Komatsu D155AX-7 Bulldozer Field Assembly Instruction Manual - PDF DOWNLOAD

GEN00108-03

Field Assembly Instruction

BULLDOZER

D155AX -7 SERIAL NUMBERS

90001

and up

Preface Since this machine is large in size, it is divided into some units to meet the transportation conditions and regulations applied to the transportation route when shipped from our factory.

This manual describes how to assemble the units into the complete machine in the field. We hope that this machine will display its quality and you will use it safely according to the operation manual.

Many units are large in size and heavy in weight and may be handled in a dangerous place or posture and many workers may have to work together to sling them with cranes.

Accordingly, before starting the assembly work, the work supervisor is required to hold a safety meeting to oblige the workers to put on protective gear and appoint a work leader and a crane work signal man and allot roles to all the workers for safe work.

In particular, the above meeting is more important when worker of different languages and customs work together.

The following is a reference supervision system diagram.

(Instruction system) Work leader Work supervisor

Crane director

Director and deputy director

Operator for assembly Liaison man Mechanics

Sharing of work

Interpreter

When the work equipment is installed, the engine must be operated.

Accordingly, before installing the work equipment, inspect and maintain the machine thoroughly.

Note that this manual does not describe the whole specification of the machine but describes only the basic specification.

If you have any question when dividing and transporting the machine by yourself in future, ask one of our distributors.

CONTENTS SPECIFICATIONS...........................................................................................................................................

1

PRECAUTIONS FOR FIELD ASSEMBLY ......................................................................................................

2

ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE ................................................

3

LAYOUT OF KIT..............................................................................................................................................

4

STYLE FOR TRANSPORTATION ..................................................................................................................

5

LIST OF TOOLS FOR FIELD ASSEMBLING.................................................................................................. 10 SKETCH OF JIGS ........................................................................................................................................... 11 TIGHTENING TORQUE .................................................................................................................................. 13 COATING MATERIALS LIST .......................................................................................................................... 18 SELECTION OF WIRE ROPES USED FOR ASSEMBLY .............................................................................. 21 A. Assembly..................................................................................................................................................... 23 A-1. Unloading and installing tractor ......................................................................................................... 24 A-2. Installation of trunnion ....................................................................................................................... 25 A-3. Installation of blade lift cylinder.......................................................................................................... 26 A-4. Assembly of blade ............................................................................................................................. 29 A-5. Installation of full roller guard............................................................................................................. 35 A-6. Installation of blade............................................................................................................................ 39 A-7. Installation of ripper assembly ........................................................................................................... 44 A-8. Check of oil and coolant levels .......................................................................................................... 56 A-9. Lubricating ......................................................................................................................................... 58 A-10. Bleeding air from hydraulic cylinders ............................................................................................... 60 A-11. Installation of additional working lamps ........................................................................................... 62 A-12. Installation of fire extinguisher ......................................................................................................... 65 M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY ......................... 67 M-1. Replacement of return filter (Standard filter to flushing filter)............................................................ 68 M-2. Flushing of hydraulic circuit, and bleeding air from hydraulic cylinders (Part 1) ............................... 70 M-3. Replacement of return filter (Flushing filter to standard filter) ........................................................... 71 M-4. Bleeding air from hydraulic cylinders (Part 2) ................................................................................... 73 M-5. Error code ......................................................................................................................................... 74 FIELD ASSEMBLY INSPECTION REPORT

SPECIFICATIONS

kg

Reinforced Sigma dozer + Multi ripper 41,400

Reinforced Semi-U + Giant ripper 40,320

Blade weight (reinforced) (including cylinders)

kg

5,637

5,695

Ripper weight (including cylinders)

kg

3,392

2,405

Engine model

–

KOMATSU SAA6D140E-6

kW/rpm × {HP/rpm}

264/1,900 {353/1,900}*

Length of track on ground

mm

3,275

Width of gauge

mm

Overall length

mm

Overall height (with ROPS, cab)

mm

Overall width (width of blade)

mm

Item

Unit

Operating weight (excluding operator’s weight)

Rated engine output

Travel speed (1st / 2nd / 3rd (Low) / 3rd)

2,140 8,325

8,375 3,310aa

4,060

4,130

Forward

km/h

3.5/5.6 / 7.5/11.6

Reverse

km/h

4.3/6.8 / 9.2/14.0 * It shows at min. fan speed. At max. fan speed, it is 239 kW {320 HP}. aa Height above GL. excluding grouser (80 mm).

•

Reinforced Sigma dozer + Variable multi ripper

•

Reinforced Semi-U dozer + Giant ripper

1

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 drawing.)

• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)

• Is the ground flat? (The ground surface must not be uneven or sloping.)

• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?

2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.

3) Avoid working outdoors while strong wind is blowing or it is raining.

4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.

2. How to do work The work supervisor or the work leader should not do the work while reading this manual but should read and understand this manual thoroughly and then start the work.

In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the work place so that all the workers will observe the precautions.

3. Preparation and check of protective gear, slings and tools The work supervisor or the work leader must perform the following checks about protective gear, slings and tools.

1) Are all the workers wearing helmets and other protective gear which they are obliged to wear?

If special protective gear is necessary, check that it is prepared and can be used without problem.

2) Are all the slings and tools prepared? Check in advance that they are ready to be used without problem. In particular, check wooden blocks for internal decay and cracking.

4. k Check during actual work The work supervisor or the work leader must check the following items constantly and make all the workers observe them.

1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with chocks during work? Are outriggers, if installed, used securely?

2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during work?

3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked that work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel control lever) is in the low idle position?

4) Is the balance of the slung item checked extremely during sling work with the crane?

5) Is entry prohibition for outsiders to the work place observed?

5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of every morning and explain the work plan of the day to them and give them instructions to observe the safe work.

2

3

Working hours Number of workers Total man-hours

Wrecker

Trailer must arrive at field before 8:00

9H 4 workers 36H

25 ton x 2 units

8H 3 workers 24H

25 ton x 1 unit

User delivery

Grand total

Cleaning and touch-up painting of machine

Trial operation and rework

2nd day

Supply and check of oil

Sub installation of ripper

Installing blade

Unloading trailer Assembly of blade subassembly

1st day 3rd day

60H

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

LAYOUT OF KIT When selecting the work field, see “PRECAUTIONS FOR FIELD ASSEMBLY”.

The dimensions in the drawings are reference dimensions for installation in the following space (30 m x 30 m).

If a wider work field is available, the shown dimensions should be increased.

Approx. 30 m

(25 ton)

(25 ton)

Ripper parts

Other parts

4

Approx. 30 m

Right straight frame Wrecker truck

Left straight frame

Right track frame

Track Chassis

Track

Left track frame

Blade

Wrecker truck

• • •

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 + track shoe)

A

Overall length (mm)

5,168

B

Overall height (mm)

3,390

C

•

Overall width (mm)

2,765

Weight (kg)

31,680

A

Overall length (mm)

1,870

B

Overall height (mm)

945

C

Overall width (mm)

4,060

Weight (kg)

3,493

Work equipment (1) Blade (Sigma)

x: 677 y: 497

Blade (semi-U)

A

Overall length (mm)

1,790

B

Overall height (mm)

1,025

Overall width (mm)

4,130

Weight (kg)

3,492

C

x: 740 y: 590

5

(2) Straight frame (L.H., reinforced type)

A

Overall length (mm)

3,624

B

Overall height (mm)

420

C

Overall width (mm)

456

Weight (kg)

647

X: 1,677 Y: 102 Z: 4

Straight frame (R.H., reinforced type)

A

Overall length (mm)

3,624

B

Overall height (mm)

420

C

Overall width (mm)

498

Weight (kg)

976

X: 1,585 Y: 93 Z: 6

(3) Oblique arm

䠝

A

Overall length (mm)

1,812

B

Overall height (mm)

305

C

Overall width (mm)

230

Weight (kg)

250

䠞 䠟

6

(4) Blade lift cylinder (left)

㻯

A

Overall length (mm)

1,950

B

Overall height (mm)

291

C

Overall width (mm)

281

Weight (kg)

172

䠞 䠝

Blade lift cylinder (right)

㻯

A

Overall length (mm)

1,950

B

Overall height (mm)

291

C

Overall width (mm)

281

Weight (kg)

172

䠞 䠝 (5) Blade tilt cylinder (dual, 2 pieces/machine)

㻯

A

Overall length (mm)

1,407

B

Overall height (mm)

272

C

Overall width (mm)

215

Weight (kg)

131

* weight : each

㻮 䠝

7

(6) Ripper Ass’y

Multi

•

Giant

B

Overall height (mm)

1,250

1,250

C

Overall width (mm)

2,150

2,150

Weight (kg)

3,392

2,405

Ripper arm

A

Overall length (mm)

1,269

B

Overall height (mm)

372

C

Overall width (mm)

1,660

Weight (kg)

625

x: 768 Z: 12

•

Ripper beam (Multi)

A

Overall length (mm)

2,320

B

Overall height (mm)

1,250

C

Overall width (mm)

700

Weight (kg)

8

1,238

•

Ripper beam (Giant)

9

A

Overall length (mm)

1,401

B

Overall height (mm)

1,250

C

Overall width (mm)

700

Weight (kg)

787

Tool names Air compressor Crane truck Forklift truck Grease pump Stepladder Small impact wrench Medium impact wrench Large impact wrench Large impact socket

Medium impact socket

Tools

Extension Air hose for impact 4-time wrench Socket for 4-time wrench Torque wrench

Standard tool Sledge hammer Bar Hydraulic jack Tap

Waste oil pan Wooden block

Wire

Slings

Shackle

Nylon sling Lever block Eyebolt

Lubricants, etc.

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

Equipments

LIST OF TOOLS FOR FIELD ASSEMBLING

Detergent liquid Hydraulic oil Grease Repair paint Glass cleaner Waste cloth

Specifications 7.5 kg/cm3 Class 245 kN {25 ton} 29 kN {3 ton} Air type 5 -stepped, 1500 mm M10 bolt M12 bolt M14 – M20 bolt M22 – M33 bolt Width across flats 50 mm Width across flats 46 mm Width across flats 41 mm Width across flats 36 mm Width across flats 24 mm Width across flats 27 mm Width across flats 30 mm L300 L150 50 m 25.4, 19 T25.4 × 50 mm T25.4 × 41 mm 412 Nm {42 kgm} – T19 mm 834 Nm {85 kgm} – T25.4 mm 4118 Nm {420 kgm} – T38.1 mm Socket, spanner, wrench 10 P 1m 196 kN {20 ton} 98 kN {10 ton} M27 × P2 M24 × P3 M30 × P3 Large, small 600 mm 700 mm 100 mm 300 × 400 mm ø10 × 3 m ø20 × 5 m ø25 × 5 m ø30 × 5 m SA60 SD12 SD22 SD34 BC36 50 mm wide × 3 m 14.7 – 29.4 kN {1.5 – 3 ton} M12 M24 Brake cleaner TO-10 G2-LI LM-P Natural yellow Black gray Bundle

10

Q’ty.

