D475a-5gen00051 Fa-03
D475a-5gen00051 Fa-03
D475a-5gen00051 Fa-03
BULLDOZER
-5E0
D475A
D475ASD -5E0
SERIAL NUMBERS
D475A30001
and up
D475ASD- 30001
Preface
Since this machine is large in size, it is divided into some units to meet
the transportation conditions and regulations applied to the transportation 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 protective 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 different languages and customs work together.
The following is a reference supervision system diagram.
(Instruction system)
Work leader
Work supervisor
Crane director
Director
and
deputy director
Sharing of work
Interpreter
CONTENTS
SPECIFICATIONS ...........................................................................................................................
PRECAUTIONS FOR FIELD ASSEMBLY .......................................................................................
DISPOSAL OF REMOVED PARTS.................................................................................................
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE.................................
KIT LAYOUT DIAGRAM ..................................................................................................................
STYLE FOR TRANSPORTATION...................................................................................................
TOOLS LIST FOR FIELD ASSEMBLY ............................................................................................
SKETCH OF TOOLS .......................................................................................................................
TIGHTENING TORQUE ..................................................................................................................
COATING MATERIALS ...................................................................................................................
1
3
4
5
6
7
13
16
25
29
SPECIFICATIONS
Item
Unit
Semi-U-tiltdozer
+ Variable giant ripper
Full U-tiltdozer
+ Variable giant ripper
Superdozer
+ Counterweight
Operating weight
(excluding operator's weight)
kg
Blade weight
(including cylinders)
kg
Ripper weight
(including cylinders)
kg
Counterweight
kg
Engine model
kW/rpm {HP/rpm}
664/2,000{890/2,000}
mm
mm
Overall width
mm
108,310
(*1)
16,500
11,560
113,120 (*2)
18,800
20,900
7,360
6,040
11,950
10,525
4,546 (4,646)
5,265
6,205
Travel speed
Forward
km/h
3.5/6.3/10.9
(1st/2nd/3rd)
Reverse
km/h
4.7/8.4/14.3
6,465
Superdozer + counterweight
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Schedule
5
4
45 ton 1
45 ton 2
2nd day
1st day
4
(2)
45 ton 1
3rd day
45 ton 1
4th day
45 ton 1
5th day
1
2
No. Item
Approx. 30 m
Accessories
CAB assembly
ROPS guard
Approx. 30 m
Chassis
Ripper parts
Right track
Track
Track
Blade
Left track
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 according to the area and land form of the work site, considering the transportation packaging of each kit (component) explained
later.
6,600
3,300
3,320
43,000
Track frame
4,800
1,500
982
Weight (kg)
12,200
WORK EQUIPMENT
(1) U-blade
6,205
2,615
2,170
Weight (kg)
14,000
5,263
2,610
1,760
Weight (kg)
13,000
6,465
2,690
Super blade
Weight (kg)
2,180
14,000
Track shoe
Shoe width
810
A (mm)
4,500
B (mm)
1,400
Weight (kg)
6,770 (1/2)
Straight frame
a Right and left straight frames are prepared for each machine.
A
B
C
Semi-U, U
4,857
674
638
1,770
Super
5,020
682
681
1,868
A
C
Semi-U, U
1,930
351
504
Super
1,754
351
508
Hydraulic cylinder
(1) Pitch, tilt cylinder
a One set of this part is used for single tilt-dozer and two
sets for dual tilt-dozer.
A
B
C
2,900
630
435
500
a Both for lifting and tilting, each one set of this part is used
on both left and right sides.
A
C
Lift
1,748
304
389
Tilt
1,698
304
394
A
B
C
1,545
1,930
1,535
2,400
A
B
C
2,290
580
1,781
1,750
10
A
B
C
115
2,800
940
1,000
A
B
C
1,210
1,930
3,065
3,450
115
2,170
775
740
3
Multi ripper shank assembly (machine with multi ripper specification only)
A
B
C
11
A
B
C
1,875
1,680
1,740
500
A
B
C
2,100
1,411
585
918
ROPS
Counterweight
A
B
C1
C2
12
1,950
1,300
1,361
1,290
7,300
Specification
Q'ty
Truck crane
Air compressor
Welding machine
(see remarks)
Part name
Belt sling:
(Made by synthetic fibers)
4
2
Hydraulic wrench
10
11
12
15
Load chain
14
13
Remarks
1
1
1
1
1
1
Spanner
17
13
1 each
16
2 each
No.
18
19
20
21
22
Part name
Eyebolt
23
Sledge hammer
24
Jack
25
Specification
Adaptable screw: M12
Using load: 2.16 kN {220 kg}
Adaptable screw: M16
Using load: 4.41 kN {450 kg}
Suitable screw: M24
Using load: 9.32 kN {950 kg}
SD16-M, using load 9.8 kN {1 t}
Q'ty
4
2
2
1
25 mm 700 mm
19 mm 300 mm
M30 pitch 3
M33 pitch 2
27
Grease pump
30
Oil jack
25 mm 1 m
29
Angle meter
26
28
Remarks
1
1
2 each
31
Chassis stand
(for fixing the machine body)
32
33
Steel plate
34
Sling jig A
35
Sling jig B
36
Sling jig C
14
1
For slinging track frame assembly
For slinging final drive assembly
and pivot shaft
For slinging final drive assembly
No.
37
Part name
Wooden bar
Specification
Height width depth (mm)
350 350 750
350 350 670
Q'ty
Remarks
4
2
95 95 180 to 200
38
39
Safety belt
40
Goggles
41
42
43
44
45
Cleaning oil
40 l
46
Paint remover
5l
47
Repair paint
48
Glass cleaner
Liquid cleaner
49
Waste cloth
50
1 wrap
51
For welding
For protecting from spray
Rope of yellow ground color with black
stripes
Standing signboard
Inner diameter 8 mm thickness 1 mm
length 3 m
Soft and transparent
Necessary
quantity
Necessary
quantity
1
200 g
3 each
For cleaning of the
Proper quantity windshield glass of
operators cab
1 kg
a General tools for manual works (such as box wrench, driver, pliers, etc.) are not listed in this list.
Prepare general tools if necessary.
15
Only movable
part
Only
movable
part
No.
01
02
03
04
05
06
07
08
09
10
11
12
13
16
Material
SS400C
SS400C
SS400C
SS400C
SS400C
SS400C
SS400C
SS400B
SS400
SS400
SS400
SS400
SS400
Q'ty
4
2
2
2
2
2
2
4
4
4
10
2
2
Material t12
Remarks
C15075t9-1332
C15075t9-829
C15075t9-829
C15075t9-510
C15075t9-548
C15075t9-453
C15075t9-355
T50-500
t25180250
t12200655
t1260128
t16124130
t257085
Fig.1
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
17
Only movable
part
Only
movable
part
No.
01
02
03
04
05
06
07
08
09
10
11
12
13
Material
SS400C
SS400C
SS400C
SS400C
SS400C
SS400C
SS400C
SS400B
SS400
SS400
SS400
SS400
SS400
Total weight
Material t12
Q'ty
4
2
2
2
2
2
2
4
4
4
10
2
2
Remarks
C15075t9-1282
C15075t9-829
C15075t9-829
C15075t9-510
C15075t9-548
C15075t9-453
C15075t9-355
T50-500
t25180250
t12200655
t1260128
t16124130
t257085
Fig.2
Crane
18
Straight shackle
04
Bow shackle
Master link
03
06
Bow shackle
02
Master link
Sling jig A
01
05
Material
No.
Q'ty
Remarks
Fig.3
19
2 places
2-36 drill
2 places
2 places
2-44 drill
Plate
Plate
Plate
02
03
Part name
01
44 drill
SS400
SS400
SS400
Material
Qty
t36
t36
t36
Remark
Fig.4
Fig.5
Crane
Master link
Using load: 80 kN {8.16 t}
JIS B8817 or equivalent
Sling jig B
Bow shackle
Using load: 78.5 kN {8 t}
BB28 (S level) of JIS B2801
or equivalent
Straight shackle
Using load: 78.5 kN {8 t}
BB28 (S level) of JIS B2801
or equivalent
Sling jig C
20
Apply chamfering on
the ridges and corners
so that they would not
hurt hands.
21
The scale is indefinite.
Plate
Plate
02
Part name
01
No.
36 drill
2-36 drill
SS400
SS400
Material
Qty
t22
t28
Remark
Fig.6
2-33 drill
2-36 drill
22
Part name
Plate
Boss
01
02
SS400
SS400
Material
No.
Qty
Before welding
56
t32
Remark
Fig.7
Fig.8
Straight shackle
Type SB
Type Nominal
Type SD
Using load
d1
M level
S level
T level
16
16
32
16
36
64
20
9.8 kN {1 t}
22
22
44
22
50
88
27
19.6 kN {2 t}
28
28
43
28
70
112
34
47.1 kN {4.8 t}
78.5 kN{8 t}
98.1 kN {10 t}
36
36
54
36
90
144
42
78.5 kN {8 t}
122.6 kN {12.5 t}
156.9 kN {16 t}
50
50
75
50
125
200
60
156.9 kN {16 t}
245.2 kN {25 t}
308.9 kN {31.5 t}
SD
SB
Bow shackle
Type BB
Type Nominal
BB
Using load
d1
B1
M level
S level
24
24
39
28
62
126
30
70
35.3 kN {3.6 t}
61.8 kN {6.3 t}
28
28
43
32
70
144
34
80
47.1 kN {4.8 t}
78.5 kN {8 t}
36
36
54
42
90
190
42
105
78.5 kN {8 t}
23
T level
98.1 kN {10 t}
6. Pinch bar
Fig.9
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.
24
TIGHTENING TORQUE
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt
TTTTT-TTTTT
EEEEE-EEEEE
Bolt specification
Thread
Bolt
length
Thread
sizediameter
(Diameter,
pitch,
length)
Applicable socket size
Tool (Socket)
Tightening torque
Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 20
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. correspond to dimension b in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ www or QQQ RR. If the target tightening torque
is set, expression of QQQ RR is applied.
