D475A-5GEN00051 FA-03

BULLDOZER

Field Assembly InstructionGEN00051-03

D475A -5E0

D475ASD-5E0

SERIAL NUMBERS D475A- 30001D475ASD-30001 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.

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.

(Instruction system)

Work leader

Work supervisor Crane directorDirector

anddeputy director

Liaison manOperator for assembly

InterpreterMechanics Sharing of work

CONTENTS

SPECIFICATIONS........................................................................................................................... 1PRECAUTIONS FOR FIELD ASSEMBLY....................................................................................... 3DISPOSAL OF REMOVED PARTS................................................................................................. 4ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE................................. 5KIT LAYOUT DIAGRAM .................................................................................................................. 6STYLE FOR TRANSPORTATION................................................................................................... 7TOOLS LIST FOR FIELD ASSEMBLY............................................................................................ 13SKETCH OF TOOLS ....................................................................................................................... 16TIGHTENING TORQUE .................................................................................................................. 25COATING MATERIALS ................................................................................................................... 29

A. ASSEMBLY PROCEDURE ......................................................................................................... 31A- 1. Setting of track shoe ........................................................................................................... 32A- 2. Setting of the machine ........................................................................................................ 33A- 3. Installation of blade lift hydraulic cylinder ........................................................................... 36A- 4. Installation of undercarriage ............................................................................................... 42A- 5. Replacement of return filter

(Replacement of standard filter ➞ special flushing parts)................................................... 58A- 6. Adding oil to pivot chamber ................................................................................................ 60A- 7. Check of oil and coolant levels ........................................................................................... 61A- 8. Installation of ripper ............................................................................................................ 63A- 9. Installation of trunnion......................................................................................................... 68A-10. Installation of track shoe..................................................................................................... 69A-11. Check track tension ............................................................................................................ 72A-12. Assembly of blade .............................................................................................................. 74A-13. Installation of blade............................................................................................................. 94A-14. Installation of operator's cab............................................................................................... 102A-15. Installation of ROPS ........................................................................................................... 122A-16. Installing direction of exhaust pipe ..................................................................................... 123A-17. Installation of giant ripper shank......................................................................................... 124A-18. Adjustment of arm joint (U-blade) ....................................................................................... 125A-19. Installation of counterweight ............................................................................................... 126A-20. Procedure for adjusting blade tilt angle limit ....................................................................... 127A-21. Method of checking auto-reset system (Superdozer)......................................................... 136A-22. Installation of ORBCOMM antenna and wiring harness ..................................................... 137A-23. Installing lunchbox band (if equipped) ................................................................................ 138A-24. Greasing each part of work equipment............................................................................... 140A-25. Bleeding air from hydraulic cylinders.................................................................................. 143A-26. Air bleeding from work equipment pump and fan pump ..................................................... 144

M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY................... 145M- 1. Check and adjustment of operator’s cab............................................................................ 146M- 2. Inspection of machine monitor ........................................................................................... 153M- 3. No-injection cranking of engine.......................................................................................... 166M- 4. Setting procedure of user adjust mode .............................................................................. 169M- 5. Flushing of hydraulic circuit ................................................................................................ 172

APPENDIX 1 INSTALLATION OF SPILL GUARDSAPPENDIX 2 PRECAUTIONS FOR INITIALIZATION PROCEDURES FOR VHMS CONTROLLERFIELD ASSEMBLY INSPECTION REPORT (U-DOZER SPECIFICATION)FIELD ASSEMBLY INSPECTION REPORT (SUPERDOZER SPECIFICATION)

1

SPECIFICATIONS

• Semi-U-tiltdozer + variable giant ripper

• Full U-tiltdozer + variable giant ripper

*1: Blade + ripper + ROPS cab + air conditioner

*2: Superdozer + counterweight + ROPS cab + air conditioner

Item Unit Semi-U-tiltdozer Full U-tiltdozer Superdozer+ Variable giant ripper + Variable giant ripper + Counterweight

Operating weight kg 108,310 (*1) 113,120 (*2)(excluding operator's weight)Blade weight kg 16,500 18,800 20,900(including cylinders)Ripper weight kg 7,360 –(including cylinders)Counterweight kg – 6,040Engine model – Komatsu SAA12V140E-3 diesel engineRated engine output kW/rpm {HP/rpm} 664/2,000{890/2,000}Overall length mm 11,560 11,950 10,525Overall height (with ROPS) mm 4,546 (4,646)Overall width mm 5,265 6,205 6,465Travel speed Forward km/h 3.5/6.3/10.9(1st/2nd/3rd) Reverse km/h 4.7/8.4/14.3

2

• Superdozer + counterweight

3

PRECAUTIONS FOR FIELD ASSEMBLY1. 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.

6. Precautions for starting engineWhen the engine is started for the first time after assembled in the field, its inside must be lubricated

with engine oil. Lubricate according to “M-3 No-injection cranking of engine” in this manual.

4

DISPOSAL OF REMOVED PARTS

As described in "Preface", when this machine is transported, it is divided into some units such as the

body, undercarriage, cab, work equipment, etc. according to the transportation measure, regulations,

etc.

Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the

hydraulic devices, and parts which must not be damaged are plugged or covered to prevent oil leakage,

entry of dirt and dust, and damage during transportation.

In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation

and to facilitate loading, unloading and crane work.

The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after

completion of the machine. Since they are useful when the machine needs to be transported in future,

however, we recommend you to keep them as long as possible.

5

ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE

• A change of the schedule caused by weather is not considered.• The special work in the field shall be adjusted separately.

Set

ting

of tr

ack

shoe

Set

ting

of th

e m

achi

ne(U

nloa

ding

of o

ther

par

ts)

1No.

Sch

edul

e1s

t day

2nd

day

3rd

day

4th

day

5th

day

4

45 to

n ×

245

ton

× 1

45 to

n ×

145

ton

× 1

45 to

n ×

1

44 (2

)4

4

Item

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 –

Inst

alla

tion

of b

lade

lift

hydr

aulic

cyl

inde

rIn

stal

latio

n of

und

erca

rria

geR

epla

cem

ent o

f ret

urn

filte

rA

ddin

g oi

l to

pivo

t cha

mbe

rC

heck

of o

il an

d co

olan

t lev

els

Inst

alla

tion

of ri

pper

Inst

alla

tion

of tr

unni

onIn

stal

latio

n of

trac

k sh

oeC

heck

trac

k te

nsio

nA

ssem

bly

of b

lade

Inst

alla

tion

of b

lade

Inst

alla

tion

of o

pera

tor's

cab

Inst

alla

tion

of R

OP

SIn

stal

latio

n of

exh

aust

pip

eIn

stal

latio

n of

gia

nt ri

pper

sha

nkA

djus

tmen

t of a

rm jo

int (

U-b

lade

)In

stal

latio

n of

cou

nter

wei

ght

Pro

cedu

re fo

r adj

ustin

g bl

ade

tilt a

ngle

lim

itM

etho

d of

che

ckin

g au

to re

set s

yste

m

Inst

allin

g lu

nchb

ox b

and

Gre

asin

g ea

ch p

art o

f wor

k eq

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ent

Ble

edin

g ai

r fro

m h

ydra

ulic

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inde

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r ble

edin

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ork

equi

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t pum

p an

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Wor

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Insp

ectio

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ne (W

ith o

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RBC

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iring

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ness

6

KIT LAYOUT DIAGRAM

• When selection the work site, see "Precautions for field assembly", too.• The delivered kits (components) should be arranged as shown in the layout below after unloaded from the trailer and

truck.• However, since the layout below is a reference image of a work site about 30 m by 30 m, decide the actual layout accord-

ing to the area and land form of the work site, considering the transportation packaging of each kit (component) explained later.

Chassis

Ripper parts

Blade

AccessoriesCAB assemblyROPS guard

Approx. 30 m

App

rox.

30

m

Left

track

Rig

ht tr

ack

Left

stra

ight

fram

e

Rig

ht s

traig

ht fr

ame

Trac

k

Trac

k

Truc

k cr

ane

(45

ton)

Truc

k cr

ane

(45

ton)

7

STYLE FOR TRANSPORTATION

Since the machine can be divided for transportation, ask us or our service shop before transportation.■ Style of each KIT.

• Body

• Track frame

• WORK EQUIPMENT(1) U-blade

A Overall length (mm) 4,800B Overall height (mm) 1,500C Overall width (mm) 982

Weight (kg) 12,200

A Overall length (mm) 6,205B Overall height (mm) 2,615C Overall width (mm) 2,170

Weight (kg) 14,000


Weight (kg) 43,000

Note: The blade lift cylinder may

be installed before delivery.

a 2 sets of the shoes are prepared for each machine.

8


Weight (kg) 13,000

• Super blade

• Track shoe

(2) Semi U-blade

Shoe width 810A (mm) 4,500B (mm) 1,400

Weight (kg) 6,770 (1/2)


Weight (kg) 14,000

fl Refer to the Appendix 1 for

welding of spill guard.

a 2 sets of the shoes are prepared for each machine.

9

• Straight frame

• Hydraulic cylinder (1) Pitch, tilt cylinder

(2) Blade lift cylinder

Semi-U, U SuperA Overall length (mm) 4,857 5,020B Overall height (mm) 674 682C Overall width (mm) 638 681

Weight (kg) 1,770 1,868

a Right and left straight frames are prepared for each machine.

a One set of this part is used for single tilt-dozer and twosets for dual tilt-dozer.

Semi-U, U SuperA Overall length (mm) 1,930 1,754C Overall width (mm) 351 351

Weight (kg) 504 508

A Overall length (mm) 2,900B Overall height (mm) 630C Overall width (mm) 435

Weight (kg) 500

Note: May be installed to chassis before delivery.

10

(3) Ripper cylinder

• Giant ripper beam

• Giant ripper arm, multi ripper arm

a Both for lifting and tilting, each one set of this part is usedon both left and right sides.

Lift TiltA Overall length (mm) 1,748 1,698C Overall width (mm) 304 304

Weight (kg) 389 394


Weight (kg) 2,400

A Overall length (mm) 2,290B Overall height (mm) 580C Overall width (mm) 1,781

Weight (kg) 1,750

a Connecting pin with the beam isattached in this part in advance.

11

• Giant ripper shank assembly

• Multi ripper beam

• Multi ripper shank assembly (machine with multi ripper specification only)

A Overall length (mm) 115B Overall height (mm) 2,800C Overall width (mm) 940

Weight (kg) 1,000

a Protector and point is attachedin this part in advance.


Weight (kg) 3,450

A Overall length (mm) 115B Overall height (mm) 2,170C Overall width (mm) 775

Weight (kg) 740Q’ty 3

a Protector and point is attachedin this part in advance.

12

• Operator cab assembly

• ROPS

• Counterweight


Weight (kg) 500

A Overall length (mm) 2,100B Overall height (mm) 1,411C Overall width (mm) 585

Weight (kg) 918

a For ROPS, see "Specifications".

A Overall length (mm) 1,950B Overall height (mm) 1,300

C1Overall width (mm)

1,361C2 1,290

Weight (kg) 7,300

13

TOOLS LIST FOR FIELD ASSEMBLY

No. Part name Specification Q'ty Remarks1 Truck crane Maximum lifting capacity: 441 kN {45 t} 2

2 Air compressor Discharge pressure: 0.69 MPa {7 kg/cm2}Discharge flow: 15 m3/min 1

3 Welding machine (see remarks)

Determine the specification and quantity in accordance with the drawings mentioned in the remarks.

It is used when spill guard (if equipped) is to be added to the blade of work equipment.For drawing see "Attached sheet".

4 Chain lever hoist (Chain block)Rated load: 15.7 kN {1.6 t} 2

JIS B8819 or equivalentRated load: 31.4 kN {3.2 t} 2

5 Wire rope sling

ø12 mm × 2 m (11 kN {1.2 t}) 4ø12 mm × 4 m (11 kN {1.2 t}) 1ø16 mm × 2 m (21 kN {2.1 t}) 4ø20 mm × 5 m (32 kN {3.3 t}) 4ø20 mm × 6 m (32 kN {3.3 t}) 4ø24 mm × 2 m (47 kN {4.8 t}) 2ø32 mm × 5 m (84 kN {8.56 t}) 4ø52 mm × 3 m (238 kN {24.3 t}) 2 For lifting the machineø65 mm × 5 m (373 kN {38 t}) 1 For lifting the machine

6 Belt sling:(Made by synthetic fibers)

Width: 25 mm × 1.5 m (4.9 kN: {0.5 t}) 1• Vertical lifting capacity is shown in parentheses.

• Class I, type E of JIS B8818 or equivalent

Width: 25 mm × 3 m (4.9 kN: {0.5 t}) 2Width: 50 mm × 3 m (9.8 kN: {1 t}) 2Width: 50 mm × 4 m (9.8 kN: {1 t}) 2Width: 100 mm × 4 m (19.6 kN: {2 t}) 2

7 Load chain Wire diameter: 12.5 mm × 1.5 m (49 kN: {5 t}) 1

8 Hydraulic wrench Tightening capacity (torque):5890 Nm {600 kgm} or more 1 For tightening master link bolts of the

track shoes9 Hydraulic wrench socket Nominal width across flats: 50 mm 1

10 16-times power wrench Tightening capacity (torque): 4400 Nm {450 kgm} or more 1

11 Socket for 16-times power wrench

Nominal width across flats (mm):50, 46, 41, 36 1 each

12 Pneumatic impact wrench

Tightening capacity (torque):2940 Nm {300 kgm} or more 1

980 Nm {100 kgm} or more 1315 Nm {32 kgm} or more 1160 Nm {16 kgm} or more 1140 Nm {14 kgm} or more 1

13 Socket (for pneumatic impact wrench)

Nominal width across flats (mm):50, 46, 41, 36, 3230, 27, 24, 22, 19

1 each

14 Extension bar600 mm long 1 Extending bar for pneumatic impact

wrench300 mm long 1

15 Torque wrench

Tightening capacity (torque):2060 Nm {210 kgm} or more 1 • Prepare torque wrench so that the

socket for air impact wrench could be used commonly.

• If torque wrench is not available, prepare the socket for torque wrench.The width across flats is the same with the socket for pneumatic impact wrench.

1375 Nm {140 kgm} or more 1590 Nm {60 kgm} or more 1412 Nm {42 kgm} or more 1

180 Nm {18 kgm} or more 1

16 SpannerNominal width across flats (mm) :

17, 19, 22, 24, 27, 3032, 36, 41, 46, 50

2 each For tightening hydraulic hose mouthpiece nut

17 Pneumatic hose and coupler (for pneumatic tools)

Inner diameter 6 to 10 mm × length 30 mService pressure: 0.69 MPa {7 kg/cm2} 1

• The size of couplers on both sides are to be same as that of air compressor, pneumatic impact wrench, grease pump and oil feeding pump.

• Vertical lifting capacity is shown in parentheses.

• JIS B8817 or equivalent• The rope is 24A of JIS

G3525 or equivalent

14

18 Eyebolt

Adaptable screw: M12Using load: 2.16 kN {220 kg} 4

• JIS B1168 or equivalent• The using load is the load for

vertical lifting

Adaptable screw: M16Using load: 4.41 kN {450 kg} 2

Suitable screw: M24Using load: 9.32 kN {950 kg} 1

19 Shackle for sling

SD16-M, using load 9.8 kN {1 t} 2

• JIS B2801 or equivalent• Symbols show the type, nominal

size and class in order. (See Fig. 8.)

SD22-M, using load 19.6 kN {2 t} 1SB28-S, using load 78.5 kN {8 t} 1SD34-M, using load 49 kN {5 t} 2SB36-S, using load 122.6 kN {12.5 t} 2SB50-S, using load 245.2 kN {25 t} 1BB24-M, using load 35.3 kN {3.6 t} 1BB28-S, using load 78.5 kN {8 t} 2SB50-V, using load 392 kN {40 t} 1

20 Master link for liftingO type, using load 80 kN {8.16 t} 1 • O type of JIS B8817 or equivalent

• See Fig. 3 and Fig. 5 for the using positions.O type, using load 125 kN {12.7 t} 2

O type, using load 160 kN {16.3 t} 1

21 Pinch bar (lever bar)Diameter of grip × full length of toolø13 mm × 400 mm or equivalent 2 • JCMAS P018 or equivalent

• See Fig. 9 for the shapesø25 mm × 900 mm or equivalent 2

22 Sling bar (steel rod)ø25 mm × 1 m 1

• S53C (JIS G4051) or equivalent is suitable for its material.ø25 mm × 700 mm 2

ø19 mm × 300 mm 123 Sledge hammer Double-headed: 4.5 kg (10 lbs) 1

24 Jack Thread typeUsing load: 147.1 kN {15 t} 2 • For assembly of the undercarriage

25 Tap (for repairing thread)M24 × pitch 3 1M30 × pitch 3 1M33 × pitch 2 1 • For master link of track shoes

26 Angle meter With leveler with a smallest scale of one degree 1

• For adjusting the tilt limit angle of the blade (see A-25 in assembly procedure)

27 Grease pump Pneumatic supplying type 1

28 Oil feed pump Manual type or pneumatic supplying type 1

29 Oil jack Capacity: Approx. 5 l 1

30 Drain oil receiver (made of steel sheet)

Height × width × depth (mm)Approx. 1000 × 700 × 150

2 eachApprox. 700 × 400 × 150Approx. 300 × 300 × 100

31 Chassis stand (for fixing the machine body)

Front stand (see Fig. 1) 1Rear stand (see Fig. 2) 1

32 Floor plate made by steel (for setting chassis stand)

Thickness × height × width (mm)16 × 1000 × 500 4 • Weld lifting hook to the corner

33 Steel platet25 × T300 (mm) 1t25 × 300 × 600 (mm) 4

34 Sling jig A See Fig. 3 and Fig. 4 1 • For slinging track frame assembly

35 Sling jig B See Fig. 5 and Fig. 6 1 • For slinging final drive assembly and pivot shaft

36 Sling jig C See Fig. 5 and Fig. 7 1 • For slinging final drive assembly

No. Part name Specification Q'ty Remarks

15

a General tools for manual works (such as box wrench, driver, pliers, etc.) are not listed in this list. Prepare general tools if necessary.

No. Part name Specification Q'ty Remarks

37 Wooden bar

Height × width × depth (mm)350 × 350 × 750 4

350 × 350 × 670 2350 × 350 × 400 4300 × 300 × 600 2100 × 100 × 750 495 × 95 × 180 to 200 2350 × 350 × 800 2

38 Stand for high lift work Height 2 m with stairs and handrail 1

39 Safety belt Trunk belt type For the number of workers For high lift works

40 GogglesFor welding Necessary

quantityFor protecting from spray

41 Safety rope and "No Entrance" board

• Rope of yellow ground color with black stripes

• Standing signboard

Necessary quantity

For preventing outsiders from entering the working area

42 Resin tube (Vinyl tube)Inner diameter 8 mm × thickness 1 mm × length 3 mSoft and transparent

1For checking air tightness (internal pressure) of operator's cab

43 Lubricating oil and grease See A-13 of assembly procedure —

44 Seizure preventing agent Molybdenum disulfide grease (LM-P) 200 g See the list of coating materials.

45 Cleaning oil For removing of preservative 40 l

46 Paint remover For removing of phthalic acid coating materials 5 l

47 Repair paint See the list of coating materials. 3 each

48 Glass cleaner Liquid cleaner Proper quantityFor cleaning of the windshield glass of operator’s cab

49 Waste cloth 1 kg

50 Adhesive cloth tape Width × Length × Color50 mm × 25 m × Not specified 1 wrap

51 Wire (metal wire) ø3.2 mm × length approx. 2 m 1 JIS G3532 #10 or equivalent

16

SKETCH OF TOOLS

• For jigs that are not available from the market, see jig drawings (Fig. 1 to Fig. 7) and make them in the field.a But Komatsu does not take the responsibility of manufacturer for the jigs made in accordance with Fig. 1 to Fig. 7

1. Chassis stand (Front side)

Onl

y m

ovab

lepa

rt

Onl

y m

ovab

lepa

rt

Mat

eria

l t12

Fig.

1

No.

Mat

eria

lQ

'tyR

emar

ks01

SS

400C

4C

150×

75×t

9-13

3202

SS

400C

2C

150×

75×t

9-82

903

SS

400C

2C

150×

75×t

9-82

904

SS

400C

2C

150×

75×t

9-51

005

SS

400C

2C

150×

75×t

9-54

806

SS

400C

2C

150×

75×t

9-45

307

SS

400C

2C

150×

75×t

9-35

508

SS

400B

4T

50-5

0009

SS

400

4t2

5×18

0×25

010

SS

400

4t1

2×20

0×65

511

SS

400

10t1

2×60

×128

12S

S40

02

t16×

124×

130

13S

S40

02

t25×

70×8

5

17

2. Chassis stand (Rear side)

Onl

y m

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Mat

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Fig.

2

No.

Mat

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ks01

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400C

4C

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9-12

8202

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150×

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9-82

903

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400C

2C

150×

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9-82

904

SS

400C

2C

150×

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9-51

005

SS

400C

2C

150×

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9-54

806

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2C

150×

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9-45

307

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2C

150×

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9-35

508

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400B

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400

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0×25

010

SS

400

4t1

2×20

0×65

511

SS

400

10t1

2×60

×128

12S

S40

02

t16×

124×

130

13S

S40

02

t25×

70×8

5

18

3. Sling jig A (Track frame assembly)

• Fig. 3 shows the example of using of sling jig A.• Bow shackle (Fig No.06) in Fig. 3 is for installing the leveling sling of the lifting object (track frame assembly).• See Fig. 4 for the details of sling jig A (Fig No.01).

Trac

k fra

me

asse

mbl

y

Cra

ne

Fig.

3

No.

Mat

eria

lQ

'tyR

emar

ks

01S

ling

jig A

1

02B

ow s

hack

le1

Usi

ng lo

ad: 1

57 k

N {1

6 t}

BB

36 (T

leve

l) of

JIS

B28

01 o

r equ

ival

ent

03M

aste

r lin

k1

Usi

ng lo

ad: 1

60 k

N {1

6.3

t}JI

S B

8817

or e

quiv

alen

t

04St

raig

ht s

hack

le4

Usi

ng lo

ad: 1

22.6

kN

{12.

5 t}

SB

36 (S

leve

l) of

JIS

B28

01 o

r equ

ival

ent

05M

aste

r lin

k2

Usi

ng lo

ad: 1

25 k

N {

12.7

t}JI

S B

8817

or e

quiv

alen

t

06B

ow s

hack

le1

Usi

ng lo

ad: 3

5.3

kN {

3.6

t}B

B24

(M le

vel)

of J

IS B

2801

or e

quiv

alen

t

19

3.1 Details of sling jig A

2-36

dril

l

44 d

rill

2-44

dril

l

2 pl

aces

2 pl

aces

2 pla

ces

Wei

ght:

App

rox.

345

kg

The

scal

e is

inde

finite

.

Fig.

4

Par

t nam

eM

ater

ial

Q’ty

Rem

ark

01P

late

SS

400

1t3

6

02P

late

SS

400

1t3

6

03P

late

SS

400

2t3

6

20

4. Sling jig B (final drive assembly and pivot shaft)• Fig. 5 shows the example of slinging of final drive assembly.

a For details of sling jigs B and C, see Fig. 6 and 7.a For example of slinging pivot shaft, see "Assembly procedure A-5".

Crane

Master linkSling jig B

Sling jig C

Bow shackle

Straight shackle

Final drive assembly

• Using load: 80 kN {8.16 t}• JIS B8817 or equivalent

• Using load: 78.5 kN {8 t}• BB28 (S level) of JIS B2801 or equivalent

• Using load: 78.5 kN {8 t}• BB28 (S level) of JIS B2801 or equivalent

Fig.5

21

4.1 Details of sling jig B

36 d

rill

2-36

dril

l

Wei

ght:

App

rox.

175

kg

The

scal

e is

inde

finite

.

App

ly c

ham

ferin

g on

th

e rid

ges

and

corn

ers

so th

at th

ey w

ould

not

hu

rt ha

nds.

Fig.

6

No.

Par

t nam

eM

ater

ial

Q’ty

Rem

ark

01P

late

SS

400

1t2

8

02P

late

SS

400

1t2

2

22

4.2 Details of sling jig C

2-33

dril

l

2-36

dril

l

The

scal

e is

inde

finite

.W

eigh

t : A

ppro

x. 1

4.5

kg

App

ly c

ham

ferin

g on

the

ridge

s so

that

th

ey w

ould

not

hur

t han

ds.

Bef

ore

wel

ding

Fig.

7

No.

Par

t nam

eM

ater

ial

Q’ty

Rem

ark

01P

late

SS

400

1t3

2

02B

oss

SS

400

2ø5

6

23

5. Selecting table of shackles (extracted from JIS B2801-1996)

Type SB Type SD

Bow shackleType BB

Fig.8Straight shackle

Type NominalDimension (Unit: mm) Using load

t B d D L d1 M level S level T level

SD16 16 32 ø16 36 64 ø20 9.8 kN {1 t} — —

22 22 44 ø22 50 88 ø27 19.6 kN {2 t} — —

SB

28 28 43 ø28 70 112 ø34 47.1 kN {4.8 t} 78.5 kN{8 t} 98.1 kN {10 t}

36 36 54 ø36 90 144 ø42 78.5 kN {8 t} 122.6 kN {12.5 t} 156.9 kN {16 t}

50 50 75 ø50 125 200 ø60 156.9 kN {16 t} 245.2 kN {25 t} 308.9 kN {31.5 t}

Type NominalDimension (Unit: mm) Using load

t B d D L d1 B1 M level S level T level

BB

24 24 39 ø28 62 126 ø30 70 35.3 kN {3.6 t} 61.8 kN {6.3 t}

28 28 43 ø32 70 144 ø34 80 47.1 kN {4.8 t} 78.5 kN {8 t} 98.1 kN {10 t}

36 36 54 ø42 90 190 ø42 105 78.5 kN {8 t} 122.5 kN {12.5 t} 156.9 kN {16 t}

24

6. Pinch bar

Fig.9

TypeDimension (Unit: mm)

L (Overall length) d (Outer diameter of grip)[For round ones]

Small 400 13

Big 900 25

a This tool is equivalent to P018-1978 (pinch bar) of JCMAS (Japan Construction Mechanization Association Standard).Similar parts are acceptable if the quality is not below this tool.P019-1978 (ply bar) of JCMAS is also acceptable for tools of smaller type.

a You can read the information about JCMAS on the website.

