Operation & Maintenance — ~“ Manual GOSIOR.: EDSIIR. BSR MOTOR GRADER GD510R-15370 SERIAL NUMBERS GD511R-10130 and up @D521R-10095 KOMATSUFOREWORD ‘This manual describes procedures for operation, handing, lubrication, ‘maintenance, checking, and adjustment. It will help the operator or anyone lie peak performance through effective, economical and safe machine operation and maintenance. © Please read this manual carefully BEFORE operating the machine. © Please continue studying this manual until proper operation is completely reinforced into personal habit. © This manual describes the basic techniques. Skill is performed as the ‘operator or anyone 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 \ marks and technical precautions with * marks in this ‘manual. The safety information contained in this manual is intended cnly to supplement safety codes, insurance requirements, local laws, rules and regulations. ‘¢ Some photographs and illustration pictures are different from your ma- chine as technical improvement is continuously reflected on it. Revision 0 up-to-date manual's content is performed in later editions. ‘© This operation & maintenance manual may contain attachments and op- tional equipment that are not available in your area, Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. FOREWORDBREAKING IN YOUR NEW MACHINE BREAKING IN YOUR NEW MACHINE Each machine is carefully adjusted and tested before shipment. However, ‘a new machine requires careful operation during the first 100 hours to breek in the various parts, fa machine is subjected to unreasonably hard use at the initial operation stage, the potential of performance will prematurely deteriorate and the service life will be reduced, A new machine must be operated with care, particularly with regard to the following items. After starting, et the engine idle © ifthe machine is delivered without * When replacing oil filter elements for 5 minutes to allow proper en- any cooling water in the radiator, (cartridges!, check their interiors gine warm-up prior to actual op- _flush the cooling system with am- _fordirtand dust. heavily collected, eration. plecleanwatertocleanthesystem, check for possible cause before '¢ Avoid operation with heavy loads then fill the radiator with cooling _starting operation. or at high speeds, water. + Hours of operation are indicated @ Sudden starting or acceleration, by the service meter. unnecessarily abrupt braking and sharp turning should be avoided.OPERATION GENERAL LOCATIONS AND SPECIFICTIONS. INSTRUMENTS AND CONTROLS. CHECK BEFORE STARTING OPERATING YOUR MACHINE OPERATING OF WORK EQUIPMENT REVERSING AND REPLACEMENT OF ‘CUTTING EDGE AND END BIT CHANGING TIRES DRIVING ALONG ROAD TOWING ......... COLD WEATHER OPERATION CONTENTS 4 21 29 46 88 56 58 59 60 MAINTENANCE PERIODIC MAINTENANCE MAINTENANCE TABLE OIL FILLER AND LEVEL GAUGE POSITIONS. F EVERY 50 HOURS SERVICE . INITIAL 250 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 GUIDE SERVICE METER . . MACHINE AND ENGINE SERIAL NUMBERS. FUEL, COOLANT AND LUBRICANTS 65 66 70 n 72 72 87 2 103 105 108 113 7 120 121 122[GENERAL LOCATIONS AND SPECIFICATIONS. GENERAL LOCATIONS AND SPECIFICATIONS 1. Blade lift cylinder 2, Rear tire 2. Blade Gpst1A-1 4. Drawbar side shift cylinder 5. Fronttire -4- MACHINE MODEL PERFORMANCE — 1. Travel speeds | Forward [ae tkervi)| Reverse 3. Graceability OPERATING WEIGHT| (kg) 4, Overturn angle | 2, Minimum turning radius (en ENGINE 1, Model | 2, Flywneet horsepower (HP) NOTE: Specifications are subject 10 change without notice.Gost | GoBrIR Gose1n-1 ams we in 266 544 , - 54.4 [104 104 7 104 a [oe i ore ~ 20" 30° 30° 10700 | ~—~10800~——| "10800 | Komatsu S6D96L-1 iesel engine | Komatsu S60108-1 diesel engine eel axceall wT {at 2900 rpm) (at 2500 rpm) (at 2500 rpm) GENERAL LOCATIONS AND SPECIFICATIONSINSTRUMENTS AND CONTROLS INSTRUMENTS AND CONTROLS METERS, GAUGE AND PILOT LAMPS 1. ENGINE COOLING WATER ‘TEMPERATURE GAUGE Engine is rormal when indicator is on green range during operation. After starting engine, continue to warm up engine until indicator points green range If indicator is over green range, keep engine in low idiing and wait til temperature drops,2, ENGINE OIL PRESSURE PILOT LAMP 3, BATTERY CHARGING LAMP This lamp indicates 2 low engine oil pressure. If the lamp goes off, the engine oil pressure is normal, ‘When engine is cool, this lamp lights up. In this case warm up ‘engine until this lamp goes off. This lamp is used to indicate the ‘generating condition of the alterna- tor. Normally, when the start- ing switch is turned ON, the lamp will light up and then go out as the ‘engine speed rises. INSTRUMENTS AND CONTROLS 4. PARKING BRAKE PILOT LAMP OO When the parking brake lever is pulled, this lamp lights up. Before. Starting the machine, release the parking brake lever and check that the lamp goss out. 5. SPEEDOMETER Indicates the running speed of the machine. It also contains an odometer,INSTRUMENTS AND CONTROLS 6. SERVICE METER The service meter indicates the total number of operating hours of the machine, ‘While the engine is running, the indicator of the meter will rotate to indicate that the meter is turing ‘0973 7. HEATER SIGNAL ‘When the starting switch is set to the HEAT position, the heater signal will glow red after about 30 seconds or so, indicating that both the ribbon heater and coil heater are on, @Ds10R The prehesting time will very depending upon the ambient temperature, Accordingly refer to the section COLD WEATHER OPERATIONINSTRUMENTS AND CONTROLS ‘SWITCHES 1. DIMMER SWITCH 2. HORN BUTTON 3. TURN SIGNAL LEVER This switches the head lamp be- When the button in the center of tween high beam and low beam. the steering wheel is pressed, the @: High beam horn will sound. ®: Low beam This lever operates the turn signal lamps © LEFT TURN: Push lever upper @ RIGHT TURN: Push lever lower % The tur signal is not canceled when the steering whebl is re- tumed. Return the lever by hand, canst -9-INSTRUMENTS ANO CONTROLS 4, STARTING SWITCH OFF we } a This switch is used to start or stop the engine. OFF At this position, the key can be inserted or removed. When the switch is turnedto this position, the electrical circuits are switched off andthe engine stops. on When this position (ON) is reached by rotating clockwise for ‘one step, the charging circuit and the lamp circuit are electrified. This position (ON) shall be held after the engine is started. GD510R START Starting motor starts revolution by rotating the switch clockwise fur- ther for one step. And the engine is started. The key will be automatically re- stored to the position ON by releas- ing the key. So, you shall release the key once the engine is started. =10-HEAT Use this position when starting in cold weather. Release the key to allow it to return automatically to OFF and then, without delay, turn it to START. + Never place starting switch key in OFF position while engine is running. This will damage the alternator. * When starting, be sure to use the starting key. INSTRUMENTS AND CONTROLS. 5. HEAD LAMP SWITCH 6. WORKING LAMP SWITCH When the switch is pulled, the ON: Working lamps light, side marker lamps, tal lamps, panel lamp and head lamps willlight up, AMWhen traveling on public. Position) ‘roads, turn the working lamps Side marker lamps, tail lamps, off. {and pane! lamp light up. Position 2) Head lamps light up in addition to above lamps. -1eINSTRUMENTS AND CONTROLS REAR WIPER SWITCH 8. CAR HEATER SWITCH 9, FRONT WIPER SWITCH ore = Low - Nigh The wiper is actuated at low After starting the engine, pull this The wiper is actuated at low speed, when the switch is pulled as switch to operate the heater. speed, when the switch is pulled as far as the first stop, ‘The temperature can be adjusted far as the first stop. ‘The wiper works at high speed, to three levels, ‘The wiper works at high speed, when it is pulled as far as the when it is pulled as far as the second stop, second stop. Turn the switch clockwise to spray solventon the glass. -12- canstINSTRUMENTS AND CONTROLS CONTROL LEVERS AND PEDALS 1. WORK EQUIPMENT CONTROL LEVER These levers operate the work equipment. 1. Left blade lift lever 5. Drawbar side shift lever 2. Blade side shift lever 6. Leaning lever 3. Power tit control lever 7. Scarifier it lever 4, Blade rotation control lever 8. Right blade tilt lever GDS10R wox78 |] ass -13-INSTRUMENTS AND CONTROLS 2. STEERING POST TILT PEDAL This lever is used to control the engine speed and output. ‘@ Low idling position: Push the lever fully. @High idling position: Pull the lever from low idling posi- tion © fully. + When the gear shift lever is in the 5th or higher speed position in either forward or reverse, it be- comes interconnected with the fual contro) lever to prevent over- tun and acts to reduce engine speed. ‘+ Use the fuel control lever only during actual work, When running the machine along a road, use the accelerator pedal. Depress the pedal, and the steer- ing post cane tted ‘Adjust to give a suitable oper ing position for your physique. -14-4, GEAR SHIFT LEVER This lever is used to change the transmission gear. 6-speed forward and 6-speed reverse transmission can be per- formed by simply moving this lever to desired speed positions. When the levers left placed in any position other than neutral, the engine is pre- vented from starting. When the lever is moved to a reverse position, the back-up buzzer sounds, 5, GEAR SHIFT LEVER GD510R This gear shift lever is operated in conjunction with the forward- reverse lever, and can control the speed in 8 stages for forward and 4 stages for reverse, -15- INSTHUMENTS AND CONTROLS 6. FORWARD-REVERSE LEVER GDS10R For lever positions shown above are 69 (high), N (neutral), (low) and ‘®reverse). in combination with the eer shift lever, this lever provided various travelling speeds of the machine. 4 As a rule, use position when the machine is only travelling and © positon when the machine is brought ia work.INSTRUMENTS ANO CONTROLS. 7. GEAR SHIFT LOOK LEVER vox J} Go fo a [¢ This is the lever for locking the gear shift lever. Pull the lever up to lock the gear shift lever. ‘When parking the machine, be sure to place the gear shift lever in neutral and lock with this lever. 8. ACCELERATOR PEDAL ‘This pedal controls the engine ‘speed and output. The engine speed can be freely controled between low idling and full speed. 9. BRAKE PEDAL The brakes are applied on the four rear wheels when this pedal is depressed. Do not put your foot on this pedal unnecessarily. 