Field Assembly D155AX-6

GEN00049-07
BULLDOZER D155AX -6
SERIAL NUMBERS 80001 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 transporta-
tion 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 pro-
tective 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 dif-
ferent languages and customs work together.
The following is a reference supervision system diagram.
(Instruction system)
Work leader
Director
Work supervisor Crane 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 main-
tain 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.................................................................................................. 9
TIGHTENING TORQUE .................................................................................................................................. 11
COATING MATERIALS................................................................................................................................... 17
Selection of wire ropes used for assembly ...................................................................................................... 21
A. Assembly..................................................................................................................................................... 23
A-1. Unloading and installing tractor ......................................................................................................... 24
A-2. Installing track shoes ......................................................................................................................... 25
A-3. Installation of blade lift cylinder.......................................................................................................... 26
A-4. Assembly of blade ............................................................................................................................. 28
A-5. Installation of full roller guard............................................................................................................. 34
A-6. Installation of blade............................................................................................................................ 38
A-7. Installation of ripper assembly ........................................................................................................... 41
A-8. Installation of operator’s cab.............................................................................................................. 53
A-9. Check track tension ........................................................................................................................... 69
A-10. Check of oil and coolant levels ........................................................................................................ 71
A-11. Lubricating ....................................................................................................................................... 73
A-12. Bleeding air from hydraulic cylinders ............................................................................................... 76
A-13. Installation of additional working lamps ........................................................................................... 78
A-14. Installation of KOMTRAX parts........................................................................................................ 80
A-15. Installation of KOMTRAX antenna................................................................................................... 86
A-16. Installation of fire extinguisher ......................................................................................................... 87
M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY ......................... 89
M-1. Testing and adjusting operator’s cab ................................................................................................ 90
M-2. Replacement of return filter (Standard filter to flushing filter)............................................................ 100
M-3. Flushing of hydraulic circuit, and bleeding air from hydraulic cylinders (Part 1) ............................... 102
M-4. Replacement of return filter (Flushing filter to standard filter) ........................................................... 103
M-5. Bleeding air from hydraulic cylinders (Part 2) ................................................................................... 105
FIELD ASSEMBLY INSPECTION REPORT

SPECIFICATIONS
Item Unit Sigma dozer + Multi ripper Semi-U + Giant ripper

Operating weight (excluding operator’s weight) kg 40,000 39,770
Blade weight (including cylinders) kg 5,550 5,823
Ripper weight (including cylinders) kg 3,376 2,389
Engine model – KOMATSU SAA6D140E-5
Rated engine output kW/rpm × {HP/rpm} 264/1,900 {354/1,900}
Length of track on ground mm 3,275
Width of gauge mm 2,140
Overall length mm 8,225 8,275
a
Overall height (with ROPS, cab) mm 3,310
Overall width (width of blade) mm 4,060 4,130
Forward km/h 3.8/5.6 / 7.5/11.6
Travel speed (1st / 2nd / 3rd)
Reverse km/h 4.6/6.8 / 9.2/14.0
a
Height above GL. excluding grouser (80 mm).
• Sigma dozer + Multi ripper
• 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 draw-
ing.)
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 prob-
lem. 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
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE
a Any change of the schedule caused by weather is not included.

a Special field work shall be arranged separately.
Schedule
1st day 2nd day

8:00 10:00 12:00 14:00 16:00 18:00 8:00 10:00 12:00 14:00 16:0018:00
Trailer must arrive at field Unloading trailer

before 8:00
Installing tracks Installing ripper
Assembling full roller

guard
Assembling blade Installing cab

sub-assembly
Installing Inspection
blade
Washing,
touching up
User delivery
Wrecker 25 ton x 2 units 10 ton x 1 unit
Working hours 8H 8H
Number of workers 3 workers 3 workers
Total man-hours 24H 24H
Grand
48H
total
3
LAYOUT OF KIT
• When selecting the work field, see “Before assembling in field”.
• The dimensions in the drawings are reference dimensions for installation in the following space
(30 m x 30 m).
• If a wider work field is available, the shown dimensions should be increased.
4
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) (Without truck)
A Overall length (mm) 5,250

B Overall height (mm) 2,615
C Overall width (mm) 2,765
Weight (kg) 26,200
• Work equipment
(1) Blade (Sigma)

B Overall height (mm) 945
Weight (kg) 3,493
x: 677
y: 497
• Blade (semi-U)

Weight (kg) 5,823
x: 740
y: 590
5
(2) Straight frame (L.H.)

C Overall width (mm) 442
Weight (kg) 589
x: 1,659
y: 99
Z: 7
Straight frame (R.H.)

Weight (kg) 868
x: 1,566
y: 87
Z: 12
(3) Ripper Ass’y
Multi Giant
B Overall height (mm) 1,250 1,250
C Overall width (mm) 2,150 2,150
Weight (kg) 3,376 2,389
A: See the next page
6
• Ripper arm

Weight (kg) 609
x: 768
Z: 12
• Ripper beam (Multi)

Weight (kg) 1,238
• Ripper beam (Giant)

Weight (kg) 787
7
• Track shoe
Shoe width 610 560

A (mm) 3,450
B (mm) 1,060
Weight (kg) 2,260 × 2
• Cab

Weight (kg) 728
x: 121.3
y: 324.4
8
LIST OF TOOLS FOR FIELD ASSEMBLING
No. Tool names Specifications Q’ty. Remarks

1 Engine compressor Komatsu, 0.74 MPa {7.5kg/cm2} Class 1
2 Crane truck 245 kN {25 ton} 2
3 Grease pump Air type 1
4 Stepladder 5 -stepped, 1500 mm 1
5 Impact wrench KW10P (for M10) 1
6 KW12PI (For M12) 1
7 KW20P (For M14 – M20) 1
8 KW45FS (Spline) 1
9 Socket for KW45FS Spline × 50 mm 1 For blade, center arm
10 Spline × 41 mm 1
11 Socket for KW20P T19 × 24 mm 1
12 T19 × 27 mm 1
13 T19 × 30 mm 1
14 T19 × 36 mm 1
15 Extension Spline × L300 1
16 Air hose 50 m 1
17 4-time wrench 25.4, 19 1
18 Socket for 4-time wrench T25.4 × 50 mm 1
19 T25.4 × 41 mm 1
20 Torque wrench 412 Nm {42 kgm} – T19 mm 1 For 16-time wrench
21 834 Nm {85 kgm} – T25.4 mm 1 For 4-time wrench
22 4118 Nm {420 kgm} – T38.1 mm 1 For counterweight and track frame
23 Standard tool Socket, spanner, wrench 2 set
24 Sledge hammer 10 P 1
25 Bar 1m 2
26 Hydraulic jack 196 kN {20 ton} 1
27 98 kN {10 ton} 1
28 Tap M27 × P2 1 For master link
29 M24 × P3 1
30 M30 × P3 1 For blade, center arm
31 Waste oil pan Large, small 2 each
32 Wooden block 550 × 400 mm 1
33 300 × 400 mm 4
34 Wire ø10 × 3 m 2
35 ø20 × 5 m 2
36 ø25 × 5 m 4
37 ø30 × 5 m 4 For body
38 Shackle 3 ton 3
39 8 ton 2
40 20 ton 2
41 Nylon sling 50 mm wide × 3 m 2
42 Lever block 14.7 – 29.4 kN {1.5 – 3 ton} 2
43 Eyebolt M12 2
44 Detergent liquid Brake cleaner 10
45 Hydraulic oil EO-10 100 l
46 Grease G2-LI 20 kg
47 Repair paint Natural yellow 5
48 Black gray 5
49 Glass cleaner 1
50 Thread tightener Silicon 200g For cab
51 Waste cloth Bundle 20 kg
9
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 diameter × Bolt length
Tool (Socket) Applicable socket size
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 26
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. cor-
respond 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 : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt
11
Table 1 Tightening torque for bolts not specified in text
Unit: Nm {kgm}
Nominal size of thread Width across flats Tightening torque