25

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.

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.

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}

a : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt head

c : Bolt length

d : Threaded part of bolt

Fig. 1

Thread size (Diameter, pitch, length)

20

c

b

26

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

Table 1 Tightening torque for bolts not specified in textUnit: Nm {kgm}

Nominal size of thread × pitcha (mm)

Width across flats(= Socket size)

b (mm)

Tightening torque

Unit : Nm

8.8 – 14.7{0.9 – 1.5}

12{1.2}6 × 1

14.7 – 34{1.5 – 3.5}

25{2.5}

34 – 74{3.5 – 7.5}

54{5.5}

54 – 123{5.5 – 12.5}

89{9}

84 – 196{8.5 – 20}

137{14}

147 – 309{15 – 31.5}

230{23.5}

201 – 427{20.5 – 43.5}

315{32}

319 – 608{32.5 – 62}

460{47}

471 – 829{48 – 84.5}

650{66.5}

588 – 1030{60 – 105}

810{82.5}

883 – 1470{90 – 150}

1180{120}

1130 – 1910{115 – 195}

1520{155}

1470 – 2450{150 – 250}

1960{200}

1860 – 3040{190 – 310}

2450{250}

2260 – 3630{230 – 370}

2940{300}

8 × 1.25

10 × 1.5

12 × 1.75

14 × 2

16 × 2

18 × 2.5

20 × 2.5

22 × 2.5

24 × 3

27 × 3

30 × 3

33 × 3

36 × 3

39 × 3

10

13

17

19

22

24

27

30

32

36

41

46

50

55

60

Unit : {kgm}

27

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}

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

Nominal sizeSteel Cast iron Light alloy

1/83.9 – 6.9

{0.4 – 0.7}

2.9 – 5.9

{0.3 – 0.6}

2.0 – 3.9

{0.2 – 0.4}

1/45.9 – 11.8

{0.6 – 1.2}

4.9 – 9.8

{0.5 – 1.0}

3.9 – 7.8

{0.4 – 0.8}

3/816.7 – 26.5

{1.7 – 2.7}

13.7 – 21.6

{1.4 – 2.2}

9.8 – 16.7

{1.0 – 1.7}

1/232.3 – 52.9

{3.3 – 5.4}

26.5 – 43.1

{2.7 – 4.4}

19.6 – 32.3

{2.0 – 3.3}

3/451.0 – 85.3

{5.2 – 8.7}

42.1 – 70.6

{4.3 – 7.2}

31.4 – 52.9

{3.2 – 5.4}

186.2 – 173.5

{8.8 – 17.7}

72.5 – 146.0

{7.4 – 14.9}

54.9 – 111.7

{5.6 – 11.4}

Material of female thread

Nominal sizeSteel Cast iron Light alloy

1/816.7 – 29.4

{1.7 – 3.0}

9.8 – 19.6

{1.0 – 2.0}

6.9 – 14.7

{0.7 – 1.5}

1/419.6 – 44.1

{2.0 – 4.5}

16.7 – 37.2

{1.7 – 3.8}

12.7 – 28.4

{1.3 – 2.9}

3/844.1 – 93.1

{4.5 – 9.5}

37.2 – 77.4

{3.8 – 7.9}

27.4 – 58.8

{2.8 – 6.0}

1/298.0 – 188.2

{10.0 – 19.2}

83.3 – 157.8

{8.5 – 16.1}

60.8 – 115.6

{6.2 – 11.8}

3/4170.5 – 316.5

{17.4 – 32.3}

141.1 – 247.0

{14.4 – 25.2}

105.8 – 186.2

{10.8 – 19.0}

1367.5 – 612.5

{37.5 – 62.5}

309.7 – 514.5

{31.6 – 52.5}

235.2 – 392.0

{24.0 – 40.0}

(in)

(in)

28

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 5Unit: mm

Thread diameter Proper sizes of sockets or spanners

M42 65

M45 70

M48 75

M52 80

M56 85

M60 90

M64 95

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.

Table 4

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

Outside diameter

of hose

(mm)

Width across

flatse.

(mm)

Tightening torque (Nm {kgm})

Range Target

Approx. 6 19 35 – 63 {3.5 – 6.5} 44 {4.5}

Approx. 10

22 54 – 93 {5.5 – 9.5} 74 {7.5}

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}

29

COATING MATERIALS

a The recommended coating materials such as adhesives, gasket sealants 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 list.

Category Komatsu code Part No. Q'ty Container Main applications, features

Adhesives

LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets, rub-

ber cushions, and cock plug fromcoming out.

LT-1B 790-129-905020 g

(2 pcs.)Polyethylene

container

• Used in places requiring an immedi-ately effective, strong adhesive.Used for plastics (except polyethyl-ene, polyprophylene, tetrafluoroeth-lene and vinyl chloride), rubber,metal and non-metal.

LT-2 09940-00030 50 gPolyethylene

container

• Features: Resistance to heat andchemicals

• Used for anti-loosening and sealantpurpose for bolts and plugs.

LT-3

790-129-9060(Set of adhesive and hardening

agent)

Adhesive:1 kg

Hardeningagent:500 g

Can

• Used as adhesive or sealant for met-al, glass and plastic.

LT-4 790-129-9040 250 gPolyethylene

container

• Used as sealant for machined holes.

HoltzMH 705

790-126-9120 75 g Tube• Used as heat-resisting sealant for re-

pairing engine.

Three bond1735

790-129-9140 50 gPolyethylene

container

• Quick hardening type adhesive• Cure time: within 5 sec. to 3 min.• Used mainly for adhesion of metals,

rubbers, plastics and woods.

Aron-alpha201

790-129-9130 2 gPolyethylene

container

• Quick hardening type adhesive• Quick cure type (max. strength after

30 minutes)• Used mainly for adhesion of rubbers,

plastics and metals.

Loctite648-50

79A-129-9110 50 ccPolyethylene

container

• Resistance to heat, chemicals• Used at joint portions subject to high

temperatures.

Gasketsealant

LG-1 790-129-9010 200 g Tube• Used as adhesive or sealant for gas-

kets and packing of power train case,etc.

LG-5 790-129-9080 1 kg Can

• Used as sealant for various threads,pipe joints, flanges.

• Used as sealant for tapered plugs,elbows, nipples of hydraulic piping.

LG-6 790-129-9020 200 g Tube

• Features: Silicon based, resistanceto heat, cold

• Used as sealant for flange surface,tread.

• Used as sealant for oil pan, finaldrive case, etc.

LG-7 790-129-9070 1 kg Tube

• Features: Silicon based, quick hard-ening type

• Used as sealant for flywheel hous-ing, intake manifold, oil pan, thermo-stat housing, etc.

Three bond1211

790-129-9090 100 g Tube• Used as heat-resisting sealant for re-

pairing engine.

Three bond1207B

419-15-18131 100 g Tube

• Features: Silicone type, heat resist-ant, vibration resistant, and impactresistant sealing material

• Used as sealing material for transfercase

30

Category Komatsu code Part No. Q'ty Container Main applications, features

Molybdenum disulphide lubricant

LM-G 09940-00051 60 g Can• Used as lubricant for sliding portion

(to prevent from squeaking).

LM-P 09940-00040 200 g Tube

• Used to prevent seizure or scufflingof the thread when press fitting orshrink fitting.

• Used as lubricant for linkage, bear-ings, etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

• General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

• Used for normal temperature, lightload bearing at places in contactwith water or steam.

MolybdenumdisulphidegreaseLM-G (G2-M)

SYG2-400MSYG2-400M-ASYGA-16CNM

400 g × 10400 g × 20

16 kg

Bellows typeBellows type

Can

• Used for heavy load portion

Hyper White Grease G2-TG0-T (*)*: For use in cold

district

SYG2-400T-ASYG2-16CNTSYG0-400T-A (*)SYG0-16CNT (*)

400 g16 kg

Bellows typeCan

• Seizure resistance and heat resist-ance higher than molybdenum di-sulfide grease

• Since this grease is white, it doesnot stand out against machinebody.

Biogrease G2BG2-BT (*)*: For high

temperature and large load

SYG2-400BSYGA-16CNBSYG2-400BT (*)SYGA-16CNBT (*)

400 g16 kg

Bellows typeCan

• Since this grease is decomposedby bacteria in short period, it hasless effects on microorganisms,animals, and plants.

Primer

SUNSTAR PAINT PRIMER 580 SUPER

417-926-3910

20 mlGlass

container

Ad

he

siv

e f

or

cab

gla

ss

• Used as primer for cab side(Expiration date: 4 months)

SUNSTAR GLASS PRIMER 580 SUPER

20 mlGlass

container

• Used as primer for glass side(Expiration date: 4 months)

Adhesive

SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"

320 mlPolyethylene

container

• "S" is used for high-tempera-ture season (April - October)and "W" for low-temperatureseason (November - April) asadhesive for glass. (Expiration date: 4 months)

Sika Japan, Sikaflex 256HV

20Y-54-39850 310 mlPolyethylene

container

• Used as adhesive for glass.(Expiration date: 6 months)

Caulking material

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920 320 mlPolyethylene

container

• Used to seal joints of glassparts.(Expiration date: 4 months)

SEKISUISILICONE SEALANT

20Y-54-55130 333 mlPolyethylene

container

• Used to seal front window.(Expiration date: 6 months)

GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27220 333 ml Cartridge

• Used to seal joint of glasses.Translucent white seal.(Expiration date: 12 months)

PaintNatural yellow SYPA-U03PNY – Spray can

Black gray SYPA-U03PBG – Spray can

31

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:

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.

(1) Plate

(2) Collar

(3) Washer

(4) Bolt

(5) Bolt

(6) Washer

Front

Left hand Right hand

Operator's seat

Rear

Sprocket

32

1. Place two sets of track shoes to the place planned in the kit layout above, and expand one set on the left side of the machinewhile the other set on the right side as shown in Fig. 1.

a When the track shoes are placed, they are folded as theshape in Fig. 2, so pay attention to the front and rear di-rections when expanding them.

a When the track shoes are placed on the ground, the jointportion with the master link on the tip of front side shoesfaces to the ground. (Fig. 3)

Assembly procedureSetting of track shoeA-1

Left track

Right trackParallel Front

Front end

Symbol Dimension (mm) RemarksW 2,770A 2,060 When shoe width is BB 710N 13,066 Number of shoes: 40

a Only master shoes are removed previously (one pieceon each side, i.e. two pieces for each machine).

Abutment jointsGround

33

1. Installation of chassis standPlace the steel plates between the tracks spread in parallel on the ground and install the chassis stands on them.a Arrange the chassis stands and steel plates as shown in the figure.a The chassis stands for the front side and rear side are different from each other.a The steel plates are required when the ground is soil. They are not required when the ground is covered with steel

plates.

Assembly procedureSetting of the machine (1/3)A-2

Chassis stand (rear)

Chassis stand (rear)

Steel plate

Steel plate

Steel plate

Ground

Chassis stand (front) Track (Left)

Track (Right)

Front end

Chassis stand (front)

Symbol Dimension (mm) RemarksH1 1,105H2 1,020t 16 Recommended thickness of steel plate

L1 2,800

L23,3002,450

34

2. Setting of the machine

(1) Front tow hook (hole diameter : 70 mm) (installed on the machine previously )

(2) Shackle (equivalent to JIS SB50 [class 5])

(3) Damage preventing pad (rubber or felt plate)

(4) Wire rope sling (ø36 mm × 5 m × 1 piece)

(5) The first crane (45 t specification)

(6) Tilt cylinder mounting pin for the ripper(installed on the machine previously)

(7) Wire rope sling (ø52 mm × 3 m × 2 pieces)

(8) The second crane (45 t specification)

(9) Equalizer bar (installed on the machine previously)

(10) Hull frame (main frame of the machine)

(11) Front chassis stand

(12) Rear chassis stand

a See the part of machine itself in above-mentioned "Style for transportation" for the machine weight.


35

As shown in Fig. 4, set wire rope sling on the machine, one in the front and two in the rear, lift the machine up with two cranestogether (one sling by one crane in the front, two slings by another crane in the rear), put down the machine from the trailer,and set it on the chassis stand on the ground.

a Install the front wire rope sling by using tow hook on the under cover installed on the machine with suitable shackle.At this time, set rubber or felt pad in the portions that the machine and the sling interfere with each other to prevent damageof the machine.

a Install the rear wire rope sling to the tilt cylinder mount of the ripper attached on the machine previously.There is one pin on each right and left side of the mount, so set one sling to each pin.

a Set the equalizer bar, attached on the machine previously, on the front chassis stand, and set the hull frame (main frameof the machine ) on the rear chassis stand.At this time, set the machine while confirming that the chassis stand is at the center of the width of the machine.

a Before releasing the lift, set wooden bars (13) on left and right sides in the clearance between equalizer bar (9) and mainframe (10) of the machine as shown in Fig. 5.

<Specification of wooden bar>

Section: 95 mm, squareLength: 180 to 200 mm

a Steel bar of the same shape can be used instead ofwooden bar.

(9) Equalizer bar(10) Main frame of the machine(11) Front chassis stand(13) Wooden bar


36

1. Make the counter mark from cylinder stay yoke (1) on thefront top of the machine to cap (2), then remove them.(Fig.1)

a Specification of bolt (3)M30, length 140 mm

a Remove bushings (5) and (6) held by cap (2) at the sametime. At this time, disconnect greasing hose connected tothe elbow of bushing (5).

(1) Cylinder stay yoke (4) Washer(2) Cap (5) Bushing (top)(3) Bolt (6) Bushing (bottom)

2. To sling and install hydraulic cylinder horizontally (Fig. 3),turn cylinder stay yoke to keep its posture as shown inFig. 2.

a Set the mounting side of greasing hose connected to thebushing to the rear side.

3. Lift up hydraulic cylinder with belt sling as shown in Fig.3, and set it on the mounting portion of cylinder stay yoke.

a Lifting load: 4.9 kN {500 kg}

a Adjust the posture of hydraulic cylinder to be horizontalduring lifting.

a Set the rod side of hydraulic cylinder to the front side.

a Tubes of hydraulic cylinder (A) on both left and right sidesare on the outer and lower side of cylinder.

Assembly procedureInstallation of blade lift hydraulic cylinder (1/6)A-3

Greasing hose

37

4. Insert bushing (5) [Sealing welded plate on which the el-bow connecting greasing hose is attached] into the trun-nion shaft that becomes top of hydraulic cylinder.

a Dust seal is embedded in the end of inserting port onbushing side. Carefully insert the bushing after applyinggrease (G2-LI), etc. in order to prevent damaging the lipof this seal.

5. After that, install it to cylinder stay yoke by using bolts (3)and washers (4) so that bushing (5) is pressed by cap (2).

a Align the dowel pin (knock pin) installed previously on thecap with the hole on bushing side.

a Temporarily tighten the bolts at this time.

6. Insert bushing (6) (Sealing welded plate on which greas-ing nipple is attached) into trunnion shaft under hydrauliccylinder from the bottom, press it with cap (2) on the topin the same way, and install it to cylinder stay yoke by us-ing bolts (3) and washers (4).

7. Tighten bolts (3) on top and bottom firmly. (2) Cap(3) Bolt (M30)(4) Washer(5) Bushing (top)(6) Bushing (bottom)(7) Blade lift hydraulic cylinder


Bolt specification M30, length 140 mm

Necessary socket 46 mm

Tightening torque Refer to Table 1, "Tightening Torques" in this manual.

Trunnion shaft

38

8. Loosen bolt (9), and remove fixing jig (8) installed on hy-draulic cylinder (7). (Fig. 5)


a Fixing jig (8):It is a special jig for supporting hydraulic cylinder whenfront work equipment (blade) is not installed, and is main-ly used when the machine is operated as a tractor.

9. After that, change the direction of fixing jig (8), reinstallhydraulic cylinder (7), and install the other side to the ma-chine body by using bolts (11) and washers (12) asshown in Fig. 6.Then hydraulic cylinder is fixed at nearly horizontal pos-ture.

a Bolts (11) and washers (12) are installed on the machinein advance, and the part numbers are listed below as areference.


10. Release the slinging.

11. Reconnect greasing hose disconnected in Item 1 to theelbow of bushing (5).


No. Part No. Part Name Q'ty11 01010-81630 Bolt 112 21T-09-11330 Washer 1

Rotating center of cylinder stay yoke

39

12. Installation of hydraulic hoses

1) Confirm the necessary quantity of parts by Fig. 7 andthe table below.

a The quantity shown in the table below is for one ma-chine, and the necessary quantity for left and right hy-draulic cylinder are both one half of the quantity forone machine.

a Reuse flange (16) and sems bolt (17) of the cover part(see Fig. 8) removed in 2).

a Specification of sems bolt (17)M12, length 50 mmWidth across flats of bolt head: 17 mm (Special dimension)


Piping on machine side

This figure shows left hydraulic cylinder. Right hydraulic cylinder is laterally symmetric with this figure.

a

No. Part No. Part Name Q'ty Remarks13 07098-01218 Hose 2 Length: 1,800 mm14 07098-01219 Hose 2 Length: 1,900 mm15 07000-F3038 O-ring 816 07371-51260 Flange 1617 07375-21250 Sems bolt 32 Bolt with washer

40

2) Remove cover parts (16 to 19) installed on hydraulichose mounting portion of hydraulic cylinder and hy-draulic hose mounting portion of machine piping forpreventing oil leak during transportation and dust en-trance into hydraulic circuit. (Fig.8)

a But flange (16) and sems bolt (17) are to be reusedfor installing hydraulic hose.

3) Install hydraulic hoses (13) (14) to hydraulic cylinder.

a See Fig. 7 and Fig. 9 for mounting position and directionof left hydraulic cylinder.For right hydraulic cylinder, install the parts laterally sym-metrically as shown in Fig. 10.


No. Part No. Part Name Q'ty18 07378-11210 Head 119 07000-F3038 O-Ring 1

Piping on machine side




(Bottom)

(Head)

This figure shows View Y in Fig. 8 for left hydraulic cylinder.

a

41

a ReferenceAs shown in Fig. 9 and Fig. 10, the installation of hydraulichose is laterally symmetric for left and right cylinders, butthe hydraulic flow of left and right cylinders is different asshown in the following table.

4) Connect the other side of hydraulic hose with pipingparts on machine side (see Fig. 7 or Fig. 8).Connecting procedures, such as tightening torque ofbolts, etc. are the same with 3).

a Avoid interference between hydraulic hoses or betweenhydraulic hose and machine during installation.

13. Items 1 to 12 are mainly described on left hydraulic cylin-der. Install right hydraulic cylinder with the same proce-dure.


Hydraulic cylinder

Hydraulic hose No.

Hydraulic cylinder connecting port

Left13 Head14 Bottom

Right13 Bottom14 Head

(Bottom)

(Head)

Avoid interference

42

1. Preparations

1) Removal of accessoriesRemove the following 10 parts (the bolts are notcounted in) from the track frame as shown in the pho-to.

2) Maintenance of track frame pivot and application ofgreaseApply grease (G2-LI) to the O-ring groove and fit theOring to the groove.

3) Check of seal for damage, maintenance of shaft, andapplication of greaseApply grease (G2-LI) to the (P) and (Q) surfaces.

Assembly procedureInstallation of undercarriage (1/16)A-4

No. Part No. Part Name1 198-30-69530 Cover

2198-30-61360 Cover (L.H.)198-50-61370 Cover (R.H.)

3 198-50-61150 Shaft (Side pin)

4198-30-69460 Cover (L.H.)198-30-69470 Cover (R.H.)

5198-30-62311 Cover (L.H.)198-30-62321 Cover (R.H.)

6 198-50-51390 Cover

7198-30-51430 Cover (L.H.)198-30-51440 Cover (R.H.)

8198-50-31270 Spacer198-50-51220 Cover assembly

9 195-30-31260 Cover

10198-30-69850 Cover (L.H.)198-30-69860 Cover (R.H.)

No. Part No. Part Name11 07000-15355 O-ring

Torsion seal

43

2. Sling work of track frame assembly

Horizontally sling track frame assembly by using sling jig A and chain lever hoist (referred as chain block hereafter) as shownin Fig. 5, and move it close to machine.

a See "Tools list for field assembly" for lifting jig A and chain block.Use two chain blocks with rated capacity of 31.4 kN (3.2 t).

a U-hook is welded to the lifting portion of track frame assembly in advance.The center hook (for slinging jig A) is set to a position a little backward (approximately 100 mm) to the center of gravity oftrack frame assembly, so adjust track frame assembly to be horizontal by chain block.

a Lifting load: approximately 124 kN (12.65 t)(Track frame assembly + lifting jig A + chain block (2 sets))


Track frame assembly

Lifting jig A

Lifting jig A

Lifting jig A

Chain lever hoist

Chain lever hoist

CraneCrane

Hook

Hook

Pivot shaft hole



44

3. Installation of track frame assembly (moving close to machine)

1) Keep track frame assembly horizontally slung, moveit close to machine, and insert pivot shaft installed onthe machine into the pivot shaft hole in track frame as-sembly.

a At this time, keep away from the space between ma-chine body and track frame assembly.

2) Keep track frame assembly horizontally slung, moveit closer to machine (Fig. 6) until the pin holes of sidepin of equalizer bar are aligned. (Fig. 7)


Pin holes

Equalizer bar

45

3) Confirm that the track frame assembly is completelymoved to the machine, and confirm that inner threadseal (12) pressed and fixed into pivot shaft in advancecontacts with the mounting surface of O-ring (11) ontrack frame described in 1-2). (Fig. 8)

(11) O-ring(12) Inner torsion seal(13) Seal pressing cover


Pivot shaft

Track frameMachine

There is UP mark

Grease tube

Mudguard for pin

Insert the pin fixing bolt from below and install the nut to the upper side.

a

4. Insertion of equalizer bar side pin

1) Adjusting with the crane, align the pin hole of equalizer bar sidepin and track frame side pin accurately, and insert side pin (3).

a The pin must be inserted in the correct directly. (Fig. 9)Head side faces the front of the machine and head UP markfaces up.

2) Connect the grease tube.

3) Install the side pin fixing bolt.

4) Install the attached cover and tighten the bolt.a Refer to the Table 1, "Tightening Torques".

Part No. of bolt 198-50-61410 (2 pieces on each side)Part No. of washer 01643-33380 (4 piece on each side)Part No. of washer 19M-09-12890 (2 pieces on each side)Length of bolt M33, Length 320 mmNecessary socket 50 mmTightening torque 2450 – 2700 Nm {250 – 275 kgm}

(3) Side pin

46

5. Assembly of end portion of pivot shaft

1) Set spacer (8) removed in "1. Preparations" on the tipportion (Fig. 11) of pivot shaft inserted into trackframe assembly. Install smaller O-ring (15) on the tipside of pivot shaft and larger O-ring (16) on torsionseal assembly (17) side. Set torsion seal assembly(17) to press spacer and O-rings. Install inner washerto pivot shaft by using bolts (18) and washers (19),and install outer washer to track frame by using bolts(20) and washers (21).

a Torsion seal assembly (17) is included in parts (8) re-moved in "1. Preparations".

2) Tightening bolts

a Set the track frame parallel with the machine.


No. Part No. Part Name Q'ty Remarks8 198-50-31270 Spacer 1 each on right and left sides

The quantity shows the number of parts for dual tilt dozer specification. For single tilt dozer, the quantity shows only for one side (right side).

15 07000-05190 O-ring 1 each on right and left sides16 07000-05315 O-ring 1 each on right and left sides

17198-50-31160

Torsion seal assembly

Inner washer 1 each on right and left sides198-50-31241 Torsion seal 1 each on right and left sides198-50-52171 Outer washer 1 each on right and left sides

18 01010-81665 Bolt 13 each on right and left sides19 01643-31645 Washer 3 each on right and left sides20 01011-82005 Bolt 10 each on right and left sides21 01643-32060 Washer 10 each on right and left sides

Bolt Specifications Nominal size of socket wrench to be used Tightening torque

18 M20, length 105 mm 30 mm Refer to Table 1, "Tightening Torques" in this manual.20 M16, length 65 mm 24 mm

47

6. Fixing of torsion seal on the larger diameter side of pivot shaft

Fix torsion seal on the larger diameter side (inner side of track frame assembly) of pivot shaft by using the seal pressing coverat the further portion (inner side).Set the cutting portion of seal pressing cover downwards (to the ground), and install it to the track frame by using bolts (25)and washers (26).


No. Part No. Part Name Q'ty25 01010-81640 Bolt 6 each on left and right sides26 01643-31645 Washer 6 each on left and right sides




Seal pressing coverTorsion seal

Track frameO-ring

Pivot shaftMachine

48

7.

1) The right and left sides of the pivot shaft are different, depending on the machine specification.

2-2) Install the unions, elbows and plugs for the tiltpiping to the pivot shaft end cover.

a1. Take care not to forget to set the O-rings.

a2. Direct the elbows to the rear.

a3. If these parts have been installed when de-livered, the above work is not necessary.

a Parts (31) to (35) are components of (6) and (7) removed in "1. Preparations".


Structure Tilt hose pipingSpecification Left side of machine Right side of machineSingle tiltdozer Not installed InstalledDual tiltdozer Installed InstalledSuper dozer Installed Installed

2) Work when tilt hose piping is installed2-1) If the tilt hose piping is installed, 2 tilt hoses are projected

from the pivot shaft end as shown in the figure.

No. Part Name Part No. Q'ty31 Cover 198-50-51390 2 pcs. (common to right and left)32 Union 02781-00628 2 pcs. (for each cover)33 Plug 07040-12412 2 pcs. (for each cover)34 Elbow 02782-1062A 2 pcs. (for each cover)35 O-ring 07002-22434 6 pcs. (for each cover)

Tightening torque of union, plug and elbow 128 – 186 Nm {13 – 19 kgm}

49

3) Install hoses (36) and (37) to the elbows of the coverassembly described in step 2) to connect to the workequipment piping.

a1. Take care not to forget to set the Orings (38).

a2. Install the red-banded hose to the elbow that willbe on the upper side when the cover assemblyis installed to the machine and the blue bandedhose to the elbow that will be on the lower side.

a3. Set the opposite side of each hose free.

