Komatsu D155A-6 Assembly Instruction Manual
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Komatsu D155A-6 Assembly Instruction Manual

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GEN00078-02
Field Assembly Instruction
BULLDOZER
D155A
-6
85001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu D155A-6

  • Page 1 GEN00078-02 Field Assembly Instruction BULLDOZER D155A 85001 SERIAL NUMBERS and up...
  • Page 2 Preface Preface Since this machine is large in size, it is divided into some units to meet the transportation conditions and regulations applied to the transporta- tion route when shipped from our factory. This manual describes how to assemble the units into the complete machine in the field.

  • Page 4: Table Of Contents

    CONTENTS Specifications ..............................1 Precautions for field assembly..........................3 Assembly procedure, necessary equipment, and schedule ................4 Layout of kit ................................ 5 Style for transportation ............................6 List of tools for field assembling ........................11 Tightening torque ............................. 12 Coating materials ............................. 16 A.

  • Page 6: Specifications

    Operating weight (excluding operator's weight) 417,000 41,100 Blade weight (including cylinders) 5,620 Ripper weight (including cylinders) 3,380 Engine model — KOMATSU SAA6D140E-5 Diesel engine Rated engine output kW/rpm {PS/rpm} 243/1,900 {325/1,900} Length of track on ground 3,150 Width of gauge 2,140 Overall length...
  • Page 7 Operating weight (excluding operator's weight) 42,100 41,500 Blade weight (including cylinders) 5,620 Ripper weight (including cylinders) 3,760 Engine model — KOMATSU SAA6D140E-5 Diesel engine Rated engine output kW/rpm {HP/rpm} 243/1,900 {325/1,900} Length of track on ground 3,150 Width of gauge 2,140 Overall length...

  • Page 8: Precautions For Field Assembly

    Precautions for field assembly Precautions for field assembly 1. Selection of work place 1) When selecting a work place, consider the following. • Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout draw- ing.) •...

  • Page 9: Assembly Procedure, Necessary Equipment, And Schedule

    Assembly procedure, necessary equipment, and schedule Assembly procedure, necessary equipment, and schedule a Any change of the schedule caused by weather is not included. a Special field work shall be arranged separately. Schedule 1st day 2nd day 8:00 10:00 12:00 14:00 16:00 18:00 8:00 10:00 12:00 14:00 16:00 18:00 Trailer must arrive at field Unloading trailer before 8:00...

  • Page 10: Layout Of Kit

    Layout of kit Layout of kit • When selecting the work field, see “Before assembling in field”. • The dimensions in the drawings are reference dimensions for installation in the following space (30 m × 30 m). • If a wider work field is available, the shown dimensions should be increased.

  • Page 11: Style For Transportation

    Style for transportation Style for transportation Since the machine can be divided for transportation, ask us or our service shop before transportation. t Style of each kit. • Tractor (Body + track frame) (With truck) Overall length (mm) 5,080 Overall height (mm) 3,395 Overall width (mm) 2,765...
  • Page 12 Style for transportation • Blade (semi-U) Overall length (mm) 1,790 Overall height (mm) 1,025 Overall width (mm) 4,130 Weight (kg) 3,500 x: 740 y: 590 (2) Straight frame (L.H.) Overall length (mm) 3,528 Overall height (mm) Overall width (mm) Weight (kg) x: 1,659 y: 99 z: 7...
  • Page 13 Style for transportation (3) Ripper Ass’y (Giant ripper) Overall height (mm) 1,275 Overall width (mm) 2,530 Weight (kg) 3,380 *A overall length : See the below Ripper Ass’y (Multi ripper) Overall height (mm) 1,250 Overall width (mm) 2,150 Weight (kg) 3,760 *A overall length : See the below •...
  • Page 14 Style for transportation • Ripper beam (Giant) Overall length (mm) 1,407 Overall height (mm) 1,250 Overall width (mm) 1,085 Weight (kg) 1,591 • Ripper beam (Multi) Overall length (mm) 2,320 Overall height (mm) 1,250 Overall width (mm) Weight (kg) 1,256...
  • Page 15 Style for transportation • Track shoe Shoe width A (mm) 3,450 B (mm) 1,060 Weight (kg) 2,485 × 2 2,720 × 2 • Overall length (mm) 1,755 Overall height (mm) 1,635 Overall width (mm) 1,735 Weight (kg) x: 121.3 y: 324.4...

