Fai GD755-5R Sn10001-Up

GEN00113-00
Field Assembly Instruction
MOTOR GRADER GD755 -5R

SERIAL NUMBERS 10001 and up
CONTENTS
0000 Introduction (1/2) to (2/2) 1
0010 Preparation - Removal of parts on floor side (1/9) to (9/9) 3
0020 Preparation - Removal of exterior parts under floor (1/3) to (3/3) 12
0030 Preparation - Removal of floor mounting bolts 15
0040 Preparation - Removal of parts on cab side 16
0050 Installation of cab (1/5) to (5/5) 17
0060 Connections with chassis (1/5) to (5/5) 22
0070 Restoration of parts around floor (1/3) to (3/3) 27
0080 Check of each operation (1/2) to (2/2) 31

Assembly procedure NO.0000 Introduction (1/2)
GD755-5R Installation procedure of operator's cab

Introduction
1: Park the machine on a flat ground, lower the blade to the ground, and then start the work.
2: When selecting the parking place, consider the size and weight of the machine.
3: A space about 6 m high is necessary for installation of the cab.
4: Before starting the work, read this manual through.
* To remove the cab, perform the procedure in this manual in the reverse order.
Overall length: 9,580 mm

5×
6×
Overall width: 2,800 mm

Weight: 21,700 kg
Overall height: 3,515 mm
To top of steering post: 2,690 mm

(when post is at max. height)
Workflow Items in this manual

Installation 1: Removal of parts on floor side
of cab 2: Removal of exterior parts on floor side
3: Removal of floor mounting bolts
4: Removal of parts on cab side
3×
4×
5: Installation of cab
Cab height: 1,995 mm
6: Connections with chassis
7: Restoration of parts around floor
Removal 8: Check of each operation
of cab 9: End of work
Cab weight: 860 kg
Precautions Tools to be used Facilities to be used

Name Q'ty Name Q'ty
Others
1×
2×
1
Assembly procedure NO.0000 Introduction (2/2)
M16 eyebolts 04530-11628 are necessary

for slinging (4 pcs.)
Nominal No. 16
Tightening 54 to 88
torque {5.5 to 9.0}
5×
6×
If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of
the same size as the part that was replaced.
Screw
Nominal dia. a Target value Allowable range Nm {kgm}
3×
4×
6 3.9 {0.4} 3.44 to 4.41 {0.35 to 0.45}

8 8.8 ｛0.9｝ 7.85 to 9.8 {0.8 to 1.0}

Name Q'ty Name Q'ty
Others
1×
2×
2
Assembly procedure NO.0010 Preparation - Removal of parts on floor side (1/9)
1. Preparation on floor side

1) The machine is delivered under the following condition
5×
6×
2) Removal of floor mat

3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
3
3) Removal of operator's seat

(1) Remove the four bolts and remove the operator's seat and its base together.
Z
Z
5×
6×
01024-D1025 x4
Operator's seat
Weight: 35 kg
3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
4
4) Removal of accessory case
01225-70616 x4
23S-55-51970 x4
5×
6×
5) Removal of KOMTRAX (if equipped)

(1) Remove the top cover of the KOMTRAX.
01024-81020 x4
3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
5
(2) Remove the left side cover.
01024-81020 x2
5×
6×
01024-D1025 x2
(3) Disconnect the KOMTRAX connector (under the additional heater) as

shown below.
01024-81020 x2
3×
4×
Disconnect
connector CN-KM1
Note) The engine does not start

while this connector is
disconnected.

Name Q'ty Name Q'ty
Others
1×
2×
6
(4) Remove the three bracket bolts of the KOMTRAX base.
01024-D1225 x2
01024-D1020 x1
Z
5×
6×
Z
(5) Remove the additional heater vent and plate together as shown at right below,
and then remove the KOMTRAX unit, bracket, and wiring harness together.
3×
4×
01024-D1020 x2

Name Q'ty Name Q'ty
Others
1×
2×
7
6) Removal of electrical parts bracket
(1) Remove one bolt to set the electrical parts bracket free.
01024-81020
5×
6×
7) Move the heater unit inward
Remove bracket
mounting bolts
01024-81020　x3
Move additional heater and bracket together

toward inside of machine.
3×
4×
Note)
Take care not to interfere
with this piping when
lowering the cab.
Note)
Do not remove the heater
unit from the bracket.