Fig. 1
a
b
c
d
25
Unit : Nm
Unit : {kgm}
61
10
12
{1.2}
8.8 14.7
{0.9 1.5}
8 1.25
13
25
{2.5}
14.7 34
{1.5 3.5}
10 1.5
17
54
{5.5}
34 74
{3.5 7.5}
12 1.75
19
89
{9}
54 123
{5.5 12.5}
14 2
22
137
{14}
84 196
{8.5 20}
16 2
24
230
{23.5}
147 309
{15 31.5}
18 2.5
27
315
{32}
201 427
{20.5 43.5}
20 2.5
30
460
{47}
319 608
{32.5 62}
22 2.5
32
650
{66.5}
471 829
{48 84.5}
24 3
36
810
{82.5}
588 1030
{60 105}
27 3
41
1180
{120}
883 1470
{90 150}
30 3
46
1520
{155}
1130 1910
{115 195}
33 3
50
1960
{200}
1470 2450
{150 250}
36 3
55
2450
{250}
1860 3040
{190 310}
39 3
60
2940
{300}
2260 3630
{230 370}
26
2.1 If the male screw is made of mild steel or cast iron, apply Table 2.
Table 2
Unit: Nm {kgm}
Material of female thread
Steel
Cast iron
Light alloy
1/8
3.9 6.9
{0.4 0.7}
2.9 5.9
{0.3 0.6}
2.0 3.9
{0.2 0.4}
1/4
5.9 11.8
{0.6 1.2}
4.9 9.8
{0.5 1.0}
3.9 7.8
{0.4 0.8}
3/8
16.7 26.5
{1.7 2.7}
13.7 21.6
{1.4 2.2}
9.8 16.7
{1.0 1.7}
1/2
32.3 52.9
{3.3 5.4}
26.5 43.1
{2.7 4.4}
19.6 32.3
{2.0 3.3}
3/4
51.0 85.3
{5.2 8.7}
42.1 70.6
{4.3 7.2}
31.4 52.9
{3.2 5.4}
86.2 173.5
{8.8 17.7}
72.5 146.0
{7.4 14.9}
54.9 111.7
{5.6 11.4}
2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Unit: Nm {kgm}
Material of female thread
Steel
Cast iron
Light alloy
1/8
16.7 29.4
{1.7 3.0}
9.8 19.6
{1.0 2.0}
6.9 14.7
{0.7 1.5}
1/4
19.6 44.1
{2.0 4.5}
16.7 37.2
{1.7 3.8}
12.7 28.4
{1.3 2.9}
3/8
44.1 93.1
{4.5 9.5}
37.2 77.4
{3.8 7.9}
27.4 58.8
{2.8 6.0}
1/2
98.0 188.2
{10.0 19.2}
83.3 157.8
{8.5 16.1}
60.8 115.6
{6.2 11.8}
3/4
170.5 316.5
{17.4 32.3}
141.1 247.0
{14.4 25.2}
105.8 186.2
{10.8 19.0}
367.5 612.5
{37.5 62.5}
309.7 514.5
{31.6 52.5}
235.2 392.0
{24.0 40.0}
27
Table 4
Tightening torque (Nm {kgm})
Outside diameter
of hose
(mm)
Width across
flatse.
(mm)
Range
Target
Approx. 6
19
35 63 {3.5 6.5}
44 {4.5}
22
54 93 {5.5 9.5}
74 {7.5}
24
59 98 {6.0 10.0}
78 {8.0}
Approx. 13
27
103 {10.5}
Approx. 16
32
157 {16.0}
Approx. 20
36
216 {22.0}
Approx. 10
Table 5
Unit: mm
Thread diameter
M42
65
M45
70
M48
75
M52
80
M56
85
M60
90
M64
95
28
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
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cock plug from
coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
LT-2
09940-00030
50 g
Polyethylene
container
LT-3
790-129-9060
(Set of adhesive
and hardening
agent)
Adhesive:
1 kg
Hardening
agent:
500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Three bond
1735
790-129-9140
50 g
Polyethylene
container
Adhesives
Aron-alpha
201
790-129-9130
2g
Polyethylene
container
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
Used as adhesive or sealant for gaskets and packing of power train case,
etc.
LG-5
790-129-9080
1 kg
Can
Tube
LG-6
790-129-9020
200 g
Gasket
sealant
LG-7
790-129-9070
1 kg
Tube
Three bond
1211
790-129-9090
100 g
Tube
Tube
Three bond
1207B
419-15-18131
100 g
29
Category
Molybdenum
disulphide
lubricant
Grease
Komatsu code
Part No.
Q'ty
Container
LM-G
09940-00051
60 g
Can
Tube
LM-P
09940-00040
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Molybdenum
disulphide
grease
LM-G (G2-M)
SYG2-400M
SYG2-400M-A
SYGA-16CNM
Hyper White
Grease G2-T
G0-T (*)
*: For use in cold
district
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)
Biogrease G2B
G2-BT (*)
*: For high
temperature
and large load
SYG2-400B
SYGA-16CNB
SYG2-400BT (*)
SYGA-16CNBT (*)
200 g
Various
Various
Various
400 g
16 kg
400 g
16 kg
Seizure resistance and heat resistance higher than molybdenum diBellows type
sulfide grease
Can
Since this grease is white, it does
not stand out against machine
body.
Since this grease is decomposed
by bacteria in short period, it has
Bellows type
less effects on microorganisms,
Can
animals, and plants.
SUNSTAR
PAINT PRIMER
580 SUPER
20 ml
Glass
container
SUNSTAR
GLASS PRIMER
580 SUPER
20 ml
Glass
container
Primer
Caulking
material
SUNSTAR
PENGUINE
SEAL 580
SUPER "S" or
"W"
320 ml
Polyethylene
container
Adhesive
417-926-3910
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Cartridge
Natural yellow
SYPA-U03PNY
Spray can
Black gray
SYPA-U03PBG
Spray can
Paint
30
A. Assembly
Remarks
1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---,
but indicated by (1), (2), (3) --- in the tables and texts.
Example:
(1)
(2)
(3)
(4)
(5)
(6)
2.
Plate
Collar
Washer
Bolt
Bolt
Washer
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 operator's seat with the sprocket at the rear as shown below, unless otherwise specified.
Front
Left hand
Right hand
Operator's seat
Sprocket
Rear
31
Assembly procedure
A-1
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 machine
while the other set on the right side as shown in Fig. 1.
Left track
Parallel
Front
Right track
Front end
2,770
2,060
710
13,066
Remarks
When shoe width is B
Number of shoes: 40
a When the track shoes are placed, they are folded as the
shape in Fig. 2, so pay attention to the front and rear directions when expanding them.
a When the track shoes are placed on the ground, the joint
portion with the master link on the tip of front side shoes
faces to the ground. (Fig. 3)
Abutment joints
Ground
32
Assembly procedure
A-2
1. Installation of chassis stand
Place 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.
Track (Left)
Steel plate
Track (Right)
Front end
Steel plate
Symbol
H1
H2
t
L1
L2
Dimension (mm)
1,105
1,020
16
2,800
3,300
2,450
Remarks
33
Assembly procedure
A-2
34
Assembly procedure
A-2
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 cranes
together (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 damage
of 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 frame
of 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 main
frame (10) of the machine as shown in Fig. 5.
<Specification of wooden bar>
Section: 95 mm, square
Length: 180 to 200 mm
a Steel bar of the same shape can be used instead of
wooden bar.
35
Assembly procedure
A-3
1. Make the counter mark from cylinder stay yoke (1) on the
front 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 same
time. At this time, disconnect greasing hose connected to
the elbow of bushing (5).
(4) Washer
(5) Bushing (top)
(6) Bushing (bottom)
Greasing hose
36
Assembly procedure
A-3
4. Insert bushing (5) [Sealing welded plate on which the elbow connecting greasing hose is attached] into the trunnion shaft that becomes top of hydraulic cylinder.
a Dust seal is embedded in the end of inserting port on
bushing side. Carefully insert the bushing after applying
grease (G2-LI), etc. in order to prevent damaging the lip
of this seal.
Trunnion shaft
Necessary socket
46 mm
Tightening torque
37
Assembly procedure
A-3
8. Loosen bolt (9), and remove fixing jig (8) installed on hydraulic cylinder (7). (Fig. 5)
a Specification of bolt (9)
M16, length 35 mm
a Fixing jig (8):
It is a special jig for supporting hydraulic cylinder when
front work equipment (blade) is not installed, and is mainly used when the machine is operated as a tractor.
Part No.
01010-81630
21T-09-11330
Part Name
Bolt
Washer
Q'ty
1
1
38
Assembly procedure
A-3
12. Installation of hydraulic hoses
No.
13
14
15
16
17
Part No.
07098-01218
07098-01219
07000-F3038
07371-51260
07375-21250
Part Name
Hose
Hose
O-ring
Flange
Sems bolt
Q'ty
2
2
8
16
32
Remarks
Length: 1,800 mm
Length: 1,900 mm
39
Assembly procedure
A-3
No.
18
19
Part No.
07378-11210
07000-F3038
Part Name
Head
O-Ring
M12, length 50 mm
Necessary socket
17 mm
Tightening torque
(Bottom)
(Head)
40
Q'ty
1
1
Assembly procedure
A-3
a Reference
As shown in Fig. 9 and Fig. 10, the installation of hydraulic
hose is laterally symmetric for left and right cylinders, but
the hydraulic flow of left and right cylinders is different as
shown in the following table.
Hydraulic
cylinder
Left
Right
Hydraulic
hose No.
13
Hydraulic cylinder
connecting port
Head
14
Bottom
13
Bottom
14
Head
(Head)
(Bottom)
Avoid interference
41
Assembly procedure
A-4
1. Preparations
1) Removal of accessories
Remove the following 10 parts (the bolts are not
counted in) from the track frame as shown in the photo.
No.
1
2
3
4
5
6
7
8
9
10
Part No.
198-30-69530
198-30-61360
198-50-61370
198-50-61150
198-30-69460
198-30-69470
198-30-62311
198-30-62321
198-50-51390
198-30-51430
198-30-51440
198-50-31270
198-50-51220
195-30-31260
198-30-69850
198-30-69860
Part Name
Cover
Cover (L.H.)
Cover (R.H.)
Shaft (Side pin)
Cover (L.H.)
Cover (R.H.)
Cover (L.H.)
Cover (R.H.)
Cover
Cover (L.H.)
Cover (R.H.)
Spacer
Cover assembly
Cover
Cover (L.H.)
Cover (R.H.)
Part No.
07000-15355
Part Name
O-ring
Torsion seal
42
Assembly procedure
A-4
2. Sling work of track frame assembly
Lifting jig A
Crane
Crane
Lifting jig A
Lifting jig A
Hook
Horizontally sling track frame assembly by using sling jig A and chain lever hoist (referred as chain block hereafter) as shown
in 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 of
track 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))
43
Assembly procedure
A-4
Pin holes
Equalizer bar
44
Assembly procedure
A-4
Pivot shaft
Track frame
Machine
(11) O-ring
(12) Inner torsion seal
(13) Seal pressing cover
There is UP mark
Grease tube
45
Assembly procedure
A-4
5. Assembly of end portion of pivot shaft
a Torsion seal assembly (17) is included in parts (8) removed in "1. Preparations".
No.
Part No.
198-50-31270
Spacer
15
07000-05190
O-ring
07000-05315
O-ring
16
Part Name
198-50-31160
17
198-50-31241
198-50-52171
Q'ty
Remarks
Inner washer
Torsion seal
Torsion seal
assembly
Outer washer
18
01010-81665
Bolt
19
01643-31645
Washer
20
01011-82005
Bolt
21
01643-32060
Washer
2) Tightening bolts
Bolt
Specifications
18
20
M16, length 65 mm
24 mm
46
Tightening torque
Refer to Table 1, "Tightening Torques" in
this manual.
Assembly procedure
A-4
Track frame
O-ring
Machine
Pivot shaft
Fix torsion seal on the larger diameter side (inner side of track frame assembly) of pivot shaft by using the seal pressing cover
at 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.
25
26
Part No.
01010-81640
01643-31645
Part Name
Bolt
Washer
Q'ty
6 each on left and right sides
6 each on left and right sides
Bolt specification
M16, length 40 mm
Necessary socket
24 mm
Tightening torque
47
Assembly procedure
A-4
7.
1) The right and left sides of the pivot shaft are different, depending on the machine specification.
Structure
Specification
Not installed
Installed
Dual tiltdozer
Installed
Installed
Super dozer
Installed
Installed
Single tiltdozer
2-2) Install the unions, elbows and plugs for the tilt
piping 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 delivered, the above work is not necessary.
No.
31
32
33
34
35
Part Name
Cover
Union
Plug
Elbow
O-ring
Part No.
198-50-51390
02781-00628
07040-12412
02782-1062A
07002-22434
Q'ty
2 pcs. (common to right and left)
2 pcs. (for each cover)
2 pcs. (for each cover)
2 pcs. (for each cover)
6 pcs. (for each cover)
128 186 Nm
{13 19 kgm}
a Parts (31) to (35) are components of (6) and (7) removed in "1. Preparations".