  • Page 16: List Of Tools For Field Assembling

    Style for transportation List of tools for field assembling Tool names Specifications Q’ty. Remarks Engine compressor Komatsu, 0.74 MPa {7.5kg/cm²} Class Crane truck 245 kN {25 ton} Grease pump Air type Stepladder 5 -stepped, 1500 mm Impact wrench KW10P (for M10)

  • Page 17: Tightening Torque

    Tightening torque Tightening torque 1. Tightening torque for bolts Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified torque. TTTTT-TTTTT Part No. of bolt EEEEE-EEEEE Part No. of washer Bolt specification Thread diameter ×...
  • Page 18 Tightening torque Table 1 Tightening torque for bolts not specified in text Unit: Nm {kgm} Tightening torque Nominal size of thread Width across flats × pitch (= Socket size) a (mm) b (mm) Target Range 8.8 – 14.7 6 × 1 {1.2} {0.9 –...
  • Page 19 Tightening torque 2. Tightening torque for pipe threads Proper tightening torque for pipe threads depends on combination of the materials of the male screw and female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of the material of the male screw.
  • Page 20 Tightening torque 3. Tightening torque for hydraulic hose connecting nut For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply tightening torque in Table 4. Table 4 Unit: Nm {kgm} Tightening torque Outside diameter Width across of hose flatse.

  • Page 21: Coating Materials

    The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this list. Cate- Komatsu Part No. Q'ty Container...
  • Page 22 Coating materials Cate- Komatsu Part No. Q'ty Container Main features and applications gory code • To be sed as lubricant (anti squeaking) for sliding LM-G 09940-00051 60 g part. • To be used for press fit, shrink fit and preventing scratching or seizure of thread.
  • Page 23 Coating materials Cate- Komatsu Part No. Q'ty Container Main features and applications gory code • "S" and "W" are used as glass adhesive com- Sunstar pen- pound in high temperature (April -October) guin seal 580 Polyethylene and in low temperature (October -April )
  • Page 24 A. Assembly Remarks In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---, but indicated by (1), (2), (3) --- in the tables and texts. Example: (1) Plate (2) Collar (3) Washer (4) Bolt (5) Bolt (6) Washer In some places of this manual, the words of front, rear, right hand and left hand...

  • Page 25: Unloading And Installing Tractor

    Assembly process No. Unloading and installing tractor 1. Front: Install shackles to the towing hook of the undercover at the front of the tractor and install wires to the right and left sides. 4 Front slinging weight: 15.1 ton 2. Rear: Install wires to the right and left ripper cylinder pins.

  • Page 26: Installing Track Shoes

    Assembly process No. Installing track shoes 1. Put blocks (400 mm) under the track shoe grousers on the front side of the machine. Track choe 2. Lift up the end of the track shoes (master links) on the rear side of the machine and mesh them with the sprocket teeth and move the machine slowly forward to install the track shoes.

  • Page 27: Assembly Of Blade

    Assembly process No. Assembly of blade (1/6) 1. Sling blade (1), place wooden blocks and a hydraulic jack under it, and set it stably and securely. Weight of blade : 3,200 kg (SIGMADOZER) 3,500 kg (Semi U) 2. Scratch the paint off the ball joint and clean the ball joint.
  • Page 28 Assembly process No. Assembly of blade (2/6) 4. Sling right straight frame (5), position it to the hole on the blade side, install pin (6), and fix the straight frame with the lock plate. Weight of straight frame: 876 kg Lock plate mounting bolt 3 Tightening torque:235 –...
  • Page 29 Assembly process No. Assembly of blade (3/6) 6. Install brace (9) with pin (10) and fix them with the lock plate. (Right side of machine) Lock plate mounting bolt 3 Tightening torque: 153 – 190 Nm {15.5 – 19.5 kgm} 7.
  • Page 30 Assembly process No. Assembly of blade (4/6) 8. Install right frame cover (13). a 4 bolts of M16 size Cover mounting bolt 3 Tightening torque: 235 – 285 Nm {23.5 – 29.5 kgm} 9. Install left straight frame (14) and blade (1) according to the procedure in step 4 above. Precautions Necessary tools Necessary equipment...
  • Page 31 Assembly process No. Assembly of blade (5/6) 10. Install tilt cylinder (15) according to the procedure in step 6, 7 above. 11. Connect tilt cylinder hose (16). • 17A-71-45870 #04 size hose, Length: 1,320 mm • 17A-71-45880 #04 size hose, Length: 935 mm Tightening torque for hose: 84 –...
  • Page 32 Assembly process No. Assembly of blade (6/6) 13. After assembling the blade, apply sufficient grease to the parts shown in the figure at right. Each part of blade: Grease (G2-LI) Precautions Necessary tools Necessary equipment Name Q'ty Name Q'ty Other remarks...
  • Page 33 Assembly process No. Installation of blade lift cylinder (1/2) 1. Remove yoke cap (18), bushing (19), grip (20) and yoke fixer (21). 2. Installation of cylinder • Install cylinder (22), bushing (19) and cap (18). At this time, align greasing pin (23) with the cap hole. a Weight of cylinder Left : 182 kg...

