Komatsu GD535-5 Motor Grader Index:

CONTENTS
FOREWORD 1- 1
READ THIS MANUAL 1- 2
SAFETY INFORMATION 1- 4
NOISE EMISSION LEVELS 1- 5
VIBRATION LEVEL 1- 6
VIBRATION – OPERATING CONDITION 1- 6
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE 1- 6
INTENDED USE 1- 7
USE OF MACHINE 1- 7
DIRECTIONS OF MACHINE 1- 7
VISIBILITY FROM OPERATOR’S SEAT 1- 8
VISIBILITY FROM OPERATOR’S SEAT 1- 9
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 11
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 11
ENGINE NUMBER PLATE 1- 11
FLUORINATED GREENHOUSE GASES 1- 12
SERVICE METER POSITION 1- 12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 12
SERIAL PLATE 1- 13
DECLARATION OF CONFORMITY 1- 14
SAFETY 2- 1
SAFETY INFORMATION 2- 2
SAFETY LABELS 2- 5
POSITION FOR ATTACHING SAFETY LABELS 2- 6
SAFETY LABELS 2- 8
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 16
PRECAUTIONS BEFORE STARTING OPERATION 2- 16
PREPARATIONS FOR SAFE OPERATION 2- 16
FIRE PREVENTION 2- 20
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 21
DO NOT GET CAUGHT IN WORK EQUIPMENT 2- 25
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES 2- 25
UNAUTHORIZED MODIFICATION 2- 26
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 26
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 26
PRECAUTIONS FOR OPERATION 2- 27
PRECAUTIONS FOR JOBSITE 2- 27
STARTING ENGINE 2- 30
OPERATION 2- 34
TRANSPORTATION 2- 39
TOWING 2- 40
PRECAUTIONS FOR MAINTENANCE 2- 41
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 41
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 47
TIRES 2- 52
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
CONTROLS AND GAUGES NAMES 3- 3
1 – 15
.
CONTENTS FOREWORD
EXPLANATION OF COMPONENTS 3- 10
EXPLANATION OF MACHINE MONITOR EQUIPMENT 3- 10
SWITCHES 3- 76
CONTROL LEVERS, PEDALS 3- 91
OPENING, CLOSING CAB DOORS 3-102
DUST INDICATOR 3-104
ARTICULATE LOCK PIN 3-104
FUSE BOX 3-105
SLOW BLOW FUSE 3-107
ELECTRIC POWER TAKEOFF 3-108
BATTERY DISCONNECT SWITCH 3-109
SYSTEM OPERATING LAMP 3-110
DIFFERENTIAL LOCK OIL PRESSURE CAUTION LAMP 3-111
BACKUP ALARM 3-112
HANDLING FRONT WIPER 3-113
HANDLE REAR VIEW MONITOR 3-113
CAR RADIO 3-114
HANDLE AIR CONDITIONER 3-119
OPERATION MANUAL STORAGE 3-131
TOOL BOX 3-131
GREASE PUMP HOLDER 3-131
ASHTRAY 3-132
FIRE EXTINGUISHER 3-132
KOMTRAX 3-133
KOMTRAX 3-134
OPERATION 3-136
CHECK BEFORE STARTING ENGINE 3-136
STARTING ENGINE 3-159
OPERATIONS, CHECKS AFTER STARTING ENGINE 3-164
STOPPING ENGINE 3-165
CHECK AFTER STOPPING ENGINE 3-165
TRAVELING POSTURE FOR MACHINE 3-166
MOVING MACHINE OFF (FORWARD, REVERSE, SHIFTING GEAR), STOPPING 3-168
TURNING MACHINE 3-179
OPERATING WORK EQUIPMENT 3-182
WORK WHICH CAN BE CARRIED OUT USING A MOTOR GRADER 3-188
PRECAUTIONS WHEN OPERATION 3-209
ADJUSTING WORK EQUIPMENT POSTURE 3-215
PARKING MACHINE 3-224
CHECKS AFTER COMPLETION OF OPERATION 3-227
LOCKING 3-228
METHOD FOR OPENING AND CLOSING CAP WITH LOCK 3-229
METHOD FOR OPENING AND CLOSING HYDRAULIC OIL FILLER PORT CAP 3-229
HANDLING THE TIRES 3-230
TRANSPORTATION 3-231
STEPS FOR TRANSPORTATION 3-231
LOADING, UNLOADING WORK 3-231
PRECAUTIONS FOR LOADING 3-232
LIFTING MACHINE 3-235
COLD WEATHER OPERATION 3-237

PRECAUTIONS FOR LOW TEMPERATURE 3-237
CAUTIONS AFTER COMPLETION OF WORK 3-238
AFTER COLD WEATHER 3-238
LONG-TERM STORAGE 3-239
BEFORE STORAGE 3-239
DURING STORAGE 3-239
AFTER STORAGE 3-239
TROUBLESHOOTING 3-240
AFTER RUNNING OUT OF FUEL 3-240
WHEN LEANING PIPING IS DAMAGED 3-241
TOWING THE MACHINE 3-242
IF BATTERY IS DISCHARGED 3-246
IF THE GEAR SHIFT LEVER OF THE TRANSMISSION HAS ANY TROUBLE 3-250
LOWERING WORK EQUIPMENT WHEN ENGINE IS STOPPED (RELEASE WORK
EQUIPMENT OIL PRESSURE) 3-250
OTHER TROUBLE 3-252
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 5
RELATING TO ELECTRIC SYSTEM 4- 11
WEAR PARTS 4- 12
WEAR PARTS LIST 4- 12
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 13
LUBRICATION CHART 4- 14
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 16
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 19
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 20
TORQUE LIST 4- 20
DEFINED LIFE PARTS 4- 21
DEFINED LIFE PARTS LIST 4- 21
MAINTENANCE SCHEDULE CHART 4- 22
MAINTENANCE SCHEDULE CHART 4- 22
SERVICE PROCEDURE 4- 25
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 25
INITIAL 1000 HOURS SERVICE (ONLY AFTER THE FIRST 1000 HOURS) 4- 25
WHEN REQUIRED 4- 26
CHECK BEFORE STARTING 4- 49
EVERY 50 HOURS SERVICE 4- 50
EVERY 250 HOURS SERVICE 4- 54
EVERY 500 HOURS SERVICE 4- 67
EVERY 1000 HOURS SERVICE 4- 76
EVERY 2000 HOURS SERVICE 4- 88
EVERY 4000 HOURS SERVICE 4- 96
EVERY 8000 HOURS SERVICE 4- 99
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
INDEX 6-