48
Assembly procedure
A-4
No.
6
36
37
38
Part Name
Part No.
Cover
Assembly in step 2.2)
Hose
198-71-62171
Hose
198-71-62270
O-ring
02896-21018
Tightening torque of hydraulic hose
(The quantity is for 1 cover assembly)
4) Remove the plugs from the tilt hoses projected from
the pivot shaft end (2 places).
Reference
Plug
07376-70628
O-ring
02896-11018
49
Q'ty
1
1
2
Remarks
Red-banded
Blue-banded
177 245 Nm {18 25 kgm}
Assembly procedure
A-4
5) Install the tilt hoses projected from the pivot shaft end
to the cover assembly described in step 2).
a1. Take care not to forget to set the O-rings.
O-ring
02896-21018
2 pcs.
No.
Part Name
Part No.
42 Bolt
01010-81695
43 Bolt
01011-81625
44 Washer
01643-31645
Note) The quantity is for 1 cover assembly.
Q'ty
9
1
10
Remarks
For tightening torque of bolts, see
refer to Table 1, "Tightening Torques"
in this manual.
50
Assembly procedure
A-4
Figure No.
Part Name
Qty
Part No.
77
Plug
07376-70522
78
O-ring
02896-11015
8) Pass hoses (45) and (46) through the track frame and
pull them out of the hole of the trunnion mounting
seat.
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 machine
have different part Nos.
No.
51
52
53
54
Part Name
Cover (Right)
Cover (Left)
Bolt
Washer
Part No.
198-30-51440
198-30-51430
01010-81635
01643-31645
Q'ty
1
1
3
3
Remarks
For tightening torque of bolts, see
refer to Table 1, "Tightening Torques"
in this manual.
Note) The quantity of bolts and washers shows for each one cover.
51
Assembly procedure
A-4
No.
61
62
63
64
65
66
Part Name
Cover
Bolt
Washer
Plate
Bolt
Washer
Part No.
198-30-51220
01010-81695
01643-31645
198-30-51330
01010-81635
01643-31645
Q'ty
1
10
10
1
3
3
Remarks
52
Assembly procedure
A-4
8. Release of slinging
Jack
Set two or more jacks or wooden bars to keep the track frame assembly to be
longitudinally horizontal.
53
Assembly procedure
A-4
54
Assembly procedure
A-4
50 mm
55
Assembly procedure
A-4
Part No.
Qty
75
Plate
198-30-69280
76
Collar
198-30-66190
77
Washer
19M-54-11770
78
Bolt
01011-62710
79
Bolt
01010-62765
80
Washer
01643-32780
81
Plate
198-30-68950
82
Collar
198-30-68960
83
Washer
19M-54-11770
84
Bolt
01011-62710
Remarks
Removal parts
Removal parts
a The quantity shows the number of parts for each one side of left and right track frame assemblies.
56
Assembly procedure
A-4
41 mm
Tightening torque
883 1,470 Nm
{90 150 kgm}
Figure No.
79
80
85
86
Part Name
Bolt
Washer
Bolt
Washer
Part No.
01010-62765
01643-32780
01010-62765
01643-32780
Q'ty
3
3
2
2
Remarks
Reuse
Reuse
Newly supply
Newly supply
a The quantity shows the number of parts for each one side of left and right track frame assemblies.
Part No.
07049-02734
Q'ty
3
a The quantity shows the number of parts for each one side
of left and right track frame assemblies.
57
Assembly procedure
A-5
1. The machine requires flushing of work equipment hydraulic oil after assembly, so in this procedure, replace the element of
hydraulic 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 with
plate (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 15C, do not use (2). Replace only the element and flush the circuit while
running the engine at low idle.
No.
1
2
Part Name
Element
Plate
Part No.
208-60-71170
21T-60-13730
Q'ty
1
1
a Removed standard element (208-60-71120), strainer (07069-25400) and valve (208-60-71160) will be used again after
flushing 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".
58
Assembly procedure
A-5
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 the
installed element with the hand.
If you can turn the element smoothly, it is installed normally.
59
Assembly procedure
A-6
Pivot chamber
Add engine oil through the hole of plug (1).
60
Assembly procedure
A-7
61
Assembly procedure
A-7
Precautions
Tools required
Name
Others
62
Equipment required
Qty
Name
Qty
Assembly procedure
A-8
1. Preparation
Do not remove the arm pin but pull it out to the state
shown in the photo.
01010-82040
(2 pieces on each side)
01643-32060
(2 pieces on each side)
Bolt specification
M20, Length 40 mm
Necessary socket
30 mm
Tightening torque
Style
It is necessary to start the engine to perform the following 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.
Block
01010-82045
(2 pieces on each side)
01643-32060
(2 pieces on each side)
Bolt specification
M20, Length 45 mm
Necessary socket
30 mm
Tightening torque
63
Assembly procedure
A-8
4. Installation of tilt cylinder
01010-82045
(2 pieces on each side)
01643-32060
(2 pieces on each side)
Bolt specification
M20, Length 45 mm
Necessary socket
30 mm
Tightening torque
L-adapters
6. Sub beam
01010-82040
(2 pieces on each side)
01643-32060
(2 pieces on each side)
Bolt specification
M20, Length 40 mm
Necessary socket
30 mm
Tightening torque
64
Assembly procedure
A-8
8. Connection of cylinder
1) Start the engine in low idle, and confirm the movement of the lift cylinder rod and the tilt cylinder rod.
Bolt specification
01010-82045
(2 pieces on each side)
01643-32060
(2 pieces on each side)
M20, Length 45 mm
Necessary socket
30 mm
Tightening torque
Note) If the engine is started for the first time in this work, lubricate it before starting according to "M-3 No-injection cranking
of engine".
65
Assembly procedure
A-8
9. Installation of pin puller hoses
Clamping positions of hoses
66
Assembly procedure
A-8
67
Assembly procedure
Installation of trunnion
A-9
Track frame
01011-83005
(12 pieces on each side)
01643-33080
(12 pieces on each side)
Bolt specification
Necessary socket
46 mm
Tightening torque
Trunnion
Washer
Bolt
Trunnion
68
Tilt hose
Assembly procedure
A-10
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 the
track shoes on the idler. (Fig. 1)
After that, set wooden bar on the grouser of track shoes
to prevent the track shoes from rewinding, and loosen the
sling.
Wire rope
slings
Slinging bar
Wooden
bars
Steel plate
Wire rope
slings
Inserted
Floated
Wooden bars
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 to
the sprocket.
Crane.
Main hoisting
Load chain
Outside
Inside
Sling bar
Crane.
Main hoisting
Belt sling
Sling bar
Sprocket
Track shoes
69
Carrier roller
Crane.
Subsidiary
hoisting
Assembly procedure
A-10
6. After that, move it forward until the fifth link pin interlocks
with sprocket, completely set track shoes on the sprocket,
and then loosen the sling on subsidiary crane to lower the
track shoes.
7. Clean the mating surface of master link to remove all
harmful sand, metal scraps, etc.
a Also clean the master link on the idler described in
item 1.
Wooden bar
10. Set the interlocked master link on master shoe (1), install
and temporarily tighten four master bolts (3) to make the
master links firmly contact with each other.
a If the shoe bolts are tightened forcibly before the contact surfaces of the master link are fitted, the threads
of them and master link may be damaged.
11. Confirm that the interlock surface is firmly contacted, and
then loosen master bolts (3) to remove master shoe (1).
12. Apply seizure preventing agent (LM-P) on the thread portion of shoe bolts.
a See "Coating materials".
No.
1
2
3
Part No.
198-32-31483
19M-32-11450
198-32-31341
Part Name
Master shoe
Key
Master bolt
Q'ty
(1 pieces on each side)
(2 pieces on each side)
(4 pieces on each side)
70
Assembly procedure
A-10
a Tightening order
Tighten 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.
71
Assembly procedure
A-11
Precautions
Name
Others
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.
Tools required
72
Equipment required
Qty
Name
Qty
Assembly procedure
A-11
INSPECTION
Stop 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.
Precautions
Tools required
Others
Name
73
Equipment required
Qty
Name
Qty
Assembly procedure
A-12
1. Installation of blade
Stand the delivered blade vertically on the assembly
ground according to the following procedure.
a Stand the blade means to set the back of the blade at
90 to the ground as shown in (Fig. 1).
[1] Sling the blade with the crane. While operating the main
and auxiliary hoists, stand the blade gradually as shown
in (Fig. 2) and (Fig. 3) until it stands vertically on the object position (ground).
Auxiliary
hoist side
Main hoist side
a Install the rope slings of the main hoist to the blade lift
hydraulic cylinder mounting pin.
a Install the rope slings of the auxiliary hoist to the lifting
holes at both ends of the blade top through shackles.
Weight of semi U-blade
Weight of full U-blade
Weight of Super dozer
Wire rope sling
Shackle
13 t
14 t
12 t
32 mm 5 m (4 pieces)
SD34 (2 pieces)
Reference: Additionally weld spill guard on the blade before setting the blade vertical.
See "Appendix: Installation of Spill Guard" for the installing (welding) procedure.
74
Assembly procedure
A-12
2 parts
a Wooden block:
T350 mm length 400 mm 2 pieces
[3] If it is difficult to stand the blade vertically with only the
wooden blocks in steps [1] and [2], add plates to adjust
finely. (Fig. 5)
[4] After confirming that the blade stands stably, loosen and
remove the slings.
Plate
Wooden block
(Insert on both sides)
No.
1
Part Name
Center link
Eyebolt
Sling bar
Mud cover
Shackle
Remarks
Components of blade assembly
M24, using load: 9.32 kN {950 kg}
(JIS B1168 or equivalent)
#10 wire, 3.2 mm approximate length 2 m
(JIS G3532 or equivalent)
SS400B, 19 mm 300 mm
(JIS G3532 or equivalent)
Welded on the back surface of the blade already
SD16, using load: 9.81 kN {1 t}
(JIS B2801).
To be used for slinging by crane
75
Assembly procedure
A-12
[1] Check that the joints at the ends of the straight frames
are installed in the correct directions. (Fig. 7)
a If the joints are installed in wrong directions, correct their directions.
Good
Part Name
Pin
Lock
Bolt
Washer
Part No.
198-72-51810
09257-11219
01010-82455
01643-32460
Q'ty
2
2
8
8
Bolt specification
M24, Length 55 mm
Tool (Socket)
36 mm
76
Wrong
Assembly procedure
A-12
Wooden block
[4] While slinging the straight frame, insert the joint at its
end in the bracket yoke on the blade and align the
connecting pin holes. (Fig. 9)
[5] Insert pin (81) removed in step [2] and fix it to the
bracket on the blade with lock (83), bolt (84) and
washer (85). (Fig. 9)
Belt sling
Wooden block
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 and
left straight frames symmetrically about the blade and
adjust the distance between both straight frames (dimension W) to approx. 3,810 mm. (Fig. 11)
a Clean each connecting part.
77
Assembly procedure
A-12
4. Installation of center brace
Part Name
Bolt
Washer
Shim (2 mm)
Shim (1 mm)
Shim (0.5 mm)
Part No.
01011-83335
01643-33380
198-71-31450
198-71-31460
198-71-31470
Q'ty
8
8
2
4
4
Detail P
View Z
[2] Install the belt sling to the center of center brace (90).
While slinging the center brace with the crane, put the
balls of the ball joints respectively to the spherical
seat (part F) of the center link and that (part G) of the
straight frame. (Fig. 12)
No.