  • Page 34: Installation Of Blade Lift Cylinder

    Assembly process No. Installation of blade lift cylinder (2/2) 3. Install grip (20). 4. Connect blade lift cylinder hose (24). • 02756-00612 #06 size hose, Length: 1,200 mm, 4 pieces Tightening torque of hose: 177 – 245 Nm {18 – 25 kgm} Precautions Necessary tools Necessary equipment...

  • Page 35: Installation Of Blade

    Assembly process No. Installation of blade (1/2) Installation of blade assembly 1. Adjust height "a" and width "b" of the right and left straight frames to the following dimensions with wooden block (1). a Height "a" of trunnion: Approx. 571 mm a Width "b"...
  • Page 36 Assembly process No. Installation of blade (2/2) 5. Sling the blade lift cylinder temporarily and start the engine. Extending the piston rod slowly, connect it to the blade assembly by cap (2) at its end. When fixing the cap, tighten the mounting bolts of cap (2) temporarily (eliminate the clearance in the axial direction of the ball joint) without inserting any shim and measure dimension "c".

  • Page 37: Installation Of Ripper Assembly

    Assembly process No. Installation of ripper assembly (1/7) a The giant ripper is used as a model in this assembly manual. The multi-shank ripper is different from the giant ripper only in the following parts. 1) Weight of ripper assembly 2) Number of shanks: 3 3) Pin puller cylinder and piping for it are not necessary.
  • Page 38 Assembly process No. Installation of ripper assembly (2/7) 2. Connecting ripper arm Sling the ripper assembly, set the pin holes of the arm and mount bracket to each other, insert the pin, and fix the pin with the lock plate. Part No.
  • Page 39 Assembly process No. Installation of ripper assembly (3/7) 4. Installation of piping 1) Connect tilt cylinder hoses (1). 2) Connect lift cylinder hoses (2). Part No. of hose: 07120-01016 (Common to 4 hoses) 3) Connect pin puller hose (3). Part No. of hose: 17A-61-41432 (2 pieces) a For connection to the block at the rear of the machine, see the detail of part P.
  • Page 40 Assembly process No. Installation of ripper assembly (4/7) 5. Installation of tilt cylinder 1) While slinging cylinder (4), extend it gradu- ally to set the pin hole. 4Tilt cylinder: 253 kg a When extending the cylinder, start the engine and operate the ripper control lever. 2) Insert pin (5) and fix it with the lock plate.
  • Page 41 Assembly process No. Installation of ripper assembly (5/7) 6. Installation of lift cylinder 1) While slinging cylinder (6), extend it gradu- ally to set the pin hole. 4 Lift cylinder: 188 kg 2) Insert pin (7) and fix it with the lock plate. Part No.
  • Page 42 Assembly process No. Installation of ripper assembly (6/7) 7. Installation of piping clamps 1) Install 2 tilt cylinder hose clamps (8). (L1 = 960 mm, L2 = 890 mm, L3 = 310 mm) 2) Install 2 lift cylinder hose clamps (9). (L4 = 670 mm, L5 = 430 mm) 3) Install 1 pin puller cylinder hose clamps (10).
  • Page 43 Assembly process No. Installation of ripper assembly (7/7) 8. Bleeding air Bleed air from the hydraulic circuit according to the following procedure. 1) Run the engine at low idle. 2) Extend and retract each cylinder and stop it about 100 mm before the stroke end 4 - 5 times. (Do not relieve the oil at the stroke end.) 3) Extend and retract each cylinder to the stroke end 3 - 4 times.
  • Page 44 (4). Do not direct your face toward plug (4) in its installing direction. If the track tension cannot be decreased by the above procedure, ask your Komatsu distributor for repair. • When removing cover (1), take care that dirt and sand will not enter.

