Komatsu GD825A-2 Motor Grader Operation & Maintenance Manual (12116 and up) - PEN00013-00

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the GD825A-2 Komatsu Motor Grader (SN: 12116 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu GD825A-2 Motor Grader
Serial Numbers : GD825A-12116 and up


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : PEN00013-00
Total Pages : 263


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COVER
FOREWORD
FOREWORD
SAFETY INFORMATION
INTENDED USE
DIRECTIONS OF MACHINE
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
ENGINE SERIAL NO. PLATE POSITION
SERVICE METER POSITION
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR

CONTENTS

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

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

MAINTENANCE
GUIDES TO MAINTENANCE
OUTLINES OF SERVICE
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
RELATING TO ELECTRIC SYSTEM
WEAR PARTS
WEAR PARTS LIST
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS
TORQUE LIST
PERIODIC REPLACEMENT OF CRITICAL PARTS
CRITICAL PARTS
MAINTENANCE SCHEDULE CHART
MAINTENANCE SCHEDULE CHART
SERVICE PROCEDURE
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
WHEN REQUIRED
CLEAN INSIDE OF COOLING SYSTEM
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
CHECK ELECTRIC INTAKE AIR HEATER
REVERSE AND REPLACE THE END BITS AND CUTTING EDGES
REPLACING RIPPER POINT
CHECK INCHING PEDAL
CLEAN ELEMENT OF AIR CONDITIONER FRESH AIR FILTER
CLEAN ELEMENT OF AIR CONDITIONER RECIRCULATION AIR FILTER
CHECK REFRIGERANT (GAS) LEVEL
SELECTION AND INSPECTION OF TIRES
INSPECTING CORROSION, WEAR OF WHEEL RIM, LOCK RING, SIDE RING
CHECK BEFORE STARTING
EVERY 50 HOURS SERVICE
LUBRICATING
INSPECT WEAR OF BLADE GUIDE
EVERY 250 HOURS SERVICE
LUBRICATING
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE
CHECK OIL LEVEL IN TRANSMISSION CASE, ADD OIL
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
CHECK OIL LEVEL IN TANDEM DRIVE CASE, ADD OIL
CHECK OIL LEVLE IN CIRCLE REVERSE GEAR CASE, ADD OIL
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
CHECK LEVEL OF BATTERY ELECTROLYTE
CHECK BALL JOINT CLEARANCE, ADJUST
CHECK AND TIGHTEN WHEEL HUB NUT AND HUB BOLT
CHECK FAN BELT TENSION, ADJUST
CHECK ALTERNATOR BELT TENSION, ADJUST
CHECK AIR CONDITIONER BELT TENSION, ADJUST
CHECK, ADJUST FOOT BRAKE
EVERY 500 HOURS SERVICE
REPLACE FUEL FILTER CARTRIDGE
CLEAN, CHECK RADIATOR FINS
CHECK CIRCLE GUIDE CLEARANCE, ADJUST
CHECK PARKING BRAKE LEVEL STROKE, ADJUST
CHECK, ADJUST SLIP LOAD FOR DRY-TYPE CLUTCH FOR BLADE ROTATION GEAR
EVERY 1000 HOURS SERVICE
GREASE DRIVE SHAFT
GEEASE FAN PULLEY AND TENSION PULLEY
REPLACE TRANSMISSION OIL FILTER ELEMENT
CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER
CHANGE OIL IN FINAL DRIVE CASE, CLEAN STRAINER
REPLACE RETURN FILTER ELEMENT AND CLEAN SUCTION STRAINER IN HYDRAULIC TANK
CHANGE OIL IN HYDRAULIC TANK
CHECK LOOSENESS IN DRAWBAR FRONT BALL JOINT AND BALL STUD
CHECK TOE-IN, ADJUST
CHECK FRONT WHEEL BEARING PLAY, ADJUST
REPLACE CORROSION RESISTOR CARTRIDGE
CHECK FOR LOOSE ROPS MOUNT BOLTS
REPLAING AIR DRYER DESICCANT
EVERY 2000 HOURS SERVICE
CHANGE OIL IN FRONT WHEEL BEARING
CHANGE OIL IN CIRCLE REVERSE GEAR CASE
CHANGE OIL IN TANDEM DRIVE CASE
CLEAN ENGINE BREATHER ELEMENT
CLEAN BREATHER
CLEAN AND INSPECT INCHING POTENTIOMETER SENSOR
CHECK ALTERNATOR, STARTING MOTOR
CHECK ENGINE VALVE CLEARANCE, ADJUST
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER
CHECK PLAY OF TURBOCHARGER ROTOR
CLEAN, CHECK TURBOCHARGER
EVERY 4000 HOURS SERVICE
CHECK WATER PUMP
CHECK VIBRATION DAMPER
CHECK FAN PULLEY AND TENSON PULLEY

SPECIFICATIONS
SPECIFICATIONS

ATTACHMENTS, OPTIONS
HANDLING EMERGENCY STEERING DEVICE
CHECKING
AIR CONDITIONER
LOCATIONS AND FUNCTIONS OF CONTROL PANEL
METHOD OF OPERATION
PRECAUTIONS WHEN USING
HANDLING AIR-SUSPENSION SEAT
ADJUST OPERATOR'S SEAT

INDEX

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