(The quantity is for 1 cover assembly)


No. Part Name Part No. Q'ty Remarks6 Cover Assembly in step 2.2) –

36 Hose 198-71-62171 1 Red-banded37 Hose 198-71-62270 1 Blue-banded38 O-ring 02896-21018 2

Tightening torque of hydraulic hose 177 – 245 Nm {18 – 25 kgm}

4) Remove the plugs from the tilt hoses projected fromthe pivot shaft end (2 places).

Reference

Plug 07376-70628

O-ring 02896-11018

50

5) Install the tilt hoses projected from the pivot shaft endto the cover assembly described in step 2).

a1. Take care not to forget to set the O-rings.

a2. Install the red-banded hose to the union that willbe on the upper side when the cover assemblyis installed to the machine and the blue bandedhose to the union that will be on the lower side.

6) Tighten cover assembly in item 5) together with thelarge washer of torsion seal assembly installed in 5)and install it.

(41) Cover assembly in 5)(45) Hose in 3)(46) Hose in 3)(47) Mounting seat of trunnion (see A-9)

P: Hydraulic hose with identification color markQ: Hydraulic hose without identification color mark

Note) The quantity is for 1 cover assembly.

7) Installation of plug to the tilt hose end.Install the oil stopper plugs to the tilt hose end (P, Q in Fig. 19) from the trunnion mounting portion.


O-ring 02896-21018 2 pcs.

No. Part Name Part No. Q'ty Remarks42 Bolt 01010-81695 9 For tightening torque of bolts, see

refer to Table 1, "Tightening Torques" in this manual.

43 Bolt 01011-81625 144 Washer 01643-31645 10

51

a Be sure to install this plug in advance.It is because that hydraulic oil pressure of work equipment may apply on the hose before front work equipment (blade as-sembly) is installed when rear work equipment (ripper) is reused in "A-10 Installation of track shoe" below.

a Plugs (77) removed in step 4.1.1) can be reused.

8) Pass hoses (45) and (46) through the track frame andpull them out of the hole of the trunnion mountingseat.

9) Install the mud cover to the front of cover assembly(41) described in step 6).The covers for the right and left sides of the machinehave different part Nos.

Note) The quantity of bolts and washers shows for each one cover.


Figure No. Part Name Part No.Q’ty

For single tilt dozer For dual tilt dozer77 Plug 07376-70522 Only two for the right side Two each on left and right sides78 O-ring 02896-11015 Only two for the right side Two each on left and right sides

No. Part Name Part No. Q'ty Remarks51 Cover (Right) 198-30-51440 1

For tightening torque of bolts, see refer to Table 1, "Tightening Torques" in this manual.

52 Cover (Left) 198-30-51430 153 Bolt 01010-81635 354 Washer 01643-31645 3

52

10) Work when tilt hose piping is not installed

10.1) As described in 1), the tilt hose is not installed tothe left end of the pivot shaft of the single tiltdozerspecification. (Part A in Fig. 22)Install the cover described in 10.2) and 10.3) (Fig. 23)

10.2) Install cover (61) together with the outer washers ofthe twist seal assembly installed in steps 5).

10.3) Close the square hole at the front of cover (61) withplate (64).


No. Part Name Part No. Q'ty Remarks61 Cover 198-30-51220 1

For tightening torque of bolts, see refer to Table 1, "Tightening Torques" in this manual.

62 Bolt 01010-81695 1063 Washer 01643-31645 1064 Plate 198-30-51330 165 Bolt 01010-81635 366 Washer 01643-31645 3

53

8. Release of slinging

If the works in 7 are completed, loosen and remove the sling.

a When the installation of track frame assembly on one side is completed, and the installation on the other side is to bestarted, set jack or wooden bar under the installed track frame assembly in order to prevent dropping when the slingingby crane is finished. (Fig.24)

9. Lowering of the machine (removing chassis stand)

1) Sling only the front of the machine by crane in accor-dance with the same procedure in "A-2 Setting of theMachine", and draw out the front chassis stand fromunder the machine. (Fig.25)

a Lifting load: Approximately 343 kN {35 t}

2) After that, draw out the wooden bar set between theequalizer bar described in Fig. 5 of the same proce-dure and the machine.

3) Slowly lower the front side of the machine, and placethe idler of track frame assembly on the track shoes.

4) Release the slinging works for front side of the ma-chine.


Jack

Set two or more jacks or wooden bars to keep the track frame assembly to belongitudinally horizontal.

54

5) After that, lift only the rear side of the machine bycrane in accordance with the same procedure of "A-2Setting of the machine", and draw out the rear chassisstand from under the machine.

a Lifting load: Approx 343 kN {35 t}

6) In order to keep enough working space for the worksin 7), insert the wooden bar put between steel plates,between rear track roller and track shoes on theground.

a Set wooden bars for the track rollers in the same po-sitions on left and right sides.

a Wooden bars: T300 × 600 (mm) – 2 piecesSteel plates: t25 × 300 × 600 (mm) – 4 pieces


Wire rope sling

55

7) Sling the rear of the machine again, and draw outwooden bars and steel plates.

8) After that, slowly lower the rear of the machine, andset all track rollers on track shoe links. (Fig. 27)

9) Release the slinging of the rear side of the machine.

10. Removal of bogie fixing jig

1) Remove the bogie fixing jig (L) for track frame assem-bly. (Fig. 28)

2) As shown in Fig. 29 (the next page), the fixing jigs areinstalled on four places on the outer side of left andright track frame assemblies. (Among the four places,only one jig has the different size.)

a Removal is to be performed after lowering the ma-chine on the track shoes.If the machine is remained on chassis stand, the trackroller will hang down, interfering the following works.

a This fixing jig is used for transporting, preventing thetrack roller from hanging down when track frame as-sembly is placed on trailer, etc. or lifted up by usingcrane when unloading.

a Follow the intention of the customer or the judgmentof service department for the storage of removed jigs.



56

a The quantity shows the number of parts for each one side of left and right track frame assemblies.


Figure No. Part Name Part No. Q’ty Remarks75 Plate 198-30-69280 3

Removal parts76 Collar 198-30-66190 377 Washer 19M-54-11770 378 Bolt 01011-62710 379 Bolt 01010-62765 3

Reinstall them in different places.80 Washer 01643-32780 381 Plate 198-30-68950 1

Removal parts82 Collar 198-30-68960 183 Washer 19M-54-11770 284 Bolt 01011-62710 2

57

3) For the portions without bolts and washers after fixingjigs are removed, supply mounting bolts and washers(79), (80), (85), (86) to triangle cover and install it.(Fig. 30)

a Among the supplied bolts and washers, reuse bolts(79) and washers (80) for mounting fixing jigs on tri-angle covers (3 places) in track roller bogie assembly.(See Fig. 29)

a The quantity shows the number of parts for each one side of left and right track frame assemblies.

4) For the portions without bolts and washers after fixingjigs are removed, knock cork plug (87) into threadholes without the following installation to protectthem. (Fig. 31)

a The quantity shows the number of parts for each one sideof left and right track frame assemblies.



Tightening torque 883 – 1,470 Nm {90 – 150 kgm}

Figure No. Part Name Part No. Q'ty Remarks79 Bolt 01010-62765 3 Reuse80 Washer 01643-32780 3 Reuse85 Bolt 01010-62765 2 Newly supply86 Washer 01643-32780 2 Newly supply

Figure No. Part Name Part No. Q'ty87 Plug 07049-02734 3

58

1. The machine requires flushing of work equipment hydraulic oil after assembly, so in this procedure, replace the element ofhydraulic oil return filter with flushing element in advance.

Replace the element of hydraulic oil return filter with exclusive flushing element (1), and replace valve and strainer withplate (2).

a Avoid entrance of dirt when removing installed standard element.Remove the dirt remaining inside the case by hands, and replace it with exclusive flushing element.

a Confirm the installing condition of the element in accordance with "2. Installing Condition of Element".

a When the atmospheric temperature is below –15°C, do not use (2). Replace only the element and flush the circuit whilerunning the engine at low idle.

a Removed standard element (208-60-71120), strainer (07069-25400) and valve (208-60-71160) will be used again afterflushing is finished. Accordingly, clean and keep them so that they will not be damaged.

a For the flushing procedure, see "Check and maintenance procedures after completion of assembly M-5".

Assembly procedure Replacement of return filter (Replacement of standard filter ➞ special flushing parts) (1/2)A-5

No. Part Name Part No. Q'ty1 Element 208-60-71170 1

Exclusive flushing element2 Plate 21T-60-13730 1

59

2. Installing condition of element

a Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig. 2.Particularly when the filter case is filled with oil, it is difficult to see if the element is installed normally. In this case, turn theinstalled element with the hand.If you can turn the element smoothly, it is installed normally.

Assembly procedure Replacement of return filter (Replacement of standard filter ➞ special flushing parts) (2/2)A-5

Element

Fig. 1 Good condition Fig. 2 Bad condition

60

• Pivot chamberAdd engine oil through the hole of plug (1).

a Quantity of oil: 26 l/each side

a Oil level (B): 10 – 30 mm from oil level (2)

a For using oil type, see "A-7 Check of oil and coolantlevels" in assembly procedure.

Assembly procedureAdding oil to pivot chamberA-6

61

Assembly procedureCheck of oil and coolant levels (1/2)A-7

62

Assembly procedureCheck of oil and coolant levels (2/2)A-7

Precautions Tools required Equipment required

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

Name Q’ty Name Q’ty

Oth

ers

63

1. Preparation

• Removal of paint and rust prevention oil from mount-ing parts

• Do not remove the arm pin but pull it out to the state shown in the photo.

• Arm pin lock bolt

• It is necessary to start the engine to perform the fol-lowing step "8. Connection of cylinder", so prepare to start the engine.

2. Installation of arm

• Sling the arm by 3 points. Set its right and left parts in parallel accurately.

• Set a wood block under the arm as shown in the photo.

Assembly procedureInstallation of ripper (1/5)A-8

Part No. of bolt 01010-82040 (2 pieces on each side)

Part No. of washer 01643-32060 (2 pieces on each side)

Bolt specification M20, Length 40 mm



Style

Block3. Installation of lift cylinder

• Lift cylinder connecting pin lock bolt






64

4. Installation of tilt cylinder

• Tilt cylinder connecting pin lock bolt

6. Sub beam

7. Installation of beam assembly

• Sling the beam assembly by the 3 points of the shank pin and cylinder pin.

• Beam connecting pin lock bolt







Straight openings

L-adapters

5. Installation of right and left lift hoses and tilt hoses

• Direct the hoses as shown in the photo.• Part No. of hose : 07097-01012

(Common to 8 hoses on right and left sides)

• Assemble the right and left grease hoses and elbows before installing them to cylinder head pin.

a Connect the pin portion after the installation.






65

8. Connection of cylinder

1) Start the engine in low idle, and confirm the move-ment of the lift cylinder rod and the tilt cylinder rod.

• If the movement of rods is abnormal, confirm the amount of hydraulic oil and fill oil.

2) Install lift cylinder while adjusting by moving the rod ofthe cylinder.

3) Install tilt cylinder while adjusting by moving the rod ofthe cylinder.

• Connecting pin lock bolt on cylinder rod side

Note) If the engine is started for the first time in this work, lubricate it before starting according to "M-3 No-injection crankingof engine".


• Set a block (Height: 670 mm) under the beam so that the arm will be horizontal.





Tightening torque Refer to Table 1, "Tightening Torques" in this mannual.

66


• Detail of installation of pin puller hoses

9. Installation of pin puller hoses• Clamping positions of hoses

1. Between clamp on side of beamand cylinder: 990 mm

2. Between connecting part ofchassis and clamp A: 1,060 mm

3. Between clamp A and clamp onside of beam: 1,370 mm

A

67

10. Installation of grease supply hoses

• Method of installing centralized greasing unit on mount side

• After completing assembly, check the operation and confirm that the hose is not abnormally slackened or tensed.


68

• Sling and install the trunnion.

• Trunnion mounting bolts

• If there are tilt hoses, pull them out of the center of the trunnion as shown in the figure.

Assembly procedureInstallation of trunnionA-9

• Remove the paint from both trunnion mounting faces.

a Weight of trunnion: 1.37 kN {140 kg}






Track frame

Trunnion

WasherBolt

Trunnion Tilt hose

69

The cooperation of crane operator, machine operator and signal worker is required for installing track shoes.Therefore, make communication between the three persons to clarify the signals.The signaler should give out signals at a position where he could be clearly seen by the operators of the machine and the crane.

1. Sling the front end of track shoes by crane, and roll thetrack shoes on the idler. (Fig. 1)After that, set wooden bar on the grouser of track shoesto prevent the track shoes from rewinding, and loosen thesling.

a Slinging bar: steel rod ø25 mm × 1 m (one piece)a Wire rope slings: ø24 mm × 2 m (2 pieces)

Using load: 47 kN {4.8 t}a Wooden bars: T300 mm × 600 mm (2 pieces)a Properly set steel plates between track shoes and

grouser to slightly adjust the height of wooden bar.

2. Start the engine, operate the ripper to vertically raise rip-per beam a little, and set wooden bar under ripper beam.Then set steel plate on the top of wooden bar, and set rip-per beam onto it. (Fig. 2)

a Steel plate: t25 mm × T300 mma Wooden bar: T300 mm × 600 mm (1 piece)

3. Move ripper beam downwards to raise the rear side ofmachine until the sprocket completely falls off the trackshoes. (Fig. 2)

4. Sling one side of the front end of the rear of track shoes(sprocket side) as shown in Fig. 3, and move it close tothe sprocket.

a Slinging bar: steel rod ø25 mm × 700 mm (one piece)a Load chain: wire diameter 12.5 mm × 1.5 m (one piece)

Using load: 49 kN {5 t}

5. As shown in Fig. 4, connect the belt sling with track shoesby using the subsidiary crane, and pull the track shoesuntil it goes beyond the sprocket.

a Sling bar: steel rod ø25 mm × 700 mm (one piece)a Belt sling: width 75 mm × 5 m

Using load: 19.6 kN {2 t}

Assembly procedureInstallation of track shoe (1/3)A-10

Wire rope slings

Wooden bars

Slinging bar

Wire rope slingsSteel plate

Inserted

FloatedWooden bars

Crane.Main hoisting

Load chain

Sling bar

Out

side

Insi

de

Crane.Main hoisting

Sling barBelt sling

Carrier roller

Crane.Subsidiary hoisting

Track shoes

Sprocket

70

6. After that, move it forward until the fifth link pin interlockswith sprocket, completely set track shoes on the sprocket,and then loosen the sling on subsidiary crane to lower thetrack shoes.

7. Clean the mating surface of master link to remove allharmful sand, metal scraps, etc.

a Also clean the master link on the idler described initem 1.

8. Start the engine, and rotate the sprocket to slowly movethe track shoes forward.After that, make the master links on the front end and onthe idler interlock with each other. (Fig. 6)

a In this work, be sure to keep cooperation betweencrane operator, machine operator and signaler.

9. The lifting of track shoes is finished when the master links

interlock with each other.

10. Set the interlocked master link on master shoe (1), installand temporarily tighten four master bolts (3) to make themaster links firmly contact with each other.

a If the shoe bolts are tightened forcibly before the con-tact surfaces of the master link are fitted, the threadsof them and master link may be damaged.

11. Confirm that the interlock surface is firmly contacted, andthen loosen master bolts (3) to remove master shoe (1).

12. Apply seizure preventing agent (LM-P) on the thread por-tion of shoe bolts.

a See "Coating materials".


Wooden bar

Interlocking of master links

No. Part No. Part Name Q'ty1 198-32-31483 Master shoe (1 pieces on each side)2 19M-32-11450 Key (2 pieces on each side)3 198-32-31341 Master bolt (4 pieces on each side)

71

13. Control of bolt tightening torque

1) Install master shoe (1) and key (2) to the master linkagain, and screw-in the master bolt (3).

2) Tighten the bolts to torque of 980 ± 98 Nm {100 ± 10kgm} first and check that the mating faces of the linkare fitted.

3) Make counter marks to bolt head and shoe with whitepaint, etc., so that the original position of the bolt headis identified.

4) After making counter marks, further tighten them byusing impact wrench to set the angle between countermarks 180 ± 10° from the original position.

a Tightening orderTighten the bolts in the order shown in Fig. 9.

a To adjust the track tension, refer to the section A-11.

14. Remove the wooden bars set in steps 1 and 2.


72

Assembly procedureCheck track tension (1/2)A-11


NOTICE• Grease inside the adjusting mechanism is under

high pressure.Grease coming from plug (4) under pressure can penetrate the body causing injury or death. For this reason, do not loosen plug (4) more than one turn. Do not loosen any part other than plug (4). Furthermore, do not bring your face in front of the grease fitting.If the track tension is not relieved by this procedure, please contact your Komatsu distributor.

• When removing cover (2), be careful not to let any dirt get inside.

• There is a safety label stuck to the back of cover (2). Be careful not to damage the safety label.


Oth

ers

WHEN INCREASING TENSION1. First remove both bolts (1) and then remove the

cover (2).

2. Pump in grease through the grease fitting (3) with a

grease pump.

3. To check that the correct tension has been achieved,

move the machine backwards and forwards.

4. Check the track tension again, and if the tension is

not correct, adjust it again.

WHEN LOOSENING TENSION1. Remove both bolts (1), then remove cover (2).

2. Loosen plug (4) gradually to release the grease.

3. Turn plug (4) a maximum of one turn.

4. If the grease does not come out smoothly, move the

machine backwards and forwards a short distance.

5. Tighten plug (4).

6. To check that the correct tension has been achieved,

move the machine backwards and forwards.

7. Check the track tension again, and if the tension is

not correct, adjust it again.

73

Assembly procedureCheck track tension (2/2)A-11



Oth

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INSPECTIONStop the machine on level ground (stop with the

transmission in FORWARD while applying the brake

slowly). Then place a straight bar on the track shoes

between the carrier roller and the idler as shown in the

figure, and measure the clearance is 20 to 30 mm, the

tension is standard.

If the track tension is not at the standard value, adjust it

in the following manner.

a Set the track tension to 30 mm for the first 100

operating hours to fit the bushings and pins.

74

1. Installation of blade

Stand the delivered blade vertically on the assemblyground according to the following procedure.

a Stand the blade means to set the back of the blade at90° to the ground as shown in (Fig. 1).

[1] Sling the blade with the crane. While operating the mainand auxiliary hoists, stand the blade gradually as shownin (Fig. 2) and (Fig. 3) until it stands vertically on the ob-ject position (ground).

a Install the rope slings of the main hoist to the blade lifthydraulic cylinder mounting pin.

a Install the rope slings of the auxiliary hoist to the liftingholes at both ends of the blade top through shackles.

a Use rope slings of JIS B8817 or equivalent having thelifting capacity of at least 84 kN {8.56 t}.

a Use shackles of JIS B2801 or equivalent having thelifting capacity of at least 49 kN {5 t}.

Reference: Additionally weld spill guard on the blade before setting the blade vertical.See "Appendix: Installation of Spill Guard" for the installing (welding) procedure.

Assembly procedureAssembly of blade (1/20)A-12

Weight of semi U-blade 13 tWeight of full U-blade 14 tWeight of Super dozer 12 t

Wire rope sling ø32 mm × 5 m (4 pieces)Shackle SD34 (2 pieces)

Auxiliary hoist side

Main hoist side

75

2. Measures to prevent blade from falling(Set the blade so that it will stand vertically and stably evenafter the slings are loosened.)

[1] Set wooden blocks under the center link brackets. (Fig. 4)

a Wooden block: T350 mm × length 400 mm – 2 pieces

[2] Set wooden blocks under the straight frame brackets onboth sides. (Fig. 5)

a Wooden block:T350 mm × length 400 mm – 2 pieces

[3] If it is difficult to stand the blade vertically with only thewooden blocks in steps [1] and [2], add plates to adjustfinely. (Fig. 5)

[4] After confirming that the blade stands stably, loosen andremove the slings.

[5] Install eye bolts (2) to center link (1).

a Remove cork plugs knocked into the thread holes inadvance, and then install eye bolts.

[6] Turn center link (1) by using eye bolts (2) and crane, andset it to a position as shown in Fig. 6 (upwards).Set bar (4) on the top of mud cover (5) welded on the backsurface of the blade on top of center link. Connect eyebolt and bar with wire (3), and twist the wire to fix the cen-ter link.


2 parts

Plate

Wooden block(Insert on both sides)

No. Part Name Remarks1 Center link Components of blade assembly

2 Eyebolt M24, using load: 9.32 kN {950 kg} (JIS B1168 or equivalent)

3 Wire (metal wire) #10 wire, ø3.2 mm × approximate length 2 m (JIS G3532 or equivalent)

4 Sling bar SS400B, ø19 mm × 300 mm (JIS G3532 or equivalent)

5 Mud cover Welded on the back surface of the blade already

— ShackleSD16, using load: 9.81 kN {1 t}

(JIS B2801). To be used for slinging by crane

76

3. Connection of straight frames to right and left of blades

[1] Check that the joints at the ends of the straight framesare installed in the correct directions. (Fig. 7)

a If the joints are installed in wrong directions, cor-rect their directions.

[2] Remove the connecting pins installed to the straightframe brackets on the blade. (Fig. 8)

a The quantity is the number of parts necessary to1 machine (1 blade).


Joint

Good Wrong

No. Part Name Part No. Q'ty81 Pin 198-72-51810 284 Lock 09257-11219 285 Bolt 01010-82455 886 Washer 01643-32460 8


Tool (Socket) 36 mm

77

[3] Sling the straight frame horizontally with belt slings. (Fig. 9)

• Lifting load : Approx. 1770 kg for each side: Approx. 1850 kg for each side (for super dozer)

• Belt sling: Both ends eye type 100 mm wide, 4 m long (2 pieces)Using load: 19.6 kN {2 t}JIS B8818 or equivalent

a If the straight frame slants to the right or left, thejoint described in [1] will not be inserted in thebracket yoke easily.Accordingly, keep the straight frames horizontally.

[4] While slinging the straight frame, insert the joint at itsend in the bracket yoke on the blade and align theconnecting pin holes. (Fig. 9)

[5] Insert pin (81) removed in step [2] and fix it to thebracket on the blade with lock (83), bolt (84) andwasher (85). (Fig. 9)

a For tightening torque of bolt, see Table 1, "Tight-ening Torque".

[6] Set a wooden block under the rear end of the straightframe (on the opposite side to the joint) and adjust theheight (H) of the trunnion mounting portion (center) ofthe machine above the ground to approx. 1,085 mm.(Fig. 10)

a Wooden block:T350 mm × length 800 mm – 1 piece

[7] Perform steps [1] – [6] on both right and left sides.

[8] Sling the straight frames again and set the right andleft straight frames symmetrically about the blade andadjust the distance between both straight frames (di-mension W) to approx. 3,810 mm. (Fig. 11)

a Clean each connecting part.


Belt sling

Connection Wooden block

Reference: A belt sling means a belt made ofsynthetic fibers used to sling heavythings. It is used to prevent damage on theproducts and protect the paint dur-ing sling work.

Belt sling

Wooden block

78

4. Installation of center brace

4.1 Temporary installation[1] Remove the shims, bolts and washers installed tem-

porarily in advance to part (F) (spherical seat) of thecenter link and part (G) (spherical seat) of the straightframe. (Fig. 12)

a "Q'ty" in above table indicates the number for eachspherical seat.Each machine has 2 parts (F) and 2 parts (G), 4 partsin total.

a For the "Part No." in above table, see (Fig. 13).a The kinds and numbers of the removed shims are so

combined that the thickness at each place will be 4.5mm. Accordingly, the shims removed from part (F)should not be mixed with those removed from part(G).

a When adjusting the thickness of 4.5 mm, keep eachcombination of (A) and (B). (Fig. 14)

[2] Install the belt sling to the center of center brace (90).While slinging the center brace with the crane, put theballs of the ball joints respectively to the sphericalseat (part F) of the center link and that (part G) of thestraight frame. (Fig. 12)

a "Q'ty" in above table indicates the number foreach machine.

a Weight of center brace: Approx. 340 kg/piecea Belt sling: Both ends eye type

50 mm wide, 4 m long (2 pieces)Using load: 9.81 kN {1 t}JIS B8818 or equivalent


No. Part Name Part No. Q'ty1 Bolt 01011-83335 82 Washer 01643-33380 83 Shim (2 mm) 198-71-31450 24 Shim (1 mm) 198-71-31460 45 Shim (0.5 mm) 198-71-31470 4

Detail P

View Z

No. Part Name Part No. Q'ty90 Center brace 198-72-51350 2

79

[3] Temporarily install the ball caps of center brace (90)to the spherical seats of the center link and straightframe (parts (F) and (G) in (Fig. 12)) with bolts (1) andwashers (2) removed in step [1], while inserting shims(3), (4) and (5) removed in step [1] in parts A. (Fig. 15)and (Fig. 16)

a Insert the sets of shims 4.5 mm thick in total (One2-mm shim, Two 1-mm shims and One 0.5-mmshim) in the Two upper and lower places.

a Tighten the bolts until the spherical seat, shimsand ball cap are fitted to each other, although theyare being installed temporarily.

[4] Install the center brace on the opposite side similarly(according to steps [1] – [3]).

a To perform the same procedure for the oppositeside, remove the eye bolts, washers and bar al-ready installed in step 2-[6].Knock the cork plug into the thread hole to whichthe eye bolt is installed.

[5] Supply a little amount of grease through part (M) (1place) and parts (N) (1 place each on the right and leftsides). (Fig. 16)

a Use grease G2-LI (See the coating material list).

[6] Install the belt sling to either of the right and leftstraight frames and move the straight frame end upand down slowly for several times with the crane asshown in (Fig. 17). (Stroke: 300 – 400 mm)While moving up and down, check the ball joints ofthe center brace for abnormal sound and ensure thatthe ball joints move smoothly (check the balls for in-ternal interference).Perform this check on both right and left straightframes.

a If no problem is detected, go to step 4.2. If anyproblem is detected, adjust the shims again (addnew shims) according to step 4.3.



Tool (Socket) 50 mm

Ball cap

Part Name Part No. Q'tyPlug 07049-02430 1

Belt sling

80

4.2 Permanent installation[1] If no problem is detected in step 4.1-[6], tighten the

ball cap bolts at both ends of the center brace (1) in(Fig. 15) permanently.

a Tighten all the bolts evenly in the diagonal order.

[2] After tightening permanently, go to step 4.4.