  • Page 45: Adjusting Track Tension

    Assembly process No. Adjusting track tension (2/2) Testing Stop the machine on a level ground (Move the 20 -- 30 mm machine forward and stop it without applying the brake). Place a straight bar over the front and rear carrier rollers as shown in the figure at right and measure the clearance between the bar and grouser at the center.
  • Page 46 Check fuel, coolant and lubricants (1/2) a For detaile of the notes (Note. 1, 2, 3, 4) in the table, see the Operation and Maintanance Manual. The details refer to an Operation and Maintanance Manual about Recommended Komatsu fiuids again.

  • Page 47: Check Fuel, Coolant And Lubricants

    Assembly process No. Check fuel, coolant and lubricants (2/2) Hydraulic Cooling Final drive Engine Damper Power system system case Fuel tank oil pan case train case (With blade, (including (each) without ripper) sub-tank) Liters Specified capacity US gal 11.89 0.40 27.74 8.19 63.41...

  • Page 48: Lubricating

    Assembly process No. Lubricating (1/3) 1. Blade lift cylinder support yoke (4 places) 2. Blade lift cylinder support shaft (2 places) (2 places each on (1 place each on right and left sides) right and left sides) 3. Blade ball joint (3 places) 4.
  • Page 49 Assembly process No. Lubricating (2/3) 5. Egualizer bar side shaft (2 places) (1 place each on right and left sides) 6. Egualizer bar center shaft (1 place) 7. Ripper tilt cylinder bottom pin (1 place) 8. Ripper lift cylinder bottom pin (1 place) 9.
  • Page 50 Assembly process No. Lubricating (3/3) 13. Decelerator pedal shaft (1 place) 14. Brake pedal shaft (1 place)

  • Page 51: Bleeding Air From Hydraulic Cylinders

    Assembly process No. Bleeding air from hydraulic cylinders A-10 a After disassembling for transpotatiton, changing the oil in the hydraulic tank, or removing hydraulic cylinders or work equipment piping, bleed the air from the hydraulic circuit as follows. 1. Blade lift cylinder (with piston valve) 1) Start the engine and run at low idling for approx.

  • Page 52: Installation Of Additional Working Lamps

    Assembly process No. Installation of additional working lamps (1/2) A-11 View E View P Detail C Loose-supply items Q’ty 17A-979-1880 17A-979-1890 17A-979-2930 17A-06-17930 17A-979-2921 17A-979-2941 Detail A Detail D 17A-06-42230 01024-D1225 Fig. 1 of additional working lamp 01643-71232 205-977-7310 04434-51012 Precautions Necessary tools Necessary equipment...
  • Page 53 Assembly process No. Installation of additional working lamps (2/2) A-11 Procedure 1. Remove the grommets from the front and rear of the cab and take out the additional lamp con- nectors. (Connector at front of cab: CN-18) (Connector at rear of cab: CN-1) 2.

  • Page 54: Reference Material (Installed When Delivered)

    S. Reference material (Installed when delivered)
  • Page 55 Assembly process No. Installation of operator's cab (1/16) a When installing the KOMTRAX, install the KOMTRAX parts before installing the cab. (See S-2.) 1. Removal of dashboard • Remove bolts (B) and bracket (A) of dashboard wiring harness connector (CN-DSH). •...