10. PEDAL FOR BANK LOCK-PIN CONTROL This pedal is used for controlling the blade to the bank cut position and shoulder reach position. ~16- 411, INCHING PEDAL Depressing this pedal cuts the power to the wheels. ‘The pedal is used for smooth stopping or starting, or when chang- ing between Forward and Reverse. When used in st 2nd or 3rd speed, it enatles fine control of the machine. (However only when the blade, ete, has no load and is on flat ground.)A. Be inching pedal can be used im Forward and Reverse, but should not be used for starting inath speed or above AX continuous use of the inching pedal to give a partially en- gaged clutch condition should be limited to 10 seconds. Never use the inching pedal in this way continuously for more than 10 seconds. It the inching pedal is used in this way for more than 10 seconds, the life of the machine willbe markedly reduced. INSTRUMENTS AND CONTROLS 12, CLUTCH PEDAL 13. PARKING BRAKE LEVER GDs10R The muin ctch is clsongaged by The brake ia applied to. the sepressing this pedal When tho output shaf ofthe wenasson by peut is depresed, the nara brake pling this vero the mt actuated The. action of the ineria brake When parking or ising the during the speed up enables easy machine, be sure to apply the ‘gear engagement. parking brake. (For adjustment, see the section ADJUSTMENT) eeINSTRUMENTS AND CONTROLS. DUST INDICATOR OPERATOR'S SEAT (For GD510R) Q a. This device indicates clogging of the air cleaner element. When red piston (1) appears in the transparent ‘part of this indicator, the element is, clogged. Immediately clean element. After cleaning, push indicator button (2) to return red piston to ‘original position Forward-backward Adjustment Move lever (1) to the left, set the seat in the desired position, then release the lever. Range of adjustment: 125 mm (6 stages) ~18-(For GD521R) he Forward-backward Adjustment Move lever (1) to the left, set the seat in the desired position, then release the lever. Range of adjustment: 125 mm (6 stages) Seat height adjustment To LOWER seat, turn knob (2) to RIGHT. To RAISE seat, turn knob (2) to LEFT. Range of adjustment: 190 mm (Free stages) INSTRUMENTS AND CONTROLS. FUSE BOX The fuses protect the electric devices and wiring from burning out. GDS10R Loosen bolt (1) and cover (2). % Replace a fuse with another of the same capacity. remove Aicetore replacing « fuse, ve sure to turn off the starting switch, -19-INSTRUMENTS AND CONTROLS, Fuse arrangement and circuit Terminal mark | Fuse capacity Ciruit t 10a | Lamps 1 10A = ‘Working lamp, Rear lamp, R 104 | Tursignal imp, Beck-up orp 1 108 | instruments, Horn 108 | Stoplamp vu 40a | Lamps —20-CHECK BEFORE STARTING CHECK BEFORE STARTING ‘The check before starting shall never be neglected as troubles are prevented beforehand by the check. 8, Welkaroundthemachine bodyand _¢, CHECK ELECTRICAL WIRING check whether thereisany trace of Check for damage of the fuse and leakage of oil or water. in particu- any sign of disconnection or short lar, the joint of high pressure hose circuit in the electric wiring. Check ‘and hydraulic cylinder should be also for loose terminals and tighten aid special attention, any loose parts. Check the following {In case leakage is found, inspect points carefully. the leaking location and stop the © Battery leakage. When leakage is not Starting motor stopped, youarebeggedtorequest® Alternator repair to Komatsu distributor. ' Inspect the tightening of boits and MIF the fuse is damaged or there is ‘nuts on every section. When loos- any sign of shortcircuiting in the ened ones are found, apply in- _alectric wiring, always investigate ‘creased tightening. In particular, the cause and correct it. attachment positions of air cleaner ‘and mutfler should be paid special Please contact your Komatsu dis- attention. tributor for investigation and cor: rection of the cause. pees . CHECK AND REFILL COOLANT. an Remove radiator cap (1) at the top rear ofthe machine and check that the cooling wate’ reachesthe area marked by shaded lines. Add water if neces: sary. * If the volume of coolant added is ‘more than usual, check for pos: sible water leakage.‘CHECK BEFORE STARTING Bice notremave tie cap tile cool vou weter te het, Hot water rey spout out. When removing the fever tor ator cap, lift jeve inner pressure. e. CHECK OIL LEVEL IN ENGINE OIL PAN (For GDS10R, GD511A) us (For GDs21A} 1. Use dipstick (Gi to check the ol revel 2. The oil level should be between mark Land H. Ifnecessary, add oil atoil filer + Thetype oflubricantused depends on the ambient temperature, 5 lect according tothe table “FUEL, COOLANT AND LUBRICANTS” 4 When checking the oil level, park the machine on a level surface stop the engine and wait for 15 minutos before checking -22-(CHECK BEFORE STARTING f. CHECK AND REFILL FUEL 9. DRAIN WATER AND TANK ‘SEDIMENT IN FUEL TANK (For GD510A) wha . yr. rae 1. Use of dipstick (G) to check the * A clogged cap breather hole (1) fuel level may stop the fuel flow to the 2. Top up the tank through the filler engine. {F} after the day's work is over. Check it from time to time and clean. + Fuel capacity: 227% ‘* When adding fuel, never let the fuel overflow. This may cause @ fire ~23-CHECK BEFORE STARTING h. CHECK AND REFILL BRAKE FLUID (For GD521R) 1. Check the fluid level of the brake fouid supply tank in the opera- tor's compartment. 2. Add brake fluid through the filler (F), ifnecessary If the brake fluid has to be topped up every frequently, an oil leak is indicated. Check the pip- ings for the leak Loosen fuel tank drain valve (1) and drain sediment and water accu- mulated at the bottom, together with fuel = 24% Keep the brake oil always at the MAX level % Use caution to prevent the mixing of the mineral oil with the brake fluid when refiling, as this will cause the rubber part of the bbrake oil line to perish, leading to defective brake operation. The special vessel must be used only for refiling the brake fluid. %* When refiling with brake fluid, be careful not to splash fluid about on the painted surfaces. Brake fluid, if splashed, will affect the painted surfaces. i. CHECK AND ADJUST STEERING WHEEL. When checking steering wheel play, start engine and raise front Wheels off ground. The standard steering wheel play is 10 to 12 mm, If the play is beyond standard or steering is abnormal, contact your Komatsu distributor. 25 — CHECK BEFORE STARTING i. CHECK AND ADJUST TRAVEL OF BRAKE PEDAL ay The standard pedal play is 5 mm. Be ene phnaehaine iecerior een Fie neet a an eden Using the procedure given in EVERY 250 HOURS SERVICE.CHECK BEFORE STARTING . CHECK AND ADJUST BRAKING ABILITY The braking ability is enough if the braking distance is 14 m or below at the initial speed of 35 ken/h. For insufficient braking ability, refer to EVERY 250 HOURS ‘SERVICE (WHEEL BRAKE) 1. CHECK PARKING BRAKE FOR NORMAL LEVER TRAVEL ‘The lever travel is found normal it 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 adjustment procedures. -26- If the machine is started in travel with the parking brake lever left in pulled position, brake lining will be burnt and braking effect will be greately deteriorated. Mostly, this will be accompanied with discoloration of the brake drum. If a brake lining is once burnt, normal braking effect will not recover unless very thin, burnt layer on the lining surface is polished with sandpaper.m.CHECK AND ADJUST TIRE PRESSURE Standard pressure (13,00-24~8PR) Front whee! 1.8 kg/cm? Rear wheel 1.8 kg/om? Make sure that tire and rim is free from wear and damage, and that hub nuts are not loose, 1. CHECK DUST INDICATOR (For GDS10R, GD511R} (For GDS21R) 27 - CHECK BEFORE STARTING When air cleaner element is clogged, the red piston of dust in- dicator (1) reaches service lavel and gets locked. In that case, clean element refer- ring to the section "WHEN REQUIRED” ‘ter cleening element, push button to return red piston,CCHECK BEFORE STARTING 0, CHECK LAMPS FOR SWITCHING, DIRT AND DAMAGE. p. CHECK HORN. q. IS THE COLOR OF EXHAUST GAS NORMAL? F, DO THE INSTRUMENTS FUNCTION NORMALLY? s, HAVE ANY DEFECTS WHICH WERE FOUND DURING THE PREVIOUS DAY'S OPERATION BEEN CORRECTED? t. CHECK THE DOOR LOCK FOR NORMAL FUNCTION. (MOTOR GRADER WITH CAF u, CHECK THE WINDSHIELD WIPER, WINDOW WASHER AND DEFROSTER FOR NORMAL FUNCTION. CHECK FOR SUFFICIENT WASHER FLUID LEVEL. (MOTOR GRADER WITH CAB) v. CHECK FOR SEDIMENT AND WATER IN THE WATER SEPARATOR The water separator separates water mixed in the fuel. If float (2) is ‘at or above red line (1), drain the water. For the draining procedure, see section “WHEN REQUIRED”. ‘* Even if a water separator is installed, be sure to check the fuel tank to remove water and sedimentiin the fuel. 28 -‘OPERATING YOUR MACHINE OPERATING YOUR MACHINE @ For GDS10R BEFORE STARTING THE 1. Before starting the engine, check 3. Is gear snift lever (2) in the NEU- ENGINE the position of all levers. TRAL position? x Carryout aninitel inspection. (For _* Engine wil not start unless gear Artiivecontrtieveraretouchedby —~ detaisofthe inspection seCHECK "shitter NEUTRAL accident theworkequipmentmay BEFORE STARTING} move suddenly. When leaving the 2. Is parking brake lever (1) in lock operator's compartment, always position? set the safety lock securely to the ee er damp cloth to wipe off the dust prsurow peenirbepietan the battery. 4. Is work equipment control levers (3) at the neutral (HOLD) position? 0390 -29-‘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. + Put the fuel contro! 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, oFF as Of wer Ww Bs — 30 - * Do not leave key in START for ‘more than 20 seconds, 4 If engine will not start, repeat the starting procedure after about 2 minutes. % When using low cetane fuel, starting ability at normal tem- peratures will be reduced. in such cases, starting will be facilitated by adopting the procedure for low-temperature starting. % Never place starting switch key in OFF position while engine is running % To start engine in cold weather, tefer to COLD WEATHER OPERATION. Special starting ‘When starting after running out of fuel, fil with fuel , then fill the fuel filter cartridge with fuel and bleed the air from the fuel system before starting, Refer to FUEL FILTER in EVERY 500 HOURS SERIVCE.‘OPERATING YOUR MACHINE CHECKS AFTER STARTING After starting the engine, do not 1. Pull fuel control lever (1) and run 2. Run engine with light load unti ‘operate the machine immediately. the engine at medium speed for engine water tempereture gauge First carry out the following opera- about § minutes with no load. indicator (2) moves into green tions and checks. range. 3. Afterwarm-uprun,checkall gauges and warning lamps for proper operation. 4. Check for normal coloration of exhaust, any abnormal sound or vibration, Donot run the engine at tow idling or high idling for more than 20 minutes. Ifitisnecessary torunthe engine at idling, apply a load from time to time or raise the engine speed to a midrange speed. -31-OPERATING YOUR MACHINE TO MOVE THE MACHINE OFF 2. Free parking brake lever (3) and check that parking brake pilot lamp goes off 1. Depress clutch pedal (1) and put the gear shift lever (2) in the desired speed position. ® chine will start. 3, Release clutch pedal (1), depress. ‘accelerator pedal (4), and the ma- + When starting machine, keep the following care in mind. © The vacuum pressure warning i Vi buzzeris not sounding, WS ‘@ The parking brake pilot lamp OE | goes out. -32- + If some difficulty is felt for mesh- ing gears, once place the gear shift lever in the neutral position, Try slightly depressing the clutch pedal repestedly to vary gear po- sition, Then, move the gear shift lever again to the desired posi- tion. If a difficulty still remains, do not atiempt to engage the ‘gears forcedly, but repeat the ‘abovementioned precedure. + Before starting to climb a steep hill, move the gear shift lever to ‘the 1st spaed position and dep- tess the accelerator pedal while releasing the clutch pedal with the parking brake lever left locked. As soon as the machine ‘moves, unlock the packing brake lever and release the clutch pedal completely.CHANGING GEAR SPEED Acceleration 1. Push gear shift lever (1) lightly back in the direction of the N (Neutral) position, release accel- erator pedal (2), then depress clutch pedal (3) to the first stage ‘and move gear shift lever (1) to the N (Neutral) position, 2. Depress clutch pedal (3) fully, wait for approx. 