× pitch (= Socket size)
a (mm) b (mm) Target Range
12 8.8 14.7
6×1 10
{1.2} {0.9 1.5}
25 14.7 34
8 × 1.25 13
{2.5} {1.5 3.5}
54 34 74
10 × 1.5 17
{5.5} {3.5 7.5}
89 54 123
12 × 1.75 19
{9} {5.5 12.5}
137 84 196
14 × 2 22
{14} {8.5 20}
230 147 309
16 × 2 24
{23.5} {15 31.5}
315 201 427
18 × 2.5 27
{32} {20.5 43.5}
460 319 608
20 × 2.5 30
{47} {32.5 62}
650 471 829
22 × 2.5 32
{66.5} {48 84.5}
810 588 1030
24 × 3 36
{82.5} {60 105}
1180 883 1470
27 × 3 41
{120} {90 150}
1520 1130 1910
30 × 3 46
{155} {115 195}
1960 1470 2450
33 × 3 50
{200} {150 250}
2450 1860 3040
36 × 3 55
{250} {190 310}
2940 2260 3630
39 × 3 60
{300} {230 370}
12
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
Nominal size
3.9 6.9 2.9 5.9 2.0 3.9
1/8
{0.4 0.7} {0.3 0.6} {0.2 0.4}
5.9 11.8 4.9 9.8 3.9 7.8
1/4
{0.6 1.2} {0.5 1.0} {0.4 0.8}
16.7 26.5 13.7 21.6 9.8 16.7
3/8
{1.7 2.7} {1.4 2.2} {1.0 1.7}
32.3 52.9 26.5 43.1 19.6 32.3
1/2
{3.3 5.4} {2.7 4.4} {2.0 3.3}
51.0 85.3 42.1 70.6 31.4 52.9
3/4
{5.2 8.7} {4.3 7.2} {3.2 5.4}
86.2 173.5 72.5 146.0 54.9 111.7
1
{8.8 17.7} {7.4 14.9} {5.6 11.4}
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
Nominal size
16.7 29.4 9.8 19.6 6.9 14.7
1/8
{1.7 3.0} {1.0 2.0} {0.7 1.5}
19.6 44.1 16.7 37.2 12.7 28.4
1/4
{2.0 4.5} {1.7 3.8} {1.3 2.9}
44.1 93.1 37.2 77.4 27.4 58.8
3/8
{4.5 9.5} {3.8 7.9} {2.8 6.0}
98.0 188.2 83.3 157.8 60.8 115.6
1/2
{10.0 19.2} {8.5 16.1} {6.2 11.8}
170.5 316.5 141.1 247.0 105.8 186.2
3/4
{17.4 32.3} {14.4 25.2} {10.8 19.0}
367.5 612.5 309.7 514.5 235.2 392.0
1
{37.5 62.5} {31.6 52.5} {24.0 40.0}
13
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 Tightening torque (Nm {kgm})

Width across
of hose flats of nut (mm) Range Target
(mm)
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}
Table 4.2 Hydraulic hose of taper seal type
Type that does

not use O-ring
at this position
Outside diameter Tightening torque (Nm {kgm})

Width across
of hose flats of nut (mm) Range Target
(mm)
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}
Note: When connecting hose, take care not to twist them.
14
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
15
COATING MATERIALS LIST
(Rev. 2009.08)
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.
Cate- Komatsu Part No. Capacity Container Main features and applications
gory code
• Use to prevent rubber gaskets, rubber cushions, and

LT-1A 790-129-9030 150 g Tube
cork plugs from coming out.
• Use for plastic (except polyethylene, polypropylene,

20 g Polyethylene tetrafluoroethylene and vinyl chloride), rubber, met-
LT-1B 790-129-9050 (2 pcs.) container al, and non-metal parts which require immediate
and strong adhesion.
Polyethylene • Features: Resistance to heat and chemicals.

LT-2 790-129-9040 50 g container • Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of 1 kg
LT-3 Can • Use to bond and seal metal, glass and plastics.
adhesive and Hardener:
hardener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Use to seal plugs for blank holes
container
Holtz 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.

MH 705
• Instantaneous adhesive.
ThreeBond Polyethylene • Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Use mainly to bond metals, rubbers, plastics, and
woods.
• Instantaneous adhesive.
Aron-alpha Polyethylene • Quick-curing type (max. strength is obtained after 30
790-129-9130 2g
201 container minutes)
• Use mainly to bond rubbers, plastics, and metals.
Loctite Polyethylene • Features: Resistance to heat and chemicals.

79A-129-9110 50 cc
648-50 container • Use for fitted portions subjected to high temperature.
• Use to seal various threaded portions, pipe joints, and

Polyethylene flanges.
LG-5 790-129-9080 1 kg container • Use to seal taper plugs, elbows, and nipples for hy-
draulic piping.
• Features: Silicon-based heat and cold-resistant seal-
ant.
LG-6 790-129-9160 200 g Tube
• Use to seal flange surfaces and threaded portions.
Liquid gasket
• Use to seal oil pan, final drive case, etc.

• Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake manifold, oil pan,
thermostat housing, etc.
LG-8 • Features: Silicon-based, heat and cold-resistant, vi-
ThreeBond 419-15-18131 100 g Tube bration-resistant, impact-resistant sealant.
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the circle gear top
LG-9 seal which is not clamped by bolts, gaps in the weld
ThreeBond 790-129-9310 200 g Tube
1206D which must be caulked, etc.
• Can be coated with paint.
17
gory code
LG-10 • Use as lubricant/sealant when installing the radiator
ThreeBond 790-129-9320 200 g Tube hoses to the water tubes.
Liquid gasket
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube • Use for covers of the transmission case and steering
1121 case etc.
ThreeBond 790-129-9090 100 g Tube • Liquid gasket used to repair engine.
1211
• Use to prevent galling and seizure of press-fitted por-
Molybdenum disulfide
tions, shrinkage-fitted portions, and threaded por-

LM-P 09940-00040 200 g Tube
tions.
lubricant
• Use to lubricate linkages, bearings, etc.

• Spray type
• Thin molybdenum disulphide films are made on metal
— 09995-00250 190 g Can surfaces to prevent the metals from galling.
• Use for the drive shaft splines, needle bearings, vari-
ous link pins, bolts, etc.
prevention compound
• Feature: Seizure and galling prevention compound

Seizure
LC-G with metallic super-fine-grain, etc.

NEVER- — — Can • Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharger,
etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI SYG2-160LI • Feature: Lithium grease with extreme pressure lubri-
G0-LI (*) SYGA-160CNLI Various Various
*: For cold cation performance, general purpose type.
SYG0-400LI-A
district (*)
SYG0-160CNLI
(*)
• Use for parts under heavy load.
Caution:
Molybdenu
m disulfide SYG2-400M 400 g × 10 Bellows-type • Do not use this grease for rolling bearings like
grease SYG2-400M-A 400 g × 20 container swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can • Use this grease for work equipment pins only
(G2-M)
when installing them, but do not use it after-
ward.
Grease
SYG2-400T-A
Hyper White SYG0-400T-A • Seizure resistance, heat resistance and water resis-
G2-T, Bellows-type
(*) 400 g
G0-T (*) container tance higher than molybdenum disulfide grease.
SYG2-16CNT
*: For cold Can • Not conspicuous on machine since color is white.
SYG0-16CNT 16 kg
district (*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT • Since this grease is biodegradable in short period, it
Bellows-type
*: For use at (*) 400 g container has less impact on microorganisms, animals, and
high SYGA-16CNB Can plants.
temperature SYGA-16CNBT 16 kg
and under (*)
high load
• Feature: Silicone grease with wide usable tempera-
G2-S ture range, high resistance to thermal-oxidative
ThreeBond — 200 g Tube degradation and performance to prevent deteriora-
1855 tion of rubber and plastic parts.
• Use for oil seals of the transmission, etc.
18
gory code
• Feature: Urea (organic system) grease with heat re-
Grease G2-U-S
sistance and long life, can be packed into the con-
427-12-11871 2 kg Can fined space and left intact until next overhaul.
ENS grease
• Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR • Use as primer for painted cab sheet metal sur-
PAINT Glass face.
20 ml
PRIMER container (Effective period: four months after date of
580 SUPER manufacture)
417-926-3910
SUNSTAR • Use as primer for glass.
GLASS Glass
20 ml (Effective period: four months after date of
For adhered window glass