  • Page 56: Installation Of Operator's Cab

    Assembly process No. Installation of operator’s cab (2/16) 2. Removal of dashboard • Remove screws (K) (4 pieces) and cover (L). • Install the dashboard to the cab and fix it with bolts (1) (8 pieces). • Fix the wiring harness bracket (A) with bolts (B). •...
  • Page 57 Assembly process No. Installation of operator’s cab (3/16) 3. Installation of open lock stopper • Install the right and left open lock stopper brackets with bolts (4) and washers (5) as shown in Fig. 3. (2 pieces on each side) •...
  • Page 58 Assembly process No. Installation of operator’s cab (4/16) 4. Prepare the floor. • Corks (M) for M16 tap (12 pieces), corks (N) for M20 tap (15 pieces), and corks (P) for M24 tap (6 pieces). • Remove bolt (Q) and ground surface protector plate (R). •...
  • Page 59 Assembly process No. Installation of operator’s cab (5/16) 5. Installation of seals to joints of operator's cab (1) Sling the operator's cab assembly. 4 Cab assembly: 737 kg (2) Remove dirt and oil from the seal sticking surfaces. (3) Remove the release paper from seals (8) and stick the seals as shown in Fig. 5. Fig.
  • Page 60 Assembly process No. Installation of operator’s cab (6/16) To be cut. Detail of composition of seals Detail of part Q Fit seal into groove. Fig. 5 Sticking of seals Precautions Necessary tools Necessary equipment Name Q'ty Name Q'ty When sticking the seals, eliminate clearance in each joint.
  • Page 61 Assembly process No. Installation of operator’s cab (7/16) 6. Removal of covers (1) Remove the B-pillar cover. • Remove bolts (AB) in the cap of handle (AB) (1 pieces each on the right and left sides) and remove handle (AB). a At this time, collar (Z) comes off, too.
  • Page 62 Assembly process No. Installation of operator’s cab (8/16) 7. Installation of operator's cab • Lower the operator's cab assembly onto the floor frame slowly. a Set the lock lever in the lower position. a Take care that the cover and cap will not interfere with each other since the clearance between them is narrow.
  • Page 63 Assembly process No. Installation of operator’s cab (9/16) Position for tightening bolt Long M20 socket is used in this picture. Long M24 socket is used in this picture. Precautions Necessary tools Necessary equipment Name Q'ty Name Q'ty Other remarks...
  • Page 64 Assembly process No. Installation of operator’s cab (10/16) Position for angle-tightening bolt Tightening with hand Impact wrench Tools in this picture M20/M24 with extension of 145 mm and socket (standard) of spline type Tools used for tightening with hand M20/M24 with extension of 200 mm and long socket (100 mm long)
  • Page 65 Assembly process No. Installation of operator's cab (11/16) 8. Installation of covers (1) Reassemble the B-pillar cover. (Reassembly of cover removed in step 5) • Install B-pillar covers (U) and (V) with bolt (Y), collar (W), and washer (X). • Install handles (AA) (1 pieces each on the right and left sides) with bolts (AB).
  • Page 66 Assembly process No. Installation of operator's cab (12/16) 9. Installation of floor ducts Install floor ducts (15) – (19) as shown in Fig. 10. No. Loose-supply items Q’ty 17A-54-46182 17A-54-45851 17A-54-46842 Fig. 10 Installation of floor ducts 01024-81225 01024-81260 Precautions Necessary tools Necessary equipment Name...
  • Page 67 Assembly process No. Installation of operator's cab (13/16) 10. Connection of wiring harnesses and washer hoses (1) Connect the dashboard wiring harness. 3 Tightening torque: 2.83 ± 0.28 Nm {0.289 ± 0.029 kgm} • Fix connector (CN-DSH) with bolt (C) (removed in step 1). •...
  • Page 68 Assembly process No. Installation of operator's cab (14/16) (4) Connect cab wiring harness connectors (CN-CBPW and CN-WST). • Fix the connectors to the clip of bracket (26). • Fix bracket (26) with bolts (27) and washers (28). (5) Connect the washer hoses. a Connect the hoses having marks of the same colors to each other.
  • Page 69 Assembly process No. Installation of operator's cab (15/16) 11. Installation of floor right and left ducts and covers (1) Install right duct (S). (Carry out installation in the reverse order to removal.) • Connect right duct (S) and hose removed in step 1 with band (W). •...
  • Page 70 Assembly process No. Installation of operator's cab (16/16) 12. Installation of interior parts Detail of part Q Do not use collar (44) on inside (2 places) of cover (34). Loose-supply items Q’ty 17A-979-2751 Fig. 14 Installation of floor garnish 17A-979-2781 (1) Fix rear cover (35) with collars (44) (2 pieces), 17A-979-2761 washers (46) (2 pieces), and bolts (45) (2 pieces).