1 second, then move gear shift lever (1) up to the next gear position, [i i }. Release clutch pedal (3) and dep- ‘ess accelerator pedal (2), iss) ‘OPERATING YOUR MACHINE Deceleration 1. Push gear shift lever (1) lightly back in the direction of the N (Neutral) position, release accel- erator padal (2), then depress clutch pedal (3) to the first stage and mova gear shift lever (1) to the N (Neutral) position, 2. Release clutch pedal (3) and dep- ress accelerator pedal (2) to raise the engine speed.‘OPERATING YOUR MACHINE 3, Depress clutch pedal (3) to the first stage, then move gear shift lever (1) down to the next gear position, 4, Release clutch pedal (3) and dep- reee accelerator pedal (2). ‘* Do not decelerate when the ‘engine is running at full throttle. High-Low shifting ‘The procedure for switching be- ‘tween high and low speed is the ‘same as the procedure for shifting up or down, but when shifting, the ‘engine speed should be as follows. + When increasing speed, lower the engine speed to approx. 1/2 of the speed before shitting, %* When reducing speed, reduce the engine speed to approx. 900 rpm before shifting. ~34— FORWARD: REVERSE SHIFTING ‘Always stop the machine when switching between FORWARD and REVERSE. 1. Depress brake pedal (1) to reduce the travel speed, then depress clutch pedal (2) to stop ‘the machine.2. Set forward-reverse lever (3) to the desired position, then depress. accelerator pedal while slowly releasing clutch pedal (2) to start the machine, ‘Speedometer ranges. The white range on the speed- ‘ometer is installed mainly as a guide for deceleration, * He Fa (Forward high 3D) Forward high 4TH) 2 . (Forward high 2ND} When decelerating, reduce the travel speed to the top part of the white range of the speed range for fone gear below, then shift down one gear. 36 - * ‘OPERATING YOUR MACHINE When the speed goes down on uphill slopes, use the method given above, but when reducing speed on downhill slopes, do as follows. When decelerating, reduce the travel speed to slightly lower than the top part of the white range of the speed range for one ear below, then shift down one gear. When traveling downhill, use the engine as a brake to prevent the travel speed from going over the white range for that gear speed position.OPERATING YOUR MACHINE TURNING ‘TO STOP THE MACHINE The grader turns to the desired side by turning the steering wheel (1) to that side. 3. Set gear shift lover (4) to eutral position, then pull perking brake lever (5) to apply the parking 1. Release accelerator pedal (1) 2. Depress brake pedal (2). Before the machine come to a stop, dep- ing to the turning side will _ ress clutch pedal (3). Astop the machine on hard and minimize the turing radius. ‘even ground to prevent it from tn case the grader tums while falling down o slipping. reversing, leaning t0 the opposite of the turing side wil minimize Ainvton the machine is to be left the turing radius ‘topped for a while, leave the + In case the leaning wes used for fengine in low iling or stop the turing, return the steering whee! fengine. Apply the gear shift after the leaing was returned fever lock’ and. the parking brake 36 - cosTO STOP THE ENGINE \ i) 1. Idle the engine at low speed for about § minutes to cool it. 2. Turn the key of starting switch (1) to the OFF position to stop the en- gine, and remove the key. %* Do not attempt to stop a hot engine immediately unless it is necessary. Such unreasonable operation will cause remarkable shortage of life of the various engine parts. % Specially when stopping an over- heated engine, be sure to cool the engine gradually by idling it at ‘a middle idling speed, -37- ‘OPERATING YOUR MACHINE(OPERATING YOUR MACHINE @ For GD511R, GD521R BEFORE STARTING THE ENGINE 1. Before starting the engine, check 3. Is gear shift lever (2) in the NEU- the position ofall overs. ‘RAL positon and locked? Aitiinecontotloversaretouchedby # Carry outaniniiainspection. (For Engine wil not star unless gear dccident thewerkequipmentmay detalsofthe inspectionsze CHECK shit overs in NEUTRAL. trove suddenly. When leaving te BEFORE STARTING) A operator's compartment, always 2. Is parking brake lever (1) in lock : Cotihe safety lock securely tothe position? LOCK position. Bi betore starting the engine, use a damp cioth to wipe off the dust accumulated onthe top surface of the better. 4, 1s work equipment contro! levers {@) at the neutral (HOLD) position? = 38-TO START THE ENGINE 1. To start the engine, put the key (2) to the START position and turn over the starting motor. ofr wen awwss 2.As soon as the engine starts, release the starting switch key {2) to allow it to return automati- cally to ON position. + Put the fuel control lever (1) in the low idling position. ~39- OPERATING YOUR MACHINE % Do not leave 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 OPERATION. Special starting ‘When starting after running out of fuel, fil with fuel , then fill the ‘uel filter cartridge with fuel and bleed the air from the fuel system before startirg Refer to FUEL FILTER in EVERY 500 HOURS SERIVCE.(OPERATING YOUR MACHINE CHECKS AFTER STARTING ‘After starting the engine, do not 1. Pull fuel control lever (1) and run 2. Run engire with light load until ‘operate the machine immediately. the engine at medium speed for engine weter temperature gauge First carry out the following opera- about 5 minutes with no load. indicator (2) moves into green tions and checks. range. 3, Afterwarm-uprun,checkall gauges and warring lamps for proper operation. 4, Check for normal coloration of ‘exhaust, eny abnormal sound or vibration. + Do not run the engine at low idling ‘or high idling for more than 20 minutes. Hitis necessary to runthe engine at idting, apply a load from time to time or raise the engine speed to « midrange speed. —40-TO MOVE THE MACHINE OFF 11. Depress inching pedal (1) and set gear shift lever (2) to 1st, 2nd ‘and 3rd speed, * Do not start with the gear shift rin Ath speed or above. (OPERATING YOUR MACHINE CHANGING GEAR SPEED 2. Free parking brake lever (3) and check that parking brake pilot lamp goes off. Acceleration 3, Release inching pedal (1), dep- Partially release accelerator pedal ress accelerator pedal (4), and (1) and shift gear shift lever (2) the machine will start. to the nex: stepped-up position. * When starting the machine, ccheck that the parking brake pilot lamp goes out. -41-(OPERATING YOUR MACHINE Deceleration Release accelerator pedal (1) to decrease traveling speed and shift gear shift lever (2) to the next stepped-down position. ‘%* When shifting gear, always shitt ‘one speed at a time, © Speedometer range ‘White ranges on the speedome- ter are for the 6th speed, 5th ‘peed and Ath speed from the right to the left. They are mainly used for guessing the time at which stepped-down shifting is to be made. 5th, tn On deceleration, watch the speedometer pointer. When the pointer reaches the right end of 2 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 indicator reaches the right end of the white range. ing downhill use the engine brake or wheel brake to keep the indicator within the white range for that speed. ~42— FORWARD-REVERSE SHIFTING ‘Always stop the machine when switching between FORWARD and REVERSE. 1. Depress brake pedal (1) to reduce the travel speed, then depress irching pedal (2) to stop the machine.2. Set gear shift lever (3) to the desired position, then depress ac- colerator pedal while slowly releasing inching pedal (2) to start the machine, TURNING ‘The grader turns to the desired side by turning the steering wheel (1) to that side. ~" tl %* Leaning to the turning side will minimize the turning radius, In 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 turing, return the steering wheel after the leaning was returned. (oer =43— ‘OPERATING YOUR MACHINE ‘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)(OPERATING YOUR MACHINE TO STOP THE ENGINE 3. Set gear shift lever (4) to neutral position, then pull parking brake lever (5) to apply the parking brake. 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 en- Aistop the machine on hard and AM Emergency brake gine, and remove the key. leven ground to prevent it from If an emergency stop has to be falling down or slipping. made when the machine is traveling, use the parking Ainven ine machine is to be left brake together with the wheel stopped for a while, leave the bak engine in low idling or stop the When the emergency brake engine. Apply the gear shift has been used, check the park- lever lock and the parking 19 brake lining, then replace brake. the lining. = 44+ Donotattemptto stopahot engine immediately unless itis necessary. ‘Such unreasonable operation will cause remarkable 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 clayey stant will ‘cause the machine to slip easily. © If the engine stops, depress the brake pedal immediately with full force, and at the same 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 shift lever to the neutral position or depress inching pedal during downhil traveling. ease ‘OPERATING YOUR MACHINE © This machine has two brake con- trol systems. If one breakes down the other is still offective. However because braking capacity is re- ‘duced drive slowly when traveling, © Usetheperking brake asnecessary to compensate insufficient effect Of the wheel brake. Ai the engine stops, the brake booster will not work, so the pedal: will become heavier and the brak- ing effect will drop even ifthe brake is depressed withthe same force.(OPERATING OF WORK EQUIPMENT OPERATING OF WORK EQUIPMENT OPERATION METHOD OF THE WORK EQUIPMENT CONTROL LEVER There are provided eight work equipment control levers, which are operated as are indicated in the fol- lowing figures. * When operating the work equip- ment control lever, sufficient at- tention is required for the move- ment of the work equipment and its movement range must be limited, as the work equipment or the hydraulic cylinder possibly hit against parts, damaging them, Left-side Control Lever Right-side Control Lever Blade iting Blade hovzontat Drawbar side Bact tog (ets shifting Powertiit_ Bade rotation shting Seater (ight Bool eG) _ fh i A.CAUTIONS IN OPERATION OF WORK EQUIPMENT © When the work equipment is operated, special attention should be given to contacts at the following parts. Front wheel and blade Rear wheel and blade Blade and step (For GDS10R, GD511R) (For GDS10R, GD511R) (For GDS10R, GD511R) -47—LOFERATING OF WORK EQUIPMENT Blade and frame (For GDS10R, GDS11R) sae (For GD521R) ADJUSTMENT IN SHIFTING OF WORK ATTACHMENT It is essential to shift the work at- tachment to an optimum position for each work, to allow high job 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. fe Projection toleft_ Position (1) (For GDS10R, GDS11R) —48- (For GD521RiPROPULSION ANGLE OF BLADE ‘Angle of blade and body center line is called the blade propulsion angle. {In the normal scraping 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 soil in front of the blade is difficult to carry or throw to the side. momen fl ADJUSTMENT OF BLADE CUTTING ANGLE {In hard soil cutting, it is advisable to lean the blade forward. As the soil becomes softer, lean the blade ‘more backward. This operation will improve job efficiency. It is essential to adjust the blade cutting angle, depending on the soil condition, ‘The range through which the blade cutting angle can be adjusted is 26.5° to 75.5°. This range is step- less, so any angle within the range can be chosen freely, — 49 ~ OPERATING OF WORK EQUIPMENT ‘ Installation of this power tilt blade gives the following advantages. 