” ot: : -. =” GEN00031-00 ~~” FIELD ASSEMBLY _ INSTRUCTION _ DISSA. 5 ~ === BULLDOZER | Ore COLD WEATHER SPEDFICATIN “MACHINE MODEL = S “SERIAL NUNIBER DISsAS 2S 66278 andj up. - KomaYsuPreface You are required to execute full inspection and maintenance before starting the engine and assembling the work equipment. Since the work is often carried out in dangerous places and positions by a team, hold a safety meeting in advance and appoint a crane director, work leader, etc. so that the all member can work safely. When the work is carried out in an overseas country, difference in language, customs, etc. lowers safety. Accordingly, the field liaison man and work supervisor must examine the above point and take necessary measures. Instruction system Work feader ; Director Work supervisor {Crane director and deputy director {Operator for assembly Liaison man L.-———— L____ "Mechanics __|--— Sharing of work. Interpreter L We hope that the all members will cooperate with each other and assemble the work equip- ment quickly in the field, observing the safety, quality, and delivery time.CONTENTS PRECAUTIONS FOR FIELD ASSEMBLY TIGHTENING TORQUE... A. Assembly procedure A-1. Installation of operator's cab A-2. Installation of additional cab heater (Extremely cold weather specification). M. Check and maintenance procedures after completion of assembly... M1, Testing and adjusting operator's cab.PRECAUTIONS FOR FIELD ASSEMBLY 1. Selection of workplace 1) When selecting a workplace, consider the following items so that you can load and unload the machine, + Width * Hardness + Flatness + Access road, place for turn 2) Donot workin a place where dust, rainwater, etc. may enter the hydraulic circuit during assembling work. 3) Do not assemble while a strong wind is blowing or itis raining. 2. Preparation and check of slings and tools 1) Check each sling and tool thoroughly. When using wood blocks, etc., check that their inside is not rotten or broken. 3. ACheck of actual work 41) Apply the parking brakes of the trailer and crane truck securely and put chocks under their wheels. 2) Before starting the work lower the temperature and pressure of the engine oil, hydraulic oil, cooling wa- ter, etc. '3) When starting the engine, make an arranged sign such as sounding of the hom and check that the work equipment control lever and travel lever are in neutral and the fuel control dial (or fuel contro! lever) is at the low idling position. 4) When using the crane, balance the load. 5) Allow only the persons concerned into the workplace. 4, Before starting the work, read this manual thoroughly and keep the precautions in your mind. ‘The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: © = (1)) 5. The supervisor shall write down the precautions for each work process and explain them to the workers. 6. Hold a meeting every morning to check today's work plan and safe work.TIGHTENING TORQUE Remove the plugging parts (flanges, heads, caps, and O-rings) of the work equipment piping and undercar- ‘iage piping, plugs of the greasing piping, oylind4175r fixing jigs, and plugs of the tap holes of the oose-Supply items which were used for transportation and keep them carefully so that they can be used again for the next transportation. Tighten the bolts to the torque shown in the following table, unless otherwise specified. 1. Tightening torque of bolts When tightening the bolts with an impact wrench/spanner, apply Table 1. Tighten the bolts according to Table 1 asa rule. When this rule is applied, the tightening torque is not shown inthe drawing. Table 1 Unit: Nim {kgm} Mataral ‘S430, SCM435H or equivalent Nominal size of thread (mm) Range Target a 38-147 2 {0.9- 1.5} 0.2) 5 147-34 25 (15-38) 25) m7 Ey 0 5-75) 65) 5 A123 © {5.5 - 125) 8 7 84-196 137 {8.5- 20) {14} fa 147 — 309 230 (15-31.5) 23.5) a 201-427, 318 (205-43.5) {82} 319 — 608 460 20 (32.5 - 62) 147} 5 471 — 629 650 (48-845) (65.5) AA 588 — 1030 #10 {60 - 105} (82.5) 5 883-1470 1780 {90 - 150} (120) aa 1130-1810 1520 (115-195) (155), a 1470-2450 1960 {150 ~ 250} (200) 5 18603040 2480 {190-310} 1250) 7 2260 — 3630 2840 (230-370) {300}When tightening the bolts with a torque wrench, apply Table 2. Apply Table 2 when