Name Q'ty Name Q'ty
Others
1×
2×
8
8) Removal of lever link cover

5×
6×
01023-20812 x6
01023-20810 x7
01643-70823 x7
9) Removal of cab harness clip
01024-81020
04434-81020
3×
4×
45 deg.

Name Q'ty Name Q'ty
Others
1×
2×
9
10) Move the work equipment lever link and bracket together.
01024-81025 x6
5×
6×
Move the work equipment lever link backward, keeping it assembled with the base bracket.
3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
10
11) Tilt the steering post.
Tilt the post toward the rear of the machine.

5×
6×
Tilt pedal
12) Remove the right console box cover and put the right air conditioner
duct hose in the right console box.
3×
4×
01024-D0616
Cover

Name Q'ty Name Q'ty
Others
1×
2×
11
Preparation - Removal of exterior parts under floor
Assembly procedure NO.0020
(1/3)
2. Removal of exterior parts under floor

1) Removal of right lower cover (washer fluid tank)
(1) Disconnect the washer fluid tank harness and remove one harness clamp.
(2) Remove one washer fluid hose clamp.
(3) Remove the cover mounting bolts.
(4) Remove the cover and washer fluid tank.
(1) Remove the connector from the motor on the washer fluid tank and remove
one harness clamp.
Right side under

the floor
5×
6×
Front of machine
View from underside of machine

CN-L08
(FRONT UPPER WASHER MOTOR) CN-L09
(FRONT LOWER WASHER MOTOR)
CN-L10
(REAR WASHER MOTOR)
Harness clamp
01024-81020 x1
04434-51410 x1
3×
4×
(2) Remove the windshield washer hose clamp on the reverse of the cover at the rear of the
machine.
01024-81020 x1
04434-51410 x1

Name Q'ty Name Q'ty
Others
1×
2×
12
(2/3)
(3) Remove the six cover mounting bolts.

5×
6×
Cover outside bolt

01024-D1025 x4
There are two bolts
inside the cover.
Open
Bolts inside the cover

01024-D1025 x2
23B-54-31990 x2
Loosen
3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
13
(3/3)
(4) Remove the cover and washer fluid tank assembly together.
Stop the water from flowing out of the hose by using tapes, etc.
5×
6×
Appearance of removed assembly
2) Removal of left lower cover

Remove four bolts to remove the cover.
01024-D1030 x4
3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
14
Assembly procedure NO.0030 Preparation - Removal of floor mounting bolts
3. Removal of floor mounting bolts
These nuts are not used after

the cab is installed.
5×
6×
Remove these bolts in advance
23B-957
7520 110 110
(16) 440 60
23B-957 23B-957 01643 01011 23B-957

3×
4×
5520 5510 32780 82730 5570

(8) (8) (8) (8) (4)
TIGHTEN TORQUE
883 - 1001 Nm
(90 - 102 kgm)
Section of structure of mounting portion

Name Q'ty Name Q'ty
Others
1×
2×
15
Assembly procedure NO.0040 Preparation - Removal of parts on cab side
4. Preparation on cab side

1) Removal of cover and duct at rear in cab
(1) Remove the cover at the inside rear of the cab and
the cushion material on the reverse.
(2) Remove the fresh air intake duct of the air
conditioner.
(1) Remove the four bolts to remove the cover and the cushion on the reverse.
5×
6×
01024-D0612x3
01024-D0816
(2) Remove the two bolts to remove the fresh air intake duct of the air conditioner.
3×
4×
01024-81016

Name Q'ty Name Q'ty
Others
1×
2×
16
Assembly procedure NO.0050 Installation of cab (1/5)
5. Mounting cab
1) Slinging cab
(1) Open the cab door and hitch it to the door open lock. Remove four caps on the
(2) Install the sling to the four seats of the cab ceiling. ceiling and install M16
* If the revolving warning lamp may be eyebolts.
damaged when the cab is slung, remove it.
5×
6×
Cab weight: 860 kg
View from top of the cab

Note) Restore the caps after
installing the cab.
Install M16 eyebolts 04530-11628

instead of the caps.
<<Caution for slinging cab>>
Nominal No. 16
Tightening 54 to 88
3×
4×
torque {5.5 to 9.0}
Sling the cab with its rear part lower

than its front part.
You can lower it smoothly to the floor,
preventing its rear part from interfering
with other parts.