Remarks 1 2 1 1 1 1 Torque range 30 – 170 Nm 1 1 Torque range 200 – 700 Nm 1 Torque range 1000 – 2500 Nm 1 For blade, center arm 1 1 1 1 1 1 1 For large impact 1 For medium impact 1 1 1 1 1 35 – 420 Nm 1 420 – 1050 Nm 1 1050 – 4200 Nm 2 each 1 2 1 1 1 For master link 1 1 For blade, center arm 2 each 1 1 2 4 3 2 4 4 For body 1 3 2 2 2 2 2 2 1 10 100 l Hydraulic tank 20 kg 200 g 5 5 1 20 kg For cleaning

SKETCH OF JIGS Note 1) We are not liable for any result of use of jigs manufactured according to these drawings.

Stand (Front side)

11

Stand (Rear side)

12

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.

Part No. of bolt

TTTTT-TTTTT

Part No. of washer

EEEEE-EEEEE

Bolt specification

Thread size (Diameter, pitch, length) Applicable socket size

Tool (Socket) Tightening torque

Nm {QQQ kgm}

If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.

Remarks 1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 20 mm is expressed as M20.

The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit: mm).

2. The bolt length is dimension (c) in Fig. 1.

3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. correspond to dimension (b) in Fig. 1, an applicable socket can be selected from Table 1, too.

4. Tightening torque is expressed as QQQ – www or QQQ ± RR. If the target tightening torque is set, expression of QQQ ± RR is applied.

Fig. 1

a b c d

: Bolt thread diameter (Nominal diameter) : Width across flats of bolt head : Bolt length : Threaded part of bolt

13

Table 1 Tightening torque for bolts not specified in text Unit: Nm {kgm} Nominal size of thread × pitch a (mm)

Width across flats (= Socket size) b (mm)

M6 × 1

Tightening torque Target

Range

10

12 {1.2}

8.8 – 14.7 {0.9 – 1.5}

M8 × 1.25

13

25 {2.5}

14.7 – 34 {1.5 – 3.5}

M10 × 1.5

17

54 {5.5}

34 – 74 {3.5 – 7.5}

M12 × 1.75

19

89 {9}

54 – 123 {5.5 – 12.5}

M14 × 2

22

137 {14}

84 – 196 {8.5 – 20}

M16 × 2

24

230 {23.5}

147 – 309 {15 – 31.5}

M18 × 2.5

27

315 {32}

201 – 427 {20.5 – 43.5}

M20 × 2.5

30

460 {47}

319 – 608 {32.5 – 62}

M22 × 2.5

32

650 {66.5}

471 – 829 {48 – 84.5}

M24 × 3

36

810 {82.5}

588 – 1030 {60 – 105}

M27 × 3

41

1180 {120}

883 – 1470 {90 – 150}

M30 × 3

46

1520 {155}

1130 – 1910 {115 – 195}

M33 × 3

50

1960 {200}

1470 – 2450 {150 – 250}

M36 × 3

55

2450 {250}

1860 – 3040 {190 – 310}

M39 × 3

60

2940 {300}

2260 – 3630 {230 – 370}

a For symbols "a" and "b" in the table, see Fig.1.

14

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. If tightening torque is specified specially in explanation, however, apply that tightening torque.

2.1 If the male screw is made of mild steel or cast iron, apply Table 2.

Table 2 Unit: Nm {kgm} Material of female thread

Steel

Cast iron

Light alloy

1/8

3.9 – 6.9 {0.4 – 0.7}

2.9 – 5.9 {0.3 – 0.6}

2.0 – 3.9 {0.2 – 0.4}

1/4

5.9 – 11.8 {0.6 – 1.2}

4.9 – 9.8 {0.5 – 1.0}

3.9 – 7.8 {0.4 – 0.8}

3/8

16.7 – 26.5 {1.7 – 2.7}

13.7 – 21.6 {1.4 – 2.2}

9.8 – 16.7 {1.0 – 1.7}

1/2

32.3 – 52.9 {3.3 – 5.4}

26.5 – 43.1 {2.7 – 4.4}

19.6 – 32.3 {2.0 – 3.3}

3/4

51.0 – 85.3 {5.2 – 8.7}

42.1 – 70.6 {4.3 – 7.2}

31.4 – 52.9 {3.2 – 5.4}

1

86.2 – 173.5 {8.8 – 17.7}

72.5 – 146.0 {7.4 – 14.9}

54.9 – 111.7 {5.6 – 11.4}

Nominal size (in)

2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.

Table 3 Unit: Nm {kgm} Material of female thread

Steel

Cast iron

Light alloy

1/8

16.7 – 29.4 {1.7 – 3.0}

9.8 – 19.6 {1.0 – 2.0}

6.9 – 14.7 {0.7 – 1.5}

1/4

19.6 – 44.1 {2.0 – 4.5}

16.7 – 37.2 {1.7 – 3.8}

12.7 – 28.4 {1.3 – 2.9}

3/8

44.1 – 93.1 {4.5 – 9.5}

37.2 – 77.4 {3.8 – 7.9}

27.4 – 58.8 {2.8 – 6.0}

1/2

98.0 – 188.2 {10.0 – 19.2}

83.3 – 157.8 {8.5 – 16.1}

60.8 – 115.6 {6.2 – 11.8}

3/4

170.5 – 316.5 {17.4 – 32.3}

141.1 – 247.0 {14.4 – 25.2}

105.8 – 186.2 {10.8 – 19.0}

1

367.5 – 612.5 {37.5 – 62.5}

309.7 – 514.5 {31.6 – 52.5}

235.2 – 392.0 {24.0 – 40.0}

Nominal size (in)

15

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 4.1 and 4.2.

If the tightening torque is specified specially in explanation, apply that tightening torque.

Table 4.1 Hydraulic hose of face seal type Type that uses O-ring at this position

Outside diameter of hose (mm)

Width across flats of nut (mm)

Range

Target

Approx. 6

19

34 – 54 {3.5 – 5.5}

44 {4.5}

Approx. 10

22

54 – 93 {5.5 – 9.5}

74 {7.5}

Approx. 13

27

84 – 132 {8.5 – 13.5}

103 {10.5}

Approx. 16

32

128 – 186 {13.0 – 19.0}

157 {16.0}

Approx. 20

36

177 – 245 {18.0 – 25.0}

216 {22.0}

Tightening torque (Nm {kgm})

Table 4.2 Hydraulic hose of taper seal type

Type that does not use O-ring at this position

Outside diameter of hose (mm)

Width across flats of nut (mm)

Range

Target

Approx. 6

19

34 – 63 {3.5 – 6.5}

44 {4.5}

Approx. 10

24

59 – 98 {6.0 – 10.0}

78 {8.0}

Approx. 13

27

84 – 132 {8.5 – 13.5}

103 {10.5}

Approx. 16

32

128 – 186 {13.0 – 19.0}

157 {16.0}

Approx. 20

36

177 – 245 {18.0 – 25.0}

216 {22.0}

Tightening torque (Nm {kgm})

Note: When connecting hose, take care not to twist them.

16

4. Proper socket sizes for bolts of M39 and larger (Reference) For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and larger, see Table 5.

Table 5 Unit: mm Thread diameter

Proper sizes of sockets or spanners

M42

65

M45

70

M48

75

M52

80

M56

85

M60

90

M64

95

17

COATING MATERIALS LIST a The recommended coating materials such as adhesives, liquid gaskets, 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 manual.

Adhesive

Category

Komatsu code

Part No.

Capacity

Container

LT-1A

790-129-9030

150 g

Tube

LT-1B

790-129-9050

20 g (2 pcs.)

Polyethylene container

LT-2

790-129-9040

50 g

Polyethylene container

LT-3

790-129-9060 (Set of adhesive and hardener)

Adhesive: 1 kg Hardener: 500 g

Can

LT-4

790-129-9040

250 g

Polyethylene container

Holtz MH 705

790-129-9120

75 g

Tube

50 g

Polyethylene container

ThreeBond 1735

790-129-9140

Main features and applications q

Use to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

q

Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and nonmetal parts which require immediate and strong adhesion.

q

Features: Resistance to heat and chemicals.

Use to fix and seal bolts and plugs.

q q

Use to bond and seal metal, glass and plastics.

q

Use to seal plugs for blank holes

q

Heat-resistant seal used to repair engines.

q

Instantaneous adhesive.

Curing time: From 5 sec. to 3 min.

Use mainly to bond metals, rubbers, plastics, and woods.

q q

q

Aron-alpha 201

790-129-9130

2g

Polyethylene container

q q

q

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

1 kg

Polyethylene container

q

q

LG-5

790-129-9080

q

q

LG-6

790-129-9160

200 g

Tube

q

Liquid gasket

q q

LG-7

LG-8 ThreeBond 1207B

790-129-9170

1 kg

Tube

q

q

419-15-18131

100 g

Tube q q

LG-9 ThreeBond 1206D

790-129-9310

200 g

Tube q

18

Instantaneous adhesive.

Quick-curing type (max. strength is obtained after 30 minutes) Use mainly to bond rubbers, plastics, and metals.

Features: Resistance to heat and chemicals.

Use for fitted portions subjected to high temperature.

Use to seal various threaded portions, pipe joints, and flanges.

Use to seal taper plugs, elbows, and nipples for hydraulic piping.

Features: Silicon-based heat and coldresistant sealant.

Use to seal flange surfaces and threaded portions.

Use to seal oil pan, final drive case, etc.

Features: Silicon-based quick-curing sealant.

Use to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Features: Silicon-based, heat and coldresistant, vibration-resistant, impact-resistant sealant.

Use to seal transfer case, etc.

Use for rough surfaces such as the circle gear top seal which is not clamped by bolts, gaps in the weld which must be caulked, etc.

Can be coated with paint.

Described in this manual

Seizure prevention compound

Molybdenum disulfide lubricant

Liquid gasket

Category

Komatsu code

Part No.

Capacity

Container

LG-10 ThreeBond 1206E

790-129-9320

200 g

Tube q q

790-129-9330

200 g

Tube

ThreeBond 1211

790-129-9090

100 g

Tube

09940-00040

200 g

q

q

Use to prevent galling and seizure of press-fitted portions, shrinkage-fitted portions, and threaded portions.