4.3 Shim adjustment (Addition of shims)[1] If any problem is detected (interference of the ball is

felt) in step 4.1-[6], remove bolts (1) and washers (2)which are fixing the ball caps temporarily at both endsof the center brace and add 0.5-mm thick shim (5) tothe shim set in part (A), and then install the ball capstemporarily with bolts (1) and washers (2) accordingto step 4.1-[3]. (Fig. 18)

a Numbers in above fig. show the quantity requiredfor each spherical seat.

a When adjusting the thickness of 4.5 mm, keepeach combination of (A) and (B). (Fig. 14)

4.4 Adjustment of distance between tilt cylinder mountingpin holes

[1] Sling the straight frame again with the belt sling asshown in (Fig. 19) and adjust the distance betweenthe mounting pin holes of the tilt cylinder (dimensionK) (or the brace assembly on the left side in step 6 forthe single tilt dozer specification) to about 1,845 mm.Then, adjust the position of the wooden block underthe straight frame so that the distance between theholes will be stabilized and then remove the sling.a Perform this adjustment on the right and left

sides.




No. Part Name Part No. Q'ty5 Shim (0.5 mm) 198-71-31470 2

Shim

BoltWasher

Ball joint

View Z

Belt sling

Wooden block

81

5. Installation of tilt hydraulic cylinders

5.1 In case of dual tiltdozer specification[1] Install hydraulic hoses and hose protection covers to

the right and left hydraulic cylinders. (Fig. 20)

a Flange (10), bolt (11) and washer (12) are in-stalled to each hydraulic cylinder in advance.(Marked ª) However, do not reuse the sleeve head (oil stopcover) installed to the hydraulic cylinder with (10),(11) and (12) when installing the hydraulic hoses.

a Replace O-ring (9) with new one, as a rule.


No. Part Name Part No. Q'ty6 Hydraulic cylinder 707-01-0X760 2

7 Hydraulic hose (Overall length: 1,650 mm) 198-71-62131 2


9 O-ring 07000-23025 4ª 10 Flange 07371-30640 8ª 11 Bolt 07372-21035 16ª 12 Washer 01643-51032 16

13 Cover 198-71-62211 214 Bolt 01010-82045 1215 Washer 01643-32060 12

Bolt specification Tool (Socket)

M10 17 mm

M20 30 mm


When assembling, make sure that the shorter hose (bottom side) has been located on R.H. side of the cylinder (both R.H. and L.H. cylinders).

82

[2] Remove the covers and hydraulic cylinder mountingpins installed to the hydraulic cylinder mounting sec-tions of the right and left straight frames. (Fig. 21)(Same as super dozer specification)

[3] While slinging hydraulic cylinder (6) with belt sling(20), with the cover side (hydraulic hose side) up,align the mounting pin hole on the bottom side (clevisside) with that of the straight frame.Then, insert mounting pin (16) removed in step [2]and fix it to the straight frame with lock (17), bolt (18)and washer (19). (Fig. 21)

• Sling weight (Weight of hydraulic cylinder assembly) R.H. and L.H. sides, approx. 510 kg each

• Belt sling: The same with 4.1-[2]

[4] Set a wooden block between hydraulic cylinder (hy-draulic hose protection cover) and straight frame sothat hydraulic cylinder (6) will be positioned as shownin (Fig. 22), and then loosen and remove the sling.

a Do not connect the head side of hydraulic cylinder(6) (part (R) in Fig. 22) at this time.Connect it after installing the blade assembly tothe machine. See "assembly procedure A-13"



M12 19 mm

M20 30 mm


Tool (Socket) 30 mm


Wooden block TIE

83

[5] Connect the free ends of hydraulic hoses (7) and (8)installed to hydraulic cylinder (6) in step [1] to the el-bows of flange (21) installed to the straight frame.(Fig. 23)Connect according to the letters stamped on theflange.

a Take care not to forget to install O-rings (22).

a When connecting the hydraulic hoses, remove the oilplugs (Part No.: 02789-00628) installed to the elbowsof the flange in advance.


Stamp Hose to be connected

H Longer hydraulic hose (Head side)

B Shorter hydraulic hose (Bottom side)

No. Part Name Part No. Q'ty22 O-ring 02896-11018 4

84

5.2 In case of single tiltdozer specificationa For the single tiltdozer specification, install the tilt

hydraulic cylinder to only the right side.

[1] Install the hydraulic hoses and hose protection coverto the hydraulic cylinder. (Fig. 24)

a Flange (35), bolt (36) and washer (37) are in-stalled to hydraulic cylinder (31) in advance.(Marked ª)However, do not reuse the sleeve head (oil stopcover) installed to the hydraulic cylinder with (35),(36) and (37) when installing the hydraulic hoses.

a Replace O-ring (34) with new one, as a rule.


No. Part Name Part No. Q'ty31 Hydraulic cylinder 707-01-0X760 2



34 O-ring 07000-23025 4ª 35 Flange 07371-30640 8ª 36 Bolt 07372-21035 16ª 37 Washer 01643-51032 16

38 Cover 198-71-62211 239 Bolt 01010-82045 1240 Washer 01643-32060 12


M10 17 mm

M20 30 mm


When assembling, make sure that the shorter hose (bottom side) has been located on R.H. side of the cylinder

85

[2] Remove the covers and hydraulic cylinder mountingpin (41) installed to the tilt hydraulic cylinder mountingsection of the right straight frame. (Fig. 25)

[3] While slinging tilt hydraulic cylinder (31) with belt sling(20), with the hydraulic hose cover side down, alignthe mounting pin hole on the bottom side (clevis side)with that of the straight frame.Then, insert mounting pin (41) removed in step [2]and fix it to the straight frame with lock (42), bolt (43)and washer (44). (Fig. 25)

• Sling weight (Weight of hydraulic cylinder assembly): Approx. 510 kg each

• Belt sling: The same with 4. 1-[2]

[4] Set a wooden block between hydraulic cylinder (hy-draulic hose protection cover) and straight frame sothat the hydraulic cylinder (31) will be positioned asshown in (Fig. 26), and then loosen and remove thesling.

a Do not connect the head side of the hydraulic cyl-inder (31) (part (R) in Fig. 26) at this time.Connect it after installing the blade assembly tothe machine.(See "Assembly procedure A-13")



M12 19 mm

M20 30 mm


Tool (Socket) 30 mm


Wooden block TIE

86

[5] Connect the free ends of hydraulic hoses (32) and(33) installed to the hydraulic cylinder (31) in step [1]to the elbows of flange (46) installed to the straightframe. (Fig. 27)Connect according to the letters stamped on theflange.

a Take care not to forget to fit O-rings (47).

a When connecting the hydraulic hoses, remove the oilplugs (Part No.: 02789-00628) installed to the elbowsof the flange in advance.

[6] Reinstall the covers removed in step [2].


Stamp Hose to be connected

H Longer hydraulic hose (Head side)

B Shorter hydraulic hose (Bottom side)

No. Part Name Part No. Q'ty47 O-ring 02896-11018 4

Bolt specification M12 Length 25 mm

M20 Length 40 mm

Tool (Socket) 19 mm 30 mm


87

5.3 For super dozer specification

[1] Install tube and tube protection covers to the right andleft hydraulic cylinders.


No. Part Name Part No. Q'ty

88 Hydraulic cylinder (For super dozer) 707-01-0X990 2

89 Tube (L.H.) 198-72-62570 190 Tube (R.H.) 198-72-62580 191 O-ring 07000-F3030 692 Bolt 07372-21045 493 Washer 01643-51032 494 Bolt 07372-21060 495 Washer 01643-51032 496 Block (L.H.) 198-72-62550 197 Block (R.H.) 198-72-62560 198 Bolt 07372-21035 899 Washer 01643-51032 8

100 Bolt 01010-81095 8101 Washer 01643-51032 8102 Cover 198-72-62590 2103 Bolt 01011-82025 2104 Bolt 01010-82040 12105 Washer 01643-32060 14106 Hose 198-72-52110 4107 O-ring 07000-F3025 4


M10 17 mm

M20 30 mm


88

[2] Set the cover side of hydraulic cylinder (88) facing up-wards, lift the cylinder up by using belt sling (20), andalign the mounting pin holes on the bottom side (Cle-vis side) of the cylinder and on straight frame.Then, insert mounting pin (110) removed in step [2]and fix it to the blade with lock (111), bolt (108) andwasher (109).

• Sling weight (Weight of hydraulic cylinder assembly) R.H. and L.H. sides, approx. 510 kg each


[3] Set a wooden block between hydraulic cylinder andstraight frame so that hydraulic cylinder (88) will bepositioned as shown in (Fig. 26), and then loosen andremove the sling.

a Do not connect the head side of hydraulic cylinder(88) (part (R) in Fig. 26) at this time.Connect it after installing the blade assembly tothe machine. (See "assembly procedure A-13")



Tool (Socket) 30 mm


89

[4] Connect flange (114), bolt (115) and washer (116) tojoint of flange (113), which the free side of hose (112)is installed to hydraulic cylinder (88) in step [1].

a Take care not to forget to fit O-rings (117).

a When connecting the hydraulic hoses, remove the oilhead (Part No.: 07378-10600) installed to the joint inadvance.

[5] Reinstall the covers removed in step [2].


No. Part Name Part No. Q'ty117 O-ring 07000-F3025 4


M10 17 mm

Bolt specification M12 M20 Tool (Socket) 19 mm 30 mm


90

6. Installation of brace assembly

a The brace assembly is applied to the single tilt dozerspecification in the portion shown in Fig. 28.Not necessary for super dozer

[1] Remove covers (51 – 54) and brace assembly mount-ing pins (55 – 58) installed to the brace assemblymounting section of the left straight frame in advance.(Fig. 29)

[2] Remove brace assembly mounting pins (59 – 62) in-stalled to the brace assembly mounting section of theblade in advance. (Fig. 30)


Bolt specification of 53, 57 M20

Tool (Socket) 30 mm

91

[3] The brace assembly consists of the following parts.(Fig. 31)

[4] Supply grease (See step [9]) through fitting (64) in-stalled to brace (63) and rotate brace (63) with at-tached lever (73) to adjust dimension (L) between theholes at both ends of brace assembly to approximate-ly 1,850 mm. (Fig. 32)

ReferenceIf brace (63) is rotated with lever (73) while screws(66) and (67) at both ends are fixed, dimension (L) in-creases or decreases by 12.7 mm performance turn.Accordingly, if only one side screw in the both endscrews is rotated by a half turn, dimension (L) can beadjusted by 3.175 mm.


No. Part Name Part No. Q'ty63 Brace 198-72-53260 164 Fitting 07020-00000 265 Seal 2989-01-2580 166 Screw 198-71-21280 167 Screw 198-71-21272 168 Bushing 195-71-51254 169 Ring 195-71-52360 170 Handle 198-71-32150 171 Bolt 01010-81660 272 Washer 01643-31645 2

92

[5] While slinging brace assembly with the belt sling, withthe handle (70) up, align the mounting pin hole of thebrace assembly with that of the straight frame. Then,insert mounting pin (55) removed in step [1] and fix itto the straight frame with lock (56), bolt (57) andwasher (58). (Fig. 33)

• Sling weight (Weight of brace assembly):Approx. 280 kg


[6] While still slinging the brace assembly with the beltsling (21), align the mounting pin hole on the oppositeside of step [5] with the mounting pin hole of the brace.

a At this time, if the mounting pin holes cannot bealigned because of dimension (L) adjusted in step[4], rotate screw (67) one half by one to adjust di-mension (L) finely while locking brace (63).

Then, insert mounting pin (59) removed in step [2]and fix it to the blade with lock (60), bolt (61) andwasher (62). (Fig. 33)

[7] Loosen and remove the sling.



Tool (Socket) 30 mm



Tool (Socket) 30 mm


If brace (63) is rotated with lever (73)to adjust dimension (L), the directionof handle (70) changes. According,do not apply this method.

93

[8] Reinstall covers (51) – (54) removed in step [1].

[9] Greasing

After finishing installation, supply grease to the 5 plac-es indicated with the arrows in (Fig. 34) until it comesout.

a G2-LI in "Coating material list" in this manual isrecommended as grease for the above purpose.


No. 53 57

Bolt specification M20 Length 40 mm

M20 Length 50 mm

Tool (Socket) 30 mm


Single tiltdozer 6 places indicated by arrowsDual tiltdozer 4 places indicated by arrowsSuper dozer 4 places indicated by arrows

Single tiltdozer

Dual tiltdozer, Super dozer

94

Condition 1) Before starting the following work, complete "Assembly procedure A-12".2) Before starting the following work, set the engine so that it can run to move the machine.

1) Posture of blade assembly before installation

Adjust the posture of the blade assembly before installation with wooden blocks (E) and (F) as shown in (Fig. 1) and (Fig. 2).

a Dimension (a) in the table is set on the assumption that the machine is used on a hard ground where the track shoe grous-ers will not sink. If the machine is used on a ground where the grousers sink, the trunnion height decreases by the sinkingdistance. Accordingly, dimension (a) must be lowered by the decrease of the trunnion height.

a If the center link falls, dimension (b) increases. To prevent this, set wooden block (F) under the center link or arm.

a Leave wooden block (G) set to erect the blade vertically in "assembly procedure A-12" as it is.

2) Connection of blade assembly and machine

2.1) Peel off the paint from the spherical part of the trun-nion and clean its surface.

a Apply grease [G2-LI] to the spherical part of the trunnion.G2-LI : See [Coating materials]

2.2) Set the machine within dimension (b) of the blade assembly and move it forward so that the right and left clearanceswill be the same.

2.3) Move and press the machine forward until the trunnion is seated in the trunnion holder (bushing) of the blade assem-bly (straight frame). (Fig. 3)

Assembly procedureInstallation of blade (1/8)A-13

Dimension (a) Dimension (b) (Disconnect between sphere centers)

Approx. 1,085 mm Approx. 3,810 mm

Seat

95

a If the trunnion and trunnion holder are different in height, trunnion holder bushing (2) in (Fig. 4) may move when thetrunnion is pressed.If the trunnion and trunnion holder are different in height, sling the straight frame of the blade assembly with a craneetc. and adjust their heights.

2.4) Set the trunnion parts (Fig. 4) and tighten the bolts.

2.5) Remove wooden block (E) set under the straight frame in step 1).


No. Part Name Part No. Q'ty Remarks1 Straight frame — — See "assembly procedure A-12"2 Bushing 198-71-51340 23 Plate 198-72-00110 44 Cap 198-71-51390 15 Nut 195-71-11510 46 Bolt 198-61-11250 47 Washer 01643-33380 4


Tool (Socket) 50 mm


96

3) Connection of hydraulic hoses for tiltdozer and super dozer

3.1) Remove the plug at the tip of the hydraulic hosecoming out from the center hole of trunnion.

a Take care not to lose the "O-rings".

3.2) Remove the upper and lower plugs from the nip-ples of the flange (7) in (Fig. 5) on the blade assem-bly side.

3.3) Connect the hydraulic hoses to the nipples of theabove flange. (Fig. 5)

a When connect it, certainly assemble O-ring (02896-11018) removed in step 3.1).

a Connect the hydraulic hoses according to the following table.

a The part Nos. of the plug and nut removed from the nipple of the flange in step 2) are shown below for reference.

This part is not necessary any more after the blade assembly is installed to the machine.Keeping this part is recommended, however, since it is necessary again when the blade assembly is removed fromthe machine and stored.

a When the front work equipment is the single tiltdozer, perform this work only on the right side.


Hose indentification Selection of connecting nippleColor identification mark (red) at the tip of hose Connect to upper nipple.

Color identification mark (blue) at the tip of hose Connect to lower nipple.

Part name/Part No.Dual tiltdozer Single tiltdozer Super dozer

Q'ty Q'ty Q'ty

Plug 02789-00628 2 pieces each on right and left

2 pieces on only right

2 pieces each on right and left

97

4) Installation of tiltdozer hydraulic hose protection cover

Install tiltdozer hydraulic hose protection cover (8) (Fig. 6) connected in step 3).

a Before installing the protection cover, check the operation of the tilt cylinder in the blade adjustment work describedlater and confirm that there is not oil leakage or another problem in the tilt hose connection.


No. Part Name Part No. Q'ty Remarks1 Blade assembly — —4 Trunnion cap — — See 2.4) of this procedure8 Cover 198-71-21240 1 each on right and left9 Bolt 01010-82050 6 each on right and left

10 Washer 01643-32060 6 each on right and left


Tool (Socket) 30 mm


98

5.2) Start the engine and operate the blade control leverto extend/retract the hydraulic cylinder rod andalign it with the connecting hole (joint link) of theblade assembly. Part (A) in (Fig. 9)

a The work shall be performed by the machine op-erator, crane operator, and "signalman". The sig-nalman must arrange the signaling method inadvance and give proper directions to both oper-ators.

5.3) Insert the connecting pin in part (A). (Fig. 9)

5.4) Stop the engine.

5.5) Set the lock to the connecting pin head and bolt itto the joint link. (Fig. 9)

5.6) Install blade cylinder holdfast (11) on the upper side of the cylinder facing inside of cylinder to fix the cylinder.


Belt sling

Sling bracket

5) Connection of blade assembly and blade lift cylinders

5.1) Sling the hydraulic cylinder with the belt sling andremove the transportation sling bracket.(Fig. 7), (Fig. 8)

a Connect the hydraulic cylinders one by one.

Connecting pin part No. 198-72-62140 (1 piece each on right and left)

Part No. of lock 198-72-62170 (1 piece each on right and left)

Part No. of bolt 01010-81635 (2 pieces each on right and left)

Part No. of washer 01643-31645 (2 pieces each on right and left)


Tool (Socket) 24 mm


99

6) Connection of blade assembly and blade tilt hydraulic cylinder

6.1) Remove the pins from the right and left of the cylin-der connecting side (blade). (Fig. 11)

a For the single tiltdozer, remove the pin from onlythe right side. For the left side, see "assembly pro-cedure A-12" Installation of brace assembly.

• For super dozer

6.2) The bottom side (clevis side) of the hydraulic cylin-der has been connected to the straight frame al-ready. See "assembly procedure A-11". Raise one end of this hydraulic cylinder with thebelt sling and remove the wooden block placed un-der it. (Fig. 12)

6.3) With the hydraulic cylinder raised, start the engineand operate the blade control lever to extend/re-tract the hydraulic cylinder rod and align its pin hole(P) with the pin hole (Q) of the blade. (Fig. 12)

a The work shall be performed by the machine op-erator, crane operator, and "signalman". The sig-nalman must arrange the signaling method inadvance and give proper directions to both oper-ators.


No. Part Name Part No. Q'ty12 Pin 09255-06295 1 each13 Lock 09257-09014 1 each14 Bolt 01010-82045 4 each15 Washer 01643-32060 4 each


Tool (Socket) 30 mm

No. Part Name Part No. Q'ty12 Pin 198-72-51720 1 each13 Lock 09257-09014 4 each14 Bolt 01010-82045 4 each15 Washer 01643-32060 4 each

cylindercylinder

100

6.4) After aligning the pin holes, stop the engine and in-sert pin (12) removed in step 6.1) and fix it to theblade with lock (13), bolt (14) and washer (15).(Fig. 13)

a Perform the work from step 6.2) to step 6.4) onthe right and left sides.However, perform on only the right side for thesingle tiltdozer.

a For the tightening torque of bolt (14), see "Tight-ening torque", Table 1 in this manual.

6.5) Loosen and remove the slings of the hydraulic cyl-inder.

6.6) Start the engine again and operate the blade con-trol lever to raise the whole blade assembly.Then, remove all the wooden blocks placed underthe blade.

6.7) Lower the blade to the ground and stop the engine.

7) Confirmation of operation of blade assembly

7.1) Check of hydraulic oil level and supply of new oil

[1] Check the hydraulic oil level again and supply new oil,if necessary.

a Confirm the oil level after lowering the rippershank and blade to the ground and set the back ofthe blade perpendicular to the ground.

a About the kind of used fluids refer to "Assemblyprocedure A-7" Check on the amount of lubricantsand coolant.

7.2) Check of each part for interference

[1] Move the blade slowly and check that each part doesnot make interference or abnormal sound.If abnormal sounds seem to come from the ball jointsat both ends of the center brace, see step 7.5).

[2] Confirm that the blade does not interfere with the ma-chine (radiator guard) when it is tilted to the maximum(or dual-tilted to the maximum for the dual tiltdozer) atthe maximum lifting height.

[3] Confirm that there is sufficient clearances betweenthe straight frames of the blade assembly and thetracks of the undercarriage when the blade is tilted tothe maximum (or dual-tilted to the maximum for thedual tiltdozer).


101

7.3) Confirmation of operation of blade

[1] Confirm that the blade is "raised" and "lowered" ac-cording to the operation of the blade control lever.(Fig. 14)

[2] Confirm that the blade is "right-tilted" and "left-tilted"according to the operation of the blade control lever.(Fig. 15)

[3] Inspect according to the "Field assembly inspectioncheck sheet" attached to the end of this manual.

a If the lateral balance or the clearance betweenblade assembly and machine needs to be adjust-ed and the brace assembly length must be adjust-ed consequently as a result of the check, return to"assembly procedure A-12" Assembly of blade, 6.Installation of brace assembly, and readjust thoseitems.

• Confirmation of operation of dual tiltdozer

[4] In addition to [1] and [2] of the single tiltdozer specifi-cation, ensure that the blade is "pitched back" and"pitched forward" according to the operation of theblade control lever. (Fig. 16)

[5] Furthermore, confirm that the blade is "left-dual-tilted"and "right-dual-tilted" according to the operation ofthe blade control lever.

[6] Inspect according to the "Field assembly inspectioncheck sheet" attached to the end of this manual.

a For super dozer, this corfirmation of operation ofdual tiltdozer is not necessary.

7.4) Readjustment of ball joint shims at both ends of center braceWhen the blade is tilted to the right or left, if abnormal sound comes from either of the ball joints at both ends of thecenter brace, remove the ball cap of the ball joint which produces the abnormal sound and add the thinnest shim (0.5mm) according to "assembly procedure A-12" Assembly of blade, step 4, and tilt the blade again to check.


102

1) Installation of open lock strikerInstall right and left open lock striker mounting brackets(1) and (2) with sems bolts (3), washers (4) as shown in(Fig. 1). (5 pieces on each side)

a Strikers (5), nuts (6), washers (7), stopper rubbers(8), and nuts (9) are installed to the bracket when de-livered.

After mounting the operator's cab on the chassis, checkthe inspection items.

2) Installation of cab mounting bracket (L-shaped plate)Temporarily tighten the bracket (10) (L-shaped plate forindoor use) and bracket (11) (for outdoor use) to the po-sition shown in [Fig. 2] by using sems bolts (12) andwashers (13) (3 pieces on each side).Loosen the sems bolts (12) before installation of the cab.

Assembly procedureInstallation of operator's cab (1/20)A-14

No. Part Name Part No. Q'ty Remarks1 Bracket (L.H.) 198-Z11-3341 1 Left2 Bracket (R.H.) 198-Z11-3351 1 Right3 Bolt 01010-D1230 104 Washer 01643-71232 105 Striker 14X-911-1921 26 Nut 01580-11008 87 Washer 01643-31032 88 Stopper 09453-00002 29 Nut 01580-01210 2

10 Bracket 198-Z11-3571 111 Bracket 198-Z11-3581 112 Bolt 01010-D1230 1213 Washer 01643-71232 12

103

3) Installation of rubber seals (14) to dashboard bracket

3.1) Apply paste seal (55) to the mating faces of thedashboard bracket and floor as shown in (Fig. 3).

3.2) Fit rubber seal (14) to the guide plate of the dash-board bracket and apply paste seal (55) as shownin (Fig. 4).


No. Part Name Part No. Q'ty Remarks14 Rubber seal 198-Z11-3540 1 Sponge rubber55 Paste seal 198-Z11-3960 1

Apply G2-LI

3.3) Apply grease (G2-LI) to the outside of rubber seal(14) (joint face to the cap) as shown in (Fig. 5).

Remark 1: Apply grease so that the cab and rubber seal(14) will slip well against each other and rub-ber seal (14) will not be shifted or deformedwhen the cab is installed.

Remark 2: For the ease of assembly, remove both ofright and left covers (A) before installing thecab and reinstall them after installing the cab.

104

4) Installation of rubber seals to mating face of operator cab bottom (Fig. 6)

4.1) Weight of operator cab assembly: Approx. 500 kg

4.2) Remove dirt, oil and grease from the rubber seal sticking faces of operator cab bottom.

4.3) Peel off the release paper of rubber seals (15), (16) and (17) and stick those seals, referring to (Fig. 7) on the nextpage.

Remark : Since the rubber seals are made a little longer than required, cut them properly when sticking.


No. Part Name Part No. Q'ty15 Rubber seal 14X-911-5911 316 Rubber seal 198-Z11-7420 2

17-1 Rubber seal 198-Z11-7410 117-2 Rubber seal 198-Z11-7430 1

105

Fig. 7 How to stick seals (View from bottom of operator's cab)

Remark : For the base seal shown in the figure, see the next page.


17

1616

16

2017

15

17

20

106


No. Part Name Part No. Q'ty55 Paste seal 198-Z11-3960 1

⑮

⑯

⑮

⑰

⑯

Apply paste seal (55) to clearance

Apply paste seal (55) to clearance

107

5) Installation of operator cab (hereinafter referred to as cab)

5.1) Lower the operator's cab assembly slowly onto thefloor frame.

a Since the clearance between the air conditioner ducton the cab side and the machine monitor (instrumentpanel) is narrow, lower the cab carefully, taking carenot to hit it.

a Since the rubber seal has high reaction force, takecare that the cab will not swing or move laterally.

a Take care that the rubber seal will not be moved ordamaged.

a Eliminate the clearance between the rubber seal ofthe air conditioner duct on the cab side and the airconditioner duct on the dashboard side.

Remark: For the machine monitor, see "assembly procedure M-2".

5.2) Tighten bolts (18) and (20) and washers (19) tem-porarily. See (Fig. 15)

a The bolts at the cab door inlet have different length.Take care.

5.3) Confirm if there is a clearance between the matingpart (a) of the rubber seal and floor frame. (Fig. 14)

a If there is a clearance as a result of the confirmation,sling the cab again and repeat the procedure fromstep 5.1).If the clearance is very narrow, however, fill it withpaste seal (55).


After installing cab, check that there is not clearance at each corner.

Lower cab in direction of arrow.

After installing cab, check that there is not clearance at each corner.