Name Q'ty Name Q'ty
Others
1×
2×
17
2) Move the cab to above the floor, and then lower it.
<<Caution 1>>After lowing cab to height of right console

(1) Take care that the door unlock lever on the right side of the cab does not interfere with
the right console box.
Door unlock lever

5×
6×
<<Caution 2>>After lowing cab to about 300 mm above floor

(1) Take care that the air conditioner duct at the rear right of the operator's seat does not interfere
with
(2) When the mount plate at the rear of the cab lowers below the air conditioner duct, move the
cab forward
Floor seen from the rear right Inside of the cab
Air conditioner duct seen from the left
3×
4×
Move forward
CAB mount plate
Air conditioner duct Air conditioner duct

23B-809-5430 23B-809-5430
CAB
Name Q'ty Name Q'ty
Others
1×
2×
18
[Precautions for removing cab according to this manual]

(1) When lifting up the cab, take care that it does not interfere with the air conditioner
duct at the rear right of the machine.
Section of cab seen from right of machine
<<Caution>>
If the cab is lifted up as it is, it interferes with Right console box
other parts. To prevent this, lift up the cab while
moving it backward.
Air conditioner duct
5×
6×
CAB
<<Caution 3>>After lowing cab to about 200mm above floor

(1) Take care not to interfere with the additional heater hot water hose
(2) Raise the washer hose, connector, and harness on the left side to above the
fold-back portion of the cab to protect them from being crushed.
Raise windshield washer hose, harness, and connector to above fold-back portion
of cab.
* Take care not to interfere with the additional heater hot water hose.
3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
19
3) Fixing cab
(1) Place the cab on the floor and fix it by using the bolts shown in the figure.
<<Caution>>When tightening bolt A, check that the mount rubber and the spacer are
aligned with each other and the spacer is inserted to the cab floor surface.
(For preventing that the spacer squeezes the mount rubber)
Bolt B: M10, L30, 4 pcs.

Bolt C: M10, L45, 2 pcs.
6×
5×
Bolt A: M27, 4 pcs.

Bolt D: M10, L40, 4 pcs.
From underside of machine

Front of machine
* Caution (Take care not to squeeze mount rubber)
When tightening each bolt, check that the spacer and
Bolt A: M27, 4 pcs. mount rubber are aligned with each other and the spacer is
Insert them from inserted to the cab floor surface.
underside of machine
Ｐ
3×
4×
23B-957
23B-957
7520
752A 110 110
(16 440 60
01011 Cab floor

23B-957 23B-957 01643 23B-957
82730 bottom
5520 5510 32780 5570
(8) (8) (8) (8) (4)
TIGHTEN TORQUE Rubber
883 - 1001 Nm
(90 - 102 kgm) Spacer
Ｐ
Name Q'ty Name Q'ty
Others
1×
2×
20
Bolt B: M10, L30, 4 pcs Bolt C: M10, L45, 2 pcs

SHIM
t1
5×
6×
Insert them from underside of

Insert them from inside of cab
machine
Bolt D: M10, L40, 4 pcs.
Insert them from inside of cab
Tighten floor and cab together with plate of t12 between them.
3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
21
Assembly procedure NO.0060 Connections with chassis (1/5)
6. Connections with chassis

1) Connection of windshield washer hoses on floor and hoses of cab side
Connectthe three windshield washer hoses of the cab side to the windshield
Connect
washer hoses at the rear left in the floor.
Connect the hoses of the same marking color to each other.
(Hose marking color) Washer hoses on floor side
Orange: Front lower
Gray: Front
White: Rear
5×
6×
2) Connection of fresh air intake box

Connect the fresh air intake box.
Bolt: 01024-81016 x 2
3×
4×
Front of
machine

Name Q'ty Name Q'ty
Others
1×
2×
22
3) Installation of rear cover in cab

Install the cab rear cover and cushion.
5×
6×
01024-D0816 x1 01024-D0612 x3
4) Connection of parts of electrical components

Enlarged view of portion under additional heater at the left of floor
Connect the harness between the chassis and cab.