Use to lubricate linkages, bearings, etc.

q q

—

09995-00250

190 g

Can q

q

LC-G NEVERSEEZ

—

—

Can

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA160CNLI SYG0-400LI-A (*) SYG0160CNLI (*)

Various

Various

Molybdenum disulfide SYG2-400M grease SYG2-400M-A LM-G SYGA-16CNM (G2-M)

400 g × 10 Bellows-type 400 g × 20 container 16 kg Can

Hyper White G2-T, G0-T (*) *: For cold district

SYG2-400T-A SYG0-400T-A (*) SYG2-16CNT SYG0-16CNT (*)

400 g

Bellows-type container Can

Biogrease G2-B G2-BT (*) *: For use at high temperature and under high load

SYG2-400B SYG2-400BT (*) SYGA-16CNB SYGA16CNBT (*)

400 g

G2-S ThreeBond 1855

—

16 kg

16 kg

200 g

Bellows-type container Can

q

Spray type Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from galling.

Use for the drive shaft splines, needle bearings, various link pins, bolts, etc.

Feature: Seizure and galling prevention compound with metallic super-finegrain, etc.

Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

q

Feature: Lithium grease with extreme pressure lubrication performance, general purpose type.

q

Use for parts under heavy load.

Caution: q Do not use this grease for rolling bearings like swing circle bearings, etc. and spline. q Use this grease for work equipment pins only when installing them, but do not use it afterward.

q

Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease.

Not conspicuous on machine since color is white.

q

q

Since this grease is biodegradable in short period, it has less impact on microorganisms, animals, and plants.

q

Feature: Silicone grease with wide usable temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts.

Use for oil seals of the transmission, etc.

Tube q

19

Feature: Can be used together with solid gaskets.

Use for covers of the transmission case and steering case etc.

Liquid gasket used to repair engine.

Tube

Described in this manual

Use as lubricant/sealant when installing the radiator hoses to the water tubes.

Can be coated with paint.

q

q

G2-LI G0-LI (*) *: For cold district

Grease

q

LG-11 ThreeBond 1121

LM-P

Main features and applications

Q

Category

Komatsu code

Part No.

Capacity

Container

Main features and applications

SUNSTAR PAINT PRIMER 580 SUPER

Primer

SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95 SUNSTAR GLASS PRIMER 435-41

Caulking material

Adhesive

SUNSTAR SASH PRIMER GP-402

427-12-11871

2 kg

Can

20 ml

Glass container

20 ml

Glass container

20 ml

Glass container

Feature: Urea (organic system) grease with heat resistance and long life, can be packed into the confined space and left intact until next overhaul.

Use for rubber, bearing and oil seal in damper.

Caution: Do not mix with lithium grease. q

Use as primer for painted cab sheet metal surface.

(Effective period: four months after date of manufacture)

q

Use as primer for glass.

(Effective period: four months after date of manufacture)

q

Use as primer for painted cab sheet metal surface.

(Effective period: four months after date of manufacture)

q

Use as primer for black ceramiccoated glass surface and for hard polycarbonate-coated surface.

(Effective period: four months after date of manufacture)

q

Use as primer for sash (anodized aluminum surface).

(Effective period: four months after date of manufacture)

q

Use "S" in high-temperature season and "W" in low-temperature season as adhesive for glass.

(Effective period: four months after date of manufacture)

q

Use as adhesive for glass.

(Effective period: six months after date of manufacture)

q

Use as adhesive for glass.

(Effective period: six months after date of manufacture)

q

Use to seal glass-to-glass joints.

(Effective period: four months after date of manufacture)

q

Use to seal front window.

(Effective period: six months after date of manufacture)

q

Use to seal glass-to-glass joint.

Translucent white seal.

(Effective period: 12 months after date of manufacture)

417-926-3910

22M-54-27230

22M-54-27240

22M-54-27250

150 ml

Can

20 ml

Glass container

SUNSTAR PENGUINE SEAL580 SUPER "S" or "W"

417-926-3910

320 ml

Polyethylene container

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene container

SUNSTAR PENGUINE SUPER 560

22M-54-27210

320 ml

Ecocart (Special container)

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml

Polyethylene container

SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml

Polyethylene container

GE TOSHIBA SILICONES TOSSEAL 381

q

22M-54-27220

333 ml

Cartridge

20

For adhered window glass

G2-U-S ENS grease

For adhered window glass

Grease

q

Described in this manual

21

8 9 10 11.2 (12) 12.5 14 16 18 20 22.4 (24) 25 28 30 31.5 33.5 35.5 37.5 40 42.5

Sling angle Angle to vertical line Mode coefficient M Classification of wire rope Outer diameter of wire rope (2)d (mm)

Number of wire ropes

α β

Max. 4.8 {0.49} Max. 6.1 {0.63} Max. 7.6 {0.77} Max. 9.5 {0.97} Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 19 {1.9} Max. 24 {2.5} Max. 30 {3.1} Max. 38 {3.9} Max. 43 {4.4} Max. 47 {4.8} Max. 59 {6.1} Max. 68 {7.0} Max. 75 {7.7} Max. 85 {8.7} Max. 96 {9.8} Max. 107 {10.9} Max. 122 {12.4} Max. 137 {14.0}

24G

α = 0° β = 0° 1

1 pc.

Max. 5.2 {0.53} Max. 6.6 {0.67} Max. 8.2 {0.83} Max. 10 {1.0} Max. 11 {1.2} Max. 12 {1.3} Max. 16 {1.6} Max. 21 {2.1} Max. 26 {2.7} Max. 32 {3.3} Max. 41 {4.2} — Max. 51 {5.2} Max. 64 {6.5} Max. 73 {7.5} Max. 81 {8.3} Max. 92 {9.4} Max. 103 {10.5} Max. 115 {11.7} Max. 131 {13.4} Max. 148 {15.1}

24A Max. 6.7 {0.68} Max. 8.5 {0.88} Max. 10 {1.0} Max. 13 {1.3} Max. 14 {1.5} Max. 15 {1.6} Max. 19 {2.1} Max. 26 {2.6} Max. 33 {3.5} Max. 42 {4.3} Max. 53 {5.4} Max. 60 {6.1} Max. 65 {6.7} Max. 82 {8.5} Max. 95 {9.8} Max. 105 {10.7} Max. 119 {12.1} Max. 134 {13.7} Max. 149 {15.2} Max. 170 {17.3} Max. 191 {19.6}

24G

α Z 90° β Z 45° 1.4 24A Max. 7.2 {0.74} Max. 9.2 {0.93} Max. 11 {1.1} Max. 14 {1.4} Max. 15 {1.6} Max. 16 {1.8} Max. 22 {2.2} Max. 29 {2.9} Max. 36 {3.7} Max. 44 {4.6} Max. 57 {5.8} — Max. 71 {7.2} Max. 89 {9.1} Max. 102 {10.5} Max. 113 {11.6} Max. 128 {13.1} Max. 144 {14.7} Max. 161 {16.3} Max. 183 {18.7} Max. 207 {21.1}

Annex 2, Table 1 Using loads of 6 × 24 type rope slings.

Select wire ropes to be used for assembly according to the following table.

SELECTION OF WIRE ROPES USED FOR ASSEMBLY

2 pcs.

Max. 4.8 {0.49} Max. 6.1 {0.63} Max. 7.6 {0.77} Max. 9.5 {0.97} Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 19 {1.9} Max. 24 {2.5} Max. 30 {3.1} Max. 38 {3.9} Max. 43 {4.4} Max. 47 {4.8} Max. 59 {6.1} Max. 68 {7.0} Max. 75 {7.7} Max. 85 {8.7} Max. 96 {9.8} Max. 107 {10.9} Max. 122 {12.4} Max. 137 {14.0}

24G

24A Max. 5.2 {0.53} Max. 6.6 {0.67} Max. 8.2 {0.83} Max. 10 {1.1} Max. 11 {1.2} Max. 12 {1.3} Max. 16 {1.6} Max. 21 {2.1} Max. 26 {2.7} Max. 32 {3.3} Max. 41 {4.2} — Max. 51 {5.2} Max. 64 {6.5} Max. 73 {7.5} Max. 81 {8.3} Max. 92 {9.4} Max. 103 {10.5} Max. 115 {11.7} Max. 131 {13.4} Max. 148 {15.1}

90° < α Z 120° 45° < β Z 60° 1

Unit: kN {tf}

A. Assembly Remarks 1. 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) (2) (3) (4) (5) (6)

2.

Plate Collar Washer Bolt Bolt Washer

In some places of this manual, the words of front, rear, right hand and left hand of machine are used. Those words indicate the directions seen from the operator's seat with the sprocket at the rear as shown below, unless otherwise specified.

Front

Left hand

Right hand

Operator's seat Sprocket Rear

23

Assembly procedure

Unloading and installing tractor

A-1

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: Approx. 15.5 ton

2. Rear: Install wires to the right and left ripper cylinder pins.

4 Rear slinging weight: Approx. 15.5 ton

3. Lower the tractor onto the stand.

Pass either end of wire through this hole.

Precautions

Name

Necessary equipment Q’ty

ø30 × 5,000 mm wire

4

SA60 shackle

1

BC36 shackle

1

Others

When installing wires, put rubber pads or steel pads under them and take extreme care not to damage the covers and piping.

Necessary tools

24

Name 25 t crane

Q’ty 2

Assembly procedure

Installation of trunnion

A-2 1. Remove the cork plug installed to the bolt hole.

2. Install the trunnion to the track frame. (Left and right) 4 Trunnion weight : Left side 30 kg Right side 43 kg

3 Tightening torque : 785 – 980 Nm {80 – 100 kgm}

Left side Right side

Precautions

Necessary tools Name

Q’ty 1

Large size impact wrench

1

ø10 × 3,000 mm wire

1

Others

Loose-supply items 17A-71-12262 17A-71-45591 01010-82450 01643-32460

Q’ty 1 1 16 16

Necessary equipment

Socket 36 mm in width across flats

25

No. 1 1 2 3

Name 25 t crane

Q’ty 1

Assembly procedure

Installation of blade lift cylinder (1/3)

A-3

1. Remove the yoke fixing brackets (right and left). a Keep the removed parts since they are used again for transportation.

No. 1 2 3 4

Part No. 17A-61-53120 01024-81230 21T-09-11330 01011-82020

Q’ty 2 2 2 2

2. Remove the cap and bushing of the yoke. a When removing the cap, make a match mark on it for reinstallation. (The cap is a part of the yoke.)

Cap

Bushing

3. Installation of cylinder Secure the cylinder with ropes for safety as shown in the photo.

4 Lift cylinder: 165 kg Part No. of bolt

01010-82095 (4 pieces on each side)

Part No. of washer

01643-32060 (4 pieces on each side)

Length of bolt

95 mm

Necessary socket

30 mm

Tightening torque

549.2 ± 58.8 Nm {56 ± 6 kgm}

Fix the cylinder at the angle shown in the Fig. 3.