the proper tighter torque range is particularly narrow. Table 2 Unit: Nm {kgm} eee S43C, SCM435H or equivalent ‘Nominal size of thread (mm) 6 18-147 (12-1.6) 8 10 98 125 (10-125) 157 = 196 (16-20) 215 = 300 (25-315) 343 —427 (3543.5) 490 608 (50-62) 962 629 (675-845) 241080 {84 105) 1180-1470 {120— 150) 1520-1810 (155-195) 1960-2450 {200-250} 2450 = 6040 {250-310}, 2890-3690 (295-370), 12 8/8) 8/8] 8) e187 8A. ASSEMBLY PROCEDURE‘Assembly procedure A Installation of operator's cab (1/7) 1. Installation of open lock striker 1) Remove bolts (1) and (2) installed to the door tempo- rarily. (2 pieces on each side) 2) Install open lock striker mounting supports (4) and (5) to (1) in Fig. 4 with the bolts and washers removed in A) above. (2 pieces on each side) [Strikers (6), (7), and (8) are installed to the support when delivered] After mounting the operator's cab on the chassis, check ‘and adjust engagement of the open lock latch and striker and deflection of the stopper rubber. 2. Removal of monitor front cover Remove caver (14X-54-18650) from the front part of the monitor. {This cover is installed with 2 pieces of 01439-00814,] Fig. 1 Installation of open lock striker We. PartNo. DOv-54-14360 (07024-81225 14x 11-1812 T7A‘911-2510- Taxco11-1927 01649-39002 (01580-11008 co 10 | »| =| =| »19| 2 Fig. 2 Removal of monitor front cover Precautions Necessary tools Necessary equipment Name oy Name ay Other remarks‘Assembly procedure al A-t Installation of operator's cab (2/7) 3. Installation of seal to air conditioner box 1) Fit seal (9) to the guide plate of the air conditioner box. 2) Apply grease (NLGi No. 2) to the outside of the seal (sealing face against the operators cab). + Before mounting the cab onto the chassis, ap- ply grease so that the cab will sip well on the seal and the seal will not be moved or de- formed. You may use silicone seal, etc. instead of grease. 4. Installation of seal to floor frame mating face of oper- ators cab 41) Sling the operator's cab to stick the seal to its floor frame mating faces. (5 operator's cab assembly: 300 kg 2) Remove din, oil, and grease from the seal sticking {face of the operator's cab. 3) Remove the release paper from seal (10) and then stick the seal, referring to Fig. 5 on the next page. 4 Since the seal is longer than the necessary length, cut it property when sticking. + See the notes in Fig. 5. Fig. 4 Installation of seal to mating face of ‘operator's cab No. [Pawo Oy @ | vaxorraset_[ 1 To | vex-orrsott | 5 | Precautions Necessary tools Necessary equipment Namie: ay Name oy Other remarks‘Assembly procedure Al Installation of operator's cab (3/7) Fig. 5 How to stick seals (View from bottom of operator's cab)‘Assembly procedure Al Installation of operator's cab (4/7) 5. Installation of operator's cab 1) Slowly lower the operator's cab assembly, to which the seal was stuck in 4) above, onto the floor frame. + Lower the operator's cab carefully since the re- action force of the seal sponge is large. + Take care not to move or damage the seal. * Lower the operator's cab carefully since the Clearance between the operators cab and monitor cover is narrow. (Fig. 6) 2 Tighten bolts and washers (11), (12) and (13) tem- porarily. + Note that the length of the 2 bolts at the front of the operator's cab is different from that of the other bolts. (See Fig. 7 Mounting drawing) 3) Using bolts and washers (16), (15-1), and (16), in- ‘tall the operator's cab mounting L-bracket (14) to the operator's cab and air conditioner box tempo- rarily. (Fig. 8) (Tighten the bolts tightly) 4) ‘Check that there is not clearance in the joint of the air conditioner box seal and the air conditioner box, operator's cab, and floor frame. (Fig. 9) 5) Check that there is not clearance in the joint of the operator's cab and floor frame. Check all around the joint from inside of the operator's cab. (Fig. 10) 6) As a result of checks 4) and 5) above, if there is clearance, reinstall the operator's cab. Ifthe clear- ance is narrow, however, seal it with silicone seal, etc. (Use seal commercially available) 7 Permanently tighten the bolts which were tight- ened temporarily in 2) above 8) Permanently tighten the bolts which were tight- ‘ened temporarily in 3) above . 