90
Part Name
Center brace
Part No.
198-72-51350
Q'ty
2
78
Assembly procedure
A-12
Tool (Socket)
50 mm
Ball cap
Part No.
07049-02430
Q'ty
1
Belt sling
79
Assembly procedure
A-12
41 mm
Tightening torque
Shim
Bolt
Washer
Ball joint
No.
5
Part Name
Shim (0.5 mm)
Part No.
198-71-31470
Q'ty
2
View Z
4.4 Adjustment of distance between tilt cylinder mounting
pin holes
[1] Sling the straight frame again with the belt sling as
shown in (Fig. 19) and adjust the distance between
the mounting pin holes of the tilt cylinder (dimension
K) (or the brace assembly on the left side in step 6 for
the single tilt dozer specification) to about 1,845 mm.
Then, adjust the position of the wooden block under
the straight frame so that the distance between the
holes will be stabilized and then remove the sling.
a Perform this adjustment on the right and left
sides.
Belt sling
Wooden block
80
Assembly procedure
A-12
5. Installation of tilt hydraulic cylinders
Part Name
Hydraulic cylinder
Hydraulic hose
(Overall length: 1,650 mm)
Hydraulic hose
(Overall length: 1,130 mm)
O-ring
Flange
Bolt
Washer
Cover
Bolt
Washer
Part No.
707-01-0X760
Q'ty
2
198-71-62131
198-71-62121
07000-23025
07371-30640
07372-21035
01643-51032
198-71-62211
01010-82045
01643-32060
4
8
16
16
2
12
12
Bolt specification
Tool (Socket)
M10
17 mm
M20
30 mm
Tightening torque
a Flange (10), bolt (11) and washer (12) are installed to each hydraulic cylinder in advance.
(Marked )
However, do not reuse the sleeve head (oil stop
cover) 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.
81
Assembly procedure
A-12
Tool (Socket)
M12
19 mm
M20
30 mm
Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque
[4] Set a wooden block between hydraulic cylinder (hydraulic hose protection cover) and straight frame so
that hydraulic cylinder (6) will be positioned as shown
in (Fig. 22), and then loosen and remove the sling.
82
Assembly procedure
A-12
[5] Connect the free ends of hydraulic hoses (7) and (8)
installed to hydraulic cylinder (6) in step [1] to the elbows of flange (21) installed to the straight frame.
(Fig. 23)
Connect according to the letters stamped on the
flange.
Stamp
H
B
Hose to be connected
Longer hydraulic hose
(Head side)
Shorter hydraulic hose
(Bottom side)
Part Name
O-ring
Part No.
02896-11018
Q'ty
4
83
Assembly procedure
A-12
Part Name
Hydraulic cylinder
Hydraulic hose
(Overall length: 1,650 mm)
Hydraulic hose
(Overall length: 1,130 mm)
O-ring
Flange
Bolt
Washer
Cover
Bolt
Washer
Part No.
707-01-0X760
Q'ty
2
198-71-62121
198-71-62131
07000-23025
07371-30640
07372-21035
01643-51032
198-71-62211
01010-82045
01643-32060
4
8
16
16
2
12
12
Bolt specification
Tool (Socket)
M10
17 mm
M20
30 mm
Tightening torque
a Flange (35), bolt (36) and washer (37) are installed to hydraulic cylinder (31) in advance.
(Marked )
However, do not reuse the sleeve head (oil stop
cover) 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.
84
Assembly procedure
A-12
Tool (Socket)
M12
19 mm
M20
30 mm
[3] While slinging tilt hydraulic cylinder (31) with belt sling
(20), with the hydraulic hose cover side down, align
the 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)
Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque
[4] Set a wooden block between hydraulic cylinder (hydraulic hose protection cover) and straight frame so
that the hydraulic cylinder (31) will be positioned as
shown in (Fig. 26), and then loosen and remove the
sling.
a Do not connect the head side of the hydraulic cylinder (31) (part (R) in Fig. 26) at this time.
Connect it after installing the blade assembly to
the machine.
(See "Assembly procedure A-13")
85
Assembly procedure
A-12
Hose to be connected
Longer hydraulic hose
(Head side)
Shorter hydraulic hose
(Bottom side)
H
B
Part Name
O-ring
Part No.
02896-11018
Q'ty
4
Bolt specification
Tool (Socket)
Tightening torque
M12
Length 25 mm
19 mm
M20
Length 40 mm
30 mm
86
Assembly procedure
A-12
5.3 For super dozer specification
[1] Install tube and tube protection covers to the right and
left hydraulic cylinders.
No.
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
Part Name
Hydraulic cylinder
(For super dozer)
Tube (L.H.)
Tube (R.H.)
O-ring
Bolt
Washer
Bolt
Washer
Block (L.H.)
Block (R.H.)
Bolt
Washer
Bolt
Washer
Cover
Bolt
Bolt
Washer
Hose
O-ring
Part No.
Q'ty
707-01-0X990
198-72-62570
198-72-62580
07000-F3030
07372-21045
01643-51032
07372-21060
01643-51032
198-72-62550
198-72-62560
07372-21035
01643-51032
01010-81095
01643-51032
198-72-62590
01011-82025
01010-82040
01643-32060
198-72-52110
07000-F3025
1
1
6
4
4
4
4
1
1
8
8
8
8
2
2
12
14
4
4
Bolt specification
Tool (Socket)
M10
17 mm
M20
30 mm
Tightening torque
87
Assembly procedure
A-12
[2] Set the cover side of hydraulic cylinder (88) facing upwards, lift the cylinder up by using belt sling (20), and
align the mounting pin holes on the bottom side (Clevis 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) and
washer (109).
Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque
88
Assembly procedure
A-12
Part Name
O-ring
Part No.
07000-F3025
Bolt specification
Tool (Socket)
M10
17 mm
Q'ty
4
M12
M20
Tool (Socket)
19 mm
30 mm
Tightening torque
89
Assembly procedure
A-12
6. Installation of brace assembly
[1] Remove covers (51 54) and brace assembly mounting pins (55 58) installed to the brace assembly
mounting section of the left straight frame in advance.
(Fig. 29)
Bolt specification of 53, 57
M20
Tool (Socket)
30 mm
[2] Remove brace assembly mounting pins (59 62) installed to the brace assembly mounting section of the
blade in advance. (Fig. 30)
90
Assembly procedure
A-12
Part Name
Brace
Fitting
Seal
Screw
Screw
Bushing
Ring
Handle
Bolt
Washer
Part No.
198-72-53260
07020-00000
2989-01-2580
198-71-21280
198-71-21272
195-71-51254
195-71-52360
198-71-32150
01010-81660
01643-31645
Q'ty
1
2
1
1
1
1
1
1
2
2
[4] Supply grease (See step [9]) through fitting (64) installed to brace (63) and rotate brace (63) with attached lever (73) to adjust dimension (L) between the
holes at both ends of brace assembly to approximately 1,850 mm. (Fig. 32)
Reference
If brace (63) is rotated with lever (73) while screws
(66) and (67) at both ends are fixed, dimension (L) increases or decreases by 12.7 mm performance turn.
Accordingly, if only one side screw in the both end
screws is rotated by a half turn, dimension (L) can be
adjusted by 3.175 mm.
91
Assembly procedure
A-12
[5] While slinging brace assembly with the belt sling, with
the handle (70) up, align the mounting pin hole of the
brace assembly with that of the straight frame. Then,
insert mounting pin (55) removed in step [1] and fix it
to the straight frame with lock (56), bolt (57) and
washer (58). (Fig. 33)
Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque
[6] While still slinging the brace assembly with the belt
sling (21), align the mounting pin hole on the opposite
side of step [5] with the mounting pin hole of the brace.
a At this time, if the mounting pin holes cannot be
aligned because of dimension (L) adjusted in step
[4], rotate screw (67) one half by one to adjust dimension (L) finely while locking brace (63).
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque
92
Assembly procedure
A-12
53
57
Tool (Socket)
M20
M20
Length 40 mm
Length 50 mm
30 mm
Tightening torque
Bolt specification
[9] Greasing
Single tiltdozer
After finishing installation, supply grease to the 5 places indicated with the arrows in (Fig. 34) until it comes
out.
Single tiltdozer
Dual tiltdozer
Super dozer
93
Assembly procedure
A-13
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).
Dimension (b)
(Disconnect between sphere centers)
Approx. 1,085 mm
Approx. 3,810 mm
Dimension (a)
a Dimension (a) in the table is set on the assumption that the machine is used on a hard ground where the track shoe grousers will not sink. If the machine is used on a ground where the grousers sink, the trunnion height decreases by the sinking
distance. 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 trunnion and clean its surface.
Seat
2.2)
Set the machine within dimension (b) of the blade assembly and move it forward so that the right and left clearances
will be the same.
2.3)
Move and press the machine forward until the trunnion is seated in the trunnion holder (bushing) of the blade assembly (straight frame). (Fig. 3)
94
Assembly procedure
A-13
a If the trunnion and trunnion holder are different in height, trunnion holder bushing (2) in (Fig. 4) may move when the
trunnion is pressed.
If the trunnion and trunnion holder are different in height, sling the straight frame of the blade assembly with a crane
etc. and adjust their heights.
2.4)
No.
1
2
3
4
5
6
7
Part Name
Straight frame
Bushing
Plate
Cap
Nut
Bolt
Washer
Part No.
198-71-51340
198-72-00110
198-71-51390
195-71-11510
198-61-11250
01643-33380
Q'ty
2
4
1
4
4
4
Bolt specification
Tool (Socket)
50 mm
Tightening torque
Remarks
See "assembly procedure A-12"
2.5) Remove wooden block (E) set under the straight frame in step 1).
95
Assembly procedure
A-13
Remove the upper and lower plugs from the nipples of the flange (7) in (Fig. 5) on the blade assembly side.
3.3)
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.
Hose indentification
Color identification mark
(red) at the tip of hose
Color identification mark
(blue) at the tip of hose
a The part Nos. of the plug and nut removed from the nipple of the flange in step 2) are shown below for reference.
Part name/Part No.
Plug
02789-00628
Dual tiltdozer
Q'ty
2 pieces each on
right and left
Single tiltdozer
Q'ty
2 pieces on only
right
Super dozer
Q'ty
2 pieces each on
right and left
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 from
the machine and stored.
a When the front work equipment is the single tiltdozer, perform this work only on the right side.
96
Assembly procedure
A-13
No.
1
4
8
9
10
Part Name
Blade assembly
Trunnion cap
Cover
Bolt
Washer
Part No.
198-71-21240
01010-82050
01643-32060
Q'ty
Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque
Remarks
See 2.4) of this procedure
a Before installing the protection cover, check the operation of the tilt cylinder in the blade adjustment work described
later and confirm that there is not oil leakage or another problem in the tilt hose connection.
97
Assembly procedure
A-13
Belt sling
Sling bracket
a Connect the hydraulic cylinders one by one.
5.2)
a The work shall be performed by the machine operator, crane operator, and "signalman". The signalman must arrange the signaling method in
advance and give proper directions to both operators.
5.3)
5.4)
5.5)
5.6)
198-72-62140
(1 piece each on right and left)
198-72-62170
(1 piece each on right and left)
01010-81635
(2 pieces each on right and left)
01643-31645
(2 pieces each on right and left)
M16, Length 45 mm
24 mm
Refer to Table 1, "Tightening
Torques" in this manual.
Install blade cylinder holdfast (11) on the upper side of the cylinder facing inside of cylinder to fix the cylinder.