Lower cab in direction of arrow.

DashboardBracket

Cab

Flange

108


No. Part Name Part No. Q'ty18 Bolt 01010-81275 1519 Washer 124-54-26540 2120 Bolt 01010-81245 655 Paste seal 198-Z11-3960 1

Operator cab assembly

15 parts

6 parts

Floor frame assemblyLower part of door

109

5.4) Check that the clearance between the air condi-tioner duct on the cab side and monitor is even onthe right and left sides. At the same time, checkthat the air conditioner duct seal on the cab side isfitted to faces (C) on the right and left sides of theair conditioner duct on the dashboard side and it isnot moved to the right or left.

5.5) If the clearance between the air conditioner duct onthe cab side and monitor is not even, loosen the airconditioner duct mounting screws on the cab sideand move the air conditioner duct so that the clear-ance will be even.If the duct on the cab side or air conditioner side ismoved to the right or left, adjust it similarly.

5.6) Permanently tighten bolts (10), (18) and (20) whichwere tightened temporarily in step 5.2) above .

5.7) Permanently tighten mounting bolts (12) of L-plates (11) which were installed temporarily in step5.4 above.


110

5.8) Install plates (21) with bolts (22) and washers (23). (2 pieces on each side)

5.9) Install right and left foot rests (24) and (25) with bolts (26) and washers (27).

5.10) Install pedal caps (28) to the foot rests.


No. Part Name Part No. Q'ty21 Plate 198-Z11-2961 222 Bolt 01010-D1230 423 Washer 01643-71232 424 Foot rest (left) 14X-911-5711 125 Foot rest (right) 14X-911-5721 126 Bolt 01010-D1230 427 Washer 01643-71232 428 Pedal cap 203-43-56450 2

Part P

111

5.11) The bundle of window washer tubes and the powersupply wiring harness for cab (A) in (Fig. 20) comeout of the bottom of the cab left side pillar (pillar atthe left door hinge) into the cab. Take them out ofthe cab through the hole on the floor frame (B) in(Fig. 20).

5.12) Fit the grommet of the rubber boot protectingabove bundle (A) to hole (B) and connect the bootto the cab and floor frame. (Fig. 21)

5.13) Connect bundle of the window washer tubes andpower supply wiring harness for cab (A) pulled outin step 5.11) to the window washer tubes and pow-er supply wiring harness for cab installed to the ma-chine in advance at a place out of hole (B)indicated with Xo in (Fig. 20). (Fig. 22), (Fig. 23)

a The window washer tubes and power supply wir-ing harness for cab have connector No. indicatingrings at their ends as shown in (Fig. 22).Connect the tubes having the same color marksand the connectors having the same Nos. togeth-er respectively.


Operator cab

Floor frame

Grommet

112


No. Part Name Part No. Q'ty29 Clip 198-Z11-2961 130 Clip 01010-D1230 131 Sems bolt 01643-71232 1

Identification color marks

Window washer tubes

Connectors No.

Wiring harness connectors

Connector No. indicating ring

1 Phase

1 Phase

3 Phase

4 Phase

• Red For right door• Blue For left door• Black For rear window• — For front window

Window washer tubesWiring harness for cab power source

113

a When installing the garnish, be sure to install the screws shown in the figure.


Garnish

Knob(Lever)

6. Installation of left parking brake lever knob

6.1) Before installing the garnish, remove the lever knob.

6.2) After installing the garnish, apply adhesive (LT-2) tothe thread part of the knob, and then install the knobto the lever.

Screw

Screw

114

7. Installation of bellows bracket

7.1) Pull and remove bellows (101) and bellows bracket(102) of blade lever as shown in the photo.

7.2) Similarly, remove bellows (103) and bellows brack-et (104) of ripper lever.

7.3) Install cover (33).

7.4) Install the bellows bracket to fixing spring (105).

• Installing condition of cover (33) (Fig. 30)


Correct Wrong

Fig. 30

115



1. Install plate (42) on cover (38) as shown in the photo.

2. Install cover (38) first, and then install plate (42).Match the mounting holes of cover (38) before installing plate (42). After plate (42) is installed, the position of cover (38) cannot be adjusted. (Fig. 33, Fig. 34)

3. If the band to fix the optional lunch box is selected, see also A-23.


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8) Installation of interior parts

8.1) Install floor covers (35), (36), and (37) with screws(40) (14 pieces).

8.2) Install covers (38), (39), and (41) with button (43). (16places)

8.3) Install cup holder (46) with screws (47) to plate (42).Then, install ashtray (44) and cigarette lighter (45) toplate (42) with screws (47) and washers (48).

8.4) Install grille (50).

8.5) Install rubber chutes (51) and (52).

No. Part No. Q'ty35 198-Z11-6170 136 198-Z11-6190 137 198-Z11-6150 138 198-54-61511 139 198-54-61531 140 01024-D0820 1441 198-54-61521 142 198-Z11-6160 143 23D-950-4450 1644 20Y-06-21751 145 20Y-06-23472 146 17A-Z11-3180 147 01245-00616 448 01643-70623 449 01370-40408 250 201-979-7820 251 198-Z11-6230 152 198-Z11-6241 1

116


Correct installation

Wrong installation

Plate (42) is installed under cover (38).

117

8.6) Install sensor (62) to cover (61), connect CN-SLS, and then install them with screws (63) and washers (64). (4 pieces)

8.7) Install plates (57) and (58) with screws (59) and washers (60). (8 pieces)

8.8) Install cab door plate (65). (On both sides).

8.9) After installing cab door plate (65), apply liquid sealant (55) all around the plate. (On both sides) Before opening and closing the door, wait until the sealant dries up.


CN-SLS is fixed to dashboard wiring harness with band.

Cut band and connect.

Section of central part of cab

Sensor

No. Part No. Q'ty55 198-Z11-3960 157 198-Z11-2941 158 198-Z11-2951 159 01245-00616 860 01643-70623 861 198-Z11-6280 162 20Y-979-6161 163 01245-00616 464 01643-70623 465 198-Z11-6410 275 01010-D0645 676 01643-70623 6

118

8.10) Install cushion (67) and install mat (68) on it.

8.11) Install mat (69).

8.12) Install plate (65). (On both sides, See Fig. 36)




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No. Part No. Q'ty67 198-54-75681 168 198-54-15791 169 198-54-75770 170 198-54-75620 171 198-54-75610 172 198-54-74950 173 198-54-74941 174 198-54-74862 1

119

8) Install floor mat (74) while holding down its right and left ends with plates (81) and (82) attached to the bottom of the oper-ator cab doorway. (See Fig. 39)


No. Part Name Part No. Q'ty Remarks81 Plate (Left) 198-Z11-6410 182 Plate (Right) 198-Z11-6410 1

Section A-A

120

10) Installation of rear view mirror (if equipped)

10.1) Install rear view mirror (91) to bracket (92).

10.2) Install bracket (92) to the front duct top of the operator cab with bolts (93) and washers (94).

a The rear view mirror is an optional part, which is not installed to the operator cab of the standard specification.

a Each operator cab to be equipped with the rear view mirror is delivered with the rear view mirror installed, as a rule.

Accordingly, this work is required only when the rear view mirror is delivered uninstalled.


No. Part Name Part No. Q'ty Remarks91 Mirror 14X-911-6140 192 Bracket 198-Z11-3670 193 Bolt 01010-D0845 294 Washer 01643-70823 2

121

11) Change of installed angle of radio antenna

Loosen the wing bolt at the center of rotation of the radio antenna, rotate the antenna from position (T) indicated with the brokenline to position (P) indicated with the solid line, and stand it vertically.Tighten the wing bolt again to fix the antenna.

a Loosen and tighten the wing bolt with the hand.

a The radio antenna is set to position (T) indicated with the broken line for packing when the operator cab is transported fromthe factory to the field.


122

Assembly procedureInstallation of ROPSA-15



Torque wrench (2,059 Nm {210 kgm}) 1

Socket 50 mm (38.1 T) 1

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No. Part No. Q'ty1 01011-83310 162 01643-33380 16

Set stamp F on the front side.

• Sling the ROPS with the crane and install it to themounting position.

4 ROPS: 918 kg

3 Mounting bolt (1):1,960 – 2,450 Nm {200 – 250 kgm}

123

Assembly procedureInstalling direction of exhaust pipeA-16



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No. Part No. Q'ty1 6162-13-5611 22 01010-81025 43 01643-51032 4

• After installing the exhaust pipe, connect komaclone tube (4), using gasket (1), bolt (2), andwasher (3).

Install rain caps 20¡ rotated.

Right of chassis

Left of chassis

Front of chassis

124

1. Operate the machine to make the distance from the bot-tom of ripper beam to the ground as dimension (H) shownin Fig. 1.

a (H): 2700 mm or morea Make the hole for shank holder of ripper beam to be

vertical to the ground.

The following is an example of the method. Choose prop-er method according to the conditions in the field.1) Set the rear of the machine on blocks, etc. to raise it

as shown in Fig. 1.2) Raise ripper arm to the highest position, operate rip-

per beam, and set the hole for shank holder vertical tothe ground.

2. Set ripper shank on the ground under ripper beam. At thistime, the sling ring on the top of ripper shank should beright under the hole for shank holder of ripper beam.

3. Set lifting rope sling on the crane, and insert the rope slinginto the hole for shank holder of ripper beam from the topto leave the front end of the rope sling on the ground.

a Rope sling: ø12 mm × 4 mSee "Tools list for field assembly"

4. Connect the rope sling and the lifting ring of ripper shankwith shackle.

a Shackle: SD22-MSee "Tools list for field assembly"

a Weight of shank assembly: approx. 9.8 kN {1000 kg}

5. Sling ripper shank by using crane, and insert it into thehole for shank holder of ripper beam.

6. Align the pin holes of ripper shank and ripper beam, andinsert shank mounting pin to fix it.

Reference: The procedure for multi-ripper specification is al-most the same.

Assembly procedureInstallation of giant ripper shankA-17

Crane

Rope sling

Ripper

Shackle

Shank assembly

125

Assembly procedureAdjustment of arm joint (U-blade)A-18

Check of clearance in arm ball joint

fl If the clearance in arm ball joint is adjusted properl y in Assembly procedure A-8, step 4, followingcheck is not necessary.

Shim (1)

Bolt (2)

Adjustment of shim

Standard thickness of shim: 4.5 mm

Adjustment of shim

Adjustment of shim

Adjustment of shim

1. Remove shim (1) and tighten bolt (2) until theplay of the ball joint is eliminated.

2. Measure clearance “A” and remove bolt (2).

3. Install shim (1) having thickness of “A + (0 to 1)mm”.

4. Tighten bolt (2). Then, check that the ball jointrotates smoothly.

126

Assembly procedureInstallation of counterweightA-19

(1) Sling the counterweight assembly and set it to themounting position of the main frame.

Weight of counterweight: 7,300 kgLifting wire: ø20 mm ✕ 6 m ✕ 2 pieces

(2) Install the mounting pins as shown in Fig. 2.

No. Part name Part No. Q ty1 Counterweight assembly 12 —3 Lifting wire

Main frame2

4 Pin 198-78-21180 25 Plate 205-70-61560 26 Bolt 01010-82045 47 Washer 01643-32060 48 Pin 198-78-21140 29 Plate 195-78-21171 2

10 Bolt 01010-82040 411 Washer 01643-32060 4

Fig. 1

Fig. 2

127

1. Dual-tiltdozer1-1 Set the machine under the standard condition.

• Set the potentiometer rod to 425 mm.• Keep the machine horizontally.

1-2 Run the engine at low idling and set the blade in thefollowing standard position.1) Set the tilt angle to 0°.2) Set the pitch angle to the maximum pitch back.3) Lower the blade to the ground and then raise it

about 100 mm.4) Set the toggle switch of the blade lever to the

dual tilt position.

Assembly procedureProcedure for adjusting blade tilt angle limit (1/9)A-20



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Pitch back

Tilt switch

Dual tilt

128

1-3 Adjust mounting dimension "a" of rod (1) and con-nect the rod to potentiometer lever (2) and yoke (3).

• Mounting dimension "a": 425 mm

1-4 Mode and operation "Note 1"1) Hold buzzer cancel switch (3) in the posi-

tion for 2.5 seconds, and the maintenancemode is displayed.

2) Set the buzzer cancel switch to informationswitch (2), and the adjustment mode is select-ed.

3) Set the buzzer cancel switch in the position,and the adjustment mode selecting screen isdisplayed.

4) Operate the information switch to displaythe tilt limit setting screen.

5) Set the buzzer cancel switch in the select posi-tion ( ) to enter the tilt limit adjustment mode(User adjustment mode). If the pitchback but-ton (lower button) of the work equipment con-trol lever is pressed, the buzzer sounds and thereference position is saved.

6) Set the buzzer cancel switch in the cancel po-sition ( ) to leave the adjustment mode tem-porarily.



Note 1) For buzzer cancel switch and information switch, see "Assembly procedure M-2".


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129

1-5 Raise the blade tip to about 1,000 mm above theground.

1-6 Tilt the blade to the left with the blade control leverand set the left tilt angle to 12°. (User adjustmentmode)

a Since the tilt limiting function does not work, oper-ate slowly so that the tilt angle will not increasetoo much.

a Adjust the tilt angle accurately with angle gauge.

1-7 Set the toggle switch of the blade control lever inthe single tilt position, and then set it in the dual tiltposition again to save the left tilt limit in the system.

a When the saving operation is finished, the buzzersounds.




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Tilt switch

Single tilt

Dual tilt

130

1-8 Set buzzer cancel switch (3) in the cancel position( ) once to leave the adjustment mode.

1-9 Set the blade in the maximum pitch type position.(Set the work equipment horizontally.)

1-10 Set buzzer cancel switch (3) in the select position ( ) again to enter the tilt limit adjustment mode.




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131

1-11 Tilt the blade to the right with the blade control leverand set the right tilt angle to 12°.a Since the tilt limiting function does not work, op-

erate slowly so that the tilt angle will not in-crease too much.

a Adjust the tilt angle accurately with anglegauge.

1-12 Set the toggle switch of the blade control lever in the single tilt position, and then set it in the dual tilt position againto save the right tilt limit in the system.

a When the saving operation is finished, the buzzer sounds.

1-13 The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( ) to leave the adjustmentmode, and then lower the work equipment to the ground and stop the engine.

1-14 Start the engine again and tilt the blade to the right and left and check that the blade does not interfere with the trackshoe, regardless of its height.




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132

2. Superdozer2-1 Set the machine under the standard condition.

• Set the potentiometer rod to 425 mm.• Keep the machine horizontally.

2-2 Run the engine at low idling and set the blade in thefollowing standard position.1) Set the tilt angle to 0°.2) Set the pitch angle to the maximum pitch back.3) Lower the blade to the ground and then raise it

about 100 mm.

2-3 Adjust mounting dimension "a" of rod (1) and con-nect the rod to potentiometer lever (2) and yoke (3).

• Mounting dimension "a": 425 mm




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Pitch back

133

2-4 Mode and operation "Note 2"1) Hold buzzer cancel switch (3) in the posi-

tion for 2.5 seconds, and the maintenancemode is displayed.

2) Set the buzzer cancel switch to informationswitch (2), and the adjustment mode is select-ed.

3) Set the buzzer cancel switch in the position,and the adjustment mode selecting screen isdisplayed.

4) Operate the information switch to displaythe tilt limit setting screen.

5) Set the buzzer cancel switch in the select posi-tion ( ) to enter the tilt limit adjustment mode(User adjustment mode). If the pitchback but-ton (lower button) of the work equipment con-trol lever is pressed, the buzzer sounds and thereference position is saved.

6) Set the buzzer cancel switch in the cancel po-sition ( ) to leave the adjustment mode tem-porarily.

2-5 Operate the blade according to the following proce-dure so that it can be tilted.1) Raise the blade tip to 300 mm above the

ground.2) Set the blade angle to 52°.a Adjust the blade angle accurately with angle

gauge.



Note 1) For buzzer cancel switch and information switch, see "Assembly procedure M-4".


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134

2-6 Set the buzzer cancel switch in the select position( ) to enter the tilt limit adjustment mode (Useradjustment mode).

2-7 Raise the work equipment about 1,000 mm withoutchanging the blade pitch angle adjusted in step 2-5 and tilt it 8 ± 1° to the left. Under this condition,press the pitch-dump button (upper button), andthe buzzer sounds and the left limit position issaved.a Since the tilt limiting function does not work, op-

erate slowly so that the tilt angle will not in-crease too much.



135

2-8 Operate the work equipment control lever to tilt thework equipment to the right. Under this condition,press the pitch-dump button (upper button), andthe buzzer sounds and the right limit position issaved.a Since the tilt limiting function does not work, op-

erate slowly so that the tilt angle (a) becomesthe following angle in the chart.


2-9 The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( ) to leave the adjustmentmode, and then lower the work equipment to the ground and stop the engine.

2-10 Start the engine again and tilt the blade to the right and left, operate the blade following the procedure in section 2-5 and raise the blade about 1,000 mm, and check that the blade stops tilting to the right and left in the following rangeautomatically. • Automatic tilt stopping angle: 8 ± 1°




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Shoe width Tilt angle (a)810 mm 8 ± 1°910 mm 9 ± 1°

a

136

System to return the blade to the digging position automatically

1. Auto pitch back switch : ON2. Pitch the blade forward.3. Set the gear speed in R1 or R2.4. Press the pitch-back button.5. The blade is fully pitched back.6. The blade returns to the digging position and horizontal

position.

The auto-reset system is used to set the blade in the digging position automatically (to lower the blade to the ground and setits angle to 52°). To reset this system, press the pitch button.

Assembly procedureMethod of checking auto-reset system (Superdozer)A-21



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Auto pitch back switch

Pitch dump

Pitch back

Tilt forwardDigging posture

Controller

Valve

Pitch back solenoid

137

1. Remove left cover (6) (above the left fender).

2. Install the wiring harness and antenna (3) as shown in thefollowing figure.

3. Install left cover (6).

Assembly procedureInstallation of ORBCOMM antenna and wiring harnessA-22


ORBCOMM:The ORBCOMM terminal system is a communication system to use the satellite communication service of ORBCOMM Co., Ltd. (USA).


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No. Part No. Q'ty1 01010-81220 52 04434-50612 53 8A13-10-2100 14 21N-54-38451 15 01010-81225 1

138

Note) This part is optional. If not ordered, this part is not equipped.a When performing the following procedure, refer to A-14 Installing operator's cab, too.

1. After installing plate (1) to the operator's cab, pass the band through the rear U-hook as shown below.

2. Install cover (3).Slide and position cover (3) to the rear U-hook as shown in the figure of part (P), and then fix it.

Assembly procedureInstalling lunchbox band (if equipped) (1/2)A-23



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P

No. Part No. Q'ty1 198-Z11-6170 12 198-911-7350 23 198-54-61511 1

139

3. Referring to A-14 Installing operator's cab, install the lining and rubber plate.

4. Install the band as shown below.

Assembly procedureInstalling lunchbox band (if equipped) (2/2)A-23



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After installing cover (3), pass band through front and side U-hooks.

Lining

Front

Rubber plate

140

a For using oil type, see "A-7 Check of oil and coolantlevels" in assembly procedure.

a1. Blade

2. Blade lift cylinder support yoke

Assembly procedureGreasing each part of work equipment (1/3)A-24

Center ball joint

Center link pin

Left ball joint

Right ball joint

Cap upper side

Cap lower side

141

3. Blade lift cylinder support shaft

4. Ripper


Cylinder bottom LH and RH

LH & RH LH & RH

LH & RH

Arm bottom LH and RH

Support shaftLH and RH

142

5. Equalizer bar side pin

6. Equalizer bar both end.

7. Suspension(Equalizer bar center shaft) (1 place)


Equalizer bar side pin LH and RH

(Right side of engine room)

Remove cover andlubricate both end.

143

Assembly procedureBleeding air from hydraulic cylindersA-25



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

1. Blade lift cylinder (with piston valve)

1) Start the engine and run at low idling for approx. 5 minutes.

2) With the engine at low idling, extend and retract the cylinder four or five times without operatingit to the end of its stroke.fl Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the

circuit under any circumstance.

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

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

2. Blade tilt cylinder (without piston valve)

1) Start the engine and run at low idling for approx. 5 minutes.

2) With the engine at low idling, raise and lower the blade four or five times without operatingthe cylinder to the end of its stroke.fl Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the

circuit under any circumstance.

3) Repeat this operation with the engine at full throttle, then run the engine at low idling andoperate the piston rod to the end of its stroke to relieve the circuit.

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

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

144

1. Bleeding air from pumps

Procedure:Loosen air bleeding plug before starting the engine.Start the engine, and leave the pump opened until no bubbles are found in the oil flowing out.After that, tighten the plug.

Assembly procedureAir bleeding from work equipment pump and fan pumpA-26


Stop the engine before tightening work equipment pump.Or there is danger of being caught into the universal joint.


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2) Bleeding air from work equipment pump

Tighten after air is bled1) Bleeding air from fan pump (1 place)

145

M. CHECK AND MAINTENANCE PROCEDURESAFTER COMPLETION OF ASSEMBLY

146

Assembly procedureCheck and adjustment of operator’s cab (1/7)M-1

1. Measuring pressure in cab(1) Measure the pressure in the cab.

• Criterion: Measured value ≥ 98.1 Pa {10 mmH2O}• Testing condition : Run the engine at full throttle and set the engine fan to 100%.

: Max. cooling fan speed.: Set the blower to the high (Hi).

fl Set the maximum cooling fan speed of the USER ADJUST MODE of the machine monitor.Use the USER ADJUST MODE according to Assembly procedure M-4.

fl Operate the blower according to the following procedure.

1) Depress air outlet selector switch (2) on the airconditioner control panel to select the front-rear-foot area mode (shown at right).

2) Select the fresh air mode with the RECIRC/FRESHair selector switch (3).

3) Depress fan switch (1) to set the blower to thehigh (Hi).

Front-Rear-Foot area(including defroster)

<Indication on LCD and air flow>

Indication on LCD Air flow

Low

Medium 1

Medium 2

Medium 3

Medium 4

High Blowerat high (Hi)

fl If the standard pressure is not obtained, check theseals around the dashboard and the seals of thefitting faces of the cab and floor for an opening.(Run water over outside to see if it enters the cab.)If there is an opening, fill it with liquid seal.

147

(2) Outlined below is a simplified method for the internalpressure measurement of the operator’s cab:

a) Prepare a transparent vinyl hose (of an outer diame-ter of 10 mm and 3,000 mm long).

b) Pour water into the hose bore for about a half of thehose length.

c) Remove the sliding windshield lock lever located onthe side panel of the operator’s cab to insert one endof the vinyl hose before fastening an adjacent part ofthe hose to the top end of the back seat using packingtape. (See photo.)

d) Seal the hole of lock lever with tape.

e) Match the water levels of the beginning part and theending part of the water cloumn inside the transparentvinyl hose at the outside of the operator’s cab.

f) Start the engine and run it at full speed to read the dif-ference between the two water levels.

a Before measuring inner pressure, confirm that thegrommet at the position shown in Fig. A is firmlylocked.


Fig. A is the same with Fig. 21 in "Assembly Procedure A-14".

Remove lock lever and insert vinyl hose.

Fix vinyl hose to top end of back seat

Vinyl hose

10 m

m o

r mor

e

Outside(Atmospheric pressure)

Inside theoperator’s cab

Lock lever mount hole

148




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(Sealed surface)

Shower test for water-tighteness

2. Shower test for water-tightness

(1) Close all the opening sections of the operator’s cab.(2) Prepare to pour water of a flow of about 19 ¬/min. through a water hose.(3) Pour water to the area around the hatched section in Fig. for about 10 minutes.

When doing this, it is not necessary to use pressurized water.(4) Pour water horizontally to the sealed surface according to the “Cross-section A-A”.(5) Carefully check the area around the dashboard, in particular.

fl When any water leakage is found, apply due caulking before re-checking the section if thewater leakage still occurs.

149


Center of the strikerCenter of the latch

3. Checking the door lockCheck the correlation between the operator’s cab structure and the door when the door is openedand closed. When anything is found abnormal, make due adjustment to correct it.

3.1 Checking the current statuses(1) Check the mounted elevation of the damper rubber. (Located at 4 places per a side and

check them on both L.H and R.H sides.)Applying a packing tape strip over the contact surfaces of the damper rubber, open andclose the door for 2 to 3 times. After finishing this opening and closing cycles of thedoor, check the contact surface of the packing tape with the operator’s cab structure.Normal: The back surface of the packing tape comes in light contact the operator’s

cab structure when the door is being closed.Abnormal: The back surface of the packing tape does not come in contact with the

operator’s cab structure when the door is being closed, or if the two sectionscome in a harsh contact such as peeling off the applied packing tape.

(2) Check the correlation between the door latch and the striker (on both, L.H and R.H side).Moving the door toward the closing direction, observe the engaging state between thelatch and the striker.

Check if the center of the striker and thecenter of the latch are not deviated.

Packing tape stripDoor

Damper rubber (14X-911-1690)Mounting screw (01023-20616)

Shim (14X-911-1761)

Latch

Striker

Make the observation tocheck the engagement fromthis side.

StrikerLatch

150



When the grease adhering over the latch surface dries out, the turning effort for the knob will become heavier.Therefore, apply grease sufficiently in order not to allow it to become dried up.


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3.2 Adjustments(1) Adjusting the elevation of the damper rubber

When adjusting the elevation of the damper rubber, supplement or reduce the shimsbeing inserted below the damper rubber to adjust the elevation of the damper rubberproperly.

Shims

Door structure

Damper rubber

The shape of the shim(14X-911-1761)

t1.2

(2) Adjusting the correlation between the latch and the striker(a) Loosening the striker mounting bolts to a temporarily tightened state, open and

close the door 2 to 3 times to aligh the centers of the latch and the striker.(b) Check the engaging state between the latch and the striker.(c) Tighten the striker mounting bolts back to their original tightened state.(d) Try to open and close the door to see if the door lock can be released smoothly.

When the door lock cannot be released smoothly (when the turning effort to movethe knob feels too heavy), repeat the adjustment all over again. (Appropriate knobturning effort: 68.6 ± 19.6 N {7 ± 2 kg}

(3) Apply grease (G2-LI) over the latch surface.

151




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Releasing lever

(2) Check the mounted elevation of the stopper rubber. (At 2 places each on one side. Checkthem on both L.H and R.H sides.)(a) Shaking the door back and forth in open-locked state, check for rattling.