1. Optimum blade cutting angle can be obtained by operating the contol lever for soil quality, Large ‘Smat Sollqualiy: Hard Sollquatity: Soft 2. Since the cutting edge can be set to the desirable angle, a powerful breaking is available to cut the frozen surface during snow removal. \\torae \ Smal \ Frozen sutace Solt nowOPERATING OF WORK EGUIeMeN ‘SAFETY DEVICE OF BLADE 3. If the blade is operated with the hydraulic tip control, the distance (For GDS10R, GD511R) between the cutting edge and the excavation surface changes. This means that fine adjustment of the excavation surface is possible. pp on) (For GD521R} A shear pin (1) is provided on the CIRCLE to prevent the blade from unexpected failure, because of ab- normal impact load placed on the blade edge during operation. if the shear pin is broken during operation, remove bolt (2) and lock plate and pull out the shear pin to replace by % If the deformation of the shear pin hole is more than 0.6 mm. use another hole. 4, In the iow-banking position when raising the dirt and snow, the op- timum blade cutting angle can be selected to increase operating efficiency. sorBANK-CUTTING POSTURE (RIGHT SIDE) to 1. Fully protrude the blade and the drawbar to the right so that the blade angle shown in the figure can be obtained, 2. Depress lifter lock pin pedal (1) ‘on operator's compartment to remove pin (2) + If the pin cannot be removed be- cause of interference with lifter (3), operate the blade lift cylin ders as necessary, = 3, ae Rotate lifter (3) by protruding the right-hand blade lift cylinder piston rod and retracting the left- hand blade lift cylinder piston rod. When top hole {A} jin lifter approaches pin (2), r Jock pin pedal (1) and slowly rotate the lifter until pin (2) enters hole (A). Eee OPERATING OF WORK EQUIPMENT 4, Retract the right-hand lift cylinder and protrude the left-hand cyli der. Repeat this several times so that the crcle is rotated with the blade raised on the right-hand side, and desired bank-cut pos- ture can be attained. * When bringing the blade into bank-cut posture, be careful not to clash the blade against various protions of the machine,OPERATING OF WORK EQUIPMENT + When bringing the biade into bank cut posture on the left-side of the machine, changeevery “left-hand” and “right-hand” in the above mentioned description with each other. + Relocating the blade side-shift cyl- inder piston rod mounting position to the right (when right-hand bank cutting is made) or tothe left (when left-handbankcuttingis made) will improve bank cutting efficiency. (See side-shifting of the Blade.) Adonotattempttodepressthebank control lock pin removing pedal unless the blade is rested on the ‘ground. ifthe pin is removed with the blade raised off the ground, dangerousfalling of thebladewith rotation of the circle may result. ‘SHOULDER REACH POSTURE (RIGHT SIDE) 1, Rotate lifter (1) in a similar manner to the bank cutting posture, and Jock it using bank control lock pin @. 2, Rotate the circle to the desired position. ‘ Put the machine in the left hand side shoulder reach posture using the same procedure as the above. —52- When increasing the size of the shoulderreach,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 @ posi- tion where the blade is thrusted to left. When banking to left, to a position where thebladeisthrusted oright,ADJUSTMENT OF SCARIFIER a, ADJUSTMENT OF CUTTING ANGLE As the soil becomes harder, a ‘wider cutting angle increases job efficiency, ‘Adjustment ni Me Remove bolt (1) and select a bolt hole adequate to the cutting angle. ‘The cutting angle is adjustable from 61°, 68° (standard) 74°. ‘OPERATING OF WORK EQUIPMENT PRECAUTIONS FOR b. ADJUSTMENT OF CUTTING SCARIFIER OPERATION DEPTH As the cutting depth is adjustable from tooth, adjust the tooth to job property. Adjustment © When the machine body is raised by using the blade as a jack, = while the scarifier is left lifted to al the top position, the drawbar will come into collision with the scari Remove the cotter .pin, pull _—_fier. This will cause damage to wedge (1) and change the notch uf ——the drawer. tooth (2). —53-‘OPERATING OF WORK EQUIPMENT ee we ‘© When turning the blade, with it several cm off the ground, the blade may touch the scarifier. This may damage the upper part of the blade -54-prior to replacing, TURNING AND REPLACING 1. Lift the blade to a suitable height ‘ond put a block undernesth the blade rail to prevent its falling Ado not «: ‘cossarily high. Be sure not to put your body un- ath the blade when block- ‘the blade unne- REVERSING AND REPLACEMENT OF CUTTING EDGE AND ENO &T 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 edges before they wear dowr to ‘a width of less than 10 mm from blade base). When wear is extended to the mounting faces, their repair must be done sa ay 2. Clean the mounting face after detaching the cutting edge and the end bit. 3. Mount the cutting edges after in- verting it, or replacing it with new one. 4. Mount the end bits after inverting ‘and switching right for left, or replacing with new ones. ~55— * Tightening torque for the mount- ing nuts: 26.8 + 3.5 kgm + Tighten the nuts again after several hour's operation. * If both ends of the cutting edge and side edges are worn out, re- place them with new ones.chancine TineS CHANGING TIRES HOW TO CHANGE TIRES: 1. Front wheel 1) Lower the work equipment to the 4) Ininstallingnewtires, tighten lightly ground, set the gear shift (parking _with the tires lifted and tighten the brake) lever to the P position to _tires to the specified torque in the apply the parking brake. ‘order shown in the photos, after 2) Then, attach the socket wrench _ placing the tires on the ground. (accessorymachinetool)tothehub _% Coatthethreaded part with molyb- nuts and {loosen allthe hubnutsby -—-_denumdisulphidegrease (NLGINo. 3/4 t0 1 turn. 1) before tightening. 3) Depressthe lifteylinder. tthe front Tightening torque: 405 kgm tiresarelifted, ockthe control lever, remove the hub nuts and change Aj Wheneverthefront tires areraised all the tires. off the ground, support the front ale center frame on the block to assure safety. —56— 2 3 Rear wheel Repeat the front wheel change procedures 1) and 2) Depress fully the right and left lift cylinders and the front tires are lifted about 50 om off ground. Re- tract the lift cylinder on the side wherethe :ireis notremoved, to lift the rear wheels. Install new tires according to the procedure ) of the front wheel tire change, Coat the threaded part with molyb: denumdisulphidegrease(NLGINo. 1) before tightening, + Tightening torque: 40% 5kgm Aiwhenover the rear wheels are raised off the ground, stably sup- port the tandem on the block to assure salety.CHANGING TIRES. HOW TO USE LEANING STOPPER AXwiren a front tie punctures, do When the leaning pipe is dam- not attempt to travel the ma- aged, temporarily prevent the front chine by temporarily applying a wheels from leaning so that the ma- ppad to the swing stopper. fit is chine can be successfully self- necessary, travel the machine propelled to the nearest repair shop. slowly only within the min 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. to0l box, Ait tHe machine is travelled with the leaning 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 Have the faulty leaning paired by mechanics quickly. coon -s7~DRIVING ALONG ROAD DRIVING ALONG ROAD In addition to strict observance of traffic laws and rules concerned. keep the following in min POSITION OF BLADE WHEN PRECAUTIONS WHEN TRAVELING (For GDS10R, GDS11R) TRAVELING ON ROADS When traveling, set the blade at To relieve operator's fatigue, the minimum propulsion angle and take a rest by 30 minutes ~ 1 hour raise the blade fully = 30 minutes mode, every 80 ‘ Be careful to keep a clearance be- tween the blade and front tres. kilometers or every 2 hours of trav- eling (whichever term expires earlier. (For GD521R) neo ~58—‘TOWING THE MACHINE This machine must not be towed ‘except in emergencies. When towing the machine, take the follow- ing precautions, ‘When engine can be used. ‘© Always keep the engine running when towing the machine, so that the steering and braking can be used, When engine cannot be used. @ When transporting 9 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 than the above mentioned, or if more than ‘one 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 oi! will _be supplied to the transmission. The gears and bear- S are rotated, so this may ‘cause them to be damaged, * When the engine cannot be used (the steering booster cannot be used, operation of steering wheel is difficult, so run the machine slowly, —59- TOWING‘COLD WEATHER OPERATION COLD WEATHER OPERATION PREPARATION FOR LOW TEMPERATURE f the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, 0 do as follows. FUEL AND LUBRICANTS Change to fuel and oil with tow viscosity for all components. 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 mix- ture when changing the coolant, ‘see WHEN REQUIRED. —60- Care in using Antifreeze Use a Permanent Antifreeze (ethylene glycol mixed with corro- sion inhibitor, antifoam agent, etc! meeting the standard requirements a8 shown below. With permanent antifreeze, no change of coolant is required for a year. If it is doubtful ‘that an available antifreeze meets the standard requirements, ask the supplier of that antifreeze for Information, Standard requirements for perma: nent antifreeze e SAE. : @ FEDERAL STANDARD : 0-A-5480 J1034‘* Never use methanol, ethanol or propanol based antifreeze, * Where no permanent antifreeze is available, an ethylene glycol an- tifreeze without corrosion inhibi- tor may be used only for the cold season. In this case, clean the cooling system twice a year in spring and autumn). When refill- 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. Aantitrosze is tiammabie, so keep it away from any flame. row BATTERY As ambient temperature drops, battery capacity will drop, and elec- trolyte may sometimes freeze if bet- tery charge is low. Maintain battery at a charge level of approx. 100% and insulate it against cold tempers ture 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 Ta {RE aoe | or | soe] -ae tos Piae | ize] 190 | vai sox | 126] 127] 126 | 129 ton | 126 | 125 126 | 127 rom _| 123 [120] 126 | 126 1 COLD WEATHER OPERATION % When electroiyte level is low, add distilled water in the morning before work instead of after the day's werk. This is to prevent fluid from freezing at night. AX1o avoid gas explosions, do not bring fire or sparks near the battery. Ait the otectrotyte gets on your skin or clothes, immediately wash with plenty of clean water.