98
Assembly procedure
A-13
Remove the pins from the right and left of the cylinder connecting side (blade). (Fig. 11)
Part Name
Pin
Lock
Bolt
Washer
Part No.
09255-06295
09257-09014
01010-82045
01643-32060
Q'ty
1 each
1 each
4 each
4 each
Bolt specification
M20, Length 45 mm
Tool (Socket)
30 mm
No.
12
13
14
15
Part Name
Pin
Lock
Bolt
Washer
Part No.
198-72-51720
09257-09014
01010-82045
01643-32060
Q'ty
1 each
4 each
4 each
4 each
6.2)
The bottom side (clevis side) of the hydraulic cylinder has been connected to the straight frame already. See "assembly procedure A-11".
Raise one end of this hydraulic cylinder with the
belt sling and remove the wooden block placed under it. (Fig. 12)
6.3)
cylinder
a The work shall be performed by the machine operator, crane operator, and "signalman". The signalman must arrange the signaling method in
advance and give proper directions to both operators.
99
Assembly procedure
A-13
6.4)
After aligning the pin holes, stop the engine and insert pin (12) removed in step 6.1) and fix it to the
blade with lock (13), bolt (14) and washer (15).
(Fig. 13)
6.6)
Start the engine again and operate the blade control lever to raise the whole blade assembly.
Then, remove all the wooden blocks placed under
the blade.
6.7)
[1] Check the hydraulic oil level again and supply new oil,
if necessary.
a Confirm the oil level after lowering the ripper
shank and blade to the ground and set the back of
the blade perpendicular to the ground.
a About the kind of used fluids refer to "Assembly
procedure A-7" Check on the amount of lubricants
and coolant.
7.2)
[1] Move the blade slowly and check that each part does
not make interference or abnormal sound.
If abnormal sounds seem to come from the ball joints
at both ends of the center brace, see step 7.5).
[2] Confirm that the blade does not interfere with the machine (radiator guard) when it is tilted to the maximum
(or dual-tilted to the maximum for the dual tiltdozer) at
the maximum lifting height.
[3] Confirm that there is sufficient clearances between
the straight frames of the blade assembly and the
tracks of the undercarriage when the blade is tilted to
the maximum (or dual-tilted to the maximum for the
dual tiltdozer).
100
Assembly procedure
A-13
7.3)
[1] Confirm that the blade is "raised" and "lowered" according 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 inspection
check sheet" attached to the end of this manual.
a If the lateral balance or the clearance between
blade assembly and machine needs to be adjusted and the brace assembly length must be adjusted consequently as a result of the check, return to
"assembly procedure A-12" Assembly of blade, 6.
Installation of brace assembly, and readjust those
items.
[4] In addition to [1] and [2] of the single tiltdozer specification, ensure that the blade is "pitched back" and
"pitched forward" according to the operation of the
blade control lever. (Fig. 16)
[5] Furthermore, confirm that the blade is "left-dual-tilted"
and "right-dual-tilted" according to the operation of
the blade control lever.
[6] Inspect according to the "Field assembly inspection
check sheet" attached to the end of this manual.
a For super dozer, this corfirmation of operation of
dual tiltdozer is not necessary.
7.4)
101
Assembly procedure
A-14
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Part Name
Bracket (L.H.)
Bracket (R.H.)
Bolt
Washer
Striker
Nut
Washer
Stopper
Nut
Bracket
Bracket
Bolt
Washer
Part No.
198-Z11-3341
198-Z11-3351
01010-D1230
01643-71232
14X-911-1921
01580-11008
01643-31032
09453-00002
01580-01210
198-Z11-3571
198-Z11-3581
01010-D1230
01643-71232
Q'ty
1
1
10
10
2
8
8
2
2
1
1
12
12
Remarks
Left
Right
102
Assembly procedure
A-14
3.2)
Fit rubber seal (14) to the guide plate of the dashboard bracket and apply paste seal (55) as shown
in (Fig. 4).
3.3)
Apply G2-LI
No.
14
55
Part Name
Rubber seal
Paste seal
Part No.
198-Z11-3540
198-Z11-3960
Q'ty
1
1
Remarks
Sponge rubber
103
Assembly procedure
A-14
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 next
page.
Remark : Since the rubber seals are made a little longer than required, cut them properly when sticking.
No.
15
16
17-1
17-2
Part Name
Rubber seal
Rubber seal
Rubber seal
Rubber seal
Part No.
14X-911-5911
198-Z11-7420
198-Z11-7410
198-Z11-7430
Q'ty
3
2
1
1
104
Assembly procedure
A-14
17
17
16
17
20
16
16
20
15
Remark : For the base seal shown in the figure, see the next page.
105
Assembly procedure
A-14
Part Name
Paste seal
Part No.
198-Z11-3960
Q'ty
1
106
Assembly procedure
A-14
Tighten bolts (18) and (20) and washers (19) temporarily. See (Fig. 15)
5.3)
Flange
Cab
Dashboard
Bracket
107
Assembly procedure
A-14
15 parts
6 parts
No.
18
19
20
55
Part Name
Bolt
Washer
Bolt
Paste seal
Part No.
01010-81275
124-54-26540
01010-81245
198-Z11-3960
108
Q'ty
15
21
6
1
Assembly procedure
A-14
5.4)
Check that the clearance between the air conditioner duct on the cab side and monitor is even on
the right and left sides. At the same time, check
that the air conditioner duct seal on the cab side is
fitted to faces (C) on the right and left sides of the
air conditioner duct on the dashboard side and it is
not moved to the right or left.
5.5)
5.6)
5.7)
Permanently tighten mounting bolts (12) of Lplates (11) which were installed temporarily in step
5.4 above.
109
Assembly procedure
A-14
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).
Part P
No.
21
22
23
24
25
26
27
28
Part Name
Plate
Bolt
Washer
Foot rest (left)
Foot rest (right)
Bolt
Washer
Pedal cap
Part No.
198-Z11-2961
01010-D1230
01643-71232
14X-911-5711
14X-911-5721
01010-D1230
01643-71232
203-43-56450
110
Q'ty
2
4
4
1
1
4
4
2
Assembly procedure
A-14
Operator cab
Floor frame
a The window washer tubes and power supply wiring harness for cab have connector No. indicating
rings at their ends as shown in (Fig. 22).
Connect the tubes having the same color marks
and the connectors having the same Nos. together respectively.
Grommet
111
Assembly procedure
A-14
Connectors No.
1 Phase
1 Phase
3 Phase
4 Phase
Connector No. indicating ring
Wiring harness
for cab power source
No.
29
30
31
Part Name
Clip
Clip
Sems bolt
Part No.
198-Z11-2961
01010-D1230
01643-71232
112
Q'ty
1
1
1
Assembly procedure
A-14
6.2)
Garnish
Knob
(Lever)
a When installing the garnish, be sure to install the screws shown in the figure.
Screw
Screw
113
Assembly procedure
A-14
7.2)
Similarly, remove bellows (103) and bellows bracket (104) of ripper lever.
7.3)
7.4)
Fig. 30
Correct
Wrong
114
Assembly procedure
A-14
8.2)
Install covers (38), (39), and (41) with button (43). (16
places)
8.3)
8.4)
8.5)
No.
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Precautions
Tools required
Name
Others
115
Part No.
198-Z11-6170
198-Z11-6190
198-Z11-6150
198-54-61511
198-54-61531
01024-D0820
198-54-61521
198-Z11-6160
23D-950-4450
20Y-06-21751
20Y-06-23472
17A-Z11-3180
01245-00616
01643-70623
01370-40408
201-979-7820
198-Z11-6230
198-Z11-6241
Q'ty
1
1
1
1
1
14
1
1
16
1
1
1
4
4
2
2
1
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-14
Correct installation
Wrong installation
116
Assembly procedure
A-14
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)
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.
Cut band
and connect.
Sensor
117
No.
55
57
58
59
60
61
62
63
64
65
75
76
Part No.
198-Z11-3960
198-Z11-2941
198-Z11-2951
01245-00616
01643-70623
198-Z11-6280
20Y-979-6161
01245-00616
01643-70623
198-Z11-6410
01010-D0645
01643-70623
Q'ty
1
1
1
8
8
1
1
4
4
2
6
6
Assembly procedure
A-14
No.
67
68
69
70
71
72
73
74
Precautions
Tools required
Others
Name
118
Part No.
198-54-75681
198-54-15791
198-54-75770
198-54-75620
198-54-75610
198-54-74950
198-54-74941
198-54-74862
Q'ty
1
1
1
1
1
1
1
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-14
8) Install floor mat (74) while holding down its right and left ends with plates (81) and (82) attached to the bottom of the operator cab doorway. (See Fig. 39)
Section A-A
No.
81
82
Part Name
Plate (Left)
Plate (Right)
Part No.
198-Z11-6410
198-Z11-6410
119
Q'ty
1
1
Remarks
Assembly procedure
A-14
No.
91
92
93
94
Part Name
Mirror
Bracket
Bolt
Washer
Part No.
14X-911-6140
198-Z11-3670
01010-D0845
01643-70823
Q'ty
1
1
2
2
Remarks
120
Assembly procedure
A-14
Loosen the wing bolt at the center of rotation of the radio antenna, rotate the antenna from position (T) indicated with the broken
line 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 from
the factory to the field.
121
Assembly procedure
Installation of ROPS
A-15
Precautions
Tools required
Name
122
T)
No.
Part No.
Q'ty
01011-83310
16
01643-33380
16
Equipment required
Qty
Others
1
1
Name
Qty
Assembly procedure
A-16
After installing the exhaust pipe, connect komaclone tube (4), using gasket (1), bolt (2), and
washer (3).
Right of chassis
Left of chassis
Front of chassis
Precautions
Tools required
Others
Name
123
No.
Part No.
Q'ty
6162-13-5611
01010-81025
01643-51032
Equipment required
Qty
Name
Qty
Assembly procedure
A-17
1. Operate the machine to make the distance from the bottom of ripper beam to the ground as dimension (H) shown
in Fig. 1.
a (H): 2700 mm or more
a Make the hole for shank holder of ripper beam to be
vertical to the ground.
The following is an example of the method. Choose proper 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 ripper beam, and set the hole for shank holder vertical to
the ground.
2. Set ripper shank on the ground under ripper beam. At this
time, the sling ring on the top of ripper shank should be
right under the hole for shank holder of ripper beam.
3. Set lifting rope sling on the crane, and insert the rope sling
into the hole for shank holder of ripper beam from the top
to leave the front end of the rope sling on the ground.
Crane
Rope sling
Ripper
a Rope sling: 12 mm 4 m
See "Tools list for field assembly"
4. Connect the rope sling and the lifting ring of ripper shank
with shackle.
a Shackle: SD22-M
See "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 the
hole for shank holder of ripper beam.
6. Align the pin holes of ripper shank and ripper beam, and
insert shank mounting pin to fix it.
Reference: The procedure for multi-ripper specification is almost the same.
124
Shackle
Shank assembly
Assembly procedure
A-18
Shim (1)
Bolt (2)
Adjustment of shim
Adjustment of shim
Adjustment of shim
125
Assembly procedure
A-19
Installation of counterweight
Fig. 1
Fig. 2
No.
Part name
Part No.
Q ty
Counterweight assembly
Main frame
Lifting wire
Pin
198-78-21180
Plate
205-70-61560
Bolt
01010-82045
Washer
01643-32060
Pin
198-78-21140
Plate
195-78-21171
10
Bolt
01010-82040
11
Washer
01643-32060
126
Assembly procedure
A-20
1. Dual-tiltdozer
1-1 Set the machine under the standard condition.