PRIMER container
580 SUPER manufacture)
SUNSTAR • Use as primer for painted cab sheet metal sur-

PAINT Glass face.
Primer
22M-54-27230 20 ml
435-95 manufacture)
• Use as primer for black ceramic-coated glass
SUNSTAR surface and for hard polycarbonate-coated
GLASS 22M-54-27240 150 ml Can surface.
PRIMER
435-41 (Effective period: four months after date of
manufacture)
SUNSTAR • Use as primer for sash (anodized aluminum
SASH Glass surface).
22M-54-27250 20 ml
GP-402 manufacture)
SUNSTAR • Use "S" in high-temperature season and "W" in
PENGUINE low-temperature season as adhesive for
Polyethylene
SEAL580 417-926-3910 320 ml glass.
container
SUPER "S" (Effective period: four months after date of
or "W"
Adhesive
manufacture)
Sika Japan, • Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
For adhered window glass
container
256HV manufacture)
SUNSTAR Ecocart • Use as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Effective period: six months after date of
SUPER 560 container) manufacture)
SUNSTAR • Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI • Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE • Use to seal glass-to-glass joint. Translucent
TOSHIBA white seal.
SILICONES 22M-54-27220 333 ml Cartridge
TOSSEAL (Effective period: 12 months after date of
381 manufacture)
19
Selection of wire ropes used for assembly 18
Select wire ropes to be used for assembly according to the following table. B 8817-1991
Annex 2, Table 1 Using loads of 6 × 24 type rope slings.

Unit: kN {tf}
Number of wire ropes 1 pc. 2 pcs.
Sling angle   = 0°  Z 90° 90° <  Z 120°

Angle to vertical line   = 0°  Z 45° 45° <  Z 60°
Mode coefficient M 1 1.4 1
Classification of wire rope
Outer diameter of 24G 24A 24G 24A 24G 24A
wire rope (2)d (mm)
8 Max. 4.8 {0.49} Max. 5.2 {0.53} Max. 6.7 {0.68} Max. 7.2 {0.74} Max. 4.8 {0.49} Max. 5.2 {0.53}
9 Max. 6.1 {0.63} Max. 6.6 {0.67} Max. 8.5 {0.88} Max. 9.2 {0.93} Max. 6.1 {0.63} Max. 6.6 {0.67}
21
10 Max. 7.6 {0.77} Max. 8.2 {0.83} Max. 10 {1.0} Max. 11 {1.1} Max. 7.6 {0.77} Max. 8.2 {0.83}
11.2 Max. 9.5 {0.97} Max. 10 {1.0} Max. 13 {1.3} Max. 14 {1.4} Max. 9.5 {0.97} Max. 10 {1.1}
(12) Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 15 {1.6} Max. 10 {1.1} Max. 11 {1.2}
12.5 Max. 11 {1.2} Max. 12 {1.3} Max. 15 {1.6} Max. 16 {1.8} Max. 11 {1.2} Max. 12 {1.3}
14 Max. 14 {1.5} Max. 16 {1.6} Max. 19 {2.1} Max. 22 {2.2} Max. 14 {1.5} Max. 16 {1.6}
(24) Max. 43 {4.4} — Max. 60 {6.1} — Max. 43 {4.4} —
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) Plate
(2) Collar
(3) Washer
(4) Bolt
(5) Bolt
(6) Washer
2. 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 opera-
tor's seat with the sprocket at the rear as shown below, unless otherwise speci-
fied.
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 undercov-

er at the front of the tractor and install wires to the right
and left sides.
4 Front slinging weight: 13.0 ton
2. Rear: Install wires to the right and left ripper cylinder pins.
4 Rear slinging weight: 13.2 ton
3. Lower the tractor onto the track shoe.

Track gauge: 2,140 mm
SA60
BC36 (2 pieces)
Pass either end of wire

through this hole.
2140mm
Precautions Necessary tools Necessary equipment
When installing wires, put rubber pads or Name Q’ty Name Q’ty
steel pads under them and take extreme care ø30 × 5,000 wire 4
not to damage the covers and piping.
SA60 shackle 1
BC36 shackle 1
Others
24
Assembly procedure
Installing track shoes
A-2

Name Q’ty Name Q’ty
Others
25
Assembly procedure
Installation of blade lift cylinder (1/2)
A-3
1. Remove the yoke fixing brackets (right and left).

a Removed parts are used again for transport.
Accordingly, ask the user to store these parts.
No. Part No. Q’ty
1 17A-61-43120 2
2 01024-81230 2
3 21T-09-11330 2
4 01011-82015 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

01010-82095
Part No. of bolt (4 pieces on each side)
01643-32060
Part No. of washer (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.)

Nylon sling 1
KW20P impact wrench 1
M30 socket 1
Others
26
Assembly procedure
Installation of blade lift cylinder (2/2)
A-3
4. Cylinder sling bracket

Remove cylinder sling bracket, then install the cylinder to
the sling posture position.
In addition, after the blade is installed, assemble it to be-
come former position and former direction.
Sling bracket
5. Installation of hose
Install the hose without twisting and secure clearance of
㻟㻝 )LJ
at least 30 mm between the hose and cover as shown in
Fig. 6 and 7.
Fig.7
Min. 30mm
No. Part name Part No. Remarks

1 Hose 17A-61-51290 (1 piece on each side) l=1050mm
2 Hose 17A-61-51290 (1 piece on each side) l=1050mm
3 O-ring 02896-11018 (2 pieces on each side)
6. Check after installation

Lift and tilt the blade and check that the hose does not interfere with the cover in all position. If it interferes, modify it.
27
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)
1
: 3,572 kg (Semi U)
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 clear-
ance 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 - 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.
3 4
a Standard thickness of shim: 4.5 mm a Set wooden blocks under the center arm to the height of
Weight of center arm: 251 kg the straight frame.
(3) Part No. of bolt 01011 – 83335

(4) Part No. of washer 01643 – 33380
1,961 – 2,451.7 Nm
Tightening torque {200 – 250 kgm}

ø20 x 5,000 wire 2 25 t crane 1
BC36 shackle 2
300 × 400 wooden block 4
50 × 3,000 nylon sling 2
KW45F impact wrench 1
SP extension, L300 1
M50 SP socket 1
Others
28
Assembly procedure
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
3 Tightening torque: 245 - 309 Nm {25 - 31.5 kgm}
6
5
5. Install right straight frame (5) and center arm (2) with pin (7) and fix them with lock plate (8).
3 Tightening torque: 490 - 608 Nm {50 - 62 kgm}

8
5
2 7

50 × 3,000 nylon sling 2 25 t crane 1
M24 socket 1
M30 socket 1
Others
29
Assembly procedure
A-4
6. Install right pitch cylinder (9) with pin (10) and fix them with
the lock plate. Semi-U sigma dozer
(Dual tilt)
3 Tightening torque: 157 – 196 Nm {16 – 20 kgm}
7. Sling right pitch cylinder (9) and tighten cap mounting bolts
(11) and (12) temporarily without inserting a shim (to elimi-
nate 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 – 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.
Semi-U
(Single tilt)
a When machine has the single tilt specifi-

Sigma dozer
cation, part (9) is the brace.
(Single tilt)
(Standard length: 1,292 mm)
Spacer (40 mm)

Shim
Dual tilt (Semi-U, sigma dozer)