(COLO WEATHER OPERATION STARTING IN COLD WEATHER 1. Set fuel control lever (1) at the For attention of engine starting, HALF OPEN position refer to section “OPERATING YOUR ay MACHINE", \ TO START THE ENGINE Gosi0R oe : CaS po ae ey ae Ql + \o @D810R *% oa2. Put starting switch (2) in the HEAT position to red-hot heater signal (3). ok OFF Net oy a + Never put the fuel control lever or the accelerator pedal in the full speed position when starting the engine. Necessary preheating time is as follows, Ambient temperature | Preheat time ‘Above O"C : C10 ~ 10 10 seconds =10C1 20° | 30seconds % If the preheating time is too short or too long, the engine will be dif- ficult to start, so always keep to the correct preheating time. 3. When the heater signal (3) glows red, turn the key to the START position to start the engi WAT OFF 4. Release the key of starting switch (2), and the key will return ‘automatically to ON. COLD WEATHER OPERATION 5. Put fuel control lever (1) in LOW IDLING position, GD510RCOLD WEATHER OPERATION % Do not leave key in START for ‘more than 20 seconds. % If the engine does not start up despite carrying out the above ‘operations, leave it for about 2 minutes and then repeat the above procedure 2 and 3, % Once the engine starts up, thor- oughly warm up the engine before putting the machine into operation. Initially, put the gear shift lever in the lowest position, and then gradually apply the load. Ai nover use starting aid tds 08 they may cause explosions CAUTIONS AFTER COMPLETION OF WORK 1. Mud and water attached on the machine. Mud can easily be removed soon after it has adhered to the ma- chine, Dried or frozen mud will not only become difficult to remove, but also cause various defects. In particular, water drops collect- ed on the surface of the piston rod of the hydraulic cylinder shalt be fully wiped out. When water drops is frozen on the surface of the piston rod, the seal may be broken. 2. When washing the machine, be careful not to throw water on the alternator and breathers. —64— AFTER COLD WEATHER When weather becomes warm, perform the following without fail: '@ Replace lubricating oils for vari- us units with the ones specified for warm-weather use. fe If for any reason permanent anti- freeze cannot be used, and an ethyl glycol base antifreeze (winter, one season type) is used instead, cr if no antifreeze is Used, drain the cooling system completely, then clean out the inside of the cooling system thor~ ‘oughly, and fill with fresh water.PERIODIC MAINTENANCE PERIODIC MAINTENANCE Proper lubrication and maintenance assure trouble-free operation and fong machine life. Time and money spent for scheduled periodic mainte- nance will be amply compensated by prolonged machine operation and re duced operating cost. All hourly figures given in the following descriptions are based on service meter readings. In practice, however, it is recommended to rearrange all of ‘them into units of days, weeks and months to make the maintenance ‘schedule more convenient. Under rough job site or operating conditions, itis necessary to somewhat shorten the maintenance intervals stated in this ‘manual, -65-MAINTENANCE TABLE MAINTENANCE TABLE No. item ‘SERVICE No. rem SERVICE PAGE CHECK BEFORE STARTING 0 | Lamps: ‘Check | 8 ‘2 | Olt and water leak ‘check mE Horn | creck 28 | Nuts and bots Check ane rt a | eet pt cole [eneee [as «| Electric wring check tighten | 2 | Instruments eck | | Coolant eck and only | 2 Previous dav's defects Chek «| Font Check andupoly | 23 | Hepa, window water ond | | @ | Fuiwe Deena oy | acer snarar | inspect float postion | 28 | erate tia check andsupniy | 24 . al mi i_| Stering we! pay Cheek [as "EVERY 60 HOURS SERVICE 7_| Broke peda! wavet Grecxanaaaue | 2 a | tvtriatng | in | Braking aby Cmckenaeowwe | 28 | cree tube | “Tieinguatawarsae’” POwatwasaoe [38g] em gamiar Tanase om | Fie presre Check and oat | | Bust ndietor Check IMAINTENANCE TABLE No. Tem SERVICE [PAGE Wo TEM SERVICE [PAGE EVERY 250 HOURS SERVICE “3 | Crawbar ba join Lubriewte point | 78 (The ina marke "are cari out aftr the fit 250 hours only new machines) 8 Scarier ball oint Lubricate 4 points | 74 + | Fost oer Revioce caries | 72 10 Scarier ytinger pin Lebrieate 2 points | 78 «+ | Transmision cae ara tiver | Grange OTE 13a | ies it cyngor you Lubricate 6poims | 74 «+ | Fit aie ca Change ot 72-12 Blade it eyinder ba joint | Lubricate 2 points | 75 + | ete rverse ar ce Chong ot 7213, | Bae SAR Ngee poms | 78 + | Fane rive cave hone ot 7214 | Bank contol guide LubrieateSpoins | 75 + | Hvdrautie tank and filter sags aa 2 | Transmission case ‘Check and supply | 75 gS Check ansasust | 72 _¢ | Eranwalloanandiiw [Shamans 1 75 | Lerieating 72a | Final rive ca Cheek and supeiv | 78 3 | Leaning evince im Lubricate poms | 72 | Tandemariwcam (| Chackandsuppw | 78 2| Leaning regent Luricate2points | 72 | Ciel everse gear cae Check naspely | 79 3 | Tieroa uorcate 2points | 72 | Hydraulicrank =| Chuck andwupply | 79 “4 | te breker kingpin Lubricate 4 pointe | 79 h | Fan bere 7 20° 5 | Leaning in Looriate2points | 731 | Baljoint 7 32 Steering evlinder Luricate 4 points | 72. |_| Battry elctvoiye tre @ -7 [Front ate conte in Lubriatet point | 73 | Wheel hub mut Check andvetightan | 53MAINTENANCE TABLE me rem senvice [rae re senvice pace (EVERY 280 HOURS SERVICE) + | Foam ee [emer a 1 | Parking bake ever heck raved fot | Hvarauictank ana titer | anmegrand, | 96 | Wane crac inonauar | as 8 | rnber ont ato | Cmexiontnw | of TF - | | toon check iodadn | ~ — TH [Fontan beringpiey | Gheckandociow | 99 [EVERY soo HOURS SERVICE i | Corrosion resistor Replace candor | 100 = | Fetter enero | a7 arco wo) sc kant non [02 © | Grete guice ‘heck cewrance | 88 | __ EVERY 2000 HOURS SERVICE @ | Radiator fin Clean co | Front when bearing | Largs eet Fh" yop ~ - | [nen tGo5B) | Cow [ EVERY 1000 HOURS SERVICE © | Aternator and wating motor | Check [08 2 | Cobricating TG | Engine vane ciewrance | Gheckandachast | 108 Orwestot GORIGRT | Libram Sonne | 91. © | Viretoncemoer __| oneck 104 > | Tranuision eve [Cranes and [oy | Turbocharaer Checkandcien | 104 | inal drive ene Changeot | 98 EVERY 4000 HOURSSERVICE | | Circle reverse gear care ‘Change oi 4 Wier pum heck 105inca ances oe WHEN REQUIRED == = i ‘cme Races [09 = i ss erm -69- (MAINTENANCE TABLEOL FILLER ANO LEVEL GAUGE POSITIONS. OIL FILLER AND LEVEL GAUGE POSITIONS 1. Fuel tank level gauge and oi filler 8, Tandem drive case drain plug 2. Hydraulic tank oil filler 9. Tandem drive case level gauge plug 3. Hydraulic tank level gauge 10. Transmission case ol filer 4. Cooling water inlet 11, Transmission case drain plug 5. Engine oil pan oi filer ond level gauge 12, Circle reverse gear case drain plug 6. Final drive case oil filer 13. Circle reverse gear case oi filer 7. Tandem drive case oil filler wi 1098765 = 70- coun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 GDS10R, GDS11R) (For GDS10R, GDS11R) (For GD521R) (For GD521R}) “1EVERY 250 HOURS SERVICE + Maintenance for every 50 hours should be carried out at the same time. Carry out the following mainte- nance only after the first 250 hours. a. LUBRICATING Apply grease to the grease fittings FUEL FILTER, REPLACE shown by arrows. CARTRIDGE 4, Leaning cylinder pin (2 points) ¢ TRANSMISSION CASE AND (For GDS10R, GD511R) FILTER, CHANGE OIL AND 8, REPLACE ELEMENT FINAL DRIVE CASE, CHANGE OIL © CIRCLE REVERSE GEAR CASE, CHANGE OIL ¢ TANDEM DRIVE CASE, CHANGE ol ¢ 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, seethe section ‘on EVERY 500 HOURS, 1000 HOURS: AND 2000 HOURS SERVICE. 2. Leaning rod end (2 Points) 3. Tie rod (For GD510R, GDS11R) (2 points) 10423EVERY 250 HOURS SERVICE (For GD521R) 5. Leaning pin (2 points) (For GD521R) 4. Knuckle bracket king pin 6. Steering cylinder (4points) 7. Front axlecenter pin (1 point) (4 points) (For GDS10R, GD511R}) (For GD510R, GD511R)EVERY 250 HOURS SERVICE (For GD521R) (For D521) 10, Scarifier cylinder pin (2 points) 8. Drawbar ball joint (1 point) 11, Blade lift cylinder yoke (For GD510R, GD511R} 9. Scarifier ball joint (4 points) (6 points)EVERY 250 HOURS SERVICE b. TRANSMISSION CASE 12. Blade lift cylinder bail joint (2 points) ‘cylinder ball joint (2 points) (For GD510R, GD511R}) 14, Bank controlguide (3 points) Check the oll level with oil level gauge (G). essary, add oil through filerEVERY 200 HOURS SERVICE ¢. ENGINE OIL PAN AND FILTER (For GDS10R, GD511R) ‘& Make an oil lvel check 5 minutes after the engine is stopped, % The type of lubricant used de- pends on the ambient tempera~ ture. Select according to the table “FUEL, COOLANT AND LUBRICANTS”, -76-1 2. Loosen drain plug (P) to drain oil After draining, tighten it Using a fier 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. Wait atleast 10, minutes after stopping the engine before replacing the filter cartridge. 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 a turn. After replacing cartridge, fill with engine oil through oil filler (F. After refilling with oil, start the engine and idle it for a while. Then, stop the engine and check the vil level -17- EVERY 250 HOURS SERVICE Refill capacity: GDB10R, GDST1A: 9 GDs21F: 22¢ Tho type of lubricant used depends on the ambient temperature. Se- lect according to the table “FUEL, COOLANT AND LUBRICANTS". Replace once every 6 months, re- gardiess of the number of hours operated, Use API category CD class oil, CC class oil must be used, change the oil and replace the oil filter at half the usual intervalEVERY 280 HOURS SERVICE d, FINAL DRIVE CASE @. TANDEM DRIVE CASE (For GD510R, GDS11R) Check the oil level with oil level plug (P) 3 minutes after stopping the engine. if necessary, add oil through filler () The type of lubricant used de- pends on the ambient tempera- ture. Select according to the table “FUEL, COOLANT AND LUBRICANTS” -78-(For GD5218) ia Check the oil level with oil level plug (G). necessary, add oil through filer (F. % The typeof lubricant used depends ‘on the ambient temperature. Se- lect according to the table “FUEL, COOLANT AND LUBRICANTS”, f. CIRCLE REVERSE GEAR CASE Remove plug (F). Check if the oi level is atthe gear upper face. Add the {gear oil through filler (F), ifnecessary. + The typeof lubricant used depends on the ambient temperature. Se- lect according to the table “FUEL, COOLANT AND LUBRICANTS”. -79- 1 EVERY 250 HOURS SERVICE HYDRAULIC TANK Set the machine in position as fol- lows to check the oil evel. Return the leaning of the front tires tothe upright position and face the wheels straight to the front. Return the drawbar sideshift and blade sideshift to the center of the machine, 20t the blade at right angles to tre chassis and lower it lightly to the ground. Raise the scarifier fullyfh. FAN BELT (For GDS10R, GD511R) 2. Check the oillevel with sight gauge (G). Add engine oil through filer {F}, if necessary. Thetypeoflubricantused depends on the ambient temperature. Se- lect according to the table “FUEL, COOLANT AND LUBRICANTS”. Funpulley pont) sr ntey \ conan Adnieen cit temperature not removecap. Hot ‘spouts out. When removing the cap, turn it slowly to relieve inner pressure. high, do sometimes = 80 -EVERY 250 HOURS SERVICE (For GD521R) 1. The belt tension should normally deflect by about 8 mm when Pressed with the finger at e point midway between the alternator pulley and the fan pulley (approx. 6 kg). 2. To adjust the belt tension, loosen bolt (1) and nut (2) and shift alter- ‘nator (3) slightly 3. After adjustment, tighten bolt (1) and nut (2) securely, + Check for the damage to each Pulley, wear of the V groove, and Fanputey wear of V belt. In. particular, | Or check if the V belt contact with | x the bottom af the V groove. | Avera pulley ae HF the belt is 80 over-extended that no adustment allowance D ‘oxist, oF if eutings or cracks are OM eranesnatt pty found, replace both belts -81-EVERY 260 HOURS SERVICE i, BALL JOINT (For GD510R, GD511R) Remove all shims. Tighten the cap in such @ manner that the clear- ances (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 clear- ance by one shim. Then, retighten the cap. One shim is equal to 0.2 mm thickness. % Repeat this procedure for each ball joint in the work equipment linkage. -82- j. BATTERY ELECTROLYTE LEVEL If the electrolyte level is below the prescribed level of 10 to 12 mm. above the plate, add distilled water. ‘Should any of the acid be spilt, have it replenished by the nearest battery shop with acid of the correct specit- ie gravity. % Clean the air hole of battery cap along with the level check. + Never use metal funnel for elec- trolyte supply.Ai. 7o avoid gas explosions, do not bring fire or sparks near the bat- tery. Bitte sectrtyte gets on your skin or clothes immeatly wash with plenty of clean water. k. WHEEL HUB NUT Loose wheel hub nuts (1) will result in shortened life of ties or troubles. Carefully check loosening of the nuts. + Coat the threaded part with molyb- denum disulphide grease (NLGINo. 