• Cap mounting bolts Note: Do not install the yoke to the position shown in Fig. 4.

(If it is installed to this position, it is pushed out by the grease pressure.)

Precautions

Necessary tools Name

Necessary equipment Q’ty 1

Socket 30 mm in width across flats

1

Medium size impact wrench

1

Others

Nylon sling

26

Name Wrecker

Q’ty 1

Assembly procedure

Installation of blade lift cylinder (2/3)

A-3

4. Cylinder sling bracket Remove cylinder sling bracket, then install the cylinder to the sling posture position as indicated in the figure.

After installing the blade, check their potisions and directions. a Be careful of the sling bracket installation hole (Fig. 7).

)LJ

㻼㼘㼡㼓

㻿㼘㼕㼚㼓㻌㼎㼞㼍㼗㼑㼠

5. Installation of hoses Remove the plug and install the hose. a Install the hoses as shown in the Fig. 6 so that they will not interfere with each other. a Reuse the plug side (machine side) O-rings.

䠎

)LJ

䠍

)LJ 㻰㼛㻌㼚㼛㼠㻌㼡㼟㼑㻌㼠㼔㼕㼟㻌㼔㼛㼘㼑 㼁㼟㼑㻌㼠㼔㼕㼟㻌㼔㼛㼘㼑

No.

Part name

Part No.

Remarks

1

Hose

17A-61-51290 (2 pieces on each side)

2

O-ring

02896-11018 (4 pieces on each side)

Precautions

Necessary tools Name

Necessary equipment Q’ty

Nylon sling

1

Socket 30 mm in width across flats

1

Medium size impact wrench

2

Spanner 36 mm in width across flats

1

Others

Keep the removed plug in order to use it when transporting.

Reuse the machine side O-rings.

27

Name

Q’ty

Assembly procedure

A-3

Installation of blade lift cylinder (3/3)

6. Bleeding air from blade lift cylinder a When operating the hydraulic cylinder at the first time after assembling it, bleed the air from the hydraulic circuit as follows.

6-1.Cylinder with piston valve (Blade lift cylinder) 1) Check the oil level in the hydraulic tank.

(Check that the oil level is above "L" of the sight gauge. If it is not above "L" , add oil to the "H" level.)

2) Start the engine and run at low idle for approx. 5 minutes. a Keeping the engine at low idle, extend the cylinder to a point 100 mm before the end of the stroke. a Check the oil level in the hydraulic tank. If the oil level is not above the "L" of the sight gauge, add oil to the "H" level.

(Oil capacity inside of each lift cylinder : Approx.24 l) 3) While running the engine at low idle, extend and retract the cylinder for 5 minutes.

However, do not move the cylinder to the stroke end. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

4) Keeping the engine at low idle, extend the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of its stroke. Hold it in this position for 3 minutes.

5) With the engine at high idle, extend the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of its stroke. Hold it in this position for 1 minute. k

k

If from the beginning the engine is run at full throttle; or the cylinders are operated to the end of their stroke, the piston packing may be damaged, so never operate in this way.

Check the oil level, and add oil to the specified level if necessary.

6-2.After bleeding air, extend the cylinder and leave the engine stopped for 1 hour.

1) After leaving for 1 hour, check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.) a If another cylinder is to be installed, perform this operation at the last.

28

Assembly procedure

Assembly of blade (1/6)

A-4

1. Sling blade (1), place wooden blocks and a hydraulic jack under it, and set it stably and securely.

Weight of blade : 3,300 kg (SIGMADOZER) : 3,572 kg (Semi U)

1

2. Scratch the paint off the ball joint and clean the ball joint.

3. Sling center arm (2) and tighten cap mounting bolts (3) and (4) temporarily without inserting a shim (to eliminate the clearance on the ball joint in the axial direction), and then insert shims so that dimension (A) will be +0.2 to 0.5 mm.

(Secure a clearance of 0.2 to 0.5 mm on the ball joint in the axial direction.)

Tighten the bolts to the specified torque and check that the ball joint moves smoothly.

2

a Standard thickness of shim: 4.5 mm Weight of center arm: 251 kg Shims packed simultaneously 17A-71-45551 x 2 : t2.0 17A-71-45561 x 4 : t1.0 17A-71-45571 x 4 : t0.5

3

a Set wooden blocks under the center arm to the height of the straight frame.

(3)

Part No. of bolt

01011-83335

(4)

Part No. of washer

01643-33380

Tightening torque Precautions

135 mm 1,961 – 2,451.7 Nm {200 – 250 kgm}

No.

Part No.

Q’TY

2

17A-71-45511

1

Necessary tools Name

Necessary equipment Q’ty

ø20 × 5,000 mm wire

2

BC36 shackle

2

300 × 400 wooden block

4

50 × 3,000 nylon sling

2

Extension, L300

1

Socket 50 mm in width across flats

1

Large size impact wrench

1

29

Name 25 t crane

Others

Length of bolt

4

Q’ty 1

Assembly procedure

Assembly of blade (2/6)

A-4

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: 864 kg Lock plate mounting bolt (6-3) :

3 Tightening torque : 245 – 309 Nm

{25 – 31.5 kgm}

㻢㻙㻝

㻡

㻢㻙㻞 㻢㻙㻟 㻢㻙㻠 a Tighten the bolt with an impact wrench. (For prevention of rotation of the pin) When using a torque wrench, tighten the bolt lightly at this time. After installing the blade to the machine, tighten the bolt while pressing the blade against the ground to secure the pin.

5. Install right straight frame (5) and center arm (2) with pin (7) and fix them with lock plate (8).

Lock plate mounting bolt (8-2) : 3 Tightening torque : 490 – 608 Nm {50 – 62 kgm} No.

Part No.

Q’TY

5

17A-71-51221

1

6-1

17A-71-51941

1

6-2

17A-71-48390

1

6-3

01010-81645

3

6-4

01643-31645

3

7

09225-06245

1

8-1

17A-71-45490

1

8-2

01010-82080

3

8-3

01643-32060

3

㻤㻙㻝 㻡

㻤㻙㻞 㻤㻙㻟

㻣

㻞

Precautions

Necessary tools Name

Necessary equipment Q’ty 2

Socket 24 mm in width across flats

1

Socket 30 mm in width across flats

1

Medium size impact wrench

1

Others

50 × 3,000 nylon sling

30

Name 25 t crane

Q’ty 1

Assembly procedure

Assembly of blade (3/6)

A-4

6. Install right pitch cylinder (9) with pin (10-1) and fix them with the lock plate (10-2).

Semi-U sigma dozer (Dual tilt)

Lock plate mounting bolt (10-3)

3 Tightening torque: 157 – 196 Nm {16 – 20 kgm}

㻝㻝

7. Sling right pitch cylinder (9) and tighten cap mounting bolts (11) and (12) temporarily without inserting a shim (to eliminate the clearance on the ball joint in the axial direction), and then insert shims so that dimension (A) will be +0.2 to 0.5 mm.

(Secure a clearance of 0.2 to 0.5 mm on the ball joint in the axial direction.)

Tighten the bolts to the specified torque and check that the ball joint moves smoothly.

㻝㻞

㻥

㻝㻜㻙㻝 Shims packed simultaneously 175-71-31270 × 2 : t2.3 175-71-31260 × 4 : t1.0 175-71-31250 × 2 : t0.5

Semi-U (Single tilt)

a When machine has the single tilt specification, part (9) is the brace.

(Standard length: 1,372 mm) (11) Part No. of bolt

01011-62700

(12) Part No. of washer

01643-32780

Length of bolt

100 mm

Tightening torque

Sigma dozer (Single tilt)

Shim

1,176 – 1,471 Nm {120 – 150 kgm}

No.

Part No.

Q’TY

10-1

154-71-21290

1

10-2

175-71-21330

1

10-3

01010-81435

4

10-4

01643-31455

4

Precautions

Necessary tools Name

Necessary equipment Q’ty 1

Extension, L300

1

Socket 41 mm in width across flats

1

Socket 22 mm in width across flats

1

Medium size impact wrench

1

Large size impact wrench

1

Others

50 × 3,000 nylon sling

31

Name 25 t crane

Q’ty 1

Assembly procedure

Assembly of blade (4/6)

A-4

8. Connect right pitch cylinder hoses (13-1) and (13-2).

㻝㻟㻙㻤

㻝㻟㻙㻥

For dual tilt (right and left) • (13-1) #04-size hose, 1,380 mm long • (13-2) #04-size hose, 980 mm long

㻝㻟㻙㻝㻝 㻝㻟㻙㻝㻞

For single tilt (left only) • (13-1) #04-size hose, 1,320 mm long • (13-2) #04-size hose, 920 mm long

㻝㻟㻙㻝㻜

3 Tightening torque for hose: 84 – 132 Nm {8.5 – 13.5 kgm}

㻝㻟㻙㻟 No.

Part No.

Q’TY

13-1

17A-71-45731

1

For dual

13-1

17A-71-45870

1

For single

13-2

17A-71-45741

1

For dual

㻝㻟㻙㻠

13-2

17A-71-45880

1

For single

㻝㻟㻙㻡

13-3

02896-11012

4

Reuse (After transportation, remove cap)

13-4

01024-81265

1

13-5

07095-00420

2

13-6

07094-30417

2

13-7

17A-71-45661

1

13-8

01010-81635

3

13-9

01643-31645

3

13-10

195-71-62151

1

13-11

01010-81660

2

13-12

01643-31645

2

㻝㻟㻙㻝

㻝㻟㻙㻢 㻝㻟㻙㻣

㻝㻠㻙㻝

9. Install right frame cover (14-1). a 4 bolts of M20 size

㻝㻟㻙㻟

㻝㻟㻙㻞

㻝㻠㻙㻟

㻝㻠㻙㻡 㻝㻠㻙㻟

Cover mounting bolt (14-3) 3 Tightening torque: 455 – 565 Nm {46.5 – 58 kgm} No.

Part No.

Q’TY

14-1

17A-71-51421

1

14-2

708-27-12581

2

14-3

01010-82045

4

14-4

154-30-51460

2

14-5

01643-32060

2

㻝㻠㻙㻠 㻝㻠㻙㻞

Machine with single tilt specification Necessary tools Name

Necessary equipment Q’ty 2

Socket 30 mm in width across flats

1

Medium size impact wrench

1

Others

Spanner 27 mm in width across flats

32

Name 25 t crane

Q’ty 1

Assembly procedure

Assembly of blade (5/6)

A-4 10. Install left straight frame (15) and blade (1) according to the procedure in step 4 above.