(b) Check if the turning effort for the releasing lever is too heavy.

Shake the doorback and forth.

Make theobservationthrough thisdirection

Check if the claw of the latch isnot riding over the bent sectionof the striker.

The status is normal if the latchis not riding over the bentsection of the striker.

Latch (20Y-54-36380)Bolt (01435-30820)

Striker (14X-911-1921)Nut (01580-11008)Washer (01643-31032)

Bracket(198-Z11-3341)(198-Z11-3351)

Check and make sure thatthe body of the latch and thestriker are not interfering.The correlation is normalif they are not interfering.

4. Checking the open-locked state of the doorCheck the correlation between the operator’s cab structure and the door when the door is inopen-locked state. When anything is found abnormal, make due adjustment to correct it.

4.1 Checking the current statuses(1) Check the correlation between the open -lock latch and the striker.

(Check them on both L.H and R.H sides.)Move the door toward the opening direction to observe the engaging state between thelatch and the striker.

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4.2 Adjustment(1) Adjusting the correlation between the latch and the striker

Loosen the striker mounting nut and adjust the position of the striker so that it does notinterfere with the latch nor the overriding over the bent section occurs before tighteningthe nut back to its original state.When the interference cannot be corrected by the adjustment on the striker side, loosenthe latch side mounting bolts to make the adjustment from the latch side.

Latch

(2) Adjusting the elevation of the stopper rubber(a) Loosen the stopper rubber fastening nut.(b) When ratting exists, bring out the stopper rubber until the clearance disappears.

However, in case the lock is hard to engage for the turning effort for the releasinglever is too heavy, bring back the stopper rubber within the range where ratting ofthe door does not occur.

(c) Tighten the fasting nut back to the original state.

Clearence

Door structureStriker

Stopper rubber

Depress the door and if it movesuntil the clearance disappears,bring out the stopper rubbertoward the depressed side.

Latch

Striker

153

Machine monitorThere are the following 2 designs in the machine monitor, the functions of which are the same.

• Serial No. 30001 – 30070

• Serial No. 30071 and up

Assembly procedureInspection of machine monitor (1/13)M-2

154


Check that the "machine monitor" on the front panel can be set in the "service mode" with its specialfunction and the "failure codes" can be displayed normally in that mode.

Note: The "Service mode" is used in "Initialization of VHMS controller" of the VHMS specification de-scribed later in "Attached material 2". Accordingly, understand the operating procedure thor-oughly.

Fig. 1 Front panel

(1) Machine monitor(2) Upper display unit

• Gear speed is displayed on this unit innormal mode (operator mode).

(3) Lower display unit (Multi-information unit)• Transmission shift mode and service

meter are displayed on this unit in nor-mal mode (operator mode).

(4) Starting switch(5) Buzzer cancel switch(6) Information switch(7) Lower cover(8) Service switch

Fig. 3

155


1) Setting in "Service mode"

1.1) Remove cover (7) under the front panel so that you can operate service switch (8).

1.2) Turn starting switch (4) "ON".

1.3) While pressing service switch (8), turn and hold buzzer cancel switch (5) toward the [U] mark for3 seconds, and P, N, F2, R2, etc. displayed on upper display unit (2) of machine monitor (1)changes to 1C, 55, etc. (See Fig. 2)

a If 1C, 55, etc. is displayed, the machine monitor is set in the "service mode". 1C and 55 are ser-vice mode codes among the 8 of 1C, EE, bE, Cb, Ld, 5R, dR and 55. For details of the servicemode codes, see "Testing and adjusting volume" of the shop manual.

2) Display check of "Failure code"In the service mode, a trouble that occurred in the machine can be displayed by a classification codenamed the "Failure code" on lower display unit (3) of machine monitor (1). With this function, theoperator can grasp the cause of the trouble precisely and repair the machine quickly.

The "Failure codes" are classified into the electrical system failure codes and mechanical systemfailure codes, which are displayed on lower display unit (3) by setting the service mode code ofupper display unit (2) to "EE (Electrical system failure code display mode)" or "bE (Mechanical sys-tem failure code display mode)".

Upper display unit (2)

Lower display unit (3)

Fig. 2

Upper display unit (2)

Lower display unit (3)

Fig. 4

156


2.1) Check of "Electrical system failure codedisplay mode"

-1) Set upper display unit (2) in the servicemode and turn information switch (6)toward the > mark or < mark to displayservice mode code "EE". (See Fig. 3)

Remark:Operation of information switch(6)• Toward > mark: Next code• Toward < mark: Previous code

-2) After service mode code "EE" is dis-played, turn buzzer cancel switch (5) tothe <> mark to settle "EE".

-3) If "EE" is settled, the "failure code" of theelectrical system is displayed on lowerdisplay unit (3).

-4) For the contents of display on lower dis-play unit (3), see step 2.3).

2.2) Check of "Mechanical system failure codedisplay mode"

-1) Turn buzzer cancel switch (5) to the tmark to cancel the "EE" mode.

-2) Turn information switch (6) toward the >mark or < mark to display service modecode "bE". (See Fig. 4)

-3) Turn buzzer cancel switch (5) to the Umark to settle "bE".

-4) If "bE" is settled, the "failure code" of themechanical system is displayed on lowerdisplay unit (3).

-5) For the contents of display on lower dis-play unit (3), see step 2.3).

2.1.1)

2.1.2)

2.1.3)

2.1.4)

2.2.1)

2.2.2)

2.2.3)

2.2.4)

2.2.5)

Fig. 5

Fig. 6

Fig. 5

Fig. 6

157


2.3) Contents of display on lower display unit

The "failure codes" of both "EE (Electrical system failure code display mode)" and "bE (Electricalsystem failure code display mode" are displayed in the same format on lower display unit (3) asshown below.

-1) When the assembly work is completed, no pasttrouble is recorded and no trouble is detected cur-rently, thus the display is as shown in Fig. 5 inboth modes.

-2) If a trouble occurs after this machine is put inoperation or if there is the record of a pasttrouble, the display of (EE) becomes as shownin Fig. 6.

(1): Record No. (up to 20 Nos.)(2): Failure code (Code of trouble occurring at

present blinks)(3): Number of occurrence up to now(4): Elapsed time by service meter after first oc-

currence(5): Elapsed time by service meter after last oc-

currence

-3) If a trouble occurs after this machine is put inoperation or if there is the record of a pasttrouble, the display of (bE) becomes as shownin Fig. 7.

(1): Record No. (up to 15)(2): Failure code (Code being output currently is

flashing)(3): Number of past occurrences(4): Time tested by service meter after first

occurrence(5): Time tested by service meter after last

occurrence

2.4) Failure code

As described above, the "failure codes" are classified and displayed into the "electrical systemfailure codes" and "mechanical system failure codes". For the details of each code, see "Testingand adjusting volume" or "Troubleshooting volume of the shop manual.

The major "failure codes" are listed on the following pages.

2.3.1)

2.3.2)

2.3.3)

Fig. 7

Fig. 8

Fig. 9

Fig. 7

Fig. 8

Fig. 9

158


Error codes list (Related to machine controller)

159


160


161


162


Error codes list (Related to VHMS controller)

163


Error codes list (Related to engine controller)

164


165


166

Assembly procedureNo-injection cranking of engine (1/3)M-3

When starting the engine for the first time, perform its no-injection cranking to lubricate it in advanceaccording to the following procedure.

Note: Before performing this work, check the oil levels and complete inspection and maintenance ofeach part.

1. Use multi-information section (3) of the machine monitor, starting switch (4), buzzer cancel switch(5) and information switch (6) to set the engine in the no-injection cranking mode.

(1) Machine monitor

(2) Upper display unit• Gear speed is displayed on this

unit in normal mode (operatormode).

(3) Lower display unit (Multi-infor-mation unit)• Transmission shift mode and

service meter are displayed onthis unit in normal mode(operator mode).

(4) Starting switch

(5) Buzzer cancel switch

(6) Information switch

Fig. 1 Front panel

167


2. Procedure

(1) Turn the starting switch "ON". The machinemonitor is turned ON.

(2) Turn buzzer cancel switch ((5) in Fig. 2) to the[ ] position (left side) and hold it for 2 – 3seconds.The display of multi-information section ((3) inFig. 1) changes to OIL, FILTER MAINTENANCEMODE (Fig. 3).After the display changes, release the switch,and it returns to the neutral position.

(3) Turn information switch ((6) in Fig. 2) to the [ ]position (left side) or [ ] position (right side)several times to change the display of the multi-information section to USER ADJUST MODE(Fig. 4).

Reference: Each time the information switch isturned, the 4 modes of OIL, FILTERMAINTENANCE MODE, PM CLINICMODE, FAULT CODE DISPLAY MODEand USER ADJUST MODE are selectedin either order repeatedly.

(4) After the display of the multi-information sectionchanges to USER ADJUST MODE, turn thebuzzer cancel switch to the [ ] position (leftside) again to settle USER ADJUST MODE. Oncethis mode is settled, it does not change toanother mode described in step (3) even if theinformation switch is turned, and the multi-information section changes to the variationselection screen in USER ADJUST MODE.

Note: If the buzzer cancel switch is turned to the [ ]position (right side) by mistake, the multi-information section returns to the state in step(1).

2.1

2.2

2.3

2.4

2.1.

168


(5) Turn information switch again to the [ ]position (left side) or [ ] position (right side)several times to change the display of the multi-information section to NO INJECTION (Fig. 5).

(6) Turn the buzzer cancel switch to the [ ]position (left side) to settle NO INJECTION.

Reference: In step (5), each time the informationswitch is turned, the 7 variations of LCDBRIGHTNES, DSP BRIGHTNES, DSPCONTRAST, FAN 100% SPEED, NOINJECTION, TILT LIMIT and PRE-LUB ONare selected in either order repeatedly.

(7) In about 3 seconds after NO INJECTION issettled, the display of the lower line of the multi-information section changes from "WAIT" to"ACTIVE" (Fig. 6) and the mode becomeseffective.

(8) Under this condition, turn starting switch ((4)in Fig. 1) to the START position to rotate thestarting motor and perform no-injectioncranking.Perform no-injection cranking for about 10seconds at the normal temperature (about 20°C), depending on the ambient temperature.

Note 1: Do not perform no-injection crankingcontinuously for more than 20 seconds.

Note 2: This function does not work while theengine is running. During this period, "NOTAVAILABLE" is displayed (Fig. 7) on thelower line of the multi-information sectionto indicate that this mode is not available.

(9) To reset this mode, turn the buzzer cancelswitch to the [ ] position (right side).The display of the multi-information sectionreturns to the state after step (1) where thestarting switch is turned "ON".

(10) Turn the starting switch "OFF".

2.5

2.6

2.7

2.8

2.9

2.1

2.10

169

Assembly procedureSetting procedure of user adjust mode (1/3)M-4

When setting the cooling fan speed to about 100% of the maximum speed forcibly for measurementof the pressure inside the cab in [M-1: Check and adjustment of operator’s cab], operate the machinemonitor to display USER ADJUST MODE in the multi-information section according to the followingprocedure.

1. Use multi-information section (3) of the machine monitor, starting switch (4), buzzer cancel switch(5) and information switch (6) to set the user adjust mode.

(1) Machine monitor

(2) Upper display unit• Gear speed is displayed on this

unit in normal mode (operatormode).

(3) Lower display unit (Multi-infor-mation unit)• Transmission shift mode and

service meter are displayed onthis unit in normal mode(operator mode).

(4) Starting switch

(5) Buzzer cancel switch

(6) Information switch

Fig. 1 Front panel

170


2. Procedure

(1) Turn the starting switch "ON". The machinemonitor is turned ON.

(2) Turn buzzer cancel switch ((5) in Fig. 2) to the[ ] position (left side) and hold it for 2 – 3seconds.The display of multi-information section ((3) inFig. 1) changes to OIL, FILTER MAINTENANCEMODE (Fig. 3).After the display changes, release the switch,and it returns to the neutral position.

(3) Turn information switch ((6) in Fig. 2) to the [ ]position (left side) or [ ] position (right side)several times to change the display of the multi-information section to USER ADJUST MODE(Fig. 4).

Reference: Each time the information switch isturned, the 4 modes of OIL, FILTERMAINTENANCE MODE, PM CLINICMODE, FAULT CODE DISPLAY MODEand USER ADJUST MODE are selectedin either order repeatedly.

(4) After the display of the multi-information sectionchanges to USER ADJUST MODE, turn thebuzzer cancel switch to the [ ] position (leftside) again to settle USER ADJUST MODE. Oncethis mode is settled, it does not change toanother mode described in step (3) even if theinformation switch is turned, and the multi-information section changes to the variationselection screen in USER ADJUST MODE.

Note: If the buzzer cancel switch is turned to the [ ]position (right side) by mistake, the multi-information section returns to the state in step(1).

2.1

2.2

2.3

2.4

2.1.

171


(5) Turn information switch again to the [ ]position (left side) or [ ] position (right side)several times to change the display of the multi-information section to NO INJECTION (Fig. 5).

(6) Turn the buzzer cancel switch to the [ ]position (left side) to settle NO INJECTION.

Reference: In step (5), each time the informationswitch is turned, the 7 variations of LCDBRIGHTNES, DSP BRIGHTNES, DSPCONTRAST, FAN 100% SPEED, NOINJECTION, TILT LIMIT and PRE-LUB ONare selected in either order repeatedly.

(7) If the engine is started under this condition, thecooling fan speed is kept controlled to about100% of the maximum speed.

fl (7) is effective only in this mode. It becomesineffective if the system is set out of this mode.

(8) To reset this mode, turn the buzzer cancelswitch to the [ ] position (right side).The display of the multi-information sectionreturns to the state after step (1) where thestarting switch is turned "ON".

Fig. 52.5

2.6

2.5

2.7

2.8

2.1

2.7

172

1. After assembly, flush the hydraulic pressure circuit of work equipment in accordance with the following procedures.

a According to "A-5 Replacing Return Filter" in Assembly Procedure, return filter element is already replaced from standardelement to exclusive flushing element for the flushing.

1) Set the levers in neutral and run the engine at low idle for 30 minutes.2) Set the levers in neutral and run the engine at medium speed for 30 minutes.3) While running the engine at speed of about 1,700 rpm, repeat the following lever operation pattern 4 times (Keep each

operation for 1 minute to 1 minute 30 seconds). The operation patterns are as follows.

4) After 1) to 3) are finished, remove the installed exclusive flushing element, replace it with stored current standard ele-ment. See Item 2 for replacing procedure.

Reference:Flushing is a cleaning method to remove dirt in hydraulic oil, which works by forcibly circulate hydraulic oil throughflushing filter installed to collect and filter the early dirt in the circuit.

Assembly procedureFlushing of hydraulic circuit (1/3)M-5


• When atmospheric temperature is at -15°C or lower, install the valve and strainer (Do not install the oil stopper plate) then perform flush-ing at low idle.


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Raise blade Lower blade Tilt blade to left Tilt blade to right

Raise ripper Lower ripper Tilt ripper in Tilt ripper back

173

2. Replacement of exclusive flushing element with standard element

1) After the flushing is finished for work equipment circuit, replace the exclusive flushing parts with stored original element(3), strainer (4) and valve (5).

a Avoid entrance of dirt when removing exclusive flushing element.

a When atmospheric temperature is at -15°C or lower, pay attention that the valve and the strainer are not replaced withthe plate.

a Keep accordance with the element installing condition in 2) as the element capacity will be lower if the installing condi-tion is wrong.

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

a Strainer, valve and replaced plate are reusable, so it is recommended to store them for the next flushing work.


No. Part Name Part No. Q'ty3 Element 208-60-71120 14 Strainer 07069-25400 15 Valve 208-60-71160 1

Standard element

174

2) Installing condition of element

a Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig. 2.Particularly when the filter case is filled with oil, it is difficult to see if the element is installed normally. In this case, turn theinstalled element with the hand.If you can turn the element smoothly, it is installed normally.



. Name Q’ty Name Q’ty

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Element

Fig. 1 Good condition Fig. 2 Bad condition

1

APPENDIX 1.

INSTALLATION OF SPILL GUARDS

DESCRIPTION

1. IntroductionWhen installing the spill guards in field, refer to the installation procedure described in this installationprocedure.

2. Additional parts

Blade Part No. Part Name Q‘ty Weight (kg) Remarks198-71-61710 Spill guard (center) 1 134.6

Semi-U 198-71-61720 Spill guard (left) 1 49.6198-71-61730 Spill guard (right) 1 49.6198-72-63910 Spill guard (center) 1 171

Full-U 198-72-63920 Spill guard (left) 1 56198-72-63930 Spill guard (right) 1 56198-72-63810 Spill guard (center) 1 224

Superdozer 198-72-63820 Spill guard (left) 1 34198-72-63830 Spill guard (right) 1 34

Refer to the fabricationdrawing

1. Introduction ...................................................................................................................................... 12. Additional parts ................................................................................................................................ 13. Spill guard fabrication drawings ..................................................................................................... 2

3-1. For semi-U blade ....................................................................................................................... 23-2. For full-U blade .......................................................................................................................... 63-3. For superdozer blade ................................................................................................................ 10

4. Installation procedure ...................................................................................................................... 14

2

3. Spill guard fabrication drawings3-1. For semi-U blade(1) Spill guard

3

(2) Spill guard (for semi-U, center) 198-71-61710 fabrication drawing

1.Th

is d

raw

ing

show

n CO

-gas

wel

ding

gro

ove

dim

ensi

ons

and

leg

leng

th f

or m

anua

l wel

ding

per K

ES 0

4.35

12.

Flat

ness

of s

urfa

ce A

in d

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ing

to b

e w

ithin

2.

Sym

.Pa

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ame

Mat

eria

lQ

‘tyW

eigh

t (kg

)Re

mar

ks

01PL

ATE

SS40

0F2

24.5

t 19

✕ 6

5

02PL

ATE

SS40

0F11

2.55

t 19

✕ 6

5

03PL

ATE

SS40

0P10

5.75

t 19

4

(3) Spill guard (for semi-U, left) 198-71-61720 fabrication drawing

1.Th

is d

raw

ing

show

n CO

-gas

wel

ding

gro

ove

dim

ensi

ons

and

leg

leng

th f

or m

anua

l wel

ding

per K

ES 0

4.35

12.

Flat

ness

of s

urfa

ces

A, B

, C, D

and

E in

dra

win

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be

with

in 2

.Sy

m.

Part

Nam

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ater

ial

Q‘ty

Wei

ght (

kg)

Rem

arks

01PL

ATE

SS40

0F1

12.6

t 19

✕ 6

5

02PL

ATE

SS40

0F1

11.9

t 19

✕ 6

5

03PL

ATE

SS40

0F1

2.30

t 19

✕ 6

5

04PL

ATE

SS40

0F1

2.15

t 19

✕ 6

5

05PL

ATE

SS40

0F1

1.90

t 19

✕ 6

5

06PL

ATE

SS40

0F1

1.75

t 19

✕ 6

5

07PL

ATE

SS40

0F1

1.45

t 19

✕ 6

5

08PL

ATE

SS40

0F1

1.35

t 19

✕ 6

5

09PL

ATE

SS40

0P1

5.10

t 19

10PL

ATE

SS40

0P1

3.95

t 19

11PL

ATE

SS40

0P1

2.80

t 19

12PL

ATE

SS40

0P1

2.30

t 19

5

(4) Spill guard (for semi-U, right) 198-71-61730 fabrication drawing

1.Th

is d

raw

ing

show

n CO

-gas

wel

ding

gro

ove

dim

ensi

ons

and

leg

leng

th f

or m

anua

l wel

ding

per K

ES 0

4.35

12.

Flat

ness

of s

urfa

ces

A, B

, C, D

and

E in

dra

win

gto

be

with

in 2

.Sy

m.

Part

Nam

eM

ater

ial

Q‘ty

Wei

ght (

kg)

Rem

arks

01PL

ATE

SS40

0F1

12.6

t 19

✕ 6

5

02PL

ATE

SS40

0F1

11.9

t 19

✕ 6

5

03PL

ATE

SS40

0F1

2.30

t 19

✕ 6

5

04PL

ATE

SS40

0F1

2.15

t 19

✕ 6

5

05PL

ATE

SS40

0F1

1.90

t 19

✕ 6

5

06PL

ATE

SS40

0F1

1.75

t 19

✕ 6

5

07PL

ATE

SS40

0F1

1.45

t 19

✕ 6

5

08PL

ATE

SS40

0F1

1.35

t 19

✕ 6

5

09PL

ATE

SS40

0P1

5.10

t 19

10PL

ATE

SS40

0P1

3.95

t 19

11PL

ATE

SS40

0P1

2.80

t 19

12PL

ATE

SS40

0P1

2.30

t 19

6

3-2 For full-U blade(1) Spill guard

7

(2) Spill guard (for full-U, center) 198-72-63910 fabrication drawing

1.Th

is d

raw

ing

show

n CO

-gas

wel

ding

gro

ove

dim

ensi

ons

and

leg

leng

th f

or m

anua

l wel

ding

per K

ES 0

4.35

12.

Flat

ness

of s

urfa

ces

A, B

, C, D

and

E in

dra

win

gto

be

with

in 2

.Sy

m.

Part

Nam

eM

ater

ial

Q‘ty

Wei

ght (

kg)

Rem

arks

01PL

ATE

SS40

0F2

29.0

t 19

✕ 6

5

02PL

ATE

SS40

0F12

2.54

t 19

✕ 6

5

03PL

ATE

SS40

0P13

6.16

t 19

04PL

ATE

SS40

0F4

0.66

t 19

✕ 6

5

8

(3) Spill guard (for full-U, left) 198-72-63920 fabrication drawing

1.Th

is d

raw

ing

show

n CO

-gas

wel

ding

gro

ove

dim

ensi

ons

and

leg

leng

th f

or m

anua

l wel

ding

per K

ES 0

4.35

12.

Flat

ness

of s

urfa

ces

A, B

, C, D

and

E in

dra

win

gto

be

with

in 2

.Sy

m.

Part

Nam

eM

ater

ial

Q‘ty

Wei

ght (

kg)

Rem

arks

01PL

ATE

SS40

0F1

14.2

t 19

✕ 6

5

02PL

ATE

SS40

0F1

13.5

t 19

✕ 6

5

03PL

ATE

SS40

0F1

2.42

t 19

✕ 6

5

04PL

ATE

SS40

0F1

2.23

t 19

✕ 6

5

05PL

ATE

SS40

0F1

1.99

t 19

✕ 6

5

06PL

ATE

SS40

0F1

1.84

t 19

✕ 6

5

07PL

ATE

SS40

0F1

1.55

t 19

✕ 6

5

08PL

ATE

SS40

0F1

1.41

t 19

✕ 6

5

09PL

ATE

SS40

0F1

1.11

t 19

✕ 6

5

10PL

ATE

SS40

0F1

0.98

t 19

✕ 6

5

11PL

ATE

SS40

0P1

5.28

t 19

12PL

ATE

SS40

0P1

3.98

t 19

13PL

ATE

SS40

0P1

2.76

t 19

14PL

ATE

SS40

0P1

2.40

t 19

15PL

ATE

SS40

0F1

0.40

t 16

✕ 3

2

9

(4) Spill guard (for full-U, right) 198-72-63930 fabrication drawing

1.Th

is d

raw

ing

show

n CO

-gas

wel

ding

gro

ove

dim

ensi

ons

and

leg

leng

th f

or m

anua

l wel

ding

per K

ES 0

4.35

12.

Flat

ness

of s

urfa

ces

A, B

, C, D

and

E in

dra

win

gto

be

with

in 2

.Sy

m.

Part

Nam

eM

ater

ial

Q‘ty

Wei

ght (

kg)

Rem

arks

01PL

ATE

SS40

0F1

14.2

t 19

✕ 6

5

02PL

ATE

SS40

0F1

13.5

t 19

✕ 6

5

03PL

ATE

SS40

0F1

2.42

t 19

✕ 6

5

04PL

ATE

SS40

0F1

2.23

t 19

✕ 6

5

05PL

ATE

SS40

0F1

1.99

t 19

✕ 6

5

06PL

ATE

SS40

0F1

1.84

t 19

✕ 6

5

07PL

ATE

SS40

0F1

1.55

t 19

✕ 6

5

08PL

ATE

SS40

0F1

1.41

t 19

✕ 6

5

09PL

ATE

SS40

0F1

1.11

t 19

✕ 6

5

10PL

ATE

SS40

0F1

0.98

t 19

✕ 6

5

11PL

ATE

SS40

0P1

5.28

t 19

12PL

ATE

SS40

0P1

3.98

t 19

13PL

ATE

SS40

0P1

2.76

t 19

14PL

ATE

SS40

0P1

2.40

t 19

15PL

ATE

SS40

0F1

0.40

t 16

✕ 3

2

10

3-3 For superdozer blade(1) Spill guard

11

(2) Spill guard (for superdozer, center) 198-72-63810 fabrication drawing

1.Th

is d

raw

ing

show

n CO

-gas

wel

ding

gro

ove

dim

ensi

ons

and

leg

leng

th f

or m

anua

l wel

ding

per K

ES 0

4.35

12.

Flat

ness

of s

urfa

ces

A, B

, C, D

and

E in

dra

win

gto

be

with

in 2

.Sy

m.

Part

Nam

eM

ater

ial

Q‘ty

Wei

ght (

kg)

Rem

arks

01PL

ATE

SS40

0F2

34.3

t 19

✕ 6

5

02PL

ATE

SS40

0P1

74.0

t 9

03PL

ATE

SS40

0P4

6.55

t 19

04PL

ATE

SS40

0P7

7.95

t 19

12

(3) Spill guard (for superdozer, left) 198-72-63820 fabrication drawing

1.Th

is d

raw

ing

show

n CO

-gas

wel

ding

gro

ove

dim

ensi

ons

and

leg

leng

th f

or m

anua

l wel

ding

per K

ES 0

4.35

12.

Flat

ness

of s

urfa

ces

A, B

, C, D

and

E in

dra

win

gto

be

with

in 2

.Sy

m.