1) before tightening. % Tightening torque: 405 kgm + Check all the nuts for loosening, Also, check the rim for damage. Ifa hub bolts broken, replacethetotal unit of the wheel stud When checking for loose nuts, always turn the nut in the tighten- ing direction to check. ~83— EVERY 250 HOURS SERVICE |. PARKING BRAKE LEVER TRAVEL Check {f the normal braking grip is effec- tive by pulling the brake lever 2 to 3 ratchets from tho brake release pos tion, the brake lever travel is consid ered norma. If six or more ratchets are counted before the parking brake comes into effect, perform the following adjust- ment.EVERY 260 HOURE SERVICE Adjustment _ Brake drum 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 turn with every 29 cm of movernent of the machine Insert the screwdriver (2) into the adjustment hole. Using the drive blade, rotate the adjusting screw in the “shoe expanding” 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 result) —84— 3. Then, adjust the yoke nut on each end of the cable until proper lever travel (135 mm) can be obtaind, % After adjustment, try traveling the machine for about 500 meters and confirm that the brake drum is free from trailing, (if some trailing 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 parking brake lever. Most of wear will be accompanied with burning of the lining and discolo- ration of the drum, ‘As. burnt brake fining causes deterioration of braking effect, remove the drum and clean the burnt ining surface with sandpaper.+ Keep the lining surface free from oil and grease. if 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 broke and start the engine. Dep- ress the inching pedal, place the gear shift lever in the forward 3rd 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 slighty % Do not attempt to repeat the above-mentioned parking brake test unnecessarily, as this test ives undue stress to the various parts in the powertrain, m. WHEEL BRAKE Check If the height from the floor (H) is, ‘not within a range of 200 to 210 mm with the foot brake pedal fully de- pressed, and the depressing height {S) is more than 80 mm, or if the braking effect is poor, adjust as fol- lows, ~85— veRY 260 HOURS ecnvice Adjustment 1. Turn the acjusting gear, with the screwdriver inserted into the hole on the lower side of back plate, Until the brake lining comes into close contact with the brake drum, 2. Back the adjusting gear 4 to 5 clicks. 3. Fit a 0.6 mm gauge in one side of the inspection window on the left and right and check that the clearance on the other side is less than 0.4 mm. 4. After adjusting, check that the de- pressing height of the brake pedal is within 80mm,EVERY 280 HOURS SERVICE + If deterioration of braking effi- ciency is suspected, check it as follows: 1) While the machine travels at about 20 km/h of traveling speed, try lightly braking the machine (so as not to cause wheel locking) three times. 2) Touch each brake drum by hand to see whether heating of drums is felt or not. 3) Cold drums, if any, may be as- sumed inoffective. % Brake lining with block surface due to burning or fining soiled with oil causes insufficient brak- ing effect. Polish such a lining with sandpay ‘* After adjusting, travel the ma- chine about 500 meters and con- firm that four brake drums are free from overheating caused by trailing, — 96 —EVERY 500 HOURS SERVICE EVERY 500 HOURS SERVICE %* Maintenance for every 50 ard 250 hours should be carried out at the same time. a FUEL FILTER (For GD510R, GDS11R) (For GD521R) 1. Close the fuel valve of the fuel tank. 2. Using a filter wrench, remove car. ridge (1) byturning itcounterclock- wise + Cleanthefikerbase, andcheck that there is no filter seal stil stuck to the filter bese. If there is any old seal still stuck to the filter base, there will be a gap when the new gasket is installed and this will cause oil leakage. 3. Fill the 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, than screw up the cartridge about 2/3 of a turn (be careful not to tighten it up ex- cessively) 4. After replacing filter cartridge (1) ‘open fuel velve of the fuel tank. ~87-[EVERY 600 HOURS SERVICE 5. Loosen air bleed plug (2) of the fuel filter 6. Loosen feed pump knob (3) and move the pump up and down to draw off fuel until air ceases to come out of vent plug (2) 7. Tighten air vent plug (2). 8. Push in feed pump knob (3) and tighten it. * After replacing the cartridge, stort up the engine and check the filter seal face possible oil leakage. * Be sure to use @ genuine Komatsu cartridge b, TRANSMISSION FILTER (GD519R, GD521R} 1. Remove bolts (1) (4 bolts on the outside) fastening the filter case (2); remove case. 2, Remove the element and discard. ‘Thoroughly clean the case inter ‘or and removed perts. Install a new element. ‘ Use genuine Komatsu element. —e8— ¢. CIRCLE GUIDE Checking With the blade raised from the ‘ground, check the circle guide clear- ances at the portions (P) and (Q), using the feeler gauge ‘Standard clearance at portion (P) is 15 £05 mm. Standard clearance at portion (a (Qi = 0 and (Q}a = 2.5 mm or (Qi (average clearance when rotat- ing circle) = (Q)a = 1 mm F: Front R: RearSection A-A (Two places on the front side) Section B. (Two places on the rear side) Adjustment Rest the blade on the ground. To adjust the clearance 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 the clearance (Q)F zero, and tem- porarily: 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 ocknut (5) fastening bolt (6) and tum 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). ~a9- EVERY 500 HOURS SERVICE With the clearance (Q)r kept in zero, back bolt (6) half rotation, and tighten locknut (5). 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 ear tooth top has decreased to zero,EVERY 500 HOURS SERVICE d, RADIATOR FIN Dust, mud, or leaves sticking to, ‘and blocking, the radiator are to be blown off by compressed air. Steam ‘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 parts are found, replace with new one. Check that the hose clamp is tight. 90 —EVERY 1000 HOURS SERVICE EVERY 1000 HOURS SERVICE ‘* Maintenance for every 50, 250 and 600 hours should be carried out at same time. a. LUBRICATING b. TRANSMISSION CASE Apply grease to the grease fit- (For GD510R! tings shown by arrows. 1. Drive shaft (2 points) @D510R eon -91-EVERY 1000 HOURE SERVICE (For GD521R) -92—EVEHY 1000 HOURS SERVICE ¢. FINAL DRIVE CASE (For GDS10R, GD511R) : : 1. Remove drain plug (P). After % The type of lubricant used de- raining ol, tighten drain plug. ends on the ambient tempera- 2, Remove bolt (1), (2) and cover ture, Select according to the @). table “FUEL, COOLANT AND Take out strainer and wash out LUBRICANTS" dust with diesel fuel + Rofilcapacity: 340 3. After cleaning it, install strainer. GDS10R: 252 4.Rofil! engine oil in specified amount through filler (F). For refiling procedure see the section EVERY 250 HOURS ‘SERVICE, ~93—EVERY 1000 HOURS SERVICE (For GDS21R) Remove drain plug (P) to drain oil After draining, tighten it Refill the engine oil through filler (F] up to the prescribed level For the refiling procedure, see the item “EVERY 250 HOURS SERV- Ice" Thetype oflubricant used depends on the ambient temperature. Se lect according to the table “FUEL, COOLANT AND LUBRICANTS’ Refill capacity: GDS10R, GDS11R: 128 G0s21F: 24g = 94— d. CIRCLE REVERSE GEAR CASE 1, Remove drain plug {P) to drain oil. After draining, tighten it. 2. Refill the gear oil through filler (F) upto the aredetermined level 3. For the reilling procedure, see the item “EVERY 250 HOURS SERV- Ice".¢. TANDEM DRIVE CASE (For Gos21R) * Thetypeoflubricant used depends on the ambient temperature. Se- lect according to the table “FUEL, COOLANT AND LUBRICANTS” + Refili capacity: 42 2, Remove oillevel plug (GI, then add engine oll through oil filler (F) until oil comes cut from level plug (G). 3. Forthe refiling procedure, see the item “EVERY 250 HOURS SERV- Ice", % Refill capacity: 39 (each side) ‘& Thetype oflubricant used depends on 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 ~95 -1. HYDRAULIC TANK AND FILTER (For GD510R) (For GD5118) (For GDS21R) 4. Set the machine in position as 2. Stop the engine and remove the 4. Refillengineoilinspecifiedamount follows to check the oil level. drain plug. After draining oil, through filler (F) © Returntheleaningofthefronttires _ tighten drain plug. 5. Forrefilling procedure, seetheitem tothe uprightpositionandfacethe 3. Removebolts(1)(4each) andcover “EVERY 250 HOURS SERVICE”. wheels straight to the front. (2) and take out element. ‘x Thotypeeflubricantused depends ‘© Return the drawbar sideshift and Then, clean the inside of the filter on the ambient temperature. Se- blade sideshift to the center of the ‘housing together with the other _lect according to the table “FUEL, machine, set the blade at right removed parts and replace with a. COOLANT AND LUBRICANTS”. angles to the chassis and lower it_ new element. % Refill capacity: 30 lightly to the ground. Use genuine Komatsu elements. © Raise the scarifier fully. — 96 -EVERY 1000 HOURS SERVICE DRAWBAR FRONT BALL fh, TOE-IN JOINT Check toe-in and adjust it so that (For GD510R, GDS11R) no side slip is caused. When no side slip tester is available, use the fol- lowing procedure. How to measure toe-i Check ball joint connecting nuts (1) at the front of the drawbar for loosening. If the connecting portions 1. Park the grader on @ level ground are loose, retighten them. without steering and leaning the wheels. Be sure to drive straight at least a few meters before parking 2. Measure the height from the ground to the center of the front wheel axle, -97-every 1000 HOURS GERVICE 3, Mark on the front tire surfaces 4, Measure the distance between 5. Drive the grader at a low speed with the same measure taken by the two marks on the right and and shift backward the mark on the above procedure. left tires. This distance in named _—the tire. Stop the grader when og the mark's height from the ground surface has 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* - 98- caneHow to Adjust Toe-in: When toe-in (B — A) is adjusted to —5 + 1 mm of standard range, side slip is decreased to zero. if any value other than the standard range is measured, adjust toe-in using the following procedure: 1. Loosen nut (1). Turn the tie rods with @ wrench put on square por- tion (2). Then, tighten the locknuts. 2.Toe-in increases when the wrench is turned in the direction shown by the arrow, and vice versa. The value of toe-in varies by 6 mm when the tie rods are tumed 1/3 rotation in the oppo- site direction to each other. ‘% Keep the front axle horizontally without any leaning, —99- EVERY 1000 HOURS SERVICE i, FRONT WHEEL BEARING PLAY Raise the front wheels off the ground, using the blade or scarifier as a jack. Check hub turning torque with a spring balance hooked to a hub bolt. e/ S WwW 1. The bearing play is normal if the front wheel is rotated smoothly with 8 10 12kg of pulling force, 2.1f the inspection shows that there is play, or that the rotating force is small, adjust as follows.EVERY 1000 HOURS SERVICE 3, Remove cover (1). Select proper shims (2) and set them tempo- rarily. Tighten bolt (3) and rotate the shaft by more than 3 revolu- tions each for clockwise and counterclockwise directions. Loosen bolt (3). Reduce the number of shims (take out at = 0.1 or t = 0.3 shim), and decide the thickness of shims properly 0 that the pulling force of the spring balance becomes to 8 to 12kg. This measurement of the pulling force should be done after shaft (4) has been rotated by more than 3 turns and after the bearing has ceased rotating. Also wait until the bearing gets down to normal room tempera- ture for adjustment. — 100 — j, CORROSION RESISTOR (For GD510R)(For GDs21R) - Close valves (1). 