㻝㻣㻙㻝㻞

㻝㻤㻙㻟

12. Install tilt cylinder hoses (17-1) and (172) and cover (18-1) according to the procedures in steps 8 and 9 above.

㻝㻣㻙㻣

㻝㻤㻙㻠

㻝㻤㻙㻝

No.

Part No.

Q’TY

15

17A-71-51211

1

16-1

154-71-21290

1

16-2

175-71-21330

1

16-3

01010-81435

4

16-4

01643-31455

4

17-1

17A-71-45731

1

For dual

17-1

17A-71-45870

1

For single

17-2

17A-71-45741

1

For dual

17-2

17A-71-45880

1

For single

17-3

02896-11012

4

Reuse (After transportation, remove cap)

17-4

01024-81265

1

17-5

07095-00420

2

17-6

07094-30417

2

17-7

17A-71-45661

1

17-8

01010-81635

3

17-9

01643-31645

3

195-71-62151

1

17-11

01010-81660

2

17-12

01643-31645

2

18-1

17A-71-51411

1

18-2

708-27-12581

2

18-3

01010-82045

4

18-4

154-30-51460

2

18-5

01643-32060

2

㻝㻣㻙㻥

㻝㻣㻙㻝㻝

㻝㻤㻙㻡

11. Install tilt cylinder (16) according to the procedure in step 6 above.

17-10

㻝㻣㻙㻤

㻝㻣㻙㻝㻜 㻝㻤㻙㻟

㻝㻤㻙㻞

㻝㻣㻙㻞 㻝㻣㻙㻟 㻝㻣㻙㻟

㻝㻢 㻝㻠㻙㻝 㻝㻣㻙㻝 㻝㻡

㻝㻣㻙㻠

㻝㻠㻙㻝

㻝㻣㻙㻡

㻝㻢㻙㻝

㻝㻣㻙㻢 㻝㻢㻙㻞

㻝㻢㻙㻟

㻝㻢㻙㻠

Shims packed simultaneously 175-71-31270 x 2 : t2.3 175-71-31260 x 4 : t1.0 175-71-31250 x 2 : t0.5

Precautions

Necessary tools Name

Necessary equipment Q’ty 2

Socket 24 mm in width across flats

1

Socket 30 mm in width across flats

1

Medium size impact wrench

1

Spanner 27 mm in width across flats

1

Others

50 × 3,000 nylon sling

33

Name 25 t crane

Q’ty 1

Assembly procedure

Assembly of blade (6/6)

A-4

13. After assembling the blade, apply sufficient grease to the parts shown in the figure below.

2 Each part of blade: Grease (G2-LI)

Machine with single tilt specification

Machine with dual tilt specification

Precautions

Necessary tools Name

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Others

Grease pump

34

Qâ&#x20AC;&#x2122;ty 1

Assembly procedure

Installation of full roller guard (1/4)

A-5

1. After installing the track shoe, remove bracket (A) for bogie sling, bolt (B) and washer (C).

6 points at the right and left outside of the machine.

2. Remove paint and rust from surfaces (W), (X), (Y) and (Z) to install the full roller guard.

4 points each at the inside and outside of the left and right side of the machine.

Track frame

1st bogie

K-bogie

35

Assembly procedure

Installation of full roller guard (2/4)

A-5

3. Installation of 1st bogie guard.

1) Temporarily tighten bolt (a) and adjust with shim (3) so that clearance (R) of bolt (b) is within 1 mm, then securely tighten the bolt.

2) Install guards (1) and (2).

Left outside/right inside

1st bogie

Bolt (a)

Bolt (b)

Tightening torque: 610 – 765 Nm {62 – 78 kgm} Apply LT-2 KES 04.123.1

Left inside/right outside

Clearance (R) Track frame

No. 1 2 3 4 5

PART No. 17A-30-47230 17A-30-47240 17A-30-47340 01010-62255 01643-32260

PART NAME GUARD GUARD SHIM BOLT WASHER

Q'TY 2 2 16 16 16

REMARKS L.H. OUT/R.H. IN L.H. IN/R.H. OUT t0.5

36

Detailed section of bolt (b)

Assembly procedure

A-5

Installation of full roller guard (3/4)

4. Install plug (16) to the track frame.

No. 16

PART No. 07049-03038

37

PART NAME PLUG

Q'TY 6

REMARKS

Assembly procedure

Installation of full roller guard (4/4)

A-5

5. Installation of K-bogie guard.

1) Temporarily tighten bolt (a) and adjust with shim (11) so that clearance (S) of bolt (b) is within 1 mm.

2) Install guards (6), (7) and (8).

Take care the installing direction of final bogie of the inside of machine.

Right and left outside of machine K-bogie

Front

Bolt (a)

Bolt (b) Tightening torque: 610 – 765 Nm {62 – 78 kgm} Apply LT-2

Tightening torque: 1520 – 1910 Nm {155 – 195 kgm} Apply LT-2

Right and left inside of machine Take care that the shape of the final bogie is different.

Front

L.H. R.H.

No. 6 7 8 9 10 11 12 13 14 15

PART No. 17A-30-47250 17A-30-47270 17A-30-47260 17A-30-47131 17A-30-47310 17A-30-47320 01011-62225 01643-32260 01010-63080 01643-33080

PART NAME GUARD GUARD GUARD GUIDE SPACER SHIM BOLT WASHER BOLT WASHER

Q'TY 10 1 1 12 24 48 24 24 24 24

REMARKS L.H. IN R.H. IN

37.16 kg/Piece 35.76 kg/Piece 35.76 kg/Piece

K-bogie

t = 0.5

Clearance (S) Contact guide (9) with K-bogie to assemble, not to loosen the bolt.

Detailed section of bolt (b)

38

Assembly procedure

Installation of blade (1/5)

A-6 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. 636 mm a Width "b" of frame: Approx. 3,053 mm

1

2. Scratch the paint off the ball joint of the trunnion and clean the ball joint.

3. Start the engine and move the machine forward slowly to connect the blade assembly to the tractor by the balls of the right and left trunnions. Apply grease to the balls of the trunnions. a Bolt size: M22 × 4 pieces, 2 places

4. Move blade lift cylinder retainer (21) from the fixing position for transportation to the position for operation.

21

Precautions

Necessary tools Name

Necessary equipment Q’ty 1

Socket 27 mm in width across flats

1

Socket 30 mm in width across flats

1

Socket 32 mm in width across flats

1

Spanner 27 mm in width across flats Medium size impact wrench

1

Large size impact wrench

1

Others

Socket 36 mm in width across flats

39

1

Name 300 × 400 mm wooden block

Q’ty 2

Assembly procedure

A-6

Installation of blade (2/5)

5. Sling the blade lift cylinder and start the engine. While extending the piston rod slowly with the engine at low idle, connect it to the blade assembly with cap (22) at the end of the lift cylinder.

When fixing the cap, tighten the mounting bolts of cap (22) temporarily (eliminate the clearance in the axial direction of the ball joint) without inserting any shim and measure dimension "c".

Insert shims having the thickness of dimension "c" + 0.2 to 0.5 mm. (Secure clearance of 0.2 to 0.5 mm in the axial direction of the ball joint.)

Tighten the bolts to the specified torque and check that the ball joint moves smoothly. a Bolt size: M18 x 4 pieces, 2 places a Standard shim thickness: 4 mm 6. Check the oil level in the hydraulic tank.

(Check that the oil level is above "L" of the sight gauge. If it is not above "L", add oil to the "H" level.)

7. Connect tilt hoses (23) of the trunnions. Connect the hoses having red marks to the upper nipples.

[For dual tilt blade specification] â&#x20AC;˘ Connect the hose of the left trunnion having a blue mark to the upper nipple.

Connect the hoses having red or blue marks to the upper side.

8. Install both trunnion caps (24). a Bolt size: M20 x 6 pieces, 2 places

Watch the inside to confirm that the hoses are not twisted.

40

Assembly procedure

A-6

Installation of blade (3/5)

9. Refilling oil (hydraulic tamk) and confirmation of operation 9-1. Bleed air from blade tilt cylinder. a When operating the hydraulic cylinder at the first time after assembling it, bleed the air from the hydraulic circuit as follows.

1) Check the oil level in the hydraulic tank.

(Check that the oil level is above "L" of the sight gauge. If it is not above "L", add oil to the "H" level.)

2) Start the engine and run at low idle for approx. 5 minutes.

3) While running the engine at low idle, extend and retract the cylinder for 5 minutes.

However, do not move the cylinder to the stroke end. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

4) While running the engine at high idle, repeat this operation for 5 minutes. Then run the engine at low idle and operate the piston rod to the end of its stroke to relieve the circuit. k

k

If from the beginning the engine is run at full throttle; or the cylinders are operated to the end of their stroke, the piston packing may be damaged, so never operate in this way.

Check the oil level, and add oil to the specified level if necessary.

41

Assembly procedure

A-6

Installation of blade (4/5)

9-2.After bleeding air, leave the engine stopped for 1 hour.

1) After leaving for 1 hour, check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.) a If another cylinder is to be installed, perform this operation at the last.

9-3.Oil level check position (Sigmadozer) Lower the blade on the ground so that angle (a) of its backside is 6°.

Lower ripper (b) on the ground vertically so that the pin is at the lowest position.

<Reference> Item

Dimension

Item

Dimension

Blade (DUAL)

Tilt cylinder length

1,294 mm

Blade (SINGLE)

Tilt cylinder length

1,294 mm

Brace

1,294 mm

Ripper (VGR, VMR)

Lift cylinder length

1,477 mm

Lift cylinder length

1,477 mm

Tilt cylinder length

1,431 mm

Ripper (VGR, VMR)

Tilt cylinder length

1,431 mm

(Semi U-dozer, U-dozer) Lower the blade on the ground so that backside (a) is upright.

Lower ripper (b) on the ground vertically so that the pin is at the lowest position.

<Reference> Item

Dimension

Blade (DUAL)

Tilt cylinder length

1,372 mm

Ripper (VGR, VMR)

Lift cylinder length

1,437 mm

Tilt cylinder length

1,431 mm

Item

42

Dimension

Blade (SINGLE)

Tilt cylinder length

1,372 mm

Brace

1,372 mm

Ripper (VGR, VMR)

Lift cylinder length

1,477 mm

Tilt cylinder length

1,431 mm

Assembly procedure

Installation of blade (5/5)

A-6

9-4.Check the oil level in the hydraulic tank.

• After bleeding air, check the oil level again.

• Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.

• •

Check that the tilting, dumping, and pitching (dual tilt) directions are normal.

Adjust the tilting amount of the blade.

10. For the single tilt specification, adjust the brace length (a) to the standard length (Sigma: 1,292 mm, Semi-U: 1,372 mm).

Reference: Oil quantity in cylinder (dual tilt).

Blade lift cylinder (L.H. and R.H.)