Set the potentiometer rod to 425 mm.
Keep the machine horizontally.
Run the engine at low idling and set the blade in the
following 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.
Pitch back
Tilt switch
Dual tilt
Precautions
Tools required
Name
Others
1-2
127
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
1-3
Adjust mounting dimension "a" of rod (1) and connect the rod to potentiometer lever (2) and yoke (3).
Mounting dimension "a": 425 mm
1-4
Precautions
Tools required
Name
Others
128
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
1-5
1-6
Tilt the blade to the left with the blade control lever
and set the left tilt angle to 12. (User adjustment
mode)
a Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase
too much.
a Adjust the tilt angle accurately with angle gauge.
1-7
Tilt switch
Single tilt
Dual tilt
Precautions
Tools required
Others
Name
129
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
1-8
1-9
Precautions
Tools required
Others
Name
130
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
1-11 Tilt the blade to the right with the blade control lever
and set the right tilt angle to 12.
a Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase too much.
a Adjust the tilt angle accurately with angle
gauge.
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 again
to 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 (
mode, 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 track
shoe, regardless of its height.
Precautions
Tools required
Others
Name
131
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
2. Superdozer
2-1 Set the machine under the standard condition.
Set the potentiometer rod to 425 mm.
Keep the machine horizontally.
2-3
Run the engine at low idling and set the blade in the
following 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.
Pitch back
Adjust mounting dimension "a" of rod (1) and connect the rod to potentiometer lever (2) and yoke (3).
Mounting dimension "a": 425 mm
Precautions
Tools required
Name
Others
2-2
132
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
2-4
2-5
Operate the blade according to the following procedure 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.
Precautions
Tools required
Name
Others
133
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
2-6
2-7
134
Assembly procedure
A-20
2-8
2-9
The adjustment work is finished. Set the buzzer cancel switch in the cancel position (
mode, 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 25 and raise the blade about 1,000 mm, and check that the blade stops tilting to the right and left in the following range
automatically.
Automatic tilt stopping angle: 8 1
Precautions
Tools required
Others
Name
135
Equipment required
Qty
Name
Qty
Assembly procedure
A-21
Pitch dump
Pitch back
The auto-reset system is used to set the blade in the digging position automatically (to lower the blade to the ground and set
its angle to 52). To reset this system, press the pitch button.
Digging posture
Tilt forward
Controller
Valve
Pitch back solenoid
Precautions
Tools required
Others
Name
136
Equipment required
Qty
Name
Qty
Assembly procedure
A-22
No.
1
2
3
4
5
Precautions
Tools required
Name
Others
ORBCOMM:
The ORBCOMM terminal system is a
communication system to use the satellite
communication service of ORBCOMM Co.,
Ltd. (USA).
137
Part No.
01010-81220
04434-50612
8A13-10-2100
21N-54-38451
01010-81225
Q'ty
5
5
1
1
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-23
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.
No.
1
2
3
Precautions
Tools required
Others
Name
138
Part No.
198-Z11-6170
198-911-7350
198-54-61511
Q'ty
1
2
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-23
3. Referring to A-14 Installing operator's cab, install the lining and rubber plate.
4. Install the band as shown below.
Precautions
Tools required
Others
Name
139
Equipment required
Qty
Name
Qty
Assembly procedure
A-24
a For using oil type, see "A-7 Check of oil and coolant
levels" in assembly procedure.
a
1. Blade
140
Assembly procedure
A-24
Support shaft
LH and RH
4. Ripper
LH & RH
LH & RH
LH & RH
141
Assembly procedure
A-24
7. Suspension
(Equalizer bar center shaft) (1 place)
142
Assembly procedure
A-25
After disassembling for transpotation, changing the oil in the hydraulic tank, or removing the
hydraulic cylinders or work equipment piping, bleed the air from the hydraulic circuit as follows.
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 operating
it to the end of its stroke.
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 end
of the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of
stroke. 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 of
the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of its
stroke. 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 operating
the cylinder to the end of its stroke.
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 and
operate 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 of
their 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.
Precautions
Tools required
Others
Name
143
Equipment required
Qty
Name
Qty
Assembly procedure
A-26
Precautions
Tools required
Name
Others
144
Equipment required
Qty
Name
Qty
145
Assembly procedure
M-1
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
146
Blower
at high (Hi)
Assembly procedure
M-1
Lock lever
mount hole
a) Prepare a transparent vinyl hose (of an outer diameter of 10 mm and 3,000 mm long).
b) Pour water into the hose bore for about a half of the
hose length.
10 mm or more
Start the engine and run it at full speed to read the difference between the two water levels.
Inside the
operators cab
Outside
(Atmospheric pressure)
Vinyl hose
147
Assembly procedure
M-1
(Sealed surface)
Shower test for water-tighteness
Precautions
Tools required
Others
Name
148
Equipment required
Qty
Name
Qty
Assembly procedure
M-1
(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 the
latch and the striker.
Latch
Striker
Latch
149
Assembly procedure
M-1
3.2
Adjustments
(1) Adjusting the elevation of the damper rubber
When adjusting the elevation of the damper rubber, supplement or reduce the shims
being inserted below the damper rubber to adjust the elevation of the damper rubber
properly.
Damper rubber
Shims
t1.2
Door structure
(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 move
the knob feels too heavy), repeat the adjustment all over again. (Appropriate knob
turning effort: 68.6 19.6 N {7 2 kg}
(3) Apply grease (G2-LI) over the latch surface.
Precautions
Tools required
Name
Others
150
Equipment required
Qty
Name
Qty
Assembly procedure
M-1
Releasing lever
Latch (20Y-54-36380)
Bolt (01435-30820)
Striker (14X-911-1921)
Make the
observation
through this
direction
Nut (01580-11008)
Washer (01643-31032)
Bracket
(198-Z11-3341)
(198-Z11-3351)
Check and make sure that
the body of the latch and the
striker are not interfering.
The correlation is normal
if they are not interfering.
(2) Check the mounted elevation of the stopper rubber. (At 2 places each on one side. Check
them 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.
Precautions
Tools required
Others
Name
151
Equipment required
Qty
Name
Qty
Assembly procedure
M-1
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 not
interfere with the latch nor the overriding over the bent section occurs before tightening
the nut back to its original state.
When the interference cannot be corrected by the adjustment on the striker side, loosen
the latch side mounting bolts to make the adjustment from the latch side.
Latch
Clearence
Striker
Door structure
Striker
Stopper rubber
Latch
Depress the door and if it moves
until the clearance disappears,
bring out the stopper rubber
toward the depressed side.
Precautions
Tools required
Name
Others
4.2
152
Equipment required
Qty
Name
Qty
Assembly procedure
M-2
Machine monitor
There are the following 2 designs in the machine monitor, the functions of which are the same.
153
Assembly procedure
M-2
Check that the "machine monitor" on the front panel can be set in the "service mode" with its special
function and the "failure codes" can be displayed normally in that mode.
Fig. 13 Front panel
Note: The "Service mode" is used in "Initialization of VHMS controller" of the VHMS specification described later in "Attached material 2". Accordingly, understand the operating procedure thoroughly.
154
Assembly procedure
M-2
Remove cover (7) under the front panel so that you can operate service switch (8).
1.2)
1.3)
While pressing service switch (8), turn and hold buzzer cancel switch (5) toward the [U] mark for
3 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 service mode codes among the 8 of 1C, EE, bE, Cb, Ld, 5R, dR and 55. For details of the service
mode codes, see "Testing and adjusting volume" of the shop manual.
Fig. 2
Fig. 4
Upper display unit (2)
Upper display unit (2)
155
Assembly procedure
M-2
2.1)
Fig. 5
2.1.2)
-2) After service mode code "EE" is displayed, turn buzzer cancel switch (5) to
the <> mark to settle "EE".
-3) If "EE" is settled, the "failure code" of the
2.1.3)
electrical system is displayed on lower
display unit (3).
-4) For the contents of display on lower dis2.1.4)
play unit (3), see step 2.3).
2.2)
Fig. 6
2.2.1)
-1) Turn buzzer cancel switch (5) to the t
mark to cancel the "EE" mode.
-2) Turn information switch (6) toward the >
2.2.2)
mark or < mark to display service mode
code "bE". (See Fig. 4)
6
-3) Turn buzzer cancel switch (5) to the U
2.2.3)
mark to settle "bE".
-4) If "bE" is settled, the "failure code" of the
2.2.4)
mechanical system is displayed on lower
display unit (3).
2.2.5)
-5) For the contents of display on lower display unit (3), see step 2.3).
156
Assembly procedure
M-2
2.3)
2.3.1)
-1) When the assembly work is completed, no past
trouble is recorded and no trouble is detected currently, thus the display is as shown in Fig. 75 in
both modes.
2.3.2)
-2) If a trouble occurs after this machine is put in
operation or if there is the record of a past
trouble, the display of (EE) becomes as shown
in Fig. 8
6.
Fig. 7
Fig. 8
Fig. 9
157
Assembly procedure
M-2
158
Assembly procedure
M-2
159
Assembly procedure
M-2
160
Assembly procedure
M-2
161
Assembly procedure
M-2
162
Assembly procedure
M-2
163
Assembly procedure
M-2
164
Assembly procedure
M-2
165
Assembly procedure
M-3
When starting the engine for the first time, perform its no-injection cranking to lubricate it in advance
according to the following procedure.
Note: Before performing this work, check the oil levels and complete inspection and maintenance of
each 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.
166
Assembly procedure
M-3
2. Procedure
2.1
(1) Turn the starting switch "ON". The machine
monitor is turned ON.
2.2
(2) Turn buzzer cancel switch ((5) in Fig. 2) to the
[
] position (left side) and hold it for 2 3
seconds.
The display of multi-information section ((3) in
Fig. 1) changes to OIL, FILTER MAINTENANCE
MODE (Fig. 3).
After the display changes, release the switch,
and it returns to the neutral position.
2.3
(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 multiinformation section to USER ADJUST MODE
(Fig. 4).
Reference: Each time the information switch is
turned, the 4 modes of OIL, FILTER
MAINTENANCE MODE, PM CLINIC
MODE, FAULT CODE DISPLAY MODE
and USER ADJUST MODE are selected
in either order repeatedly.
2.4
(4) After the display of the multi-information section
changes to USER ADJUST MODE, turn the
buzzer cancel switch to the [ ] position (left
side) again to settle USER ADJUST MODE. Once
this mode is settled, it does not change to
another mode described in step (3) even if the
information switch is turned, and the multiinformation section changes to the variation
selection screen in USER ADJUST MODE.
Note: If the buzzer cancel switch is turned to the [ ]
position (right side) by mistake, the multiinformation section returns to the state in step
2.1.
(1).
167
Assembly procedure
M-3
2.5
(5) Turn information switch again to the [ ]
position (left side) or [ ] position (right side)
several times to change the display of the multiinformation section to NO INJECTION (Fig. 5).
2.6
(6) Turn the buzzer cancel switch to the [ ]
position (left side) to settle NO INJECTION.
Reference: In step (5), each time the information
switch is turned, the 7 variations of LCD
BRIGHTNES, DSP BRIGHTNES, DSP
CONTRAST, FAN 100% SPEED, NO
INJECTION, TILT LIMIT and PRE-LUB ON
are selected in either order repeatedly.
2.7
(7) In about 3 seconds after NO INJECTION is
settled, the display of the lower line of the multiinformation section changes from "WAIT" to
"ACTIVE" (Fig. 6) and the mode becomes
effective.