9) Referring to Fig. 7, connect the operator's cab pow- ‘er wiring harness out of the center of the operator's cab. Fig. 9 Check of sealing performance around ‘conditioner box Fig. 10 Check of clearance between ‘operator's cab and floor frame. Part Ne. 7 Hoos ae 12 ‘1010-51265 13 T2454 26540 14 TaXOTT-5671 15 1010-81225 15 ‘07006-81225 16. or64s-s1282At Installation of operator's cab (5/7) + After connecting the connector, fitthe grommet on the wiring harness side securely. 10Assembly procedure A-t Installation of operator's cab (6/7) 6. Installation of interior parts 41) Using bolts (19), install covers (17) and (18). (Fig 11) 2) Using botts (22), install foot rests (20) and (21). (Fig. 11) 3) Install pedal cap (23) to the foot rest. (Fig. 11) 4) Using rivets (27), install gamishes (24), (25), and (28) around the floor. (Fig. 12) 5) Install knab (29) to the open lock release fever. Insert the knob in the direction shown in the figure untitit is locked. (Fig. 13) Fig, 12 Installation of gamishes Wo. | Panne. | Oy 17_| yaxon-25a7 [1 1e_|_yax-o77-2561 [1 18 | o1a5-41016 | 6 20_| Vexorts7i1 [1 2i_[axoirsrar 4 "2 z2_|_01a39.01205 [4 Fig. 13. Installation of open lock release lever 23_| 203-49.56450_| 2 2a | _vaxsivsert_| 1 25 | yax-ori-seat_| 1 26_[axonvszs1 [4 27_|30v-54-16690_| 72 29_| 14x911-1640_| 2 Precautions Necessary too Necessary ecuipment oy Name ay [Other remarks W[Assembly procedure Al Installation of operator's cab (7/7) 6) Install cigarette lighter (31) to ashtray mounting box (20). (Fig. 14) 7) Install the ashtray mounting box to which the cigarette lighter was installed in 6) above. (Fig. 14) (a) Connect the power supply and ground cable of the cigarette lighter. (b) Using bolts (32), install the ashtray mounting box. At this time, connect the ground cable of the cigarette lighter together with the mounting box as shown in the figure. 8) Install ashtray (33). (Simply insert it) (Fig. 14) Connect ground cable with [this mounting bot. Window side t == OH ron Connecting point of ground cable of clgaretelightor Fig. 14 Installation of ashtray and cigarette lighter 49} Install caps (34) to the working holes for the operator's cab mounting bolts on the underside of the door. (6 places) (Fig. 15) 10)Install floor mat (35). (Fig. 16) Pattie [ OF Taxonr-s161 (08913-02400 (01435-00816 — 206-54-13420 Fig. 15 Installation of cab Fig. 16 Installation of floor mat 14x-54-16150 T7ASH- 12412 12——— Installation of additional cab heater A-2 (Extremely cold weather specification) (1/7) 1. Replacement of cover Replace the existing cover with cover (16). (Fig. 1) Fig. 2. Removal of heater hose Remove the heater hose. (Fig. 2) Do not reuse the heater hose and clamp. ({t is not necessary.) No. [PartNo | Oy 16 | 1aen-1640_| 1‘Assembly procedure Az Installation of additional cab heater (Extremely cold weather specification) (2/7). 3. Installation of caps to heater Insert caps (23) (2 pieces) in heater (25). (Fig. 3) 4. Installation of heater mounting bracket (lower) 1) Remove caps, bolts, and washers (2 pieces each). (Fig. 4) 2) Install bracket (17) with bolts (4). (Fig. 5) We. ‘1024-81060 7 TAOTI-1910 23 205-977-7700. 25 Panne, | OW 2 7 2 7 206-970-2130 Precautions Necessary tools Necessary equipment Name ay Name oy [Other remarks 14SL Tene |e i tesessierver | 02. 1 [osee-bervar | er | oseiz-290e8 | er z_|_ozors4zo0 | _€ Ro | onwea ON (9-614) “Anueueuued (€) siioq pue (24) durero ueIUBLL (» ‘expo Yeo ya peubye aie seams eYs ¥o8UD (9 614) “AnuBu (€) syoq pue (21) dwejo ueryBi, (Z (9614) “(gt) Ueddn) yoxoe1q Bujunow soveey 0} (12) pue (oz) Sqn |TeISU] (1 (deddn) yooe1q Bugunow se1e9y 01 qn} 1e}Ea4 JO UONEHEISUI “S (ze) (Uoneoyoeds JeyyeaM pio AjeWe.1x3) av deyeoy qed JBUO!IPpe JO UO}}e//E}SU] }___| ainpecaid Aquossy |Asonew press Installation of additional cab heater A-2 (Extremely cold weather specification) (4/7) 6. Installation of heater mounting bracket (upper) sub-assembly 1) Place heater mounting bracket (upper) sub-assembly on bracket (17) (See Fig. 5) temporarily. (Fig. 8) Front <— SS (2 pieces) Ashtray’ Fig. 8 View from above 2) Connect the lower side of tubes (20) and (21) and fix them with clamps (12). (Fig. 9) —> Left Wo [Panne [ory 3 | o1oasstod9 | 12 @_[iv-0s-11769 [6 12 | 190-62-71350_| 3 37_[Wao1-1910 [+ ve 17911-3360 [1 Fig. 9 View from front 0_[ 17A-911-8301 | 4 a1_[ waoroat [4 "30__| o948s-s0450_[ 2 98) Tighten bolts (3) permanently. (Fig. 8)‘Assembly procedure Installation of additional cab heater A-2 (Extremely cold weather specification) (5/7) 7. Installation of heater While connecting the heater tube, fix the heater. (Fig. 10) 8. Installation of heater switch cover (Fig. 11) 1) Install switch (28) to heater switch cover (19). 