Approx. 24 l

Blade tilt cylinder (L.H. and R.H.)

Approx. 5 l

Precautions

Necessary tools Name

• If the engine is operated at high idle or the cylinders are moved to the stroke end from the first of the air bleeding operation, the piston packing may be damaged.

Accordingly, never do so.

Others

• Check the oil level each time and add oil if it is low. If the hydraulic oil level is low, the pumps may be damaged by cavitation.

(If cavitation occurs, abnormal sound such as rasp comes out.)

43

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of ripper assembly (1/12)

A-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.

1. Installation of pin puller piping 1) Remove the rear cover.

㻡

㻠

㻔㻞㻕

㻝 㻟

㻞

2) Remove the piping plugs and install the hose.

㻴

㻮

㻢

㻣 㻔㻞㻕

Precautions

Name

Q’ty 1

Small impact wrench

1

Spanner 24 mm in width across flats Spanner 22 mm in width across flats

1

44

No.

Part No.

Q’TY

1

17A-54-44211

1

2

195-33-11220

1

3

01024-81250

1

4

01024-81225

1

5

01024-81235

2

6

17A-61-41432

2

7

02896-11009

2

Necessary equipment

Socket 19 mm in width across flats

Others

a Keep the removed piping plugs since they are necessary for the next transportation

Necessary tools

㻔㻞㻕

1

Name

Q’ty

Assembly procedure

Installation of ripper assembly (2/12)

A-7 3) Install the rear cover.

Do not tighten them.

㻠

㻞

㻟

4) Installation of piping bracket and clamp

Install with (B) side up and (H) side down.

㻥

㻤

㻣 㻔㻞㻕

㻡

㻢 㻔㻞㻕

㻝㻡㼻

㻔㻞㻕

View Z

䠶

㻮

㻴

Precautions

Necessary tools Name

Q’ty 1

Socket 19 mm in width across flats

1

Small size impact wrench

1

Others

Part No.

Q’TY

2

195-33-11220

1

3

01024-81250

1

4

01024-81225

1

5

17A-61-41420

1

6

01024-81235

2

7

07094-30315

2

8

07095-00317

2

9

01024-81060

1

Necessary equipment

Socket 17 mm in width across flats

45

No.

Name

Q’ty

Assembly procedure

Installation of ripper assembly (3/12)

A-7

2. Slinging ripper assembly (by 3 points) Install shackles to beam (1 place) and arm (2 places) and install wires to them.

4 Weight of ripper assembly Giant: 2.4 ton Multi-shank: 3.4 ton

Slinging position: Beam (1 place)

Shackle: BC36

Shackle: SD22 (2 pieces) Slinging position: Arm (2 places)

3. 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.

Insert ripper mount connecting pin

01011-82040 (2 pieces each on right and left sides) 01643-32060 (2 pieces each on right and left sides) 40 mm

Part No. of bolt Part No. of washer Length of bolt Socket to be used

30 mm

Tightening torque

455 – 565 Nm {46.5 – 58 kgm}

Precautions Be sure to put wooden blocks between the arm and beam to prevent their relative positions from changing when they are slung.

Beam

Lock plate

Necessary tools Name

Necessary equipment Q’ty

Name

Q’ty

ø12 × 2,000mm wire

3

25 t crane

1

SD22 Shackle

2

100 mm wooden block

2

BC36 Shackle

1

1.5 t lever block

1

Wooden blocks

Others

Arm

46

Assembly procedure

Installation of ripper assembly (4/12)

A-7

4. Set wooden blocks under the rear part of the arm and beam. Lower the crane and put the ripper assembly on the wooden blocks.

㻣㻜㻜㼙㼙

Precautions

㻢㻜㻜㼙㼙

Necessary tools Name

Necessary equipment Q’ty

Name

Q’ty

1

25 t crane

1

Sledge hammer (10P)

1

600 mm wooden block

1

Bar

1

700 mm wooden block

1

Medium size impact wrench

1

Others

Socket 30 mm in width across flats

47

Assembly procedure

Installation of ripper assembly (5/12)

A-7

5. Installation of piping Connect ripper cylinder hoses (1) to (3).

㪈 4GF

㪉

㪈 㪊 $NWG

䌐

a For connection to the block at the rear of the machine, see the detail of part P.

㪈㪇㫦

㪈

㪈㪌㫦 㪈㪇㫦

㪊 $NWG

㪈㪌㫦

㪉

No.

Loose supply items

Q’TY

1

07120-01016

2

Red

2

17A-61-51850

1

Blue

3

17A-61-51860

1

4

O-ring

8

㪈

4GF

䌐

Precautions

Name

Necessary equipment Q’ty

L150 extension

1

Socket 14 mm in width across flats

1

Small oil receiving pan

1

Small size impact wrench

1

Others

There may be pressure in the piping.

Accordingly, when removing the oil stopper of each port, loosen it gradually to release the pressure.

Necessary tools

48

Name

Q’ty

Assembly procedure

Installation of ripper assembly (6/12)

A-7

6. Installation of tilt cylinder 1) Check the oil level in the hydraulic tank.

(Check that the oil level is above "L" of the sight gauge. If it is below "L", add oil.)

2) While slinging cylinder (3), extend it gradually to set the pin hole.

3

4 Tilt cylinder: 252 kg a When extending the cylinder, start and run the engine at low idle, and operate the ripper lever.

• Extend the cylinder slowly.

3) Check the oil level in the hydraulic tank.

(Check that the oil level is between (L) and (H) position of the sight gauge. If insufficient, refill oil.)

(Oil quantity in ripper tilt cylinder: Approx. 18 l)

4) Insert pin (4) and fix it with the lock plate.

Part No. of bolt Part No. of washer

01011-82040 (2 pieces) 01643-32060

Length of bolt

40 mm

Socket to be used

30 mm

Tightening torque

455 – 565 Nm {46.5 – 58 kgm}

4

Precautions

• Check the oil level each time and add oil if it is low. If the hydraulic oil level is low, the pumps may be damaged by cavitation.

(If cavitation occurs, abnormal sound such as rasp comes out.)

Name

Necessary equipment Q’ty

Nylon sling

1

Socket 30 mm in width across flats

1

Sledge hammer (10P)

1

Bar

1

Others

• If the engine is operated at high idle or the cylinders are moved to the stroke end from the first of the air bleeding operation, the piston packing may be damaged.

Accordingly, never do so.

Necessary tools

49

Name 25 t crane

Q’ty 1

Assembly procedure

Installation of ripper assembly (7/12)

A-7

7. Installation of lift cylinder 1) Check the oil level in the hydraulic tank.

(Check that the oil level is above "L" of the sight gauge. If it is below "L", add oil.)

2) While slinging cylinder (5), extend it gradually to set the pin hole.

4 Lift cylinder: 184 kg

5

a When extending the cylinder, start and run the engine at low idle, and operate the ripper lever.

• Extend the cylinder slowly.

3) Check the oil level in the hydraulic tank.

(Check that the oil level is between (L) and (H) position of the sight gauge. If insufficient, refill oil.)

(Oil quantity in ripper lift cylinder: Approx. 14 l)

4) Insert pin (6) and fix it with the lock plate.

Part No. of bolt Part No. of washer Length of bolt

01011-82040 (2 pieces) 01643-32060 40 mm

Socket to be used

30 mm

Tightening torque

455 – 565 Nm {46.5 – 58 kgm}

6

Precautions

• Check the oil level each time and add oil if it is low. If the hydraulic oil level is low, the pumps may be damaged by cavitation.

(If cavitation occurs, abnormal sound such as rasp comes out.)

Name

Necessary equipment Q’ty

Nylon sling

1

Socket 30 mm in width across flats

1

Sledge hammer (10P)

1

Bar

1

Others

• If the engine is operated at high idle or the cylinders are moved to the stroke end from the first of the air bleeding operation, the piston packing may be damaged.

Accordingly, never do so.

Necessary tools

50

Name 25 t crane

Q’ty 1

Assembly procedure

Installation of ripper assembly (8/12)

A-7 8. Installation of pin puller piping

㻟

㻞

㻢

㻡

㻝 㻠 㻔㻞㻕

㻔㻞㻕

㻭䠖㻝㻟㻡㻜㼙㼙

㼆

㻝㻡㼻

㻣

㻔㻞㻕

㼆

After installing the hose, confirm the operating direction of the pin-puller switch. (a) Pin extraction (b) Pin retraction

No. 1 2 3 4 5 6 7

Front

Precautions

Necessary tools

Others

Name

51

Part No. 144-947-2850 04205-11028 04050-13015 07094-30315 07095-00317 01024-81060 02896-11009

Q’ty 1 1 1 2 2 1 2

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of ripper assembly (9/12)

A-7

9. Installation of piping clamps 1) Install two tilt cylinder hose clamps (7) (L1: 520 mm, L2: 540 mm).

(Align the position of the white tape.)

2) Install two lift cylinder hose clamps (8) (L3: 380 mm, L4: 590 mm).

(Align the position of the white tape.)

㻸㻟 㻸㻞 㻸㻝

㻣 㻸㻠 㻣

㻤

㻤

Precautions

Necessary tools Name

Necessary equipment Q’ty 1

Small size impact wrench

1

Others

Socket 19 mm in width across flats

52

Name

Q’ty

Assembly procedure

A-7

Installation of ripper assembly (10/12)

10. Cheking oil level in hydraulic tanck and bleeding air 10-1. Bleed air from lift cylinder and tilt cylinder a When operating the hydraulic cylinder at the first time after assembling it, bleed the air from the hydraulic circuit as follows.

When checking the hydraulic oil level, see "11. Oil level check position".

1) Check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)

2) Start the engine and run at low idle for approx. 5 minutes.

3) While running the engine at low idle, extend and retract the cylinder for 5 minutes.

However, do not move the cylinder to the stroke end. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

4) While running the engine at high idle, repeat this operation for 5 minutes. Then run the engine at low idle and operate the piston rod to the end of its stroke to relieve the circuit. k

k

If from the beginning the engine is run at full throttle; or the cylinders are operated to the end of their stroke, the piston packing may be damaged, so never operate in this way.

Check the oil level, and add oil to the specified level if necessary.

10-2. After bleeding air, leave the engine stopped for 1 hour.

1) After leaving for 1 hour, check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.) a If another cylinder is to be installed, perform this operation at the last.

53

Assembly procedure

A-7

Installation of ripper assembly (11/12)

11. Oil level check position (Sigmadozer) Lower the blade on the ground so that angle (a) of its backside is 6°.

Lower ripper (b) on the ground vertically so that the pin is at the lowest position.