  • Page 71: Installation Of Komtrax Parts

    Assembly process No. Installation of KOMTRAX parts (1/6) Preparation for installing KOMTRAX parts (Carry out before S-1 Installation of operator's cab) (1) Installation of modem • Fix modem (1) to the right side of the floor with bolts (2) as shown in Fig. 1. Fig.
  • Page 72 Assembly process No. Installation of KOMTRAX parts (2/6) Preparation for installing KOMTRAX parts (Carry out before A-6 Installation of operator's cab) (2) Removal of interior parts from ceiling • Remove B-pillar covers (D) (right and left). • Remove mirror (A) and room lamp (C). •...
  • Page 73 Assembly process No. Installation of KOMTRAX parts (3/6) (3) Installation of antenna Referring to Fig. 3, remove the cap. (Discard the removed cap.) • Referring to the detailed view in Fig. 3, remove the paint in the hatched area. Fig. 3 Removal of cap •...
  • Page 74 Assembly process No. Installation of KOMTRAX parts (4/6) • Install the antenna to the ceiling as shown in Fig. 5. Lower from left side of A-pillar. Install grommet from inside of cab. Lower from right side of C-pillar. Fig. 5 Route of wiring harness Loose-supply items Q’ty 175-06-81610...
  • Page 75 Assembly process No. Installation of KOMTRAX parts (5/6) • Install the wiring harness to the modem as shown in Fig. 6. Connect to modem (1). Fig. 6 Route of wiring harness (Right rear of floor) Loose-supply items Q’ty 20Y-06-21460 Precautions Necessary tools Necessary equipment Name...
  • Page 76 Assembly process No. Installation of KOMTRAX parts (6/6) • Remove cover (N) and connect connector (P) and wiring harness (5) in it. • Install the cover (N) again. • Install the covers removed in step (2) in the reverse order to removal. (When cover N is removed) Fig.

  • Page 77: Installation Of Komtrax Antenna

    Assembly process No. Installation of KOMTRAX antenna 1. Install communication antenna (4). 2. Install GPS antenna (6) to the right rear of the cab. a The GPS antenna is a magnet. a Stick cover (14) with both-sided adhesive tapes. Loose-supply items Q’ty 17A-979-3960 01024-D0850...

  • Page 78: Check And Maintenance Procedures After Completion Of Assembly

    M. Check and maintenance procedures after completion of assembly...
  • Page 79 Assembly process No. Testing and adjusting operator’s cab (1/10) 1. Adjusting door duct • Loosen the duct mounting bolts and fix the duct to the rear end temporarily. • Close the door. a Do not leave the door half-open but close it securely. •...
  • Page 80 Assembly process No. Testing and adjusting operator’s cab (2/10) 2. Testing painting (1) Check that the paint of the removed and installed bolt heads is not flaked off. (2) Check that the painted surfaces are not Lock lever shifted at the sealed part between the floor mounting hole trame and tank and the joints of the covers and chassis.

  • Page 81: Testing And Adjusting Operator's Cab

    Assembly process No. Testing and adjusting operator’s cab (3/10) 4. Shower test (1) Close all the openings of the cab. (2) Supply water at the rate of 5 gal/min (about 19 liters/min) through a hose. (3) Pour water around the hatched parts in the following figure. Do not apply pressure at this time.
  • Page 82 Assembly process No. Testing and adjusting operator’s cab (4/10) 5. Testing door lock Close the door and check the relationship between the operator's cab and door. If there is any fault, repair it. 5-1.Check of condition (1) Check the installed height of the damper rubber. (Check both sides, 2 pieces on each.) Stick an adhesive tape to the contact face of the damper rubber and open and close the door 2 –...
  • Page 83 Assembly process No. Testing and adjusting operator’s cab (5/10) 5-2.Adjusting (1) Adjusting height of damper rubber Increase or decrease of the shims under the damper rubber to adjust the height of the damper rubber properly. Fig. 6 (2) Adjusting latch and striker a) Tighten the mounting bolt of the striker temporarily and open and close the door 2 –...
  • Page 84 Assembly process No. Testing and adjusting operator’s cab (6/10) 6. Testing open lock Lock the door open and check the relationship between the operator's cab and door. If there is any fault, repair it. 6-1.Check of condition (1) Check the relationship between the open lock latch and striker. (Both sides). Open the door and check the engaging condition of the latch and striker.
  • Page 85 Assembly process No. Testing and adjusting operator’s cab (7/10) Precautions Necessary tools Necessary equipment Name Q'ty Name Q'ty Other remarks...
  • Page 86 Assembly process No. Testing and adjusting operator’s cab (8/10) 6-2.Adjusting (1) Adjusting latch and striker a) If the striker is slanting from the center of the latch, loosen the striker mounting bolt, align the striker with the latch, and then tighten the striker mounting bolt. Fig.
  • Page 87 Assembly process No. Testing and adjusting operator’s cab (9/10) (2) Adjusting installed height of stopper rubber ( 2 places, upper and lower) Fig. 9, Fig. 10 a) Loosen the locknut of the stopper rubber. b) If there is any play, project the stopper rubber until the play is eliminated. If the door is not locked easily or the unlock lever is heavy, return the stopper rubber in the range that the door does not have any play.
  • Page 88 Assembly process No. Testing and adjusting operator’s cab (10/10) 7. Check of clearance between hood and cab A: Distance between front leg and clearance to be checked: 961 mm B: Distance between front and rear mounts: 1,560 mm C: Max. stroke of cab mount: 7 mm (When riding over) (On drawing: 13 mm) Max.
  • Page 89 Assembly process No. Replacement of return filter (Standard filter to flushing filter) (1/3) The return filter element for hydraulic oil is replaced with the special elements (1) and plate (2) for flushing as follows. a When replacing the elements, take out the element slowly so that refuses adhered to the element do not fall inside.