Part

Nam

eM

ater

ial

Q‘ty

Wei

ght (

kg)

Rem

arks

01PL

ATE

SS40

0F1

1.65

t 19

✕ 6

5

02PL

ATE

SS40

0P1

2.05

t 19

03PL

ATE

SS40

0F1

1.75

t 19

✕ 6

5

04PL

ATE

SS40

0P1

3.05

t 19

05PL

ATE

SS40

0F1

2.05

t 19

✕ 6

5

06PL

ATE

SS40

0P1

3.20

t 19

07PL

ATE

SS40

0F1

2.35

t 19

✕ 6

5

08PL

ATE

SS40

0F1

9.35

t 19

✕ 6

5

09PL

ATE

SS40

0F1

6.50

t 19

✕ 6

5

13

(4) Spill guard (for superdozer, right) 198-72-63830 fabrication drawing

1.Th

is d

raw

ing

show

n CO

-gas

wel

ding

gro

ove

dim

ensi

ons

and

leg

leng

th f

or m

anua

l wel

ding

per K

ES 0

4.35

12.

Flat

ness

of s

urfa

ces

A, B

, C, D

and

E in

dra

win

gto

be

with

in 2

.Sy

m.

Part

Nam

eM

ater

ial

Q‘ty

Wei

ght (

kg)

Rem

arks

01PL

ATE

SS40

0F1

1.65

t 19

✕ 6

5

02PL

ATE

SS40

0P1

2.05

t 19

03PL

ATE

SS40

0F1

1.75

t 19

✕ 6

5

04PL

ATE

SS40

0P1

3.05

t 19

05PL

ATE

SS40

0F1

2.05

t 19

✕ 6

5

06PL

ATE

SS40

0P1

3.20

t 19

07PL

ATE

SS40

0F1

2.35

t 19

✕ 6

5

08PL

ATE

SS40

0F1

9.35

t 19

✕ 6

5

09PL

ATE

SS40

0F1

6.50

t 19

✕ 6

5

14

4. Installation procedure

4-1 For disassembly and assembly procedures which are not described in this manual, see theShop Manual.

4-2 Weld the spill guard to the blade according to the drawing.

4-3 Precautions for welding

4-3-1 Remove all dirt, rust, and paint from the parts to be removed with a grinder.

4-3-2 If the parts to be welded are wet, dry them with a gas burner.

4-3-3 Do not use anti-spatter agents.

4-3-4 Use coated welding rods specified by JIS 4316 (Low-hydrogen welding rod for mild steel)or welding wires specified by JIS YGW11.

4-3-5 Before using coated welding rods, dry them at 300 - 350°C for 30 - 60 minutes.

4-3-6 Preheat the area about 50 mm from the beat to be laid at 150 - 200°C. When the ambienttemperature is below 10°C, post-heat the same area, too, at 150 - 200°C.

4-3-7 Set the welding current to the lower limit of the current range specified for the diameterof the welding rod or wire.

4.3.8 When performing multi-layer welding, weave the welding rod.

4.3.9 Do not weld by letting the melted metal flow, but weld from below to above with sufficientpenetration. Keep the arc length as short as possible, and take care not to make anoverlap, undercut, etc.

4.3.10 Before welding the spill guard, remove all the paint (or rust) from the parts to be weldedwith a grinder. Then, perform tack welding, permanent welding and finishing in order.

4.3.11 Connect the ground cable to a part of the blade where paint is removed or a part wherethe ground cable can be connected securely electrically.

(Remark) If a painted part is welded, hydrogen in the paint will be mixed in the weldedpart, and that can cause cold cracking.

1

APPENDIX 2.

PRECAUTIONS FOR INITIALIZATION PROCEDURES

FOR VHMS CONTROLLER1. Initialization procedures for VHMS controller.......................................................................................... 2

2

INITIALIZATION PROCEDURES FOR VHMS CONTROLLER 1a Initialization tools for VHMS controller

a Before starting full operation after completionof local assembly or before resuming operationafter storage for a long period, initialize theVHMS controller according to the followingprocedure.

a Machine data collected with the VHMS control-ler are stored and managed in WebCAREdatabase. To process the data smoothly on theWebCARE, it is necessary to set the VHMScontroller consistently. If it is not set correctly,data will not be taken into the WebCARE anddata in the VHMS controller may not be uti-lized. Accordingly, be sure to carry out the ini-tialization.

a For the method of installing the VHMS Initial-ization Program to the personal computer,refer to the Operation and Maintenance Man-ual contained in the package of diskette Z1.

a Since the service menu of the monitor panelwill be used in the following procedure, read“Special functions of monitor panel” and under-stand the operating procedure in advance.

a The initialization procedures cover both “ORB-COMM Specification” and “ORBCOMMLESSSpecification”. In case of “ORBCOMMLESS”Specification”, omit the procedures necessaryfor “ORBCOMM Specification” only.

a During the initialization work, confirm eachwork according to the “VHMS InitializationWork Checklist”.

1. Check of machine information, engineinformation and controller informationa This step is a work performed on the

whole machine.Check and record the machine information,engine information, VHMS controller informa-tion and ORBCOMM terminal information.

a The VHMS controller and ORBCOMM ter-minal are in the VHMS controller boxunder the left side cover of the floor.

2. Connection of personal computer1) Make sure that the starting switch is in the

OFF position.k Be sure to connect and disconnect

the personal computer while start-ing switch is in the OFF position.

2) Connect personal computer Z3 and down-load connectors VDW and DL1 by wiringharness Z2.a The download connectors are

installed to the following places.q VDW: Inside of cab (Left rear

lower part)q DL1: Rear side of chassis (Hull

frame)a Connect the personal computer to the

RS232C terminal.

Symbol Part No. Part name

Z

1 799-608-3211 Diskette

2 799-608-3220 Wiring harness

3 Commercially available

Notebook type personal com-puter (OS: Windows98/2000/NT/Me/XP Terminal "RS232C" is with it)

No. Information to be checked

1 Machine model

2 Machine serial No.

3 Current service meter reading

4 Engine serial No.

5 Transmission serial No.

6 VHMS controller serial No.

7 ORBCOMM terminal serial No.[For ORBCOMM specification only]

3

a Execute initialization of VHMS fromthe connector in the cab.

a Use the ground download connectorfor only downloading.

3. Check of operation and satellite capturingcondition of VHMS controllera This step is a work performed in the oper-

ator's cab.a Check of satellite capturing condition is

necessary o only [ORBCOMM specifica-tion].

1) Set the starting switch in the ON position.

2) Select “Service mode” and “Real-timemonitoring mode” in order on the monitorpanel.

3) Input ID = 20301.4) If the central part of the lower line of the

multi-information display unit counts up,the VHMS controller is normal.

5) Judge the operation of the ORBCOMMcontroller by the state of the dot at theright bottom of the LED digit of the VHMScontroller.

6) The dot at the right bottom of the LED digitof the VHMS controller can be checked inthe multi-information display unit of themonitor by the following method.1] Set the starting switch in the ON posi-

tion.2] For monitor panel specification:

Referring to 10. “Real-time monitoringmode” or 11. “Dual display monitoringmode”, input ID = 20301.

7) At least 3 minutes after starting the VHMS,check the decimal point at the right bottomof the LED of the VHMS controller or thedecimal point at the right bottom of thecentral part of the lower line of the multi-information display unit.

4

8) Check the controller for normal operationreferencing 7-segment LED of VHMS con-troller.a VHMS controller is fed with switch

power supply. Thus, its operation isjudged normal if its 7-segment LEDstarts flashing while rotating as thestarting switch is turned on and then ifthe controller starts counting in theascending order.

9) Watch the decimal point LED on the rightof the right-hand 7 segments of the VHMScontroller to check that the ORBCOMMcontroller is capturing the satellite [ORB-COMM specification].a Check the communication satellite

capturing condition of the ORBCOMMcontroller on the VHMS controllerside.

a If the ORBCOMM controller is nor-mal, the decimal point LED of theright-hand 7 segments flashes.

4. Startup of VHMS initialization toola This step is a work performed in the oper-

ator's cab (on the personal computer).1) Turn on the personal computer and start

the OS.2) Click the icon of [VHMS Initialization Tool]

on the personal computer screen to startthe VHMS initialization tool.a The setting screen varies with the

version No. of the VHMS setting tool.a When using a tool before Ver. 3.5.2.1

(CD-ROM), set the VHMS in step 5.a When using an updated tool (Ver.

3.5.2.1 or after), set the VHMS in step6.

a It is recommended to download thelatest VHMS setting tool from theWebCARE and update your tool.(Related material: Servicemate SMP-623)

3) Input the 10-digit service ID in [ServiceID].a Service ID: 7826146000

4) Select [Data clear and Set up] in the[Select Function] column.

5) Press the [OK] button to go to the setupscreen.

Right decimal point Display

OFF

• Power is not supplied to ORB-COMM controller.

• Communication line to VHMS controller is abnormal.

ON

• Satellite is not captured.• Power is supplied to ORB-

COMM controller.• Communication line to VHMS

controller is normal.

Blinking

• Power is supplied to ORB-COMM controller.

• Communication line to VHMS controller is normal.

• Satellite is captured.

5

5. Initialization of VHMS controller (Toolbefore Ver. 3.5.2.1)a This step is a work performed in the oper-

ator's cab (on the personal computer).a When initializing, do not change the data

of service meter [SMR].[Machine information]1) Open the [Machine information] tab.

a The [Machine information] tab is dis-played first in the [Data clear and Setup] menu.

2) Check all the data.

3) If information in the [Date/Time] box is notcorrect, change it according to the follow-ing procedures:1] Press [Edit] button (1) on the right

lower part of the [Date/Time] box todisplay the correction screen.

2] Correct the information and press the[OK] button.

4) If information in the [Machine information]box is not correct, change it according tothe following procedures:1] Press the [Edit] button (2) on the right

lower part of the [Machine informa-tion] box to display the correctionscreen.

2] Correct the information and press the[OK] button.

6

5) After checking/changing all the data in[Machine information], press [Apply] but-ton (3) to settle the setting.a Press the [Apply] button (3), and the

screen for checking the setting willappear. Check the setting again andpress the [OK] button if the setting iscorrect.

a In case of the ORBCOMM Specifica-tion, execute [Communication Set-ting] first and then settle the setting.

[Communication Setting] [For ORBCOMM spec-ification only]a Execute this setting after requesting for open-

ing of the ORBCOM terminal and finishing theopening procedure.6) Open the [Communication Setting] tab.7) Check all the data.

8) To change the setting in [SHORT FAULTHISTRY], follow the procedure below:1] Select [SHORT FAULT HISTRY] on

the screen and press [Edit] button (5)on the left lower part of the [FileTransfer Setting] block to display thesetting screen.

2] Change the setting and then pressthe [OK] button.a At initialization, select [Occur-

rence] at [Timing] and set thefunction to [ON].

7

9) To change setting in [SHORT TRENDANALYSIS], follow the procedures below:1] Select [SHORT TREND ANALYSIS]

on the screen and press [Edit] buttonon the left lower part of the [FileTransfer Setting] block to display thesetting screen.

2] Change the setting and then pressthe [OK] button.a At initialization, input [20h] to

[SMR] and set the function to[ON].

10) To change the setting of [Satellite Setting],follow the procedure below.1] Press the [Edit] button in the [Satellite

Setting] block to display the settingscreen.

2] Set the GCC Code to the applicablearea and then press the [OK] button.

11) After checking/changing all the data in[Communication Setting], press [Apply]button to settle the setting.a If the [Apply] button is pressed, the

screen for checking the sett ingappears. Check the setting again andpress the [OK] button if the setting iscorrect.

12) After checking/changing the data of[Machine Information] and [Communica-tion Setting], press the [Exit] button at theright lower part of the screen to finish[VHMS Initialization Tool].

GCC codes and applicable areas

Code Applicable Area Code Applicable

Area

1U.S.A. 121 Malaysia

Brazil 122 Korea

120 Italy 130 Japan

8

6. Initialization of VHMS controller (Ver. 3.5.2.1or after)a This step is a work performed in the oper-

ator's cab (on the personal computer).a When initializing, do not change the data

of service meter [SMR].1) Select [VHMS Setting] and press the

“Next” button.

2) Select [Set up & All clear] and press the“Next” button.

3) Check the machine information. If it doesnot need to be corrected, press the “Next”button.

a If the VHMS was installed addition-ally, the information of [Serial No.] etc.must be input.

9

4) Select the time zone.5) Input the local time.6) If the DST (Daylight Saving Time) is used

now, select it and press the “Next” button.a If the DST is selected, the clock is

advanced 1 hour automatically, thusthe time must be corrected again.

7) Set the GCC Code to the applicable areaand then press the “Next” button.

8) The contents of the setting are displayedfinally. If there is not a problem, press the“Apply” button.

9) The system asks you if you save the databefore changing the setting. If you do notneed to save, select “NO”.

10) After finishing the work of changing thecontents of initialization, press the “OK”button to finish the program.

GCC codes and applicable areas

Code Applicable Area Code Applicable

Area

1U.S.A. 121 Malaysia

Brazil 122 Korea

120 Italy 130 Japan

10

7. Procedures for executing Quick Pma The Quick Pm means the Pm Clinic exe-

cuted with the manual snap shot functionof the monitor panel.

a Data in 7 minutes 30 seconds are saved inthe VHMS controller.

k Stop the machine on a flat place.

1) Start the engine.2) Set the monitor panel to display the ser-

vice menu.a For the operating method, see “Spe-

cial functions of monitor panel”.3) Selection and execution of mode.

1] Select “Snap shot mode” on the modeselection screen.a If the mode is selected, code (55)

is displayed in gear speed dis-play unit (1) and the title is dis-played in multi-information unit(2).

Serial numbers: 30001 – 30070

Serial numbers: 30071 and up

2] Set the buzzer cancel switch in the[U] position.

3] “READY” is displayed and the systemis ready to start.a On the lower line, 15 pieces of “-”

are displayed.

4] Set the buzzer cancel switch in the[U] position, and the snap shot oper-ation starts.a After the snap shot operation

starts, the elapsed time is dis-played on the upper line.

a On the lower line, 1 “ ” is addedevery 30 seconds. While multiple“ ” are displayed, the one at theright end blinks.

a To interrupt the snap shot opera-tion, set the buzzer cancel switchin the [t] position.

11

5] After starting the snap shot operation,operate the machine according toTable 1.a Check that the engine coolant

temperature and torque con-verter oil temperature are in theoperating range.

a After 10 “ ” are displayed (After 5minutes), “#” is added up to 5.

a “ ”: The data sampling interval is10 seconds.

a “#”: The data sampling interval is1 second.

12

Table 1 Operations of machine to be executed while snap shot is operated

(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.(Note 2): Keep running the engine at low idle until the oil temperature is lowered to the normal level.a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine

speed to high idle.a After stalling the torque converter, watch the power train oil temperature gauge and take care not to

overheat the power train oil.(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperaturegauge reaches the top of the green range, return the transmission to the N (Neutral) position and run theengine at high idle to lower the oil temperature.)

No.

Star

t

Fini

sh

Tim

e (s

ec)

State of machine

Operation of machine

Transmission Steer-ing Work equipment

Fuel control

dial

Decelera-tor pedal

Brake pedal

Parking brake

1 0:00 0:25 25Low idle

N LH N LOW HI Released Released

2 0:25 0:50 25 N RH N LOW HI Released Released

3 0:50 1:40 50 High idle N N N HI HI Released Released

4 1:40 2:30 50 Deceleration slow N N N HI LOW Released Released

5 2:30 3:00 30 High-pressure relief & high idle N N Right tilt (or

pitch back in case of dual tilt

model)

HI HI Released Released

6 3:00 3:30 30 High-pressure relief & low idle N N LOW HI Released Released

7 3:30 4:00 30 Port relief &high idle N N Left tilt (or pitch

dump in case of dual tilt model)

HI HI Released Released

8 4:00 4:30 30 Port relief &low idle N N LOW HI Released Released

9 4:30 5:10 40 Torque converter stall & low idle

NoF1oF2oF3oNoR1oR2oR3oN

N N LOW HI ON Released

10 5:10 6:00 50Torque converter stall (F3) & high

idle (Note 1)

NoF3 (Shift to F3, then run engine at full

throttle)

N N HILOWo

Shift to F3, then HI

ON Released

11 6:00 6:30 30 High idle N N N HI HI Released Released

12 6:30 7:10 40Torque converter stall + High-pres-

sure relief

NoF3 (Shift to F3, then run

engine at high idle)

NLeft tilt (or pitch dump in case of dual tilt model)

HILOWo

Shift to F3, then HI

ON Released

13 7:10 7:30 20 High idleoLow idle (Note 2) N N N HIo

LOW HI Released ON

13

6] The screen shown below appears 7minutes 30 seconds after the snapshot is started, and then the initialscreen appears 5 seconds after. (Endof snap shot)

ImportantThe data of the Quick Pm is recorded onlyonce. If the Quick Pm is executed again,the current data are overwritten. Accord-ingly, be sure to save the data in the per-sonal computer after executing the QuickPm, referring to “8. Downloading of setdata”.

7] Using the analysis tool, read the dataof the Quick Pm.

a For the usage of the analysis tool,see the operation manual.

8] Open the data of the Quick Pm andtranslate them into a graph.

a Set the time to the X-axis and set thefollowing items to the Y-axis.q Engine Speedq Fuel Inject

q Blowby Pressq Exhaust Temp RB (Exhaust tem-

perature of right bank: 1, 2, 3, 4,5, 6)

q Exhaust Temp LB (Exhaust tem-perature of left bank: 1, 2, 3, 4, 5,6)

q Engine Oil Pressq Engine Oil Tempq Eng Coolant Tempq Ambient Tempq Demand Eng Speed

(Engine speed demanded bycontroller)

q T/C Oil Temp(Torque converter oil tempera-ture)

q T/M Main Press(Transmission main relief pres-sure)

q T/M Output Speed(Transmission output speed)

q Shift Position(Transmiss ion, t ravel , gearspeed)

q S/T Clutch Pos.(Steering clutch position)

q S/T Brake Pos. (Steering brakeposition)

q Hydr Oil Temp(Hydraulic oil temperature)

q Pump 1 Press(Work equipment pump 1 oilpressure)

q Pump 2 Press(Work equipment pump 2 oilpressure)

q Body Pitch Angle (Pitch angle)

14

9] Check “Click position graphic valuedisplay”.

15

10] Click a point in the graph, and thevalue of each measurement item atthat point on the X-axis is displayedunder the graph.(Example of displayed graph: This isdifferent from the actual graph.)

16

11] Enter the above value in the Pm Clinic Inspection Sheet.a The relationship between the data necessary for the Pm Clinic and the measurement condi-

tions is as follows.

a The stall speed measured with Snapshot is not the exact value. If measuring the stall speed exactly, setstall mode "0530" and measure it.

State of machine

Measurement items

Eng

ine

spee

d

Blo

w-b

y pr

essu

re

Eng

ine

oil p

ress

ure

Exh

aust

tem

pera

ture

Tran

smis

sion

mai

n re

lief p

ress

ure

Fron

t clu

tch

fill s

witc

h

Rea

r clu

tch

fill s

witc

h

1st c

lutc

h fil

l sw

itch

2nd

clut

ch fi

ll sw

itch

3rd

clut

ch fi

ll sw

itch

Stee

ring

left

clut

ch fi

ll sw

itch

Stee

ring

right

clu

tch

fill s

witc

h

Stee

ring

left

brak

e fil

l sw

itch

Stee

ring

right

bra

ke fi

ll sw

itch

Wor

k eq

uipm

ent p

ump

(FR

)

Engine at low idle Q Q Q Q Q Q Q

Engine at high idle Q Q Q

Deceleration slow Q

High-pressure relief & engine at full throttle Q Q

High-pressure relief & engine at slow Q

Port relief & engine at full throttle Q Q

Port relief & engine at slow Q

Torque converter stall & engine at slow Q Q Q Q Q Q Q Q

Torque converter stall (F3) & engine at full throttle Q Q Q

Engine at full throttle

Torque converter stall & high-pressure relief Q

Engine at high idle o Engine at low idle Q Q

17

8. Downloading of set data1) Connect personal computer Z3 and down-

load connectors VDW in the cab or grounddownload connector DL1 by wiring har-ness Z2.

a Download connector VDW in the cabis installed to the left rear lower part ofthe operator's seat.

a Ground download connector DL1 isinstalled in frame (1) at the rear of themachine.

2) When using download connector VDW inthe cab, set the starting switch in the ONposition.

3) When using ground download connectorDL1, turn switch (2) ON.a The green LED lights up.

4) Operate the icon of [VHMS TechnicalAnalysis Tool] on the personal computer tostart the VHMS technical analysis tool.

a Input [User Name] and [Password].a For the operation procedures, see the

Operation and Maintenance Manualfor VHMS Technical Analysis Tool.

18

5) Use the [Download] function to downloadthe data recorded in the VHMS controllerto the personal computer.a For the operation procedures, see the

Operation and Maintenance Manualfor VHMS Technical Analysis Tool.

a Make sure that downloading hascompleted before proceeding to thenext step.

9. Check of downloaded dataa This step is a work performed in the oper-

ator's cab (on the personal computer).1) Check the set data with the [View] func-

tion.a For the operation procedures, refer to

the Operation and Maintenance Man-ual for VHMS Technical Analysis Tool.

a Make sure that the [MFA0] code atthe time when the snapshot wasoperated is displayed in [Fault His-tory].

a Make sure that the snap shot data isrecorded.

2) After checking the set data, terminate[VHMS Technical Analysis Tool].

10. Disconnection of Personal Computer1) Make sure that the starting switch is in the

OFF position.k Be sure to turn off the starting

switch before connecting or dis-connecting the personal computer.

2) Finish the OS of the personal computerand then turn the personal computer OFF.

3) If the data was downloaded in the cab,disconnect wiring harness Z2 from down-load connector VDW.

4) If the data was downloaded on theground, turn switch (2) OFF and discon-nect wiring harness Z2 from downloadconnector DL1.

19

11. Communication to KomatsuAfter completing steps 1 to 9 successfully,send the “VHMS/WebCARE setting notificationform” to VHMS/WebCARE Support Center ofKomatsu, Tokyo.a Since Komatsu has to set the receiving

side of the satellite communication, besure to inform Komatsu of the completionof the setting.

a Send the VHMS data by Notes (LAN) orE-mail (WAN).

Komatsu VHMS/WebCARE Support Center

2-3-6, Akasaka Minato-ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)FAX: 03-5561-4766 (Domestic user)

E-mail: [email protected]

20

(Objective model: D475A-5E0 Bulldozer)

21

(Objective model: D475A-5E0 Bulldozer)

22

To: VHMS / WebCARE Support Center SEKN5051-1FAX : 81-3-5561-4766 Attached Sheet

<<DB information>>

Distributor name / Branch

Person in charge

e-mail address

DB code(GCPS code)<<Customer information>>

Customer name / Site name<<Machine information>>

Model - type

Serial No.

Unit No.

Date of Orbcomm activation

***Important***

VHMS / WebCARE support center (Product Support Div. Komatsu LTD.)TEL : 81-3-5561-2765 *** FAX : 81-3-5561-4766 *** EMAIL : [email protected]

*After entering the VHMS/WebCARE Basis Information Form,fax or email it to the following location with the initialdownload data.

Setting time (Checked by watch)

Did you initialize VHMS as described in the shopmanual ?

Time difference (GMT)

GCC code(If Orbcomm is equipped)

(Time Zone offset : 00)

Service Meter Reading

For Machine Registration into WebCARE

(Note 1)The new machine delivery or Retro - Fit(Note 1)Replace the VHMS controller.(Note 2 or 3)Replace the component.

Please describe clearly.

Reason for VHMS setting*Check the reason on the right.*For replacement,enter the serial No.of the replacedcomponent below each column (Note).

For initial download data check Result

(Note1)New VHMS controller serial number.

(Note3)New transmission serial number.

(Note2)New engine serial number.Enter both of two engines if mounted.

VHMS / WebCARE Basis Information Sheet

ON / OFF

YES

Summer time (Daylight Savings Time)

(mm:dd:yyyy) ( : : )

No.1 Engine ( )

No.2 Engine ( )

(HH :MM: SS) ( : : )

/

/

Person in charge of setting

/

Setting date

(engine or transmission)

Engine Serial No.(Enter both of two engines if mounted.)

Transmission Serial No.

U-dozer or Semi U-dozer specification 1/7

Report No.

Model-Type

Service Meter Reading (Hr):

Distributor's Name:

Address:

Delivery Report No. attached:

Inspector's comments:

KOMATSU USE ONLY:

Check sheets filling instruction:

Note:

1. Use following indexes for entry of judgement

Normal Correction made on abnormal point

Abnormal Not applied

Criteria are based on the standards when the machine is shipped out of the factory

2. Enter actually measured values in parenthese, [ ].

Sheet Receiving Date: By: Remark:

Customer's name:(Country)

Blade U Semi U. (Dual Single)

Ripper or counterweight VGR VMR CW ( Ton)

Shoe width 910 mm 810 mm 710 mm

Cab With cab, Without cab

Others(Optional/Local procurement part)

Enter specification of optional/local procurement part, if there is any

Date of Inspection Inspector's name: Location of Machine at Inspection:

Specification

Machine Serial No. User Unit No. Engine Model Engine Serial No.

D475A-5E0 SAA12V140E-3

After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.

(For Full U-dozer or Semi U-dozer)FIELD ASSEMBLY INSPECTION REPORT

Category Inspection Item Inspection CriteriaC

OO

LAN

T A

ND

OIL

LE

VE

LMain radiator coolant level Above the bottom

surfaceRadiator

Reserve tank coolant level Low – Full

Engine oil level EO15W40-DH (H+L)/2 – (H+20) Engine : Stopped

Power train oil level TO30 L – (H+20) Engine : Low idle (After 3 to 5 minutes)

Damper case oil level TO30 (H+L)/2 – (H+10) Engine : Stopped

Hydraulic tank oil level• Between H – L TO10

Center to upper level of sight gauge

Pitch back on the ground.Ripper point on the ground.Engine : stopped

Final drive oil level GO85W-140LH

H – (H–20) See operation manual.Engine : stoppedRH

Pivot shaft oil level TO30EO30-CD

LH(H+10) – (H+30) from shaft end See operation manual.

RH

Recoil spring oil level TO30EO30-CD

LHa=100 ± 10 See operation manual.

RH

Battery electrolyte level Between L and H

Check battery Must be no adhesion of grease, loosened terminal, or crack

Window washer tank water level Full

Fuel tank Full (1670 l)

Draining of fuel tank Drain fuel tank (Drain water, foreign matter, etc.)