<Reference> Item

Dimension

Item

Dimension

Blade (DUAL)

Tilt cylinder length

1,294 mm

Blade (SINGLE)

Tilt cylinder length

1,294 mm

Brace

1,294 mm

Ripper (VGR, VMR)

Lift cylinder length

1,477 mm

Lift cylinder length

1,477 mm

Tilt cylinder length

1,431 mm

Ripper (VGR, VMR)

Tilt cylinder length

1,431 mm

(Semi U-dozer, U-dozer) Lower the blade on the ground so that backside (a) is upright.

Lower ripper (b) on the ground vertically so that the pin is at the lowest position.

<Reference> Item

Dimension

Item

Dimension

1,372 mm

Blade (SINGLE)

Tilt cylinder length

1,372 mm

Brace

1,372 mm

Lift cylinder length

1,477 mm

1,477 mm

1,431 mm

Ripper (VGR, VMR)

Lift cylinder length

Tilt cylinder length

Tilt cylinder length

1,431 mm

Blade (DUAL)

Tilt cylinder length

Ripper (VGR, VMR)

54

Assembly procedure

A-7

Installation of ripper assembly (12/12)

12. Installation of shank assembly 1) Start the engine, raise the ripper assembly to the maximum, and set the beam horizontally.

2) Raise the rear of the machine body to 600 mm or move the machine to a pit where there is a clearance of at least 600 mm under the ground level.

3) Pass a wire through the shank mounting hole of the ripper beam and sling shank (9) and fix it with pin (10).

4 Weight of shank assembly Giant: 350 kg Multi-shank: 285 kg a Pull out and insert the pin with the pin puller switch.

9 10

600

Precautions • If the engine is operated at high idle or the cylinders are moved to the stroke end from the first of the air bleeding operation, the piston packing may be damaged.

Accordingly, never do so.

Necessary tools Name

Necessary equipment Q’ty

ø10 × 3,000 mm wire

2

SD12 shackle

2

Others

• Check the oil level each time and add oil if it is low. If the hydraulic oil level is low, the pumps may be damaged by cavitation.

(If cavitation occurs, abnormal sound such as rasp comes out.)

55

Name

Q’ty

Assembly procedure

Check of oil and coolant levels (1/2)

A-8

a For details of notes (Note. 1, 2, 3, 4) in the table, see the Operation and Maintenance Manual.

For the details, refer to an Operation and Maintenance Manual about Recommended Komatsu Fluids again.

• ASTM: American Society of Testing and Material Precautions

Necessary tools

Others

Name

56

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Check of oil and coolant levels (2/2)

A-8

(including work equipment) 246.5 65.13

103.5 27.3

165.13

91.5 24.17

Warning

Warning

Precautions

Necessary tools Name

Others

If any oil level or coolant level is low, add oil or coolant.

57

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Lubricating (1/2)

A-9 1. Blade lift cylinder support yoke (4 places) 2. Blade lift cylinder support shaft (2 places)

3. Blade ball joint (3 places) 4. Brace screw (1 place)

Precautions

Necessary tools Name

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Others

Grease pump

58

Qâ&#x20AC;&#x2122;ty 1

Assembly procedure

Lubricating (2/2)

A-9 5. Equalizer bar side shaft (2 places)

6. Equalizer bar center shaft (1 place)

7. Ripper tilt cylinder bottom pin (1 place) 8. Ripper lift cylinder bottom pin (1 place) 9. Ripper tilt cylinder rod end pin (1 place) 10. Ripper lift cylinder rod end pin (1 place) 11. Ripper arm pin (Front side) (2 places) 12. Ripper arm pin (Rear side) (2 places)

Precautions

Necessary tools Name

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Others

Grease pump

59

Qâ&#x20AC;&#x2122;ty 1

Assembly procedure

A-10

Bleeding air from hydraulic cylinders (1/2)

a After disassembling for transportation, changing the oil in the hydraulic tank, or removing the hydraulic cylinders or work equipment piping, bleed the air from the hydraulic circuit as follows.

When checking the hydraulic oil level, see "4. Oil level check position".

1. Cylinder with piston valve (Blade lift cylinder) 1) Check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)

2) Start the engine and run at low idle for approx. 5 minutes.

3) While running the engine at low idle, extend and retract the cylinder for 5 minutes.

However, do not move the cylinder to the stroke end. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

4) Keeping the engine at low idle, retract the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to retract the cylinder to the end of its stroke. While operating the lever, hold the cylinder in this position for 3 minutes.

5) With the engine at high idle, retract the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to retract the cylinder to the end of its stroke. While operating the lever, hold the cylinder in this position for 1 minute.

2. Cylinder without piston valve (Blade tilt cylinder, ripper lift cylinder, ripper tilt cylinder) 1) Check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)

2) Start the engine and run at low idle for approx. 5 minutes.

3) While running the engine at low idle, extend and retract the cylinder for 5 minutes.

However, do not move the cylinder to the stroke end. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

4) While running the engine at high idle, repeat this operation for 5 minutes. Then run the engine at low idle and operate the piston rod to the end of its stroke to relieve the circuit. k

k

If from the beginning the engine is run at full throttle; or the cylinders are operated to the end of their stroke, the piston packing may be damaged, so never operate in this way.

Check the oil level, and add oil to the specified level if necessary.

60

Assembly procedure

A-10

Bleeding air from hydraulic cylinders (2/2)

3. After bleeding air, leave the engine stopped for 1 hour.

1) After leaving for 1 hour, check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)

4. Oil level check position (Sigmadozer) Lower the blade on the ground so that angle (a) of its backside is 6°.

Lower ripper (b) on the ground vertically so that the pin is at the lowest position.

<Reference> Item

Dimension

Item

Dimension

Blade (DUAL)

Tilt cylinder length

1,294 mm

Blade (SINGLE)

Tilt cylinder length

1,294 mm

Brace

1,294 mm

Ripper (VGR, VMR)

Lift cylinder length

1,477 mm

Lift cylinder length

1,477 mm

Tilt cylinder length

1,431 mm

Ripper (VGR, VMR)

Tilt cylinder length

1,431 mm

(Semi U-dozer, U-dozer) Lower the blade on the ground so that backside (a) is upright.

Lower ripper (b) on the ground vertically so that the pin is at the lowest position.

<Reference> Item

Dimension

Blade (DUAL)

Tilt cylinder length

1,372 mm

Ripper (VGR, VMR)

Lift cylinder length

1,477 mm

Tilt cylinder length

1,431 mm

Item

61

Dimension

Blade (SINGLE)

Tilt cylinder length

1,372 mm

Brace

1,372 mm

Ripper (VGR, VMR)

Lift cylinder length

1,477 mm

Tilt cylinder length

1,431 mm

Assembly procedure

A-11

Installation of additional working lamps (1/3)

1. Remove the plugs installed to the cab. (5 places)

2. Install the base brackets. (2 places)

㻟 㻝

㻞

No. 1 2 3 4

Precautions

Necessary tools Name

Q’ty 1

Small size impact wrench

1

62

Loose supply items 14X-Y79-1531 01024-81230 14X-Y79-1531 01024-81230

Q’ty 1 2 1 2

Necessary equipment

Socket 19 mm in width across flats

Others

㻠

Name

Q’ty

Assembly procedure

A-11

Installation of additional working lamps (2/3)

3. Fix the wiring harnesses. (marked a : 6 places)

㻢

㻡 䖩 䖩 䖩 䖩

䖩

䖩

4. Assemble the working lamp and bracket. (2 sets)

㻣 㻔㻵㼚㼏㼘㼡㼐㼕㼚㼓㻌䖪㻝㻌㼠㼛㻌䖪㻠㻕

䖪㻝

㻤 䖪㻞

䈜㼀㼕㼓㼔㼠㼑㼚㻌㼠㼔㼑㻌㼚㼡㼠㻌㼠㼑㼙㼜㼛㼞㼍㼞㼕㼘㼥

No. 5 6 7 8

䖪㻟 䖪㻠

Precautions

Necessary tools Name

Q’ty 1

Spanner 22 mm in width across flats Small size impact wrench

1

Others

Q’ty 6 6 2 2

Necessary equipment

Socket 19 mm in width across flats

63

Loose supply items 00434-51012 01024-81220 17A-06-17931 14X-Y79-1521

1

Name

Q’ty

Assembly procedure

A-11

Installation of additional working lamps (3/3)

5. Install the working lamp assembled in step 4 to the base bracket.

㻥

6. Turn ON the working lamp switch in the operator cab and check that the lamp lights up.

7. Adjust the lighting range of the working lamp and tighten the retaining nut ( 3 Tightening torque of nut: 22 – 25 Nm {2.24 – 2.55 kgm}

) of the working lamp to the specified torque.

No. 9

Precautions

Necessary tools

Others

Name

64

Loose supply items 01024-81230

Q’ty 4

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-12

Installation of fire extinguisher (1/2)

1. Remove covers (1) and (2).

5

2. Remove cover (3). a Do not reuse coat hook (4) and clips (5).

(5)

4 3 1 2

3. Make holes on cover (3) as shown in the figure below. (6 places) (Make the holes by using a screwdriver or a knife)

ࠉࠉ

Precautions

Necessary tools

Others

Name

65

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-12

Installation of fire extinguisher (2/2)

4. Install covers (1), (2), and (3) as they were. a Do not install coat hook (4) and clips (5) (5 places).

5. Install fire extinguisher (6) as shown in the figure below.

12 13 (4)

6 7 8

(6) (6)

9 10 (6) (6)

Precautions

Necessary tools Name

Others

11

66

No.

Part No.

Q’TY

6

09495-40010

1

7

01245-00620

6

8

01643-70623

6

9

14X-Y79-3711

1

10

01245-00630

6

11

01643-70623

6

12

14X-Y79-3731

1

13

01024-D0816

4

Necessary equipment Q’ty

Name

Q’ty

M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY

67

Assembly procedure

Replacement of return filter (Standard filter to flushing filter) (1/2)

M-1

1. 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.

Also, take out refuses by hand from the case.

Replace the relief valve with this plate only at the flushing time.

Replacement

Valve

Special element for flushing, Absolute filter mesh size: 6 µ

a Confirm the installing condition of the element in accordance with "2. Installing Condition of Element". a When the atmospheric temperature is below -15°C, do not use (2). Replace only the element and flush the circuit while running the engine at low idle.

No. 1 2

Precautions

Small size impact wrench

68

Q’ty 1 1

Necessary equipment

Name Q’ty Socket 19 mm in width across flats 1

Others

Store the removed standard element (207-60-71182) and valve (20Y-60-31131) in order because they are used again after flushing.

Necessary tools

Loose-supply items 22U-60-21370 22U-60-21380

1

Name

Q’ty

Assembly procedure

M-1

Replacement of return filter (Standard filter to flushing filter) (2/2)

2. State of inserted element

Fig. 1 Correct state

Fig. 2 Incorrect state

Caution: 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. When it turns smoothly, it is considered to be inserted correctly.