3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
23
(Continued from connection of chassis and cab harness)

6×
5×
Connect the cab air conditioner harness connector to the floor harness connector.
(At the rear of floor: Two connectors)
Connector: CN-AC4 Connector: CN-AC3
View from above

3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
24
5) Connection of air conditioner duct hoses for cab

(1) Connect the duct hose on the back of the cab.
(2) Connect the air conditioner hose on the right side of the floor to the cab duct.
(3) Install the hose to the air conditioner duct on the left side of the floor and connect it
to the cab duct.
(1) Connect the two duct hoses coming down from
the back of the cab.
Band: 07281-00709 x 2
5×
6×
Right side of floor Left side of floor
(3) Connect hose 23B-809-8622 to the air conditioner

3×
4×
duct on the left side of the floor and to the cab left duct.
Band: 07281-00489 x 2
(2) Connect the hose coming from the right

box to the cab right duct.
Band: 07281-00489 x 1

Name Q'ty Name Q'ty
Others
1×
2×
25
6) Connection of windshield washer hoses under floor

Right side under the floor Connect the windshield washer hoes on the cab side and chassis
side to the check valve at the circled part. Connect the hoses of
the same marking color to each other. (See the figure below)
<<When removing the cab according to this manual>>
Stop water from flowing out of hose on the washer fluid tank side
with tapes, etc.
Front of machine
6×
5×
Gray
CN-L08 Orange
(FRONT UPPER WASHER MOTOR) CN-L09
(FRONT LOWER WASHER
MOTOR)
(Hose marking color)

Orange: Front lower White
Gray: Front CN-L10
(REAR WASHER MOTOR)
White: Rear
View from the inside of the cover under

the floor View from rear right of
the floor
Drain hose 30 deg.
3×
4×
View Z
Windshield washer harnesses
Windshield washer hoses

Name Q'ty Name Q'ty
Others
1×
2×
26
Assembly procedure NO.0070 Restoration of parts around floor (1/4)
7. Restoration of parts around floor

1) Restore the floor in the reverse order to step 1.
* When restoring, see 2), 3), and 4). (Following pages)
* See the precautions for restoration (page 29).
2) Restoration of work equipment lever link assembly

Restore the work equipment lever link according to the following procedure.
(1) Adjust the position of the link bracket assembly so that the clearance
between the lever and rod is even at the connecting portion of the rod
and lever and check that collar A rotates smoothly, and then fix the link
bracket assembly by tightening bolts 01024-81025.
5×
6×
01024-81025 x 6
(total on right
and left sides)
Examples of installation of link lever Connecting portion of rod and lever
○
3×
4×
View from above lever link Clearance is even
Link bracket B is installed diagonally
×
Clearance is uneven

Name Q'ty Name Q'ty
Others
1×
2×
27
(2) Move all control levers and check that you

can push and pull them smoothly and they
always return to the N position when they are
released slowly at the stroke end.
If the levers do not return smoothly, loosen
bolts 01024-81025, adjust the position of the
link bracket assembly, and tighten the bolts
again. Check that you can move control
levers smoothly
3) Cab harness and windshield washer hose clamp at front left of floor
(1) Clamp the cab harness to the link bracket. 01024-81020
5×
6×
(2) Fix the washer hose to the harness by using cable ties (two places) 04434-51010
Windshield
washer
hoses
BAND 30 View from above
08034-20519
45 deg.
Cab harness 30
4) Connection of KOMTRAX harness (on cab side)

3×
4×
View from rear
Connect the connector (cab side) of the

KOMTRAX antenna harness to the
KOMTRAX unit.

Name Q'ty Name Q'ty
Others
1×
2×
28
<<Precautions for restoration work 1>>

Check that the additional heater duct vent is aligned with the hole of the
outside cover (KOMTRAX bracket) for the heater vent.
If they are misaligned, the heater vent grille may interfere with the
additional heater duct and may not open or close.
Drawing of removal of
5×
6×
outside cover
Outside cover Additional heater duct If the grille interferes,

Heater vent Vent loosen the bolts and
adjust the installed
Grille position of the heater.
3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
29
<<Precautions for restoration work 2>>

(1) When installing the work equipment control lever cover at the front left, open
the front lower window of the cab so that the windshield washer hoses are not caught.
Front left of floor viewed from
above diagonally
6×
5×
After installation of cover Open window when working
(2) Install the work equipment control lever cover so that the clearance between
it and the work equipment control rod is even.
Left Right
Adjust position Adjust position
Adjust the cover position so that the clearance between

it and rod is even
3×
4×

Name Q'ty Name Q'ty
Others
1×
2×
30
Assembly procedure NO.0080 Check of each operation (1/2)
8. Check of each operation

1) Check that each operation is free from trouble.
Cab ceiling room lamp Lamp switch positions are OFF, OFF, and ON
(Center is OFF)
5×
6×
Radio switch
Upper left in cab Upper right in
Beacon lamp switch
Rear windshield wiper switch
Front lower windshield wiper switch

3×
4×
Air conditioner switch
*: When checking the windshield wiper-related parts, check that windshield washer
fluid spouts out, too.

