Komatsu GD755-5R User manual

MOTOR GRADER
Field Assembly Instruction
GEN00113-00
GD755
-5R
SERIAL NUMBERS
10001
and up

CONTENTS
0000 Introduction (1/2) to (2/2) 1
0010 Preparation - Removal of parts on floor side (1/9) to (9/9) 3
0020 Preparation - Removal of exterior parts under floor (1/3) to (3/3) 12
0030 Preparation - Removal of floor mounting bolts 15
0040 Preparation - Removal of parts on cab side 16
0050 Installation of cab (1/5) to (5/5) 17
0060 Connections with chassis (1/5) to (5/5) 22
0070 Restoration of parts around floor (1/3) to (3/3) 27
0080 Check of each operation (1/2) to (2/2) 31

Introduction
1: Park the machine on a flat ground, lower the blade to the ground, and then start the work.
2: When selecting the parking place, consider the size and weight of the machine.
3: A space about 6 m high is necessary for installation of the cab.
4: Before starting the work, read this manual through.
* To remove the cab, perform the procedure in this manual in the reverse order.
Workflow Items in this manual
1: Removal of parts on floor side
2: Removal of exterior parts on floor side
3: Removal of floor mounting bolts
4: Removal of parts on cab side
5: Installation of cab
6: Connections with chassis
7: Restoration of parts around floor
8: Check of each operation
9: End of work
Q't
y
Name Q't
y
Others
Precautions
1 × 2 ×
Tools to be used
Name
Introduction (1/2)
Facilities to be used
Assembly procedure
5 ×
NO.0000
3 × 4 × 6 ×
G
D755-5R Installation procedure o
f
operator's cab
Overall length: 9,580 mm
Overall width: 2,800 mm
Wei
g
ht: 21
,
700 k
g
To top of steering post: 2,690 mm
(
when
p
ost is at max. hei
g
ht
)
Cab height: 1,995 mm
Overall height: 3,515 mm
Cab weight: 860 kg
Installation
of cab
Removal
of cab
1

Scre
w
Q't
y
Name Q't
y
Others
Assembly procedure
5 ×
NO.0000
3 × 4 × 6 ×
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of
the same size as the
p
art that was re
p
laced
.
Tools to be used
Name
Introduction (2/2)
Facilities to be usedPrecautions
1 × 2 ×
M16 eyebolts 04530-11628 are necessary
for slinging (4 pcs.)
7.85 to 9.8 {0.8 to 1.0}
3.44 to 4.41 {0.35 to 0.45}
Nominal dia. a
6
8
Target value
3.9 {0.4}
8.8 ｛0.9｝
Allowable range Nm {kgm}
Nominal No.
Tightening
torque
16
54 to 88
{5.5 to 9.0}
2

1. Preparation on floor side
1) The machine is delivered under the following condition
2
)
Removal of floor ma
t
Q't
y
Name Q't
y
Others
Facilities to be used
Preparation - Removal of parts on floor side (1/9)
Assembly procedure
Tools to be used
5 ×
NO.0010
3 × 4 × 6 ×
Name
Precautions
1 × 2 ×
3

3
)
Removal of o
p
erator's sea
t
(1) Remove the four bolts and remove the operator's seat and its base together
.
01024-D1025 x4
Q't
y
Name Q't
y
Others
Name
Precautions
1 × 2 ×
5 ×
NO.0010
3 × 4 × 6 ×
Facilities to be used
Preparation - Removal of parts on floor side (2/9)
Assembly procedure
Tools to be used
Z
Z
Operator's seat
Weight: 35 kg
4

4) Removal of accessory case
01225-70616 x
4
23S-55-51970 x
4
5) Removal of KOMTRAX (if equipped)
(1) Remove the top cover of the KOMTRAX.
01024-81020 x
4
Q't
y
Name Q't
y
Others
Facilities to be used
Preparation - Removal of parts on floor side (3/9)
Assembly procedure
Tools to be used
5 ×
NO.0010
3 × 4 × 6 ×
Name
Precautions
1 × 2 ×
5