Single tilt (Semi-U) Single tilt (Sigma dozer)
(11) Part No. of bolt 01011 – 62700 (11-1) Part No. of bolt 01011-62740
(12) Part No. of washer 01643 – 32780 (12) Part No. of washer 01643-32780
Length of bolt 100 mm Length of bolt 100 mm
Tightening torque {120 – 150 kgm} Tightening torque {120 – 150 kgm}

KW45F impact wrench 1
SP extension, L300 1
M41 SP socket 1
M22 socket 1
Others
30
Assembly procedure
A-4
8. Connect right pitch cylinder hoses (13).
For dual tilt

• 17A-71-45731 #04-size hose, 1,380 mm long
• 17A-71-45741 #04-size hose, 980 mm long 13
For single tilt

• 17A-71-45870 #04-size hose, 1,320 mm long
• 17A-71-45880 #04-size hose, 920 mm long
3 Tightening torque for hose:

84 - 132 Nm {8.5 - 13.5 kgm}
9. Install right frame cover (14).

a 4 bolts of M16 size
14
3 Tightening torque: 245 - 309 Nm {25 - 31.5 kgm}

Cover mounting bolt
Machine with single tilt specification
14

25 t crane 1
Spanner 27 mm 2
in width across flats

M24 socket 1
Others
31
Assembly procedure
A-4
10. Install left straight frame (15) and blade (1) according to the procedure in step 4 above.
16
17
15
1
11. Install tilt cylinder (16) according to the procedure in step 6 above.
12. Install tilt cylinder hose (17) and cover (18) according to the procedures in steps 8 and 9 above.
18

M24 socket 1
M30 socket 1
Others
32
Assembly procedure
A-4
13. After assembling the blade, apply sufficient grease to the parts shown in the figure at right.
Each part of blade: Grease (G2-LI)
Machine with single tilt specification
Machine with dual tilt specification

Others
33
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
K-bogie
1st bogie
34
Assembly procedure
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

Apply LT-2
KES 04.123.1
Left inside/right outside
Clearance R
Track frame
No. PART No. PART NAME Q'TY REMARKS

Detailed section of bolt b
1 17A-30-47230 GUARD 2 L.H. OUT/R.H. IN
2 17A-30-47240 GUARD 2 L.H. IN/R.H. OUT
3 17A-30-47340 SHIM 16 t0.5
4 01010-62255 BOLT 16
5 01643-32260 WASHER 16
35
Assembly procedure
A-5
4. Install plug (16) to the track frame.

16 07049-03038 PLUG 6
36
Assembly procedure
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: Tightening torque:

610 – 765 Nm 1520 – 1910 Nm
Apply LT-2 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.

6 17A-30-47250 GUARD 10 37.16 kg/Piece K-bogie
7 17A-30-47270 GUARD 1 L.H. IN 35.76 kg/Piece
8 17A-30-47260 GUARD 1 R.H. IN 35.76 kg/Piece
9 17A-30-47131 GUIDE 12
10 17A-30-47310 SPACER 24
11 17A-30-47320 SHIM 48 t = 0.5
12 01011-62225 BOLT 24
13 01643-32260 WASHER 24 Clearance S
14 01010-63080 BOLT 24 Contact guide (9) with
15 01643-33080 WASHER 24 K-bogie to assemble,
not to loosen the bolt.
Detailed section of bolt b
37
Assembly procedure
Installation of blade (1/3)
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 1
a Width "b" of frame: Approx. 3,053 mm
2. Connect the right and left trunnions to the track frame.

a Weight of trunnion: Right side; 43 kg
Left side; 30 kg
a Size of bolt: M24 × 8 pieces, 2 places
3. Scratch the paint off the ball joint of the trunnion and clean
the ball joint.
4. 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
5. Move blade lift cylinder retainer (21) from the fixing posi-
tion for transportation to the position for operation.
21

KW45F impact wrench 1 300 × 400 wooden block 2
Socket 36 mm in SP width across flats 1
Socket 27 mm in width across flats 1
Spanner 27 mm in width across flats 1
Others
38
Assembly procedure
A-6
6. 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.)
7. Sling the blade lift cylinder and start the engine. While ex-
tending 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 di-
rection 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 ax-
ial 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
8. 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.)
(Oil quantity in right and left lift cylinders: Approx. 24 l)
9. Connect tilt hoses (23) of the trunnions. Connect the hos-

es having red marks to the upper nipples.
[For dual tilt blade specification]
• Connect the hose of the left trunnion having a blue
mark to the upper nipple.
10. Install both trunnion caps (24).

a Bolt size: M20 x 6 pieces, 2 places
39
Assembly procedure
A-6
11. Supply oil (to the hydraulic tank) and check the operation.
• Bleed air from the cylinders.
(For details, see "A-12 Bleeding air from hydraulic cyl-
inders", Cylinder with piston valve.)
• 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.
12. Adjust the standard length of the brace of the single tilt
specification to 1,292 mm.
Reference: Oil quantity in cylinder.
Blade lift cylinder (L.H. and R.H.) Approx. 24 l

Blade tilt cylinder (L.H. and R.H.) Approx. 5 l
• If the engine is operated at high idle or the Name Q’ty Name Q’ty
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.
• 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.)
Others
40
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.
㻠㻡
㻔㻞㻕
㻝
㻟㻞
2) Remove the piping plugs and install the hose.
㻴㻮
㻢㻣
㻔㻞㻕㻔㻞㻕
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
a Keep the removed piping plugs since they Name Q’ty Name Q’ty
are necessary for the next transportation Socket 19 mm in width across flats 1
Small impact wrench 1
Spanner 24 mm 1
Spanner 22 mm 1
Others
41
Assembly procedure
A-7
3) Install the rear cover.
Do not tighten them.
㻟㻞
4) Installation of piping bracket and clamp
Install with (B) side up and (H) side down.
㻥㻤㻣㻢㻡㻝㻡㼻
㻔㻞㻕㻔㻞㻕㻔㻞㻕
View Z
No. Part No. Q’TY
2 195-33-11220 1
䠶 3 01024-81250 1
4 01024-81225 1
5 17A-61-41420 1
6 01024-81235 2
㻮
㻴 7 07094-30315 2
8 07095-00317 2
9 01024-81060 1

Small size impact wrench 1
Others
42
Assembly procedure
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
01011-82040 (2 pieces each
Part No. of bolt
on right and left sides) connecting pin
01643-32060 (2 pieces each
Part No. of washer on right and left sides)
Lock plate
Socket to be used 30 mm
Tightening torque 455 – 565 Nm {46.5 – 58 kgm}

Be sure to put wooden blocks between the Name Q’ty Name Q’ty
arm and beam to prevent their relative
positions from changing when they are slung. ø12 × 2,000mm wire 3 25 t crane 1
SD22 Shackle 2 100 mm wooden block 2
BC36 Shackle 1
Beam
1.5 t lever block 1
Wooden blocks
Arm
Others
43
Assembly procedure
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.
㻣㻜㻜㼙㼙㻢㻜㻜㼙㼙

Socket 30 mm in width across flats 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
44
Assembly procedure
A-7
5. Installation of piping
Connect ripper cylinder hoses (1) to (3).
㪈
4GF 㪉
㪊
$NWG 䌐
a For connection to the block at the rear of the machine, see the detail of part P.
㪈㪇㫦㪈㪌㫦
㪈㪇㫦㪊 $NWG
㪈
㪈㪌㫦
㪉 No. Loose supply items Q’TY

㪈
1 07120-01016 2
4GF
Red 2 17A-61-51850 1
Blue 3 17A-61-51860 1
4 O-ring 8
䌐
There may be pressure in the piping. Name Q’ty Name Q’ty

Accordingly, when removing the oil stopper L150 extension 1
of each port, loosen it gradually to release
the pressure. Socket 14 mm in width across flats 1
Small oil receiving pan 1
Others
45
Assembly procedure
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 en-

gine at low idle, and operate the ripper lever.
• Extend the cylinder slowly.