2.8
(8) Under this condition, turn starting switch ((4)
in Fig. 1) to the START position to rotate the
starting motor and perform no-injection
cranking.
Perform no-injection cranking for about 10
seconds at the normal temperature (about 20
C), depending on the ambient temperature.
Note 1: Do not perform no-injection cranking
continuously for more than 20 seconds.
Note 2: This function does not work while the
engine is running. During this period, "NOT
AVAILABLE" is displayed (Fig. 7) on the
lower line of the multi-information section
to indicate that this mode is not available.
2.9
(9) To reset this mode, turn the buzzer cancel
switch to the [ ] position (right side).
The display of the multi-information section
returns to the state after step 2.1
(1) where the
starting switch is turned "ON".
2.10
(10) Turn the starting switch "OFF".
168
Assembly procedure
M-4
When setting the cooling fan speed to about 100% of the maximum speed forcibly for measurement
of the pressure inside the cab in [M-1: Check and adjustment of operators cab], operate the machine
monitor to display USER ADJUST MODE in the multi-information section according to the following
procedure.
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.
169
Assembly procedure
M-4
2. Procedure
2.1
(1) Turn the starting switch "ON". The machine
monitor is turned ON.
2.2
(2) Turn buzzer cancel switch ((5) in Fig. 2) to the
[
] position (left side) and hold it for 2 3
seconds.
The display of multi-information section ((3) in
Fig. 1) changes to OIL, FILTER MAINTENANCE
MODE (Fig. 3).
After the display changes, release the switch,
and it returns to the neutral position.
2.3
(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 multiinformation section to USER ADJUST MODE
(Fig. 4).
Reference: Each time the information switch is
turned, the 4 modes of OIL, FILTER
MAINTENANCE MODE, PM CLINIC
MODE, FAULT CODE DISPLAY MODE
and USER ADJUST MODE are selected
in either order repeatedly.
2.4
(4) After the display of the multi-information section
changes to USER ADJUST MODE, turn the
buzzer cancel switch to the [ ] position (left
side) again to settle USER ADJUST MODE. Once
this mode is settled, it does not change to
another mode described in step (3) even if the
information switch is turned, and the multiinformation section changes to the variation
selection screen in USER ADJUST MODE.
Note: If the buzzer cancel switch is turned to the [ ]
position (right side) by mistake, the multiinformation section returns to the state in step
2.1.
(1).
170
Assembly procedure
M-4
2.5
(5) Turn information switch again to the [ ]
position (left side) or [ ] position (right side)
several times to change the display of the multiinformation section to NO INJECTION (Fig. 5).
(6) Turn the buzzer cancel switch to the [ ]
2.6
position (left side) to settle NO INJECTION.
Reference: In step 2.5
(5), each time the information
switch is turned, the 7 variations of LCD
BRIGHTNES, DSP BRIGHTNES, DSP
CONTRAST, FAN 100% SPEED, NO
INJECTION, TILT LIMIT and PRE-LUB ON
are selected in either order repeatedly.
2.7
(7) If the engine is started under this condition, the
cooling fan speed is kept controlled to about
100% of the maximum speed.
(7)
2.7 is effective only in this mode. It becomes
ineffective if the system is set out of this mode.
171
Fig. 5
Assembly procedure
M-5
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 standard
element 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.
Raise blade
Raise ripper
Lower blade
Lower ripper
Tilt ripper in
4) After 1) to 3) are finished, remove the installed exclusive flushing element, replace it with stored current standard element. 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 through
flushing filter installed to collect and filter the early dirt in the circuit.
Precautions
Tools required
Name
Others
172
Equipment required
Qty
Name
Qty
Assembly procedure
M-5
No.
3
4
5
Part Name
Element
Strainer
Valve
Part No.
208-60-71120
07069-25400
208-60-71160
Q'ty
1
1
1
Standard element
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.
173
Assembly procedure
M-5
2) Installing condition of element
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 the
installed element with the hand.
If you can turn the element smoothly, it is installed normally.
Precautions
Tools required
Name
Others
174
Equipment required
Qty
Name
Qty
APPENDIX 1.
INSTALLATION OF SPILL GUARDS
1. Introduction ......................................................................................................................................
10
14
DESCRIPTION
1. Introduction
When installing the spill guards in field, refer to the installation procedure described in this installation
procedure.
2. Additional parts
Blade
Semi-U
Full-U
Superdozer
Part No.
Part Name
Qty
Weight (kg)
198-71-61710
134.6
198-71-61720
49.6
198-71-61730
49.6
198-72-63910
171
198-72-63920
56
198-72-63930
56
198-72-63810
224
198-72-63820
34
198-72-63830
34
Remarks
3
Part Name
PLATE
PLATE
PLATE
Sym.
01
02
03
SS400P
SS400F
SS400F
Material
10
11
Qty
5.75
2.55
24.5
t 19
t 19 65
t 19 65
PLATE
PLATE
PLATE
PLATE
09
11
12
PLATE
08
10
PLATE
PLATE
06
PLATE
05
07
PLATE
PLATE
PLATE
02
03
PLATE
01
04
Part Name
Sym.
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
Material
Qty
2.30
2.80
3.95
5.10
1.35
1.45
1.75
1.90
2.15
2.30
11.9
12.6
t 19
t 19
t 19
t 19
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
5
PLATE
PLATE
PLATE
PLATE
09
10
11
12
PLATE
PLATE
07
08
PLATE
PLATE
05
06
PLATE
PLATE
PLATE
02
03
PLATE
01
04
Part Name
Sym.
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
Material
Qty
2.30
2.80
3.95
5.10
1.35
1.45
1.75
1.90
2.15
2.30
11.9
12.6
t 19
t 19
t 19
t 19
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
7
PLATE
PLATE
PLATE
02
04
PLATE
01
03
Part Name
Sym.
SS400F
SS400P
SS400F
SS400F
Material
13
12
Qty
0.66
6.16
2.54
29.0
t 19 65
t 19
t 19 65
t 19 65
PLATE
PLATE
PLATE
13
14
15
PLATE
PLATE
11
12
PLATE
PLATE
09
10
PLATE
PLATE
07
08
PLATE
PLATE
05
06
PLATE
PLATE
PLATE
02
03
PLATE
01
04
Part Name
Sym.
SS400F
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
Material
Qty
0.40
2.40
2.76
3.98
5.28
0.98
1.11
1.41
1.55
1.84
1.99
2.23
2.42
13.5
14.2
t 16 32
t 19
t 19
t 19
t 19
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
PLATE
PLATE
PLATE
13
14
15
PLATE
PLATE
11
12
PLATE
PLATE
09
10
PLATE
PLATE
07
08
PLATE
PLATE
05
06
PLATE
PLATE
PLATE
02
03
PLATE
01
04
Part Name
Sym.
SS400F
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
Material
Qty
0.40
2.40
2.76
3.98
5.28
0.98
1.11
1.41
1.55
1.84
1.99
2.23
2.42
13.5
14.2
t 16 32
t 19
t 19
t 19
t 19
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
10
11
Part Name
PLATE
PLATE
PLATE
PLATE
Sym.
01
02
03
04
SS400P
SS400P
SS400P
SS400F
Material
Qty
7.95
6.55
74.0
34.3
t 19
t 19
t9
t 19 65
12
PLATE
PLATE
PLATE
PLATE
PLATE
05
06
07
08
09
PLATE
PLATE
PLATE
02
03
PLATE
01
04
Part Name
Sym.
SS400F
SS400F
SS400F
SS400P
SS400F
SS400P
SS400F
SS400P
SS400F
Material
Qty
6.50
9.35
2.35
3.20
2.05
3.05
1.75
2.05
1.65
t 19 65
t 19 65
t 19 65
t 19
t 19 65
t 19
t 19 65
t 19
t 19 65
13
PLATE
PLATE
PLATE
PLATE
PLATE
05
07
08
09
PLATE
04
06
PLATE
PLATE
02
PLATE
01
03
Part Name
Sym.
SS400F
SS400F
SS400F
SS400P
SS400F
SS400P
SS400F
SS400P
SS400F
Material
Qty
6.50
9.35
2.35
3.20
2.05
3.05
1.75
2.05
1.65
t 19 65
t 19 65
t 19 65
t 19
t 19 65
t 19
t 19 65
t 19
t 19 65
4. Installation procedure
4-1 For disassembly and assembly procedures which are not described in this manual, see the
Shop 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
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 - 350C for 30 - 60 minutes.
4-3-6
Preheat the area about 50 mm from the beat to be laid at 150 - 200C. When the ambient
temperature is below 10C, post-heat the same area, too, at 150 - 200C.
4-3-7
Set the welding current to the lower limit of the current range specified for the diameter
of the welding rod or wire.
4.3.8
4.3.9
Do not weld by letting the melted metal flow, but weld from below to above with sufficient
penetration. Keep the arc length as short as possible, and take care not to make an
overlap, undercut, etc.
4.3.10 Before welding the spill guard, remove all the paint (or rust) from the parts to be welded
with 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 where
the ground cable can be connected securely electrically.
(Remark) If a painted part is welded, hydrogen in the paint will be mixed in the welded
part, and that can cause cold cracking.
14
APPENDIX 2.
PRECAUTIONS FOR INITIALIZATION PROCEDURES
FOR VHMS CONTROLLER
1. Initialization procedures for VHMS controller.......................................................................................... 2
Symbol
Part No.
Part name
799-608-3211
Diskette
799-608-3220
Wiring harness
Commercially
available
1.
Information to be checked
Machine model
2.
The VHMS controller and ORBCOMM terminal are in the VHMS controller box
under the left side cover of the floor.
2)
3)
4)
a
a
5)
6)
3.
7)
9)
Right decimal
point
Display
OFF
ON
Blinking
8)
4.
5.
3)
4)
5)
8)
9)
Applicable
Area
Code
Applicable
Area
U.S.A.
121
Malaysia
Brazil
122
Korea
Italy
130
Japan
6.
3)
2)
If the VHMS was installed additionally, the information of [Serial No.] etc.
must be input.
4)
5)
6)
7)
8)
9)
Code
1
120
Applicable
Area
Code
Applicable
Area
U.S.A.
121
Malaysia
Brazil
122
Korea
Italy
130
Japan
7.
2]
3]
1)
2)
10
5]
11
Time (sec)
Finish
Start
No.
0:00 0:25 25
0:25 0:50 25
0:50 1:40 50
2:30 3:00 30
Transmission
Fuel
SteerWork equipment control
ing
dial
Decelerator pedal
Brake
pedal
Parking
brake
LH
LOW
HI
Released Released
RH
LOW
HI
Released Released
HI
HI
Released Released
HI
LOW
Released Released
High-pressure
relief & high idle
HI
HI
Released Released
3:00 3:30 30
High-pressure
relief & low idle
LOW
HI
Released Released
3:30 4:00 30
4:00 4:30 30
4:30 5:10 40
Torque converter
stall & low idle
Torque converter
10 5:10 6:00 50 stall (F3) & high
idle (Note 1)
11 6:00 6:30 30
Low idle
High idle
High idle
Torque converter
12 6:30 7:10 40 stall + High-pressure relief
13 7:10 7:30 20
High idleo
Low idle (Note 2)
HI
HI
Released Released
LOW
HI
Released Released
NoF1oF2oF
3oNoR1oR2
oR3oN
LOW
HI
ON
Released
NoF3 (Shift to
F3, then run
engine at full
throttle)
HI
LOWo
Shift to F3,
then HI
ON
Released
HI
HI
NoF3 (Shift to
F3, then run
engine at high
idle)
HI
LOWo
Shift to F3,
then HI
ON
Released
HIo
LOW
HI
Released
ON
Released Released
(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 temperature
gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the
engine at high idle to lower the oil temperature.)