(2) Remove the left side cover.
01024-81020 x
2
01024-D1025 x2
01024-81020 x
2
Q't
y
Name Q't
y
Others
Precautions
1 × 2 ×
Facilities to be used
Preparation - Removal of parts on floor side (4/9)
(3) Disconnect the KOMTRAX connector (under the additional heater) a
s
shown below.
Assembly procedure
Tools to be used
Note) The engine does not star
t
while this connector is
disconnected.
5 ×
NO.0010
3 × 4 × 6 ×
Name
Disconnect
connector CN-KM1
6

(4) Remove the three bracket bolts of the KOMTRAX base.
01024-D1225 x2
01024-D1020 x1
01024-D1020 x2
Q't
y
Name Q't
y
Others
5 ×
NO.0010
3 × 4 × 6 ×
Tools to be used
Name
Facilities to be used
Preparation - Removal of parts on floor side (5/9)
(5) Remove the additional heater vent and plate together as shown at right below
,
and then remove the KOMTRAX unit, bracket, and wirin
g
harness to
g
ether
.
Assembly procedure
Precautions
1 × 2 ×
Z
Z
7

6) Removal of electrical parts bracket
(1) Remove one bolt to set the electrical parts bracket free
.
01024-81020
7) Move the heater unit inward
01024-81020 x3
Q't
y
Name Q't
y
Others
Name
Precautions
1 × 2 ×
5 ×
NO.0010
3 × 4 × 6 ×
Facilities to be used
Preparation - Removal of parts on floor side (6/9)
Assembly procedure
Tools to be used
Note)
Take care not to interfere
with this piping whe
n
lowerin
g
the cab.
Note)
Do not remove the heater
unit from the bracket.
Remove bracket
mountin
g
bolts
Move additional heater and bracket together
toward inside of machine.
8

8) Removal of lever link cove
r
01023-20812 x
6
01023-20810 x
7
01643-70823 x
7
9) Removal of cab harness cli
p
01024-81020
04434-81020
Q't
y
Name Q't
y
Others
Facilities to be used
Preparation - Removal of parts on floor side (7/9)
Assembly procedure
Tools to be used
5 ×
NO.0010
3 × 4 × 6 ×
Name
Precautions
1 × 2 ×
45 deg.
9

10) Move the work equipment lever link and bracket together.
01024-81025 x6
Q't
y
Name Q't
y
Others
Name
Precautions
1 × 2 ×
5 ×
NO.0010
3 × 4 × 6 ×
Facilities to be used
Preparation - Removal of parts on floor side (8/9)
Assembly procedure
Tools to be used
Move the work equipment lever link backward, keeping it assembled with the base bracket.
10

11) Tilt the steering post.
01024-D0616
Cover
Q't
y
Name Q't
y
Others
5 ×
NO.0010
3 × 4 × 6 ×
Tools to be used
Name
Facilities to be used
Preparation - Removal of parts on floor side (9/9)
12) Remove the right console box cover and put the right air conditione
r
duct hose in the ri
g
ht console box.
Assembly procedure
Precautions
1 × 2 ×
Tilt the post toward the rear of the machine.
Tilt pedal
11

2. Removal of exterior parts under floor
1) Removal of right lower cover (washer fluid tank)
(1) Disconnect the washer fluid tank harness and remove one harness clamp
.
(2) Remove one washer fluid hose clamp.
(3) Remove the cover mounting bolts.
(4) Remove the cover and washer fluid tank
.
Harness clamp
01024-81020 x1
04434-51410 x1
01024-81020 x1
04434-51410 x1
Q't
y
Name Q't
y
Others
Name
Precautions
1 × 2 ×
5 ×
NO.0020
3 × 4 × 6 ×
Facilities to be used
Preparation - Removal of exterior parts under floo
r
(
1/3
)
Assembly procedure
Tools to be used
(1) Remove the connector from the motor on the washer fluid tank and remove
one harness clam
p
.
Right side under
the floor
Front of machine
View from underside of machine
(2) Remove the windshield washer hose clamp on the reverse of the cover at the rear of the
machine.
CN-L10
(REAR WASHER MOTOR)
CN-L09
(FRONT LOWER WASHER MOTOR)
CN-L08
(FRONT UPPER WASHER MOTOR)
12