Name Q'ty Name Q'ty
Others
1×
2×
31
5× Assembly procedure NO.0080 Check of each operation (2/2)
6×
(1) Starting switch (10) Hazard lamp switch

(2) Starting aid switch (13) Creep mode switch
(3) Head lamp switch (14) Differential lock switch (if equipped)
(4) Front and rear working lamp switch (15) Machine monitor mode selector switch 2
(5) Blade accumulator (16) Machine monitor mode selector switch 1
(6) Front working lamp switch (17) Dimmer switch
(7) Cigarette lighter (18) Turn signal lever
(8) Lift arm switch (19) Horn button
(9) Front upper wiper switch (21) Car heater switch
3×
4×
*: When checking the windshield wiper-related parts, check that windshield washer
fluid spouts out, too.
2) Move the work equipment control lever and check that you can push and
pull it smoothly and it always returns to the N position when it is released
slowly at the stroke end. If the lever does not return smoothly,
perform the adjustment on page 28 again.
9. End of work
Name Q'ty Name Q'ty
Others
1×
2×
32
GD755-5R MOTOR GRADER
Form No. GEN00113-00
©2011 KOMATSU
All Rights Reserved
Printed In Japan 09-11

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GEN00113-00

Field Assembly Instruction

MOTOR GRADER GD755 -5R

0000 Introduction (1/2) to (2/2) 1

0010 Preparation - Removal of parts on floor side (1/9) to (9/9) 3

0020 Preparation - Removal of exterior parts under floor (1/3) to (3/3) 12

0030 Preparation - Removal of floor mounting bolts 15

0040 Preparation - Removal of parts on cab side 16

0050 Installation of cab (1/5) to (5/5) 17

0060 Connections with chassis (1/5) to (5/5) 22

0070 Restoration of parts around floor (1/3) to (3/3) 27

0080 Check of each operation (1/2) to (2/2) 31

GD755-5R Installation procedure of operator's cab

Overall length: 9,580 mm

Overall width: 2,800 mm

To top of steering post: 2,690 mm

Workflow Items in this manual

Precautions Tools to be used Facilities to be used

M16 eyebolts 04530-11628 are necessary

6 3.9 {0.4} 3.44 to 4.41 {0.35 to 0.45}

Precautions Tools to be used Facilities to be used

1. Preparation on floor side

2) Removal of floor mat

Precautions Tools to be used Facilities to be used

3) Removal of operator's seat

Precautions Tools to be used Facilities to be used

4) Removal of accessory case

5) Removal of KOMTRAX (if equipped)

Precautions Tools to be used Facilities to be used

(2) Remove the left side cover.

(3) Disconnect the KOMTRAX connector (under the additional heater) as

Note) The engine does not start

Precautions Tools to be used Facilities to be used

(4) Remove the three bracket bolts of the KOMTRAX base.

Precautions Tools to be used Facilities to be used

6) Removal of electrical parts bracket

7) Move the heater unit inward

Move additional heater and bracket together

Precautions Tools to be used Facilities to be used

8) Removal of lever link cover

9) Removal of cab harness clip

Precautions Tools to be used Facilities to be used

Precautions Tools to be used Facilities to be used

11) Tilt the steering post.

Tilt the post toward the rear of the machine.

Precautions Tools to be used Facilities to be used

2. Removal of exterior parts under floor

Right side under

View from underside of machine

Precautions Tools to be used Facilities to be used

(3) Remove the six cover mounting bolts.

Cover outside bolt

Bolts inside the cover

Precautions Tools to be used Facilities to be used

Appearance of removed assembly

2) Removal of left lower cover

Precautions Tools to be used Facilities to be used

3. Removal of floor mounting bolts

These nuts are not used after

Remove these bolts in advance

23B-957 23B-957 01643 01011 23B-957

5520 5510 32780 82730 5570

Section of structure of mounting portion