(Check that the oil level is between (L) and (H) posi-
tion 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 01011-82040 (2 pieces)

Part No. of washer 01643-32060
cylinders are moved to the stroke end from Nylon sling 1 25 t crane 1
piston packing may be damaged. Socket 30 mm in width across flats 1
Accordingly, never do so. Sledge hammer (10P) 1
• Check the oil level each time and add oil if Bar 1
as rasp comes out.)
Others
46
Assembly procedure
A-7
7. Installation of lift cylinder

(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 en-

gine at low idle, and operate the ripper lever.
• Extend the cylinder slowly.

(Check that the oil level is between (L) and (H) posi-
tion 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 01011-82040 (2 pieces)

Part No. of washer 01643-32060
cylinders are moved to the stroke end from Nylon sling 1 25 t crane 1
piston packing may be damaged. Socket 30 mm in width across flats 1
Accordingly, never do so. Sledge hammer (10P) 1
• Check the oil level each time and add oil if Bar 1
as rasp comes out.)
Others
47
Assembly procedure
A-7
8. Installation of pin puller piping
㻟㻞㻝
㻢㻡㻠
㻔㻞㻕㻔㻞㻕
㻭䠖㻝㻟㻡㻜㼙㼙
㻝㻡㼻
㻣
㻔㻞㻕
After installing the hose, confirm the operating 㼆
direction of the pin-puller switch.
(a) Pin extraction
(b) Pin retraction No. Part No. Q’ty
1 144-947-2850 1
2 04205-11028 1
3 04050-13015 1
4 07094-30315 2
Front 5 07095-00317 2
6 01024-81060 1
7 02896-11009 2

Others
48
Assembly procedure
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
㻸㻠
㻣
㻤
㻤

Others
49
Assembly procedure
A-7
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".

(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 circum-
stances.
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 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.
k 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 hy-
draulic tank.
a If another cylinder is to be installed, perform this
operation at the last.
50
Assembly procedure
A-7
11. Oil level check position

(Sigmadozer)
Lower the blade on the ground so that angle (a) of its back-
side is 6°.
Lower ripper (b) on the ground vertically so that the pin is at
the lowest position.
<Reference>
Item Dimension Item Dimension
Blade Blade Tilt cylinder length 1,294 mm

(DUAL) Tilt cylinder length 1,294 mm (SINGLE) Brace 1,294 mm
Ripper Lift cylinder length 1,477 mm Ripper Lift cylinder length 1,477 mm
(VGR, VMR) Tilt cylinder length 1,431 mm (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.
<Reference>

Tilt cylinder length 1,372 mm
(DUAL) (SINGLE) Brace 1,372 mm
51
Assembly procedure
A-7
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
cylinders are moved to the stroke end from ø10 × 3,000 mm wire 2
piston packing may be damaged. SD12 shackle 2
Accordingly, never do so.
• Check the oil level each time and add oil if

as rasp comes out.)
Others
52
Assembly procedure
Installation of operator’s cab (1/16)
A-8
a When installing the KOMTRAX, install the KOMTRAX parts before installing the cab. (See A-12.)
1. Removal of dashboard
E • Remove bolts (B) and bracket (A) of dashboard wiring
harness connector (CN-DSH).
F G
• Remove screw (C) and separate the connector.
J • Remove bolt (D) which is fixing clip (J) and remove the
clip.
D
• Remove bolts (F) and washers (G) and lift off bracket
(E) and dashboard assembly together. (Weight: 84 kg)
• Keep the removed parts carefully since they will be
reused to transport the machine.
• Remove bolt (H) and separate the dashboard and
bracket (E).
H C B
Fig. 1 Removal of dashboard assembly

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53
Assembly procedure
A-8
2. Removal of dashboard
L K • Remove screws (K) (4 pieces) and cover (L).
• Install the dashboard to the cab and fix it with bolts
(1) (8 pieces).
• Fix the wiring harness bracket (A) with bolts (B).
• Fix cover (L) with screws (K) (4 pieces).
K
L
Fig. 2 Installation of dashboard assembly to cab No. Loose-supply items Q’ty

1 01024-81030 8

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54
Assembly procedure
A-8
3. Installation of open lock stopper

• Install the right and left open lock stopper brackets with bolts (4) and washers (5) as shown in Fig. 3. (2 pieces on
each side)
• Fix wiring harness bracket (A) with bolt (B).
• Fix stopper rubber (6) with nut (7).
4 5
2 3
6
7
No. Loose-supply items Q’ty

Fig. 3 Installation of open lock stopper 2 17A-979-3480 1
3 17A-979-3490 1
4 198-54-42260 4
5 01643-71645 4
6 17A-Z11-3591 2
7 01580-11210 2

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55
Assembly procedure
A-8
4. Prepare the floor.

• Corks (M) for M16 tap (12 pieces), corks (N) for M20 tap (15 pieces), and corks (P) for M24 tap (6 pieces).
• Remove bolt (Q) and ground surface protector plate (R).
• Remove mounting bolts (T) (3 pieces) of duct (S), loosen band (W), and remove duct (S).
W Q R
P
N
S

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56
Assembly procedure
A-8
5. Installation of seals to joints of operator's cab

(1) Sling the operator's cab assembly.
4 Cab assembly: 737 kg
(2) Remove dirt and oil from the seal sticking surfaces.
(3) Remove the release paper from seals (8) and stick the seals as shown in Fig. 5.
Fig. 4 Installation of seals to joints of operator's cab

8 17A-979-3480 5
Since the seals are rather long, cut them Name Q’ty Name Q’ty
properly when using.
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57
Assembly procedure
A-8
To be cut.
Detail of composition of seals
Detail of part Q
Fit seal into groove.
Fig. 5 Sticking of seals
When sticking the seals, eliminate clearance Name Q’ty Name Q’ty
in each joint.
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58
Assembly procedure
A-8
6. Removal of covers
(1) Remove the B-pillar cover.
• Remove bolts (AB) in the cap of handle (AB) (1 pieces each on the right and left sides) and remove handle (AB).
a At this time, collar (Z) comes off, too. Take care not to drop it.
• Remove bolt (Y) and B-pillar covers (U) and (V).

a At this time, collar (W) and washer (X) come off, too. Take care not to drop them.
(2) Remove the C-pillar cover.

• Remove screws (AF) (2 pieces each on the right and left sides), clips (AD), and C-pillar cover (AC).
V U
AF AE
Y X W
AB AC
AA Z
AD
Fig. 6 B-pillar cover
Take care not to lose the removed parts Name Q’ty Name Q’ty
since they will be installed again after the cab
and floor are connected.
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59
Assembly procedure
A-8
7. Installation of operator's cab

• Lower the operator's cab assembly onto the floor frame slowly.
a Set the lock lever in the lower position.
a Take care that the cover and cap will not interfere with each other since the clearance between them is narrow.
a Take care that wiring harnesses and hoses will not be pinched between the cab and floor frame.
• Tighten the bolts in the order shown in Fig. 7. (Snug torque)

Tighten the bolts on the front side in the order indicated by the arrows.
• Tighten bolts (1) - (21) with an impact wrench or a torque wrench further by 60°.
• Tighten bolts (22) and (23) until they are settled perfectly.
Tighten to 294 Nm {30 kgm}, and then

tighten further by 60°.
M16 M24 M20

12 bolts 6 bolts 15 bolts
Either impact wrench or
torque wrench may be
used to retighten bolts.
Fig. 7 Cab mounting bolts

9 01010-81655 12
Torque 10 01643-31645 12
M16 279 ± 27.9 Nm 11 01011-82020 15
Snug torque Retightening 12 01643-32060 15
M20 294 ± 29.4 Nm 60° ± 10° 13 01011-82425 6
M24 294 ± 29.4 Nm 60° ± 10° 14 01643-32460 6
Use the separate check sheet to check the Name Q’ty Name Q’ty
tightening torque and retightening. KW20P impact wrench 1
When using an impact wrench near a glass,
put cowhide or thick cloth between the KW3800 impact wrench 1
impact wrench and glass so that the impact
wrench will not touch the glass directly. Long M24 socket 1
Long M30 socket 1
Long M36 socket 1
200 mm joint 1
KW4500 impact wrench 1
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60
Assembly procedure
A-8
Position for tightening bolt
M20
Long M20 socket is used in this picture.
M24
Long M24 socket is used in this picture.
M16