Cover outside bolt
01024-D1025 x4
Bolts inside the cove
r
01024-D1025 x2
23B-54-31990 x2
Loosen
Q't
y
Name Q't
y
Others
Facilities to be used
Preparation - Removal of exterior parts under floo
r
(
2/3
)
Assembly procedure
Tools to be used
5 ×
NO.0020
3 × 4 × 6 ×
Name
Precautions
1 × 2 ×
Open
There are two bolts
inside the cover.
(3) Remove the six cover mounting bolts.
13

2) Removal of left lower cove
r
01024-D1030 x
4
Q't
y
Name Q't
y
Others
Name
Precautions
1 × 2 ×
5 ×
NO.0020
3 × 4 × 6 ×
Facilities to be used
Preparation - Removal of exterior parts under floo
r
(
3/3
)
Assembly procedure
Tools to be used
(4) Remove the cover and washer fluid tank assembly together.
Appearance of removed assembly
Stop the water from flowing out of the hose by using tapes, etc.
Remove four bolts to remove the cover.
14

3. Removal of floor mounting bolts
Remove these bolts in advanc
e
Section of structure of mounting portion
Q't
y
Name Q't
y
Others
Facilities to be used
Preparation - Removal of floor mounting bolts
Assembly procedure
Tools to be used
5 ×
NO.0030
3 × 4 × 6 ×
Name
Precautions
1 × 2 ×
23B-957
7520
These nuts are not used after
the cab is installed.
TIGHTEN TORQUE
883 - 1001 Nm
23B-957
5520
23B-957
5570
01011
82730
23B-957
5510
110
(90 - 102 kgm)
(16)
(8) (8) (8) (8) (4)
44
0
110
60
01643
32780
15

4. Preparation on cab side
1) Removal of cover and duct at rear in cab
01024-D0612x
3
01024-D0816
01024-81016
Q't
y
Name Q't
y
Others
Tools to be used
Name
3 × 4 ×
5 × 6 ×
Facilities to be used
Preparation - Removal of parts on cab sideNO.0040
Assembly procedure
(1) Remove the cover at the inside rear of the cab an
d
the cushion material on the reverse.
(2) Remove the fresh air intake duct of the ai
r
conditioner.
Precautions
1 × 2 ×
(1) Remove the four bolts to remove the cover and the cushion on the reverse.
(2) Remove the two bolts to remove the fresh air intake duct of the air conditioner.
16

5. Mounting cab
1) Slinging cab
(1) Open the cab door and hitch it to the door open lock
.
(2) Install the sling to the four seats of the cab ceiling
.
Q't
y
Name Q't
y
Others
Precautions
1 × 2 ×
Facilities to be used
Installation of cab (1/5)
* If the revolving warning lamp may b
e
dama
g
ed when the cab is slun
g
, remove it
.
Assembly procedure
Tools to be used
5 ×
NO.0050
3 × 4 × 6 ×
Name
Remove four caps on the
ceiling and install M16
e
y
ebolts.
Install M16 eyebolts 04530-11628
instead of the caps.
View from top of the cab
Note) Restore the caps after
installing the cab.
Sling the cab with its rear part lower
than its front part.
You can lower it smoothly to the floor,
preventing its rear part from interfering
with other parts.
<<Caution for slinging cab>>
Cab weight: 860 kg
Nominal No.
Tightening
torque
16
54 to 88
{5.5 to 9.0}
17