  • Page 90: Replacement Of Return Filter (Standard Filter To Flushing Filter)

    Assembly process No. Replacement of return filter (Standard filter to flushing filter) (2/3) Reinstall the removed return filter element (1) and valve (2). a When replacing the elements, take out the element slowly so that refuses adhered to the element do not fall inside. Also, take out refuses by hand from the case.
  • Page 91 Assembly process No. Replacement of return filter (Standard filter to flushing filter) (3/3) State of inserted element Fig. 1 Correct state Fig. 2 Incorrect state a Do not insert the element so that it stands on the step at the bottom of the case as shown in Fig. 2. When the filter case is filled with oil, it is difficult to check if the element is inserted correctly, so turn the element by hand after inserting it in the case.

  • Page 92: Flushing Of Hydraulic Circuit

    Assembly process No. Flushing of hydraulic circuit After the assembly work is completed, flush the hydraulic circuit. Run the engine at mid-range speed, extend and retract each cylinders for several minutes not to reach cylinders to the stroke end. a Never run the engine at high idle to avoid the damage to the flushing elements. (a) Extension and retraction of blade lift cylinder for 5 minutes (b) Extension and retraction of blade tilt...

  • Page 94: Field Assembly Inspection Report

    (1) Criteria are based on the standards when the machine is shipped out of the factory. SUBMITTANCE OF THIS REPORT (AND CHECK SHEETS) TO KOMATSU IS ONE OF THE CONDITIONS OF WARRANTY VALIDATION, COPY FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY SERVICE RE- PORT.
  • Page 96 Cate- Inspec- Inspection item Criteria gory tion Check of electrolyte level Must be between L and H. Check of battery unit Must be free from grease, looseness of terminals, and cracking. Use the diagram below for reference, and check if the electro- The electrolyte level is up to the bottom of the sleeve, so the sur- lyte reaches the bottom of the sleeve.
  • Page 98 Cate- Inspec- Inspection item Criteria gory tion Check of auto shift-down function (When stalled) Auto shift-down function must not work when stalled. Effect of parking brake lever When parking brake lever is in FREE position, engine must not start. Travel and gear shifting must be prohibited when locked.
  • Page 100 Cate- Inspec- Inspection item Criteria gory tion Clearance between straight frame and track Difference between right and left must be 30 mm or Left less (when measured on flat ground). Move the blade up and down and stop it at 100 mm Right above ground, then measure.
  • Page 102 Cate- Inspec- Inspection item Criteria gory tion Portions to be lubricated Q’ty Example: When U-blade is used • Equalizer bar side pin shaft • Equalizer bar center pin shaft • Blade lift cylinder support shaft and yoke • Brace center pin •...
  • Page 104 Engine speed Cate- Item Condition Unit Standard Result gory Engine speed Low idling (low speed). Power train 740 ± 25 (P mode) oil tempera- High idling (at full throttle). Transmission: N 1575 ± 25 ture: 80 °C Deceleration slow 875 ± 25 Torque converter stall 1665 ±...
  • Page 106 Check sheet for tightening torque for bolts of cab Sketch Record • Locations of bolts • Check the torque at each No. shown at left and enter the measured torque in the following torque recording box. • As for the M20 and M24 (1 – 21) bolts, tighten them to the specified torque first, then retighten them and check the retightening work and then record the measured torque.
  • Page 108 GEN00078-02...

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