2. Using the filter wrench provided, remove cartridge (2) by turning it counterclockwise. Fita new cartridge after applying a dab of engine oil to the seal face, + To fit the cartridge, put the seal face in contact with head, then ‘screw it up about 2/3 of a turn, 4. Afterreplacement, open vaives(1) % Be sure to use a genuine Komatsu cartridge. 4% Be careful not to screw in more then required, = 101 EVERY 1000 HOURS SERVICE k. TURBOCHARGER ROTOR PLAY Have the turbocharger inspected by Komatsu to check it by yourself using the following procedure: Remove the intake 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 2. Play in the radial direction Move the rotor in the radial direc- tion in parsilel by holding it with your hands on both ends and measure radial play. Standard radial play: 0.075 - 0.180 mm, * If necessary play cannot he ob. tained, have the turbocharger re- paired by Komatsu distributor. If the rotor is excessively soiled with dust or carbon or if any oil leakage caused by turbocharger trouble is noted, have the turbo- charger repaired by Komatsu dis- tributor.EveRY 1000 toune seAVice |. TURBOCHARGER VARIOUS FASTENERS, The performance of turbocharger will be deteriorated when air or gas leakage exists at the joint section of intake and exhaust pipings. Further, when leakage exists at oil feed piping, or pressure may drop and bearings may be seized. Periodically inspect 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 boit Tightening torque: 1.15 - 1.50 kgm Turbocharger mounting bolt (for securing the exhaust manifold and turbine housing together) Tightaning torque: 6.0-7.5 kgm Turbocharger oll feed pipe (inlet fine) Tightening torque: 28-36 kgm Turbocharger oil feed pipe (outlet tine) Tightening torque: GDS10R, GOS11R: Gps2ik: 28-35 kgm 6.0-7.5 kgm = 102 -EVERY 2000 HOURS SERVICE @, FRONT WHEEL BEARING GREASE (ON BOTH RIGHT AND LEFT SIDES) 1, Support the front axle on a block to reise the front wheel off the ground. Remove the wheels. + When raising the front wheels, securely apply the parking brake ‘and rest the blade and scarifier ‘on the ground. 2. Take off cover (1), remove lock (2) and holder (3), then remove hub shaft (4), 3, Clean the axle and bearing, and clean out all the old grease from inside the hub. Fill the grease pan about half full with new grease. Replace the hub seal and spacer with new parts Coat the lip surface of the hub ‘seal and the surface of sliding parts with grease, fill the spacer between the lip with grease, then assemble, Fill with grease so that groase is Pushed between the axle and bearing. Make sure that grease also comes up around the bearing {also the outside bearing) before installing the hub shaft. After installing the hub shaft, adjust the rotating force. For details, see Inspecting and Ad- justing Play of Front wheel Bearing, ‘When carrying out this mainte- nance, please contact your Komatsu ‘* Maintenance for ‘hours should be carried outat the same time EVERY 2000 HOURS SERVICE jery 60, 250, 500 and 1000 b. ENGINE BREATHER (For GD521R) 1, Remove breather (1) from the cylinder head. nse the whole breather in diesel oil or flushing oi, dry with compressed air, then install again in the cylinder block. + Before taking the breather out of place, wipe the dust off the sur- rounding area. ‘* When restoring the element to its original position, be sure to coat the new O-ring with engine ol¢, ALTERNATOR AND STARTING MOTOR The brush may be worn, or the bearing may have run out of grease, 0 please contact your Komatsu dis- tributor for inspection or repair. + If the engine is started frequently, carry out inspection every 1000 hours. d, ENGINE VALVE CLEARANCE ‘Ask Komatsu distributor to check ‘engine valve clearance because spe- cial tools should be used. @. VIBRATION DAMPER Check that there are no cracks in the damper rubber. If there is any abnormality, contact your Komatsu distributor for repaires. {. TURBOCHARGER Excessive carbon or oil sludge ad- hering to turbocharger blower impeller may lead to deterioration of normal charger performance, and possible damage. Have turbocharger cleaned by Komatsu distributor. 1, Remove the turbocharger oil filler pipe and drain pipe, then remove the intake air pipe connector and blower housing so that the blower impeller can be seen. 2. Using light oil as a cleaning agent, remove the carbon, sludge and other dirt from the blower impeller. Do not use @ wire brush or other tool which may damage the impeller. 3. Pour in light oil through the tur- bocharger oil filler and rotate the blower impeller several times to wash out the sludge. ~ 104 = 4, Rotate the impeller by handat least ‘one turn at speed to check that there is contact noise or catching inside. If the impetier does not turn smoothly, contact your Komatsu distributor for repair or replace: ment 5. If there is no abnormality, dry off the light oil with compressed air after inspection, then add engine oilEVERY 4000 HOURS SERVICE a. WATER PUMP. Check that there is no play in the pulley, grease leakage, water leak- age, or clogging of the drain hole. if any abnormality is found, please contact your Komatsu distributor for disassembly and repair or replace- ment. ‘every 4000 HOURe cenvier ‘& Maintenance for every 50, 250, 500, 1000 and 2000 = 105 - hours should be carried out at the same time.WHEN REQUIRED a. CLEAN INSIDE OF COOLING SYSTEM Clean the inside of the cooling * Be sure to replace the corrosion system, change the coolant, and re- resistor cartridge. placethe corrosion resistor, according x Use city water for the cooling wa: to the table. ter. + Stop the machine on level ground _If river water, well water or other when cleaning or changing the such water supply must be used, coolant. contact your Komatsu distributor Une a permonenttype of antioez, ihforsometeason tisimpossibe fy Antitreezeis flammable, sokeep it tose permanent type anifeeze, away trom any ame viene giveol Closning sido of cooling system and changiag coolant ‘Type of anitroere Replacing corrosion every year tatu) oF fevery 2000 hours wichover | Permanent type antitreexe (Altseacon type) Non permanent typ0 Every 6 months pre, 1 1000 hours and when ntteeze containing ‘autumn! ‘leaning the nda of the ‘thylene yen! |) [Drain aniteece in spring, | cooing system and when fintersone season type) | addantiteezein autumn)” | changing coolant Every 8 monthe or Wien not using anirsse | every 1000 hours whichever — 106 ~ Add antifreeze in the cooling water When deciding the ratio of anti- freeze to water, check the lowest ‘temperatureinthe past, and decide from the mixing rate table given below. It is actually better to estimate a temperatu’e about 10°C lower when decicing the mixing rate. Mixing rate of water and antifreeze atmospheric rec) (feel “Amount of { ~ a Ls! * We recommend use of an anti- freeze density gauge to control the mixing proportions.Corrosion resistor (For GD510R) (For GDs21R) 1. Stop the engine and tighten up corrosion resistor vaive (1). 2. Turn cap (2) siowly until it comes off. Add not remove the cap while coal ing water is hot. Hot water may spout out. When removing radiator cap, lift 107 - WHEN REQUIRED Water filler 3. Open drain vaive (3) at the bottom of the radiator and plug (4) on the side of cylinder block to drain off the cooling water. 4. Drain off all the water, then close up drain valve (3), plug (4), and our in soft water (ax: city water) Up to the vicinity of the water fille, 5. When the water reaches the vicin. ity ofthe water filler, puttheengine at low idling, open drain vaive (3) and plug 14), then pass water through the cooling system for 10 minutes,WHEN courte Drain plug (cylinder block) (For GD510R, GO511R) (For GDS21R) ay 4 When doing this, adjust the inflow 9. When the water reaches the vi 11. Replacethecorrosion esistorcar- and outflow of water so that the Cinity of the water filler, put the tridge and open corrosion resis radiator is always ful engine at low idling, open drain tor valve 11). 6. After flushing with water, stop the valve (3) and plug (4), then pass For details of replacement of the engine, Close drain vaive (3) and water through the cooling sys. corrosion resistor, see the main- drain plug (4) after draining water. tem until clean water comes out tenance section. 7. Afterdraining water, usea flushing from drain valve (3) and plug (4). 12. Supply water up to the vicinity of agent to clean. 10, When the water becomes com: the water filer. 8. After washing the cooling system, pletely clean, stop the engine, drain off all the water, then close close drain valve (3) and plug (4), up drain valve (3) and plug (4), and pour in soft water (ex: city water) upto the vicinity of the water filler — 108 —13, 14 Run the engine for 5 minutes at lowidlingtoeliminateairtrapped inthecooling system, andrun the ‘engine for minutes athigh idling (leave water filler cap (2) off dur- ing this operation.) Stop the engine and 3 minutes later supply water again up to vicinity of the water filler and tighten water filer cap (2) WHEN REQUIRED b. CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT Checking (For GD510R, GD511R) Whenever the red piston in dust indicator (1) appears, clean the air cleaner outer element. Stop the en- gine when cleaning the element. f H — 109 —wren REQUIRED Cleaning or replacing outer element (For GD510R, GD511R) 1 2 3, Loosen wing nut (2), remove cover (3) and outer element. Clean the air cleaner body interior and the removed cover. Cleanandinspectthe element. (See the item "Cleaning outer element” for cleaning procedure.) Install the cleaned element. Push the dust indicator reset but- ton to return the red piston to the original position, Replace the outer element which has been cleaned 6 times repeat ‘edly or used throughout a year Replace the inner element at the ‘same time. = 110- % Replace seal washer (4) 07 + Replace both inner and outer ele. ments when the dust indicator red piston appears soon after install: ingthe cleaned outer elementeven though it rs not been cleaned 6 times, 4% Remove cne seal from the outer ‘element. The number of times the outer element has been cleaned can be seen by the number of removed seals. gut (2) if they are broken. 4 When inspecting or cleaning the aircleaner, removeevacuatorvalve (6) and clean with compressed air.Replacing the inner element 1. After removing the cover and ‘outer element, remove the inner element. .. Cover the intake opening, After cleaning inside the body remove the intake opening cover. 