2) Fix the switch connector to the cover. 38) Connect the switch connector to the connector (CN-AHS) of the floor frame wiring hamess. 4) Fix the heater switch cover with bolts (3).. ‘Connector (CN-SP1) Connector (CN-AH) @ ‘Connector (CN-AHS) (2 pieces) @ (1 piece each) Fig. 11 9. Connection and fixing of wiring hamesses (Fig. 11) 1) Fix the floor wiring harness with clip (7) and bolts (3). No. Part No, 2) Connect the heater connector to the connector (CN-AH) of 4 01024-81020 the floor frame wiring hamess. (04434-51412 3 ny-06-11760) 93) Fix the heater connector and heater switch wiring hamess to eee the floor frame wiring hamess with band (9). EL 19 | 17aon-3360 Jal Tale! ‘2a | 20v-977°2500 7cesses paces Installation of additional cab heater A-2 (Extremely cold weather specification) (6/7): 10.Assembly of pre-heater switch box (Fig. 12) 1) Install switch panel (14), spring (26), and grommet (10) to bracket (15). 2) Take out the switch panel wiring hamess through the grommet and fix the connector to the clip. 8) Stick plate (27) as shown in the figure. No._[_ PartNo. 1 | 07029-10406. 2 [01034-80616 5_| 01370-00406. 6 | 01640-20408. 70__| 08037-09614 11] 09460-00000. 14 | 1706-21210 15 [1754-17310 26_| 208-64-12210 RAAB RRRARR ‘27 | 20¥-00-12690 18‘Assembly procedure A-2 Installation of additional cab heater (Extremely cold weather specification) (7/7) 11.Installation of pre-heater switch box Fix the switch box with bolts (2). (Fig. 12) 13.Inspection 12.Connection of pre-heater wiring hamess Connect the switch panel connector to the floor wiring hamess connector (CN-SP1). (Fig. 11) 1) Check that water does not leak through the hot water hose joints. 2) Operate heater switch (28) (Fig. 11) and check that the heater fan rotates at low speed and high speed. 8) Retersing to the operation & maintenance manual, check the operation of pre-heater switch panel (14) (Fig. 12). Precautions Necessary tools Necessary equipment Name ay Name ay [Other remarks 19M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY a1‘Assembly procedure M-1 Testing and adjusting operator’s cab (1/6) | 1. Testing painting (1) Check that the paint of the removed and installed bolt heads is not flaked off. (2) Check that the painted surfaces are not shifted at the sealed part between the floor frame and tank and the joints of the covers and chassis. % If the appearance is bad, apply the paint again. 2. Pressurizing test (1)Measure the internal pressure of the cab. Criterion: Measured value = 5 mmaq 4 Testing condition: Run engine at full throttle. % Blower speed: High + Fresh/Recirculation lever: Fresh air IN position * If the measured value is lower than the standard val- ue, check the plugs of the control box, etc. for omis- sion. (2) A simple method of measuring the internal pressure is as follows. a) Prepare a transparent vinyl hose. (Outside diameter: 10 mm, Length: 3,000 mm. b) Pour water in the hose up to about half. ©) Remove the lock lever of the slide glass on the side of the cab and put either end of the vinyl hose in the cab and secure it to the top of the back seat with a tape. 4) Seal the hole of the lock lever with a tape. ) Set the water level in the vinyl hose out of the cab to that in the cab. ) Run the engine at full throttle and measure the wa- ter level difference. Precautions Necessary tools Necessary equipment Name Oy Name ay [Other remarks | 22‘Assembly procedure M-1 Testing and adjusting operator’s cab (2/6) 3. Shower test (1) Close all the openings of the cab. (2) Supply water at the rate of 5 gal/min (about 19 liters/min} through a hose. (8) Pour water around the hatched parts for 10 minutes in the following figure. Do not