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61
Assembly procedure
A-8
Position for angle-tightening bolt
Tightening with hand Impact wrench
M20
M20
M24
M20
M24
Tools in this picture
M20/M24 with extension of 145 mm and
socket (standard) of spline type
M24 Tools used for tightening with hand

M20/M24 with extension of 200 mm and
long socket (100 mm long)
62
Assembly procedure
A-8
8. Installation of covers
(1) Reassemble the B-pillar cover. (Reassembly of cover removed in step 5)
• Install B-pillar covers (U) and (V) with bolt (Y), collar (W), and washer (X).
• Install handles (AA) (1 pieces each on the right and left sides) with bolts (AB).
a At this time, set collar (Z) on the handle seat as it was.
(2) Reassemble the C-pillar cover. (Reassembly of cover removed in step 6)

• Install C-pillar cover (AC) with clips (AD).
• Install coat hook (AE) with screw (AF).
V U
AF AE
Y X W
AB
AC
AA
Z
AD
P
Section of P-handle
Fig. 8 B-pillar cover Fig. 9 C-pillar cover
Take care not to lose the removed parts Name Q’ty Name Q’ty
since they will be installed again after the cab
and floor are connected.
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63
Assembly procedure
A-8
9. Installation of floor ducts

Install floor ducts (15) - (19) as shown in Fig. 10.
16
18
19
15
19
17

Fig. 10 Installation of floor ducts 15 17A-54-4618F 1
16 17A-54-4585B 1
17 17A-54-4684A 1
18 01024-81225 4
19 01024-81260 7

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64
Assembly procedure
A-8
10. Connection of wiring harnesses and washer hoses

(1) Connect the dashboard wiring harness.
3 Tightening torque: 2.83 ± 0.28 Nm {0.289 ± 0.029 kgm}

• Fix connector (CN-DSH) with bolt (C) (removed in step 1).
• Fix connector bracket (A) with bolts (B) (2 pieces).
(2) Fix wiring harness cover (20) with bolts (21) (4 pieces) and washers (22) (4 pieces).
• Fix connector bracket (A) with bolts (B) (removed in step 1).
(3) Fix duct (23) with bolts (24) (4 pieces) and washers (25) (4 pieces).
23 24 25
20 21 22
C B
Tightening torque:
2.83 ± 0.28 Nm
Fig. 11 Connection of wiring harnesses and hoses

20 17A-06-4173C 1
21 01245-00816 4
22 01643-70823 4
23 17A-979-247D 1
24 01245-00825 4
25 01643-70823 4
Insert each connector until it clicks. Name Q’ty Name Q’ty

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65
Assembly procedure
A-8
(4) Connect cab wiring harness connectors (CN-CBPW and CN-WST).

• Fix the connectors to the clip of bracket (26).
• Fix bracket (26) with bolts (27) and washers (28).
(5) Connect the washer hoses.

a Connect the hoses having marks of the same colors to each other.
Connector Connector
CN-CBPW CN-WST
Washer hoses
Red: Right door
Blue: Left door
26 27 28 Black: Rear window
No marks: Front window
Right rear of floor
Left rear of floor
Fig. 12 Connection of wiring harnesses and hoses

26 17A-979-279A 1
27 01245-00620 4
28 17A-Z11-2813 4
Insert each connector until it clicks. Name Q’ty Name Q’ty

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66
Assembly procedure
A-8
11. Installation of floor right and left ducts and covers

(1) Install right duct (S). (Carry out installation in the reverse order to removal.)
• Connect right duct (S) and hose removed in step 1 with band (W).
• Fix right duct (S) with bolts (T) (3 pieces) and washers (X) (3 pieces) (removed in step 1).
(2) Fix left duct (29) with bolts (32) (3 pieces) and washers (33) (3 pieces).
(3) Fix right cover (30) with bolts (32) (4 pieces) and washers (33) (4 pieces).
(4) Fix left cover (31) with bolts (32) (5 pieces) and washers (33) (5 pieces).
(5) Fix L-plates (54) (2 pieces) with bolts (32) (4 pieces) and washers (33) (4 pieces).
Fig. 13 Installation of floor covers and ducts

29 17A-54-46222 1
30 17A-54-46342 1
31 17A-54-46351 1
32 01245-00825 16
33 01643-70823 16
54 17A-979-2120 2

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67
Assembly procedure
A-8
12. Installation of interior parts
46
43
45
Q 35
44
41 Detail of part Q
37
42
34
Do not use collar (44) 38 39
on inside (2 places) of 36
cover (34).
34 40
Fig. 14 Installation of floor garnish
(1) Fix rear cover (35) with collars (44) (2 pieces), wash-
ers (46) (2 pieces), and bolts (45) (2 pieces).
34 17A-979-2751 1
35 17A-979-2781 1
(2) Install cigarette lighter (39) and 12V outlet (40) to left 36 17A-979-2761 1
cover (34). 37 17A-979-2771 1
Connect connector (CN-CIG) to cigarette lighter (39) 38 20Y-43-41491 1
39 20Y-06-23472 1
and connect connector (CN-ACC) to 12V outlet (40).
40 198-Z11-6890 1
Connect ACC1 to the + side of the 12V outlet and 41 17A-979-1650 6
connect ACC2 to the - side. 42 17A-979-1660 2
43 198-911-7350 4
(3) Install the cover as shown in Fig. 13. 44 12Y-978-2660 23
45 01643-70623 25
46 01245-00625 25

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68
Assembly procedure
Check track tension (1/2)
A-9
ADJUSTMENT

• Since grease may spurt out due to the internal high pres- Name Q’ty Name Q’ty
sure, do not loosen plug (1) by more than one turn.
Do not loosen any other parts than plug (1) at that
time.
Furthermore do not turn your face toward plug (1).
If the track tension is relieved by this procedure,
please contact your Komatsu distributor.
Wen removing cover (2), be careful not to let any dirt
get inside.
There is a safety label struck to the back of cover (2).
Be careful not to damage the safety label.
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69
Assembly procedure
Check track tension (2/2)
A-9

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70
Assembly procedure
Check of oil and coolant levels (1/2)
A-10
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.

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71
Assembly procedure
Check of oil and coolant levels (2/2)
A-10
If any oil level or coolant level is low, add oil Name Q’ty Name Q’ty
or coolant.
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72
Assembly procedure
Lubricating (1/3)
A-11
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)

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73
Assembly procedure
Lubricating (2/3)
A-11
5. Egualizer bar side shaft (2 places)
6. Egualizer 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)

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74
Assembly procedure
Lubricating (3/3)
A-11
13. Decelerator pedal shaft (1 place)
14. Brake pedal shaft (1 place)
75
Assembly procedure
Bleeding air from hydraulic cylinders (1/2)
A-12
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)

stances.
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 cyl-
inder 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)

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)
stances.
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
76
Assembly procedure
Bleeding air from hydraulic cylinders (2/2)
A-12
3. After bleeding air, leave the engine stopped for 1 hour.
1) After leaving for 1 hour, check the oil level in the hy-
draulic tank.
4. Oil level check position

(Sigmadozer)
Lower the blade on the ground so that angle (a) of its back-
side is 6°.
<Reference>

Tilt cylinder length 1,292 mm
(DUAL) (SINGLE) Brace 1,292 mm

Lower the blade on the ground so that backside (a) is upright.
<Reference>

(DUAL) Tilt cylinder length 1,292 mm (SINGLE) Brace 1,372 mm
77
Assembly procedure
Installation of additional working lamps (1/2)
A-13
View E
View P
Detail C

