To TT 77 ea [any INRNTAS TI Da7BNor Fuel nk ome ae | zr iw cooing syst vow | Addn 4 es ASTM 0975 0.1 — 132 — fi ). @0521A, COSZ5ANoTE: (1) When fuel sulphur contents less than 0.59%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according tw the following table If fuel sulphur content is above 0.5%. Fuel eulphur content | Change interval of oil in | engine oil pan 0.5 to 1.0% 1/2 of regular interval ‘Above 1.0% ‘V4 of regular interval ‘ASIM: American Society ot Testing and Material SAE: Society of Automotive Engineers ‘API: American Petroleum Institute Specified capacity: Total amount of oi Refill capacity: @ eo “ 6 Pe = 133 - FUEL. COOLANT AND LUBRICANTS. When starting the engine in an atmospheric tem- erature of lower than 0°C, be sure to use engine oll of SAE10W, SAE10W-30 and SAE1SW-40, even Though an atmospheric temperature goes up to 10°C more or less in the day time, Use API classification CD as engine oll and if API classification CC, reduce the engine oll change interval to hal. ‘There is no problem if single grade oil is mixed with ‘Muttigrade oil (SAETUW-30, ISW-60), but be sure to add single grade oil that matches the temperature in the table on the left. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applica- tions. including oil for components and oil in piping. Amount of oil needed to refill system during normal inspection and maintenance.FUGL, COOLANT AND LUBRICANTS. ana Anthfreece Bre - Gear ou creme Gosant wo.| suppor | SAEIOW, 38, 10 austere — | teenene Set worms | Sec | eee oy set eee) eor0c0 fesneo cose cou hi a €010-30cD Gor0 G2 SSIES Deval soma § 2| sce Stowrdesimt, | nova Me cawuer y | cxsmo, | cextiper | Hraoy Shera ena tee @ | erevnon | > eo ao Univenaisear | Ueeauy avaee2 = 134-FUEL, COOLANT AND LUBRICANTS. 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