apply pressure at this time. (4) Pour water to the sealed surface horizontally as shown in section A-A. (6) In particular, check around the dashboard carefully. % If water leaks, caulk the leaking part and test it again. AA (Seal) Precautions Necessary tools Necessary equipment Name oy Name ay ‘Ciher remarks 23‘Assembly procedure M-1 Testing and adjusting operator's cab (3/6) 4. Testing door lock Close the door and check the relationship between the operator's cab and door. if there is any fault, repair it. 4-1. Check of condition (1) Check the installed height of the damper rubber. (Check both sides, 4 pieces on each.) Stick an adhesive tape to the contact face of the damper rubber and open and close the door 2 - 8 times. Then, check the contact face of the adhesive tape against the operator's cab. Normal: When the door is closed, the damper rubber comes in contact lightly. ‘Abnormal: When the door is closed, the damper rubber does not come in contact or comes in contact so strongly that the adhesive tape is removed. ‘Mounting screw (01023-20616) ‘Adhesive tape} ‘Shim (14X-911-1764 Fig. 3 (2) Check the relationship between the door latch and striker (on both sides). Close the door and check the engaging condition of the fatch and striker. striker | Latch this side. Center of striker [Center or atch 7, Meredith each ober Fig. 4 24‘Assembly procedure M-1 Testing and adjusting operator’s cab (4/6) 4-2, Adjusting (1) Adjusting height of damper rubber Increase or decrease of the shims under the damper rubber to adjust the height of the damper rubber property Damper rubber ‘Shim 66 12 Door Shape of shim (14X-811-1761) Fig. 5 (2) Adjusting latch and striker ) Tighten the mounting bolt of the striker temporarily and open and close the door 2-3 times to align the latch and striker with each other. b) Check the engaging condition of the latch and striker. ‘¢) Tighten the mounting bolt of the striker permanently 1d) Open and close the door and check that itis locked and unlocked smoothly. If the door is not locked and unlocked smoothly (If the knob is heavy), perform the adjustment pro- ‘cedure from the first. + Operating ettort of knob: 68.6 = 19.6 N {7 #2 kg} (@) Apply grease NLGL (MIL-G-10924 C) to the latch. Precautions Necessary tools Necessary equipment T the latch isnot greased, the knob becomes heavy. Name ay Name ay Accordingly, apply grease sufficiently. [Other remans 25‘Assembly procedure M-1 Testing and adjusting operator’s cab (5/6) 5. Testing open lock Lock the door open and check the relationship between the operator's cab and door. If there is any fault, repair it. 5-1. Check of condition (1) Check the relationship between the open lock latch and striker. (Both sides). (Open the door and check the engaging condition of the latch and striker. (Check that latch pow is nok over bent part of siiker Unlock ovo, {creek tom near Its not tis OK. Check that ach body does ok intecoro wit tik, Hit does not, itis OK (2) Check the installed height of the stopper rubber. (Check both sides, 1 piece on each.) 8) Lock the door open and move itn the forward and reverse directions to see ifithas any Play. (Fig. 6) b) Check that the operating effort of the unlock lever is not heavy. (Fig. 6) Precautions Necessary tools Necessary equipment Name ay Name ay [Other remarks 26‘Assembly procedure | M-1 Testing and adjusting operator’s cab (6/6) 52 Adjustment (1) Adjustment of latch and striker Loosen the strixer mounting nut and adjust the striker so that it will not interfere with the latch and will not be over the bent part, and then tighten the nut. If you cannot prevent interference by adjusting the striker, loosen the latch bolt and adjust the latch. Press door. fit moves until clearance is eliminated, project stopper rubber in Fig. 7 pressing direction. (2) Adjustment of stopper rubber height a) Loosen the stopper rubber fixing nut. b) If there is play, project the stopper rubber until the play is eliminated. Ifthe door is not locked easily or the unlock lever is heavy, retum the stopper rubber within the range where the door does not have play. ©) Tighten the fixing nut. Precautions: Necessary tools Necessary equipment Name ay Name ay [Other remarks 27