1 17A-979-1880 1
2 17A-979-1890 1
3 17A-979-2930 1
4 17A-06-17930 4
Detail D Detail A 5 17A-979-2921 1
6 17A-979-2941 1
Fig. 1 of additional working lamp 7 17A-06-42230 1
8 01024-D1225 12
9 01643-71232 12
10 205-977-7310 1
11 04434-51012 4
Seal around the grommets with caulking Name Q’ty Name Q’ty
material
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78
Assembly procedure
Installation of additional working lamps (2/2)
A-13
Procedure
1. Remove the grommets from the front and rear of the cab and take out the additional
lamp connectors.
(Connector at front of cab: CN-18)
(Connector at rear of cab: CN-1)
2. Connect connector CN-18 of wiring harness (5) to connector CN-18 at the front of the cab.
Connect connector CN-1 of wiring harness (7) to connector CN-1 at the rear of the
cab.
Seal around the grommets with caulking material.
3. Install brackets (1), (2), and (6) to the cab with bolt (9).
4. Install lamps (4) to brackets (1), (2), and (6) temporarily.
5. Install the connectors of wiring harnesses (5) and (7) to the clamps of brackets (1), (2),
and (6), and then connect them to the connectors of lamps (4).
6. Fix wiring harnesses (5) and (7) with clips (10) and (9).
7. Remove the switch panel cover at the right upper part in the cab, take out cab wiring
harness connector CN-10, and connect lamp switch (8).
8. Turn the key switch ON, and then turn lamp switch (8) ON and check that the lamps
are lighted.
9. Adjust the radiating directions of lamps (4) and tighten the locknuts to 22 – 25 Nm
{2.24 – 2.55 kgm}.

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79
Assembly procedure
Installation of KOMTRAX parts (1/6)
A-14
Preparation for installing KOMTRAX parts (Carry out before A-7 Installation of operator's cab)
(1) Installation of modem

• Fix modem (1) to the right side of the floor with bolts (2) as shown in Fig. 1.
2
1
Fig. 1 Installation of modem

1 7826-23-3010 1
2 01024-80612 4

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80
Assembly procedure
A-14
Preparation for installing KOMTRAX parts (Carry out before A-6 Installation of operator's cab)
(2) Removal of interior parts from ceiling

• Remove B-pillar covers (D) (right and left).
• Remove mirror (A) and room lamp (C).
• Remove switch panel (F).
• Remove radio (G).
• Remove speaker (H).
• Remove C-pillar garnish (I) (both left and right).
• Remove the A-pillar cover (both left and right).
• Remove the A-clip and ceiling interior parts (B) and (E).
A B C D E F G H I
Fig. 2 Removal of interior parts

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81
Assembly procedure
A-14
(3) Installation of antenna

Referring to Fig. 3, remove the cap. (Discard the removed cap.)
• Referring to detail of Fig.3, peel off the paint from the part indicated by the slanting line.
Fig. 3 Removal of cap

• Pass wiring harness (5) through hole (K) and pass GPS wiring harness (6) through hole (L).
Install grommet (10) to bracket (9).
• Referring to Fig. 4, install antenna (4) to bracket (9).
Install GPS (6) to the top of bracket (9).
• Fix bracket (9) to (M) with bolt and washer (8).
• Connect wiring harness (5) to antenna (4).
Parts (7), (8) and

Apply LOCTITE to (9) are made
connecting parts of antenna transparent to
(4) and cable (5). indicate the inside.
Seal around grommet.

4 8A13-10-2100 1
5 8A13-10-2200 1
6 8A13-10-4300 1
7 17A-979-3970 1
8 01024-D0850 2
Fig. 4 Installation of antenna 9 17A-979-3960 1
10 175-06-81610 2

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82
Assembly procedure
A-14
• Install the harness (5) to the ceiling and GPS (6) to the right C-pillar as shown in Fig. 5.
Lower from left side of A-pillar.

5
Install grommet from
inside of cab.
10
Lower from right side of C-pillar.
Fig. 5 Route of wiring harness

10 175-06-81610 2

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83
Assembly procedure
A-14
• Install the wiring harness to the modem as shown in Fig. 6.
Connect to modem (1). 10

11 12 13
Fig. 6 Route of wiring harness (Right rear of floor)

10 08034-20414 2
11 04434-50508 3
12 01245-00620 3
13 01643-70623 3

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84
Assembly procedure
A-14
• Remove cover (N) and connect connector (L) and wiring harness (5) in it.
• Install the cover (N) again.
• Install the covers removed in step (2) in the reverse order to removal.
(Cover (N) removed)
Fig. 7 Route of wiring harness (Dashboard)

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85
Assembly procedure
Installation of KOMTRAX antenna
A-15
1. Install antenna cable (1) to the ROPS guard and roof.

2. Install communication antenna (2).
3. Install GPS antenna (3) to the top of the ROPS roof.
a The GPS antenna is a magnet.

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86
Assembly procedure
Installation of fire extinguisher (1/2)
A-16
1. Remove covers (1) and (2).

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

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87
Assembly procedure
Installation of fire extinguisher (2/2)
A-16
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.
6
7
(6)
8
9
(6)
10
(6)
English 6 09495-40010 1
Chinese 6 09495-90010 1
Arabic 6 09495-11010 1
Indonesian 6 09495-31010 1
French 6 09495-50010 1
Persian 6 09495-12010 1
Portuguese 6 09495-80010 1
7 01024-D0620 6
8 17A-979-1770 1
9 01245-00625 6
10 01643-70823 6

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88
M. CHECK AND MAINTENANCE PROCEDURES
AFTER COMPLETION OF ASSEMBLY
89
Assembly procedure
Testing and adjusting operator’s cab (1/10)
M-1
1. Adjusting door duct

• Loosen the duct mounting bolts and fix the duct to the rear end temporarily.
• Close the door.
a Do not leave the door half-open but close it securely.
• Loosen the mounting bolts and adjust the distance between the seal fitting surface of the duct and the seal contacting
surface of the door to 14 mm.
a Adjust the clearance evenly at the top and bottom.
Duct
Duct
Fig. 1 Door duct

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90
Assembly procedure
M-1

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91
Assembly procedure
M-1

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92
Assembly procedure
M-1

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93
Assembly procedure
M-1
If the latch is not greased, the knob becomes Name Q’ty Name Q’ty
heavy.
Accordingly, apply grease sufficiently.
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94
Assembly procedure
M-1

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95
Assembly procedure
M-1

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96
Assembly procedure
M-1

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97
Assembly procedure
M-1

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98
Assembly procedure
M-1
7. Check of clearance between hood and cab

A: Distance between front leg and clearance to be checked: 961 mm
B: Distance between front and rear mounts: 1,560 mm
C: Max. stroke of cab mount: 7 mm (When riding over) (On drawing: 13 mm)
Max. rocking distance of cab D = A / B × C = 4.3 mm
If the standard clearance is 18 mm, a clearance of at least 13.7 mm (18 mm – 4.3 mm) is secured.
Secure 18 mm.
99
Assembly procedure
Replacement of return filter
M-2 (Standard filter to flushing filter) (1/2)
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 ele-

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

1 22U-60-21370 1
2 22U-60-21380 1
Store the removed standard element Name Q’ty Name Q’ty

(207-60-71182) and valve (20Y-60-31131) in Socket 19 mm in width across flats 1
order because they are used again after
flushing. Small size impact wrench 1
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100
Assembly procedure
M-2 (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.

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101
Assembly procedure
Flushing of hydraulic circuit, and bleeding air from
M-3 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-2 to M-5, the assembly procedure A-12 "Bleeding air from hydraulic cylin-
ders" 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-12-4. 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
a Check the oil level, and add oil to the specified level if necessary.
1. Flushing of fan circuit

a When checking the hydraulic oil level, see
assembly procedure “A-12-4. Oil level check
position”.
2) Start the engine and run it for approximately 10 min-

utes at low idle.
3) Then run the engine for approximately 30 minutes in
1,000 to 1,200 rpm.
a When checking the hydraulic oil level, see
assembly procedure “A-12-4. Oil level check
position”.
2. Bleeding air and flushing of cylinder with piston valve (blade lift cylinder)
stances.
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 cyl-
inder 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)

stances.
102
Assembly procedure
M-4 (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
• Scrap the used flushing element. Keep accor- Name Q’ty Name Q’ty
dance with the local laws for scraping.
• Replaced plate is reusable, so it is recom-
mended to store it for the next flushing work.
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103
Assembly procedure
M-4 (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.