INS

PEC

TIO

N

Horn Must be of no beat sound or sound deterioration.

Backup alarm(Starting engine)

Backup alarm must sound when the PCCS lever is at the back position.

Must be of no beat sound or sound deterioration.

Monitor displayMonitor must be turned on with buzzer sound, then go off after 3 seconds. After that all gauge lamps must come on.

Operation of service meter(Engine: Low idle)

No error code indicated in the service meter.

Before engine start, meter must not operate when the key switch turned on.

Charge lamp (Engine: Low idle) Must not light up when all lamps are turned on.

Lamp ON (Head lamp, tail lamp and work lamp) Must light up when turned on.

Preheating switch (Auto preheating when at ON position) (Manual preheating when turned to left) Preheating lamp (green) must light up

Corrosion resistor valve Must be fully open.

Heater hose valve Winter: Open valve fully (Close valve fully in summer)

Controller error code indication (make sure that error does not recur) Clear error code after confirming it.

Flushing(Before starting engine, replace standard filter with flushing filter. After flushing, replace flushing filter with standard filter.)

Execute flushing

After flushing, replace flushing filter with standard filter

Air bleeding of the hydraulic cylinder Perform air bleeding of the hydraulic cylinder

Measurement of cab pressurizationMax. 0.10 kPa {10 mm Aq.}(If pressure is below standard value, adjust it, referring to M-1, pages 4/7 – 7/7.)

Confirmation of VHMS controller initialization Must be done.


Strainer

Oil level

UPPER LEVELLOWER LEVEL

Category Inspection Item Inspection CriteriaFU

NC

TIO

N /

OP

ER

ATIO

NParking lever The engine must not be started when the parking

lever is free.

The machine must not be moved when the parking lever is locked.

Operability of the travel lever• Gear change• Forward-reverse• Steering (right/left)Play of the lever at “N" position

Must be of no pinching or abnormal sound.Notch must not be released.

Must be of no pinching or abnormal sound.Must return to the N position smoothly.

Play: Max. 5 mm

Check of the gear speed indication on the monitor panel.• Must be able to be shifted to any position with the engine at low

idle and the brake turned on.

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

Must be no indication error.

Check of front/rear adjustment of the travel lever box• 10-level position adjustment• Check of the box lock (up/down)

Must be adjustable.

Must not move after locking.

Check of the brake pedal operation Must work smoothly.• Full stroke: 60 to 88 mm

Check of the deceleration pedal operation• Set the fuel dial to high idle position.• Check the deceleration RPM

Must work smoothly.

High idle: 2,000 ± 50 rpm

Low idle: 900 ± 50 rpm

Check of the fuel dial operation Must move smoothly.

SIN

GLE

Check of tilt direction

LH tilt Blade must move to left(RH tilt cylinder is lengthened)

RH tilt Blade must move to right(RH tilt cylinder is retracted)

DU

AL

Check of dual tilt and pitch directionCheck of tilt direction Pitch back Blade must move backward. D + B

Pitch dump Blade must move forward. D + ALH dual tilt Blade must move to left (both cylinders move) a + BRH dual tilt Blade must move to right (both cylinders move) a + ALH tilt Blade must move to left (LH cylinder retracted) B + bRH tilt Blade must move to right (LH cylinder lengthened) A + b

Check of tilting restriction adjustment• Measure tilting angle at the top of the cutting edge

when the tilting limit switch is turned on.

Note: See manual of tilting restriction.

LH tilt 12 ± 1°

RH tilt 12 ± 1°


Case

Free

LockCase

RH tilt

LH tiltRH tilt

LH tilt

Category Inspection Item Inspection CriteriaW

OR

K E

QU

IPM

EN

T

Check of the clearance between frame and track(Difference of LH and RH)

Difference of LH and RH is max. 30 mm (Measure on flat ground)Move blade up and down and stop 100 mm above ground, and then measure.

Check of the work equipment lock lever lock function

No actuator must work when the work equipment lock lever is at ON position(Lever can move but work equipment must not move)

Check of the blade lever floatingCheck of the blade lever floating notch release

Must be of no hydraulic drift (Engine: Low idle)

Engine stops at floating, then notch must be released.

Check of the quick drop valve operation• Quick dropping of the blade from top position.

At the engine full, set the blade lever at down position. When the lever is set at the N position after the blade drops by 1000 mm, it must stop.

Main relief valve function (Engine: Low idle) Must be bridged with the blade and the ripper (Chassis)

Check of the accumulator function (blade, ripper) Must function immediately after the engine stops then drop from the top to the ground.

Blade cylinder oil leakage• Leakage from U-packing, damaged rod, quick drop valve,

tube, flange or dust sealMust be none.LH

RH

Tilt cylinder/pitch cylinder oil leakage• Leakage from U-packing, damaged rod, tube, flange or

dust sealMust be none.LH

RH

UN

DE

RC

AR

RIA

GE

Track tension adjustment• With the gear at F1 and the engine at low idle, travel on flat

place for about 10 m, and when the grouser comes over the first carrier roller, stop the machine by depressing the brake pedal.

• Tense a string or a bar between the first carrier roller and the idler to measure distance between the string (bar) and the grouser.(Difference between LH and RH : Max. 20 mm)

• Target is 30 mm when new.

LH 20 – 30 mm

RH 20 – 30 mm

Carrier roller alignment• Travel on flat place with the gear at F1 and R1 for about

10 m, repeatedly about 3 or 4 times, then gradually apply brake to stop.

* Check only when track frame is installed in field(Check is not necessary if track frame has been installed)

Flanges must be free from contact with links at all times.

LH

RH

Undercarriage oil leakage• Leakage from idler, carrier roller, bogie, pivot shaft, adjustment cylinder, and lubricated track (plug, seal)

Must be none.LH

RH

CA

B

Beat noise inside the cab, beat noise of the outer cover Must be none.

Opening/closing and locking effect of the cab doors. Must work smoothly to securely lock the doors by door-locking or key-locking.

Cab door-open lock release lever

Lever must operate smoothly and unlock securely.(Unlock: Door is pushed out of stopper rubber section.)

Opening/closing and locking effect of the left/right side slide glass Must work smoothly to securely lock.

Lighting of the room lamp Must come on/go off by turning the switch on/off.

Operation of the window wiper and the window washerMust be on/off by turning the switch on/off.Wiper: Must operate smoothly (without beat noise)

Operation of the radio and cassette system(Volume, tuning, AM/FM switching, cassette) Must operate correctly

Operation of the cigar lighterAsh tray installation

Must be red-heated.Must be installed.

Operation of the air conditionerCold and warm air must be able to be switched by monitor operation.Air flow amount must be able to be adjusted

Air flow amount must be able to be adjusted (Hi, Mid or Lo)• Louver must be smoothly switched Air comes out from each blowout port.


Category Inspection Item Inspection CriteriaLU

BR

ICAT

ION

Portions to be lubricated Q'ty Example: U blade

• Equalizer bar side pin shaft 2

• Equalizer bar center pin shaft 1

• Blade lift cylinder support shaft and yoke 6

• Blade center pin 1

• Blade oblique arm ball joint 3

• Brace screw (Single tiltdozer) 2

BLA

DE

Interference and twist of blade lift cylinder hoses(Check through operation range)

When blade is tilted up, down and to right and left, hoses must not interfere or twist.

RIP

PE

R

Check of ripper direction

a Raise

c Lower

A Tilt in

B Tilt out

Ripper lift cylinder oil leakage• U-packing, damaged rod, tube, flange, dust seal

loosingMust be noneLH

RH

Ripper tilt cylinder oil leakage• U-packing, damaged rod, tube, flange, dust seal

loosingMust be of no contact.LH

RH

Interference and twist of hoses during ripper operation(Ripper lift and tilt hoses, pin-puller hoses)(Check through operation range)

When ripper is raised, lowered and tilted in and out, hoses must not interfere or twist.

Creak of the ripper link pin Must be of no creak.

Check of the pin puller switch directionA: Pin outB: Pin in

Must be the same as the pin puller cylinder operation direction

Check of the pin puller cylinder hose clamp position(Entire operation area must be checked)

Must be of no contactMust be of no excess hose tension.

Pin puller cylinder oil leakage• Leakage from U-packing, damaged rod, tube or flange Must be none

Check of ripper lubricated hose installation(Add grease)

LHMust be no contact or no excess bend.

RH

Grease must not leak

Portions to be lubricated Q'ty Must be lubricated (right and left)

• Ripper lift cylinder head 8 2

• Ripper lift cylinder bottom 6 2

• Ripper tilt cylinder head 7 2

• Ripper tilt cylinder bottom 5 2

• Ripper arm pin (front) 9 2

• Ripper arm pin (rear) 0 2


<Precautions for measurement>Measure each performance value after each oil temperature has increased.(Reference) Engine coolant temperature: Within operating range Power train oil temperature: 75 – 85°C Hydraulic oil temperature: 45 – 55°C

Engine speedCategory Item Condition Unit Standard Result

Eng

ine Engine speed Run engine at low idle (low speed). rpm 600 – 700

Run engine at high idle (engine high). *2 rpm 2100 – 2200Set decelarator at low speed. rpm 850 – 950Stall torque converter. *1 rpm 1640 – 1740

*1: Measure stall speed 1 segment before red range of torque converter oil temperature gauge. Measure with ID "0530" in adjustment mode of monitor.*2: Measure high idle speed with adjustment mode ID "0007" of monitor.

Power train oil pressureCategory Item Condition Unit Standard Result

Trans

miss

ion Main relief pressure *3 Run engine at low speed and set transmission in N. MPa{kg/cm2}

2.35 – 2.89{24.0 – 29.5}

Run engine at full throttle and set transmission in N. MPa{kg/cm2}

2.65 – 2.98{27.0 – 30.4}

*3: Measure main relief pressure with monitoring mode ID "43000" of monitor.

Work equipment oil pressure *4• Single tilt specificationCategory Item Condition Unit Standard Result

Wor

k eq

uipm

ent o

il pr

essu

re High pressure relief pressure

Blade right tilt Run engine at low speed and set transmission in N.

MPa{kg/cm2}

26.0 – 28.8{266 – 294}

F pumpR pump

Run engine at full throttle and set transmission in N.

MPa{kg/cm2}

26.0 – 28.8{266 – 294}

F pumpR pump

Port relief pressure Blade left tilt Run engine at low speed and set transmission in N.

MPa{kg/cm2}

21.6 – 24.4{221 – 249}

F pumpR pump


MPa{kg/cm2}

23.1 – 25.9{236 – 264}

F pumpR pump

Control circuit basic pressure

Lever neutral Run engine at full throttle and set transmission in N.

MPa{kg/cm2}

3.92 – 4.51{40 – 46}

F pumpR pump

• Dual tilt specificationCategory Item Condition Unit Standard Result

Wor

k eq

uipm

ent o

il pr

essu


Pitch back Run engine at low speed and set transmission in N.

MPa{kg/cm2}

26.0 – 28.8{266 – 294}

F pumpR pump


MPa{kg/cm2}

26.0 – 28.8{266 – 294}

F pumpR pump

Port relief pressure Pitch dump Run engine at low speed and set transmission in N.

MPa{kg/cm2}

19.7 – 22.5{201 – 229}

F pumpR pump


MPa{kg/cm2}

23.1 – 25.9{236 – 264}

F pumpR pump



MPa{kg/cm2}

3.92 – 4.51{40 – 46}

F pumpR pump

*4: Measure work equipment relief pressure of F pump with monitoring mode ID "70700" of monitor. Measure work equipment relief pressure of R pump with monitoring mode ID "70702" of monitor.

Work equipment speedCategory Item Condition Unit Standard Result

Blade lift RAISE Run engine at full throttle and set transmission in N. sec 4.5 – 5.5

LOWER Run engine at full throttle and set transmission in N. sec 1.5 – 2.1

Ripper tilt Tilt IN Run engine at full throttle and set transmission in N. sec 4.7 – 5.7

Tilt BACK Run engine at full throttle and set transmission in N. sec 2.8 – 3.8

Hydraulic drift of work equipmentCategory Item Condition Unit Standard Result

Blade lift Engine stopped, Cutting edge height: 500 – 800 mm. mm/min Max. 50/5

Ripper lilt Engine stopped, Ripper point height: 300 – 600 mm. mm/min Max. 30/5


Check sheet for tightening torque for bolts of ROPS

Sketch Record

1. Tightening torque of ROPS From right to left of machine rear A – H From right to left of machine front I – P (rear 8 + front 8, total 16)

Position Location Record Standard tightening torque

Mac

hine

bac

kwar

d

A

1960 – 2450 Nm{200 – 250 kgm}

B

C

D

E

F

G

H

Mac

hine

forw

ard

I

J

K

L

M

N

O

P


Superdozer specification 1/7

Report No.

Model-Type

Service Meter Reading (Hr):

Distributor's Name:

Address:

Delivery Report No. attached:

Inspector's comments:

KOMATSU USE ONLY:

Check sheets filling instruction:

Note:

1. Use following indexes for entry of judgement

Normal Correction made on abnormal point

Abnormal Not applied

Criteria are based on the standards when the machine is shipped out of the factory

2. Enter actually measured values in parenthese, [ ].

Sheet Receiving Date: By: Remark:

Customer's name:(Country)

Blade Super

Ripper or counterweight VGR CW ( Ton)

Shoe width 910 mm 810 mm

Cab With cab, Without cab

Others(Optional/Local procurement part)

Enter specification of optional/local procurement part, if there is any

Date of Inspection Inspector's name: Location of Machine at Inspection:

Specification

Machine Serial No. User Unit No. Engine Model Engine Serial No.

D475ASD-5E0 SAA12V140E-3

After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.

(For Superdozer)FIELD ASSEMBLY INSPECTION REPORT

Category Inspection Item Inspection CriteriaC

OO

LAN

T A

ND

OIL

LE

VE

LMain radiator coolant level Above the bottom

surfaceRadiator

Reserve tank coolant level Low – Full

Engine oil level EO15W40-DH (H+L)/2 – (H+15) Engine : Stopped

Power train oil level TO30 L – (H+20) Engine : Low idle (After 3 to 5 minutes)

Damper case oil level TO30 (H+L)/2 – (H+10) Engine : Stopped

Hydraulic tank oil level• Between H – L TO10

Center to upper level of sight gauge

Pitch back on the ground.Ripper point on the ground.Engine : stopped

Final drive oil level GO85W-140LH

H – (H–20) See operation manual.Engine : stoppedRH

Pivot shaft oil level TO30EO30-CD

LH(H+10) – (H+30) from shaft end See operation manual.

RH

Recoil spring oil level TO30EO30-CD

LHa=100 ± 10 See operation manual.

RH

Battery electrolyte level Between L and H

Check battery Must be no adhesion of grease, loosened terminal, or crack

Window washer tank water level Full

Fuel tank Full (1670 l)

Draining of fuel tank Drain fuel tank (Drain water, foreign matter, etc.)

INS

PEC

TIO

N

Horn Must be of no beat sound or sound deterioration.

Backup alarm(Starting engine)

Backup alarm must sound when the PCCS lever is at the back position.

Must be of no beat sound or sound deterioration.

Monitor displayMonitor must be turned on with buzzer sound, then go off after 3 seconds. After that all gauge lamps must come on.

Operation of service meter(Engine: Low idle)

No error code indicated in the service meter.

Before engine start, meter must not operate when the key switch turned on.

Charge lamp (Engine: Low idle) Must not light up when all lamps are turned on.

Lamp ON (Head lamp, tail lamp and work lamp) Must light up when turned on.

Preheating switch (Auto preheating when at ON position) (Manual preheating when turned to left) Preheating lamp (green) must light up

Corrosion resistor valve Must be fully open.

Heater hose valve Winter: Open valve fully (Close valve fully in summer)

Controller error code indication (make sure that error does not recur) Clear error code after confirming it.

Flushing(Before starting engine, replace standard filter with flushing filter. After flushing, replace flushing filter with standard filter.)

Execute flushing

After flushing, replace flushing filter with standard filter

Air bleeding of the hydraulic cylinder Perform air bleeding of the hydraulic cylinder

Measurement of cab pressurizationMax. 0.10 kPa {10 mm Aq.}(If pressure is below standard value, adjust it, referring to M-1, pages 4/7 – 7/7.)

Confirmation of VHMS controller initialization Must be done.


Strainer

Oil level

UPPER LEVELLOWER LEVEL

Category Inspection Item Inspection CriteriaFU

NC

TIO

N /

OP

ER

ATIO

NParking lever The engine must not be started when the parking

lever is free.

The machine must not be moved when the parking lever is locked.

Operability of the travel lever• Gear change• Forward-reverse• Steering (right/left)Play of the lever at “N" position

Must be of no pinching or abnormal sound.Notch must not be released.

Must be of no pinching or abnormal sound.Must return to the N position smoothly.

Play: Max. 5 mm

Check of the gear speed indication on the monitor panel.• Must be able to be shifted to any position with the engine at low

idle and the brake turned on.

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

Must be no indication error.

Check of front/rear adjustment of the travel lever box• 10-level position adjustment• Check of the box lock (up/down)

Must be adjustable.

Must not move after locking.

Check of the brake pedal operation Must work smoothly.• Full stroke: 60 to 88 mm

Check of the deceleration pedal operation• Set the fuel dial to high idle position.• Check the deceleration RPM

Must work smoothly.

High idle: 2,000 ± 50 rpm

Low idle: 900 ± 50 rpm

Check of the fuel dial operation Must move smoothly.

Check of pitch directionPitch dump Blade must move to forward smoothly.

Pitch back Blade must move to backward smoothly.

Check of tilt direction

LH tilt Blade must move to left

RH tilt Blade must move to right

Check of tilting restriction adjustment• Measure tilting angle at the top of the cutting edge

when the tilting limit switch is turned on.

Note: See manual of tilting restriction.

LH tilt 7 ± 1°

RH tilt 7 ± 1°

Check of auto pitch back operation• After pitch dumping, move backward with the speed gear at R1,

then turn the pitch back switch on.

52 ± 3°Blade should be horizontal after pitch back to the stroke end, and pitch dumping is performed to return to the digging posture.


Case

Free

LockCase

RH tilt

LH tiltRH tilt

LH tilt

Pitch dump

Pitch back

Pitch backward

Pitch forward

Category Inspection Item Inspection CriteriaW

OR

K E

QU

IPM

EN

T

Check of the clearance between frame and track(Difference of LH and RH)

Difference of LH and RH is max. 30 mm (Measure on flat ground)Move blade up and down and stop 100 mm above ground, and then measure.

Check of the work equipment lock lever lock function

No actuator must work when the work equipment lock lever is at ON position(Lever can move but work equipment must not move)

Check of the blade lever floatingCheck of the blade lever floating notch release

Must be of no hydraulic drift (Engine: Low idle)

Engine stops at floating, then notch must be released.

Check of the quick drop valve operation• Quick dropping of the blade from top position.

At the engine full, set the blade lever at down position. When the lever is set at the N position after the blade drops by 1000 mm, it must stop.

Main relief valve function (Engine: Low idle) Must be bridged with the blade and the ripper (Chassis)

Check of the accumulator function (blade, ripper) Must function immediately after the engine stops then drop from the top to the ground.

Blade cylinder oil leakage• Leakage from U-packing, damaged rod, quick drop valve,

tube, flange or dust sealMust be none.LH

RH

Tilt cylinder/pitch cylinder oil leakage• Leakage from U-packing, damaged rod, tube, flange or

dust sealMust be none.LH

RH

UN

DE

RC

AR

RIA

GE

Track tension adjustment• With the gear at F1 and the engine at low idle, travel on flat

place for about 10 m, and when the grouser comes over the first carrier roller, stop the machine by depressing the brake pedal.

• Tense a string or a bar between the first carrier roller and the idler to measure distance between the string (bar) and the grouser.(Difference between LH and RH : Max. 20 mm)

• Target is 30 mm when new.

LH 20 – 30 mm

RH 20 – 30 mm

Carrier roller alignment• Travel on flat place with the gear at F1 and R1 for about

10 m, repeatedly about 3 or 4 times, then gradually apply brake to stop.

* Check only when track frame is installed in field(Check is not necessary if track frame has been installed)

Flanges must be free from contact with links at all times.

LH

RH

Undercarriage oil leakage• Leakage from idler, carrier roller, bogie, pivot shaft, adjustment cylinder, and lubricated track (plug, seal)

Must be none.LH

RH

CA

B

Beat noise inside the cab, beat noise of the outer cover Must be none.

Opening/closing and locking effect of the cab doors. Must work smoothly to securely lock the doors by door-locking or key-locking.

Cab door-open lock release lever Must work smoothly to securely lock.

Opening/closing and locking effect of the left/right side slide glass Must work smoothly to securely lock.

Lighting of the room lamp Must come on/go off by turning the switch on/off.

Operation of the window wiper and the window washerMust be on/off by turning the switch on/off.Wiper: Must operate smoothly (without beat noise)

Operation of the radio and cassette system(Volume, tuning, AM/FM switching, cassette) Must operate correctly

Operation of the cigar lighterAsh tray installation

Must be red-heated.Must be installed.

Operation of the air conditionerCold and warm air must be able to be switched by monitor operation.Air flow amount must be able to be adjusted

Air flow amount must be able to be adjusted (Hi, Mid or Lo)• Louver must be smoothly switched Air comes out from each blowout port.


Category Inspection Item Inspection CriteriaLU

BR

ICAT

ION

Portions to be lubricated Q'ty Example: Super blade

• Equalizer bar side pin shaft 2

• Equalizer bar center pin shaft 1

• Blade lift cylinder support shaft and yoke 6

• Blade center pin 1

• Blade oblique arm ball joint 3

BLA

DE

Interference and twist of blade lift cylinder hoses(Check through operation range)

When blade is tilted up, down and to right and left, hoses must not interfere or twist.

RIP

PE

R

Check of ripper direction

a Raise

c Lower

A Tilt in

B Tilt out

Ripper lift cylinder oil leakage• U-packing, damaged rod, tube, flange, dust seal

loosingMust be noneLH

RH

Ripper tilt cylinder oil leakage• U-packing, damaged rod, tube, flange, dust seal

loosingMust be of no contact.LH

RH

Interference and twist of hoses during ripper operation(Ripper lift and tilt hoses, pin-puller hoses)(Check through operation range)

When ripper is raised, lowered and tilted in and out, hoses must not interfere or twist.

Creak of the ripper link pin Must be of no creak.

Check of the pin puller switch directionA: Pin outB: Pin in

Must be the same as the pin puller cylinder operation direction

Check of the pin puller cylinder hose clamp position(Entire operation area must be checked)

Must be of no contactMust be of no excess hose tension.

Pin puller cylinder oil leakage• Leakage from U-packing, damaged rod, tube or flange Must be none

Check of ripper lubricated hose installation(Add grease)

LHMust be no contact or no excess bend.

RH

Grease must not leak

Portions to be lubricated Q'ty Must be lubricated (right and left)

• Ripper lift cylinder head 8 2

• Ripper lift cylinder bottom 6 2

• Ripper tilt cylinder head 7 2

• Ripper tilt cylinder bottom 5 2

• Ripper arm pin (front) 9 2

• Ripper arm pin (rear) 0 2


<Precautions for measurement>Measure each performance value after each oil temperature has increased.(Reference) Engine coolant temperature: Within operating range Power train oil temperature: 75 – 85°C Hydraulic oil temperature: 45 – 55°C

Engine speedCategory Item Condition Unit Standard Result

Eng

ine Engine speed Run engine at low idle (low speed). rpm 600 – 700

Run engine at high idle (engine high). *2 rpm 2100 – 2200Set decelarator at low speed. rpm 850 – 950Stall torque converter. *1 rpm 1640 – 1740

*1: Measure stall speed 1 segment before red range of torque converter oil temperature gauge. Measure with ID "0530" in adjustment mode of monitor.*2: Measure high idle speed with adjustment mode ID "0007" of monitor.

Power train oil pressureCategory Item Condition Unit Standard Result

Trans

miss

ion Main relief pressure *3

Run engine at low speed and set transmission in N. MPa{kg/cm2}

2.35 – 2.89{24.0 – 29.5}

Run engine at full throttle and set transmission in N. MPa{kg/cm2}

2.65 – 2.98{27.0 – 30.4}

*3: Measure main relief pressure with monitoring mode ID "43000" of monitor.

Work equipment oil pressure *4• Superdozer specificationCategory Item Condition Unit Standard Result

Wor

k eq

uipm

ent o

il pr

essu


Pitch back Run engine at low speed and set transmission in N.

MPa{kg/cm2}

26.0 – 28.8{266 – 294}

F pumpR pump


MPa{kg/cm2}

26.0 – 28.8{266 – 294}

F pumpR pump

Port relief pressure Pitch dump Run engine at low speed and set transmission in N.

MPa{kg/cm2}

19.7 – 22.5{201 – 229}

F pumpR pump


MPa{kg/cm2}

23.1 – 25.9{236 – 264}

F pumpR pump



MPa{kg/cm2}

3.92 – 4.51{40 – 46}

F pumpR pump

*4: Measure work equipment relief pressure of F pump with monitoring mode ID "70700" of monitor. Measure work equipment relief pressure of R pump with monitoring mode ID "70702" of monitor.

Work equipment speedCategory Item Condition Unit Standard Result

Blade lift Superdozer specification

RAISE Run engine at full throttle and set transmission in N. sec 4.6 – 5.6

LOWER Run engine at full throttle and set transmission in N. sec 1.4 – 2.0

Ripper tilt Tilt IN Run engine at full throttle and set transmission in N. sec 4.7 – 5.7

Tilt BACK Run engine at full throttle and set transmission in N. sec 2.8 – 3.8

Hydraulic drift of work equipmentCategory Item Condition Unit Standard Result

Blade lift Engine stopped, Cutting edge height: 500 – 800 mm. mm/min Max. 50/5

Ripper lilt Engine stopped, Ripper point height: 300 – 600 mm. mm/min Max. 30/5


Check sheet for tightening torque for bolts of ROPS

Sketch Record

1. Tightening torque of ROPS From right to left of machine rear A – H From right to left of machine front I – P (rear 8 + front 8, total 16)

Position Location Record Standard tightening torque

Mac

hine

bac

kwar

d

A

1960 – 2450 Nm{200 – 250 kgm}

B

C

D

E

F

G

H

Mac

hine

forw

ard

I

J

K

L

M

N

O

P


Documents

D475A-5GEN00051 FA-03