4.Fix a 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 1 install a cleaned inner element. Aico not clean or replace the a cleaner element with the snaine running. Arwen using compressed Cleaning outer element With compressed: Direct dry compressed air (less than 7 kg/cm#) to element from inside along its folds, then direct it from outside along its folds and again from inside, and check element. ‘wear safety glasses and other things required to maintain safety. ~Mm- nen REQUIRED The following methods 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 require With cleaning agent For removing oils and fats as well 1s carbon etc. attached on the ele- ‘ment, the element may be cleaned jn lukewarm solution of mild deter- gent, then rinsed in clean water and lett to drip dry. * Drying can be speeded up by blowing cried compressed air less than 7 kg/cm*) from the inside to the outside of the ‘element. Never lement, * Using warm water (about 40°C) instead of soapy water may also be effective. attempt to heat theween Reauinco + If small holes or thinner parts are found on element when it 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 ‘or gasket or seal are damaged. ‘%* When cleaning element, do not hit it or beat it against something, ¢. ELECTRICAL INTAKE AIR HEATER, Check electrical intake air heater ‘once a year before commencing work in the cold season. Remove electrical intake 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, 12 - 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 float reaches the bottom, 2. Tighten drain plug (3). 3.1t the air is sucked into tue! tine when drain the water, be sure to bleed air in the same manner as for the fue filter {See Fue) Filter Cartridge in EVERY 500 HOURS SERVICE section)ADJUSTIMEN ADJUSTMENT ADJUSTMENT OF INCHING PEDAL (For GDS11R, GDS21R) 1. At full engine speed, the machine * These abnormal conditions con- When any abnormal pedal condi- © moves when the inching pedal cerning inching pedal operation tion such as mentioned below inno- (1) is depressed and the gear are sometimes caused by trans- ticed, consult your Komatsu dis- shift lever (2) is placed in the for-__ mission troubles. Therefore, care- tributor for checking, readjustment ward 1st speed position (The ful inspection of faulty conditions or repair of the inching pedal parking brake lever (3) is left must be made by your Komatsu system, released). distributor not only about the 2. With parking brake lever (3) ap- _inching pedal control system, but plied, the brake pedal (4) de- also about he transmission, Pressed and the gear shift lever Placed in the forward 6th (or reverse 6th) position, the engine does not stop within 3 seconds when the inching pedal is re- leased from the depressed position. —113ApuusTMENT ADJUSTMENT OF INERTIA BRAKE (6D610R) If the effect of the inertia brake is poor when accelerating and shifting Lup, adjust as follows. 1. Loosen locknut (2), and screw in rod (1) to bring inertia brake drum (3) and band (4) into close contact 2. Tum rod (1) back approx. 12.5 turns to give clearance “A” of 1 mm between drum (3) and band (4) 3. After adjusting, tighten locknut 2). + If the clearance between the ‘drum and band is too large, the amount the clutch pedal is de- pressed when the inertia brake is acting 1s increased -14-ADJUSTMENT OF CLUTCH (gD510R) When insufficient clutch pedai play (standard play is 45 to 55 mm when measured at the center of Pedal mounting bolt) or slipperly clutch is noticed, perform the fol- lowing adjustment: 1, Remove bolts (3), fastening side cover (2) to the clutch booster; remove the cover. 2. Loosen lock nut (4) and turn yoke (1) until piston (6) and vaive (5) come into contact with each other. 3. From this position, back the yoke 4 turns, and tighten lock nut (4) 115 = Dusen! * However, roller at yoke (1) should face in the direction shown. Install side cover (2) with bolt (3). the clutch stil slips even when adjustments 1. to 4, are carried ut, carry out adjustments 6. to 9 oF‘ADJUSTMENT. 28 90 =116- Remove bolts (7), fastening in- spection cover (8); remove the cover. Loosen nut (9), remove tock (10) Turn adjustment ring (13) until O to 1.0 mm of clearance “B” can be obtained between flange (11) and gear (12), Then, adjust the clutch pedal play using the procedure de- scribed in step 1 and go on to the step 4. IF ring (13) is turned by one step (225°), dimension “8 will be changed by 0.76 mm, Ring (13) can be turned smoothly with the clutch pedal down to keep the clutch disengaged.‘TROUBLE SHOOTING GUIDE TROUBLE SHOOTING GUIDE ENGINE Engine ol pressure pilot lamp dows not go off when engine speed is ‘ised ater completion of warm-up. '¢ Ada te eilto he specified ove. ‘© place the otter eartidge '© Cheek ol leskago from the pipe othe joint, |S Replace the pia tam, ‘Steam is emitted rom the top part ofthe radiator ithe pressure valve. “The pointer ofthe water temperature gaugeisinredrange on righthand side o the gauge. ‘+ Supply the cooling water and check leakage 1+ Adjut fan bet tension, ‘© Wash out inside of cooking system, {© Cian oF repai te radiator fn 1 Replace the thermostat, 1 Tighter the raiator cap firmly or replace te gasket of it Replace he water temperature gauge, The pointer ofthe water temperatu ‘hand side ofthe gouge. 18 Replace the thermostat, “© Ropiace the water temperature gouge 92098 sin whito range on tft ‘The engine dove not start whan the starting motor is tuned over ‘Ad fel Repair where aris lesking into fel ester. Replace the injection pump and the rezle Check the valve cleszance Check engine compression prasaure. Refer tthe section of electrical syste, Exhaust ga is white o blue 1 Aclust 0 specified oi quantity. 1 Roplace with specified tel = censionaly turns black. 1 Clean or ropiace the ai cleaner lament 4 Aloplace the naz '* Chock engine compression pracsure Combustion noise oceaionaly chan 1+ Replace the nose 10 breathing sound, Unusual combustion noise or mechanics noite, © Replace mith specifind fel © Check over heating. 1 Replace the multe. © Adjust valve clearance -uN7=TROUOLE SHOOTING GUIDE ELECTRICAL SYSTEM ‘Unusual noise is emitted from th (© Replace the alternator ‘Starting motor does not turn when starting switch is turned on. © Inspect and repair the wiring, (© Charge the batter. The pinion of the starting motor ke (© Charge the battery Starting motor turns the engi © Charge the battery © Replace the staring motor. ‘The starting motor disongages bt ‘© Check and repsic he wiring ‘© Charge the batter, ‘The heater signal does not glow red. ‘© Check and repair wing (© Replace the heater rely. {© Replace the heater signal. Outside the ribbon heater and the coil heater touched with the hand f@ Check and repair wiring ‘@ Replace the ribbon heater and the col heater (© Check and epair the heater switch. not warm when cHassis ‘Tractive force i iacking,Insutticient vavel speed (© Refer totem “Engine” 1 Inepect and adjust transmission valve. 18 oleate parking brake lover. “Machine fats to star at any gear shittiever position. © Add olto the specitie level ‘© Inspect an adjust transmission vale ‘Loud noise in the power transmitting system. fe Add oto the specifi level, Excessive wear of front whee © Adjust toon Hest generation at front wheel hub ‘© Apply grease Front wheels eway while waveting, ‘© Check wheel instalation. 1S Tighten tront wheel bearing nut — 118 — core‘Steering whee! feets heavy. © Add air to front re tthe speciied pressure, (© Apply grease 10 steering linkage, Check engagement of bal nut Comect piping Parking brake does not operate satistect ‘© Adjust broke shoes. Polish the lining with sand paper. ‘© Clean the intrie of brake crum Excessive blade swing during work ‘© Adjust shims ofballjoint and circle guide. (© Replace side bushing, (© Correct blade rai Excessive vibration of the blade when rotating during work (© Adjust postion of encie guide, Werk equipment is sow to move by operating the control i (© Add cil tothe specified level ‘Wear of parking brake lining '8 Adjust elesronce between lining and drum. comes = 119 — TROUBLE SHOOTING GUIDESERVICE METER SERVICE METER This meter indicates the in- tegrated work hours. So, use it ac- cording tothe —_ following instructions. and the end of work, this is the work record of the machine @ This record will indicate when periodical maintenance is due. @ It also indicates the integrated working hours when machine problems are encountered. ( @ Record the readings at the start (GD510R) — 120 - % How the meter progresses The service meter progresses by 1 when the engine is operated for one 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 © Location of the machine serial © Location of the engine serial mechanic or when making replace- number mark number mark ‘ment parts order, be sure to give (For GDS10R, GD511R) (For GD510R, GD511A) your Komatsu distributor the mi chine and engine serial numbers as well as the service meter reading beforementioned. These numbers are found on the plates shown in the photos below. (For GD521R) (For GD521R) on the left side of the frame on the left side of the engine cylinder block ~121—FUEL, COOLANT AND LUBRICANTS FUEL, COOLANT AND LUBRICANTS PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS KIND OF ‘AMBIENT TEMPERATURE, [capacity (a) RESERVOIR FLUID Panera ee ann 2 BRE secitea | ett En oe Engine oi! pan = pas 108 oi | a Dien ay =ishe Tawa “Tranuminnon ce Ee SES an SosT0R 34 GOs1OR.25 Tanger dive ease (ach) L 45 29 Final drive case ae To riba | 2a Hydraulic system: ines SAL IW ee 6B 30 ‘Cicl everre gear case coro eS sae om =e 3 Brake Brake tid WisAr 10 eemoeeal Fuck tank Diesel fuel bal - a | Coating system eter ‘Add antireze Pn : we ASTM D975 Not (: eps2in = 122 =NOTE: (1) When fuel sulphur contents less than 0.5%, change oil in the oi! pan every periodic maintenance hours described in this manual Change cil according to the following table if fuel sulphur content is above 0.5%. : Change interval of oil in Fuel sulphur content ‘Srgins oi pon 0510 1.0% | 2 of regular interval Above 1.0% V4 of regular interval ASTM: American Society of Testing and Material SAE: Society of Automotive Engineers APL: American Petroleum Institute FUEL, COOLANT AND LUBRICANTS (2) When starting the engine in an atmospheric tern- erature of lower than 0°C, be sure to use engine oi of SAE10W, SAE10W-30 and SAEISW-40, even though an atmospheric temperature goes up to 10°C more or less in the day time, (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4), There is no problem if single grade oil is mixed with multigrade oil (SAE 10W-30, 1SW-40}, but be sure to add single grade oil that matches the temperature in the table on the left (5) We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applica tions. Specified capacity: Total amount of oil including oil for components and oil in piping, Refill capacity Amount of oil needed to refill system during normal inspection and maintenance. ae = 123 —SAFETY AND OPERATIONCONTENTS SAFETY HINTS HANDLING OF BATTERY TRANSPORTATION PRECAUTIONS FOR MAINTENANCE STORAGE COOLANT AND LUBRICANTS: “4 W7 18 27SAFETY OPERATION GENERAL Wear wellitting helmet, safety shoes and working clothes. ifthe nature of the work requires safety, wear protective goggles or mask, thick gloves, ear plugs or other protection, Wear proper clathes 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. 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 all times. Take care of your health. Do not drive when tired, or after drinking HINTS: + > & «If there should be an accident cr fire or any other such unexpected mishap, deal with it quickly, using the nearest apparatus. Learn beforehand the locations of the first aid boxes and fire extinguishers and how to use them. Its also important to know the emergency contact system. Learn the prohibitions, cautiors and rules about work. procedures in the work site. When there is a leader, fix standard signals and always follow these signals when operating.