Others
104
Assembly procedure
Bleeding air from hydraulic cylinders (Part 2)
M-5
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)
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.
105
1/7
Report No.
FIELD ASSEMBLY INSPECTION REPORT
Please send back these check sheets to the factory.
D155AX-6 SAA6D140E-5
Air bleeding of the hydraulic cylinder Preform air bleeding of the hydraulic cylinder.
See assembly procedure A-12 "Bleeding air from
hydraulic cylinders."
2-2/7
Oil level check position
(Sigmadozer)
<Reference>
1,292 mm
1,292 mm
1,292 mm
1,543 mm 1,543 mm
1,607 mm 1,607 mm
<Reference>
1,372 mm
1,292 mm
1,372 mm
1,543 mm 1,543 mm
1,607 mm 1,607 mm
3/7
Check of dual tilt and pitch direction

Check of tilt direction Pitch back Blade must move backward. (M)+(E)
Pitch Dump Blade must move forward. (M)+(F)
LH dual tilt Blade must move to left (both cylinders move) (a)+(E)
RH dual tilt Blade must move to right (both cylinders move) (a)+(F)
LH tilt Blade must move to left (right cylinder moves) (E)+(a)
RH tilt Blade must move to right (left cylinder moves) (F)+(a)
Pitch
back
Pitch
RH tilt Dump
DUAL TILT / FLOAT
LH tilt
Check of dual tilt indication

Check of float Dual tilt indication (ON: Dual, OFF: Single)
Blade must float (b)+(C)+Lower(B)
(Raise to cancel)
(a)
(b)
4/7
5/7
Example: When Sigma-blade is used
Raise
Tilt in
Lower Tilt out
KOMTRAX
Check of cable between KOMTRAX controller and antenna Must be installed to controller and antenna side
correctly.
Check of KOMTRAX Communication Must be of no abnormality according to the
service mode of shop manual.
6/7
Engine speed
Category Item Condition Unit Criteria Result
Engine speed Low idle rpm 740 ± 50
(P mode) High idle (Transmission: N) Power train rpm 1875 ± 25
Engine
oil
Deceleration slow rpm 875 ± 25
temperature:
Torque converter stall (At fan 100%) 80ºC rpm 1610 ± 50
T/C stall + ripper relief (At fan 100%) rpm 1550 ± 50
Hydraulic pressure
Inlet pressure Engine full, Transmission: N MPa 0.49 – 0.98
Power train
converter
Torque
2
oil {kg/cm } 5 – 10
Outlet pressure Engine full, Transmission: N temperature: MPa 0.29 – 0.69
80ºC
2
{kg/cm } 3–7
Main relief pressure Engine full, Transmission: N MPa 2.99 – 3.38
Transmission
Power train {kg/cm 2} 30.5 – 34.5

Brake pressure Engine full, Transmission: N, Pedal released oil MPa 2.99 – 3.38
temperature: {kg/cm 2} 30.5 – 34.5
Engine full, Transmission: N, Pedal depressed 80ºC MPa 0
2
{kg/cm } 0
Work equipment pump Engine full, Blade tilt relief MPa 25.9 – 28.9
Oil pressure
Hydraulic
relief pressure 2
265 – 295
oil {kg/cm }
Engine full, Steering relief tempreture: MPa 36.26 – 40.67
50ºC 2
{kg/cm } 370 – 415
Work equipment speed

Blade lift 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
Ripper lift Raise Engine full sec 1.5 – 2.5
Lower Engine full sec 1.3 – 2.3
Ripper tilt Tilt in Engine full sec 4.0 – 5.0
Tilt back Engine full Hydraulic sec 3.7 – 4.7
oil
Pitch Pitch dump Engine full sec 1.3 – 2.3
tempreture:
(Dual tilt specification) sec 1.3 – 2.3
Pitch back Engine full 50ºC
Single tilt L.H. tilt Engine full sec 1.3 – 2.3
R.H. tilt Engine full
Dual tilt L.H. tilt Engine full sec 1.3 – 2.3
R.H. tilt Engine full
Hydraulic drift (Blade) Cutting edge height 800 mm mm / min 150 / 15
Hydraulic drift (Ripper) Ripper point height 600 mm mm / min 80 / 15
Push left mm 30 – 50
Pedal stroke, depressing force (Referance: Cab installed)

Brake pedal stroke, Low idle mm 69 – 89
depressing force Low idle (Pedal depressed to stroke end) kg 34 – 50
Decelerator pedal stroke, Low idle mm 35 – 65
depressing force kg 4.0 – 6.0
Low idle
7/7
Check sheet for tightening torque for bolts of ROPS and roof
Sketch Record
· Check the torque at each No. shown at left and enter the measured torque in the
following torque recording box.
Locations of bolts · As for the M20 and M24 (1 - 21) bolts, tighten them to the specified torque first, then
retighten them and check the retightening work and then record the measured torque.
(Check the box.)
Location Record of torque Check of retightening Standard tightening torque/retightening
1
2
3
4
5
6
7
8
9
10 Torque:
294 ± 29.4 Nm (30 kgm)
11
Retightening angle:
12 60 ± 10 degrees
13
14
Bolt size
15
1 to 15 : M20 16
16 to 21 : M24 17
22 to 33 : M16 18
19
20
Method of checking retightening
21
22
Mark 23
24
25
26
27 Torque:
28 279 ± 27.9 Nm (28.5 kgm)
29
30
31
32
33
Retightening
Mark
60 degrees
1. Tighten to specified torque,
then make marks.
2. Retighten to specified angle
(60 degrees).
3. Check that marks are 60
degrees off each other as
shown at left.

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GEN00049-07

Operator for assembly

Mechanics Sharing of work

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

FIELD ASSEMBLY INSPECTION REPORT

Item Unit Sigma dozer + Multi ripper Semi-U + Giant ripper

• Sigma dozer + Multi ripper

• Semi-U dozer + Giant ripper

3. Preparation and check of protective gear, slings and tools

4. k Check during actual work

a Any change of the schedule caused by weather is not included.

1st day 2nd day

Trailer must arrive at field Unloading trailer

Installing tracks Installing ripper

Assembling full roller

Assembling blade Installing cab

Wrecker 25 ton x 2 units 10 ton x 1 unit

Number of workers 3 workers 3 workers

Total man-hours 24H 24H

A Overall length (mm) 5,250

A Overall length (mm) 1,870

A Overall length (mm) 1,790

A Overall length (mm) 3,528

Straight frame (R.H.)

A Overall length (mm) 3,528

(3) Ripper Ass’y

A: See the next page

A Overall length (mm) 1,269

• Ripper beam (Multi)

A Overall length (mm) 2,320

• Ripper beam (Giant)

A Overall length (mm) 1,401

Shoe width 610 560

A Overall length (mm) 1,755

No. Tool names Specifications Q’ty. Remarks

Part No. of bolt TTTTT-TTTTT

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

a : Bolt thread diameter (Nominal diameter)

Nominal size of thread Width across flats Tightening torque

Table 4.1 Hydraulic hose of face seal type

Type that uses

Outside diameter Tightening torque (Nm {kgm})

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}

Table 4.2 Hydraulic hose of taper seal type

Type that does

Outside diameter Tightening torque (Nm {kgm})

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}

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

• Use to prevent rubber gaskets, rubber cushions, and

• Use for plastic (except polyethylene, polypropylene,

Polyethylene • Features: Resistance to heat and chemicals.

Holtz 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.

Loctite Polyethylene • Features: Resistance to heat and chemicals.