12
6]
q
q
q
q
q
q
q
Important
The data of the Quick Pm is recorded only
once. If the Quick Pm is executed again,
the current data are overwritten. Accordingly, be sure to save the data in the personal computer after executing the Quick
Pm, referring to 8. Downloading of set
data.
7]
a
8]
a
q
q
q
q
q
q
13
Blowby Press
Exhaust Temp RB (Exhaust temperature of right bank: 1, 2, 3, 4,
5, 6)
Exhaust Temp LB (Exhaust temperature of left bank: 1, 2, 3, 4, 5,
6)
Engine Oil Press
Engine Oil Temp
Eng Coolant Temp
Ambient Temp
Demand Eng Speed
(Engine speed demanded by
controller)
T/C Oil Temp
(Torque converter oil temperature)
T/M Main Press
(Transmission main relief pressure)
T/M Output Speed
(Transmission output speed)
Shift Position
( Tr a n s m i s s i o n , t r a v e l , g e a r
speed)
S/T Clutch Pos.
(Steering clutch position)
S/T Brake Pos. (Steering brake
position)
Hydr Oil Temp
(Hydraulic oil temperature)
Pump 1 Press
(Work equipment pump 1 oil
pressure)
Pump 2 Press
(Work equipment pump 2 oil
pressure)
Body Pitch Angle (Pitch angle)
9]
14
15
Deceleration slow
Q
Q
Q
Q
Exhaust temperature
Blow-by pressure
Engine speed
State of machine
Measurement items
The stall speed measured with Snapshot is not the exact value. If measuring the stall speed exactly, set
stall mode "0530" and measure it.
16
8.
2)
3)
a
4)
a
a
a
17
5)
9.
2)
18
3)
4)
19
20
21
SEKN5051-1
Attached Sheet
<<DB information>>
Person in charge
e-mail address
DB code(GCPS code)
<<Customer information>>
<<Machine information>>
Model - type
Serial No.
Engine Serial No.
Result
(Note 1)
The new machine delivery or Retro - Fit
(Note 1)
Replace the VHMS controller.
(Note 2 or 3)
Replace the component.
(engine or transmission)
Setting date
(mm:dd:yyyy)
No.1 Engine
No.2 Engine
ON
: 00)
OFF
YES
***Important***
*After entering the VHMS/WebCARE Basis Information Form,fax or email it to the following location with the initial
download data.
VHMS / WebCARE support center (Product Support Div. Komatsu LTD.)
TEL : 81-3-5561-2765 *** FAX : 81-3-5561-4766 *** EMAIL : [email protected]
22
Report No.
After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.
Model-Type
Engine Model
D475A-5E0
Service Meter Reading (Hr):
SAA12V140E-3
Date of Inspection
Inspector's name:
Distributor's Name:
Specification
Customer's name:
(Country)
Address:
Blade
Semi U.
Ripper or counterweight
VGR
Shoe width
910 mm
Cab
VMR
(Dual
Single)
CW (
810 mm
Ton)
710 mm
Inspector's comments:
By:
Remark:
Abnormal
Not applied
].
Note:
Criteria are based on the standards when the machine is shipped out of the factory
Category
Inspection Item
Inspection
Criteria
Low Full
EO15W40-DH
(H+L)/2 (H+20)
Engine : Stopped
TO30
L (H+20)
TO30
(H+L)/2 (H+10)
Engine : Stopped
TO10
Center to upper
level of sight
gauge
GO85W-140
H (H20)
(H+10) (H+30)
from shaft end
a=100 10
Oil level
LH
RH
LH
TO30
EO30-CD
RH
LH
TO30
EO30-CD
RH
Between L and H
UPPER LEVEL
LOWER LEVEL
Full
Fuel tank
Full (1670 l)
Horn
Backup alarm
(Starting engine)
Monitor display
INSPECTION
Controller error code indication (make sure that error does not recur)
Flushing
(Before starting engine, replace standard filter with flushing filter.
After flushing, replace flushing filter with standard filter.)
Execute flushing
Must be done.
Inspection Item
Inspection
Parking lever
Criteria
The engine must not be started when the parking
lever is free.
The machine must not be moved when the
parking lever is locked.
FUNCTION / OPERATION
Play: Max. 5 mm
Must be adjustable.
Must not move after locking.
Free
Lock
Case
Case
SINGLE
RH tilt
RH tilt
LH tilt
LH tilt
Pitch back
Pitch dump
LH dual tilt
RH dual tilt
DUAL
LH tilt
RH tilt
LH tilt
RH tilt
Inspection Item
Inspection
Criteria
WORK EQUIPMENT
UNDERCARRIAGE
CAB
LH
Must be none.
RH
LH
Must be none.
RH
LH
RH
LH
RH
LH
Must be none.
RH
Beat noise inside the cab, beat noise of the outer cover
Must be none.
Must be red-heated.
Must be installed.
Inspection Item
Inspection
BLADE
LUBRICATION
Portions to be lubricated
Criteria
Q'ty
Example: U blade
c Lower
A Tilt in
B Tilt out
RIPPER
LH
Must be none
RH
LH
Must be of no contact.
RH
Must be of no creak.
Must be of no contact
Must be of no excess hose tension.
Must be none
LH
RH
Portions to be lubricated
Q'ty
Engine speed
Engine
Category
Item
Condition
Engine speed
Unit
Standard
rpm
rpm
rpm
rpm
600 700
2100 2200
850 950
1640 1740
Result
*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.
Category
Item
Condition
Main relief pressure *3 Run engine at low speed and set transmission in N.
Run engine at full throttle and set transmission in N.
Unit
Standard
MPa
{kg/cm2}
MPa
{kg/cm2}
2.35 2.89
{24.0 29.5}
2.65 2.98
{27.0 30.4}
Result
*3: Measure main relief pressure with monitoring mode ID "43000" of monitor.
Category
Item
Condition
Unit
Standard
MPa
{kg/cm2}
26.0 28.8
{266 294}
MPa
{kg/cm2}
26.0 28.8
{266 294}
MPa
{kg/cm2}
21.6 24.4
{221 249}
MPa
{kg/cm2}
23.1 25.9
{236 264}
Lever neutral
MPa
{kg/cm2}
3.92 4.51
{40 46}
Unit
Standard
Pitch back
MPa
{kg/cm2}
26.0 28.8
{266 294}
MPa
{kg/cm2}
26.0 28.8
{266 294}
MPa
{kg/cm2}
19.7 22.5
{201 229}
MPa
{kg/cm2}
23.1 25.9
{236 264}
MPa
{kg/cm2}
3.92 4.51
{40 46}
Result
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R pump
Category
Item
Condition
Pitch dump
Lever neutral
Result
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R 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.
Item
Blade lift
Ripper tilt
Condition
Unit
Standard
RAISE
sec
4.5 5.5
LOWER
sec
1.5 2.1
Tilt IN
sec
4.7 5.7
Tilt BACK
sec
2.8 3.8
Unit
Standard
Result
Item
Condition
Blade lift
Max. 50/5
Ripper lilt
Max. 30/5
Result
Record
Location
Record
Machine backward
B
C
D
E
F
G
H
I
Machine forward
J
K
L
M
N
O
P
1960 2450 Nm
{200 250 kgm}
Report No.
After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.
Model-Type
Engine Model
D475ASD-5E0
Service Meter Reading (Hr):
SAA12V140E-3
Date of Inspection
Inspector's name:
Distributor's Name:
Specification
Customer's name:
(Country)
Address:
Blade
Super
Ripper or counterweight
VGR
Shoe width
910 mm
Cab
CW (
Ton)
810 mm
Inspector's comments:
By:
Remark:
Abnormal
Not applied
].
Note:
Criteria are based on the standards when the machine is shipped out of the factory
Category
Inspection Item
Inspection
Criteria
Low Full
EO15W40-DH
(H+L)/2 (H+15)
Engine : Stopped
TO30
L (H+20)
TO30
(H+L)/2 (H+10)
Engine : Stopped
TO10
Center to upper
level of sight
gauge
GO85W-140
H (H20)
(H+10) (H+30)
from shaft end
a=100 10
Oil level
LH
RH
LH
TO30
EO30-CD
RH
LH
TO30
EO30-CD
RH
Between L and H
UPPER LEVEL
LOWER LEVEL
Full
Fuel tank
Full (1670 l)
Horn
Backup alarm
(Starting engine)
Monitor display
INSPECTION
Controller error code indication (make sure that error does not recur)
Flushing
(Before starting engine, replace standard filter with flushing filter.
After flushing, replace flushing filter with standard filter.)
Execute flushing
Must be done.
Inspection Item
Inspection
Parking lever
Criteria
The engine must not be started when the parking
lever is free.
The machine must not be moved when the
parking lever is locked.
Play: Max. 5 mm
Must be adjustable.
Must not move after locking.
Free
FUNCTION / OPERATION
Lock
Case
Case
Pitch back
Pitch
dump
Pitch
back
LH tilt
RH tilt
LH tilt
52 3
Blade should be horizontal after pitch back to the
stroke end, and pitch dumping is performed to
return to the digging posture.
7 1
7 1
Inspection Item
Inspection
Criteria
WORK EQUIPMENT
UNDERCARRIAGE
CAB
LH
Must be none.
RH
LH
Must be none.
RH
LH
RH
LH
RH
LH
Must be none.
RH
Beat noise inside the cab, beat noise of the outer cover
Must be none.
Must be red-heated.
Must be installed.
Inspection Item
Inspection
BLADE
LUBRICATION
Portions to be lubricated
Criteria
Q'ty
c Lower
A Tilt in
B Tilt out
RIPPER
LH
Must be none
RH
LH
Must be of no contact.
RH
Must be of no creak.
Must be of no contact
Must be of no excess hose tension.
Must be none
LH
RH
Portions to be lubricated
Q'ty
Engine speed
Engine
Category
Item
Condition
Engine speed
Unit
Standard
rpm
rpm
rpm
rpm
600 700
2100 2200
850 950
1640 1740
Result
*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.
Category
Item
Main relief pressure
*3
Condition
Unit
Standard
MPa
{kg/cm2}
MPa
{kg/cm2}
2.35 2.89
{24.0 29.5}
2.65 2.98
{27.0 30.4}
Unit
Standard
Result
*3: Measure main relief pressure with monitoring mode ID "43000" of monitor.
Category
Item
Condition
Pitch back
Pitch dump
Lever neutral
MPa
{kg/cm2}
26.0 28.8
{266 294}
MPa
{kg/cm2}
26.0 28.8
{266 294}
MPa
{kg/cm2}
19.7 22.5
{201 229}
MPa
{kg/cm2}
23.1 25.9
{236 264}
MPa
{kg/cm2}
3.92 4.51
{40 46}
Result
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R 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.
Item
Blade lift
Superdozer
specification
Ripper tilt
Condition
Unit
Standard
RAISE
sec
4.6 5.6
LOWER
sec
1.4 2.0
Tilt IN
sec
4.7 5.7
Tilt BACK
sec
2.8 3.8
Result
Unit
Standard
Blade lift
Item
Condition
mm/min
Max. 50/5
Ripper lilt
mm/min
Max. 30/5
Result
Record
Location
Record
Machine backward
B
C
D
E
F
G
H
I
Machine forward
J
K
L
M
N
O
P
1960 2450 Nm
{200 250 kgm}