Precautions

Necessary tools

Others

Name

69

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-2

Flushing of hydraulic circuit, and bleeding air from hydraulic cylinders (Part 1)

After the assembly work is completed, flush the hydraulic circuit and bleed air from the hydraulic cylinders. a When performing the assembly procedure M-1 to M-4, the assembly procedure A-10 "Bleeding air from hydraulic cylinders" can be neglected. However, the air bleeding mentioned in assembly procedure A-6 "Installation of blade" and A-7 "Installation of ripper" must be performed. a When checking the hydraulic oil level, see assembly procedure “A-10-4. Oil level check position”. a Never run the engine at high idle to avoid the damage to the flushing elements. a If from the beginning the engine is run at full throttle, or the cylinders are operated to the end of their stroke, the piston packing may be damaged, so never operate in this way. a Check the oil level, and add oil to the specified level if necessary.

1. Flushing of fan circuit 1) Check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.) a When checking the hydraulic oil level, see assembly procedure “A-10-4. Oil level check position”.

2) Start the engine and run it for approximately 10 minutes at low idle.

3) Then run the engine for approximately 30 minutes in 1,000 to 1,200 rpm.

4) Check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.) a When checking the hydraulic oil level, see assembly procedure “A-10-4. Oil level check position”.

2. Bleeding air and flushing of cylinder with piston valve (blade lift cylinder) 1) While running the engine at low idle, extend and retract the cylinder for 5 minutes.

However, do not move the cylinder to the stroke end. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

2) Keeping the engine at low idle, retract the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to retract the cylinder to the end of its stroke. While operating the lever, hold the cylinder in this position for 3 minutes.

3. Bleeding air and flushing of cylinder without piston valve (Blade tilt cylinder, ripper lift cylinder, ripper tilt cylinder) 1) Check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.) a When checking the hydraulic oil level, see assembly procedure “A-10-4. Oil level check position”.

2) While running the engine at low idle, extend and retract the cylinder for 5 minutes.

However, do not move the cylinder to the stroke end. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

70

Assembly procedure

M-3

Replacement of return filter (Flushing filter to standard filter) (1/2)

1. 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. a When atmospheric temperature is at -15°C or lower, pay attention that the valve is not replaced with the plate. a Keep accordance with "2. State of inserted element" as the element capacity will be lower if the installing condition is wrong.

Replacement Valve

Standard element

•

Precautions Scrap the used flushing element. Keep accordance with the local laws for scraping.

Replaced plate is reusable, so it is recommended to store it for the next flushing work.

Necessary tools Name

Others

•

71

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

M-3

Replacement of return filter (Flushing filter to standard filter) (2/2)

2. State of inserted element

Fig. 1 Correct state

Fig. 2 Incorrect state

Caution: 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. When it turns smoothly, it is considered to be inserted correctly.

Precautions

Necessary tools

Others

Name

72

Necessary equipment Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-4

Bleeding air from hydraulic cylinders (Part 2)

1. Bleeding air from cylinder with piston valve (Blade lift cylinder) 1) With the engine at high idle, retract the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to retract the cylinder to the end of its stroke. While operating the lever, hold the cylinder in this position for 1 minute.

2. Bleeding air from cylinder without piston valve (Blade tilt cylinder, ripper lift cylinder, ripper tilt cylinder) 1) While running the engine at high idle, repeat this operation for 5 minutes. Then run the engine at low idle and operate the piston rod to the end of its stroke to relieve the circuit.

3. After bleeding the air, leave the engine stopped for 1 hour.

1) After leaving for 1 hour, check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.) a When checking the hydraulic oil level, see assembly procedure â&#x20AC;&#x153;A-10-4. Oil level check positionâ&#x20AC;?.

k

Check the oil level, and add oil to the specified level if necessary.

73

Assembly procedure

Error code

M-5

Turn the key switch to the ON position and check that no error code is displayed on the monitor.

If any error code is displayed, consult your Komatsu distributor.

74

6 1/7

Report No.

FIELD ASSEMBLY INSPECTION REPORT Please send back these check sheets to the factory.

7 D155AX-6

SAA6D140E-5 6

2-1/6

See operation manual.

See operation manual.

See operation manual.

Engine : Stopped

See operation manual.

See operation manual.

See operation manual.

See operation manual.

23 to 28 mm

23 – 28 mm

See assembly procedure A-10 “Bleeding air from hydraulic cylinders.”

2-2/6

Oil level check position (Sigmadozer)

<Reference>

1,294 mm

1,294 mm 1,294 mm

1,477 mm

1,477 mm

1,431 mm

1,431 mm

(Semi U-dozer, U-dozer)

<Reference>

1,372 mm

1,372 mm 1,372 mm

1,477 mm

1,477 mm

1,431 mm

1,431 mm

3/7 6

N, F1, F2, F3L, F3, R1, R2, R3L, and R3 are all indicated.

Must be of no indication error.

Check of longitudinal adjustment of travel lever box (L.H.) • Adjustment of 10 steps • Check of lock lever of box (Upper and lower)

Travel lever BOX

FREE

Check of vertical adjustment of right LOCK armrest • Adjustment of 4 steps • Check of lock lever (Left and right)

Right armrest Case

R

F FREE

LOCK

FREE

LOCK

1000 – 1050 rpm

Check of dual tilt and pitch direction Check of tilt direction

DUAL TILT / FLOAT

Pitch back RH tilt

Pitch back (H ➞ F) Pitch Dump (H ➞ G) LH dual tilt (A ➞ D) RH dual tilt (A ➞ E) LH tilt (A ➞ D) RH tilt (A ➞ E)

Blade must move backward. (M)+(E) H➞F H➞G Blade must move forward.

(M)+(F) Blade must move to left (both cylinders move) Blade must move to right (both cylinders move) Blade must move to left (right cylinder moves) Blade must move to right (left cylinder moves)

Pitch Dump

LH tilt

Check of dual tilt indication Check of float Dual tilt indication (ON: Dual, OFF: Single)

Dual/Single Selector switch

Blade (b)+(C)+Lower(B) Blade must must float be floated.

(Raise to cancel)button "I", While pressing move from A to B (LOWER) stroke end (Reset by RAISE operation).

A (a)+(E) ➞D (a)+(F) A ➞E (E)+(a) A ➞D (F)+(a) A ➞E

6

oil leakage

oil leakage

Example: When Sigma-blade is used

• Blade center pin

UNDERCARRIAGE

• Brace screw • Travel about 10 m with the engine at low idle and gear speed in F1. When the grouser reaches above the 1st carrier roller, stop the machine slowly without applying the brake.

1 1 2

30 – 40 mm 30 – 40 mm

Tense a string or bar between the first carrier roller and the idler to measure distance between the string (bar) and the grouser.

Difference between LH and RH: Max.20 mm

oil leakage

Air flow must be able to be adjusted (Hi, Mid, Lo)

5/6

Raise Ripper (A ➞ B) Lower Ripper (A ➞ C) Tilt in (D ➞ F) Tilt out (D ➞ E)

Raise

Tilt in Lower

Tilt out

oil leakage

oil leakage

(a): Pin out (b): Pin out Machin front

KOMTRAX

oil leakage

Check of cable between KOMTRAX controller and antenna Check of KOMTRAX Communication

Must be installed to controller and antenna side correctly.

Must be of no abnormality according to the service mode of shop manual.

6/6

Engine speed Item Engine speed (P mode)

Engine

Category

Condition Low idle High idle (Transmission: N) Deceleration slow Torque converter stall (At fan 100%)

Power train oil temperature: 80ºC

T/C stall + ripper relief (At fan 100%)

Unit

Criteria

rpm

740 ± 25

rpm

1875 ± 50

rpm

1025 ± 25

rpm

1540 ± 50

rpm

1512 ± 50

Result

Stall speed measurement mode Stall speed measurement mode

Hydraulic pressure

Torque converter

Category

Item Inlet pressure

Outlet pressure

Condition Engine full, Transmission: N Power train oil temperature: 80ºC

Engine full, Transmission: N

Unit

Criteria

MPa

0.49 – 0.98

{kg/cm 2}

5 – 10

MPa

0.29 – 0.69

Oil pressure

Transmission

2

Main relief pressure

Engine full, Transmission: N

Brake pressure

Engine full, Transmission: N, Pedal released

Work equipment pump relief pressure

Power train oil temperature: 80ºC Engine full, Transmission: N, Pedal depressed

Engine full, Blade tilt relief

Hydraulic oil tempreture: 50ºC

Engine full, Steering relief

{kg/cm }

3–7

MPa

2.99 – 3.38

{kg/cm 2} MPa

30.5 – 34.5 2.99 – 3.38

2

30.5 – 34.5

2

{kg/cm }

0

{kg/cm } MPa

Result

0

MPa

25.9 – 28.9

2 {kg/cm } MPa

36.26 – 40.67

2 {kg/cm }

370 – 415

265 – 295

Work equipment speed Category

Condition

Unit

Criteria

Blade lift

Item Raise

Engine full

sec

2.5 – 3.5

Lower

Engine full

sec

1.0 – 1.7

Blade tilt

L.H. tilt

Engine full

sec

1.8 – 2.8

R.H. tilt

Engine full

sec

1.8 – 2.8

Raise

Engine full

sec

1.5 – 2.5

Engine full

sec

1.3 – 2.3

Engine full

sec

4.0 – 5.0

sec

3.7 – 4.7

sec

1.3 – 2.3

sec

1.3 – 2.3

Ripper lift

Lower Ripper tilt

Tilt in

Hydraulic oil tempreture: 50ºC

Tilt back

Engine full

Pitch (Dual tilt specification)

Pitch dump

Engine full

Pitch back

Engine full

Single tilt (Dual tilt specification)

L.H. tilt

Engine full

sec

1.1 – 2.1

R.H. tilt

Engine full

sec

1.1 – 2.1

Dual tilt (Dual tilt specification)

L.H. tilt

Engine full

sec

1.1 – 2.1

sec

1.1 – 2.1

Hydraulic drift (Blade)

Engine full R.H. tilt Cutting edge height 800 mm

mm / min

150 / 15

Hydraulic drift (Ripper)

Ripper point height 600 mm

mm / min

80 / 15

mm

30 – 50

Push left

Result

Pedal stroke, depressing force (Referance: Cab installed) Category

Condition

Item Brake pedal stroke, depressing force

Low idle

kg

32 – 56

Decelerator pedal stroke, depressing force

Low idle

mm

35 – 65

Low idle

kg

4.0 – 6.0

Low idle

(Pedal depressed to stroke end)

Unit

Criteria

mm

70 – 90

Result

GEN00108-03