D475a 5eo PDF

GEN00051-02
Field Assembly Instruction
BULLDOZER D475A -5E0
D475ASD -5E0
D475A- 30001
SERIAL NUMBERS 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 transporta-
tion route when shipped from our factory.
This manual describes how to assemble the units into the complete
machine in the field. We hope that this machine will display its quality
and you will use it safely according to the operation manual.
Many units are large in size and heavy in weight and may be handled
in a dangerous place or posture and many workers may have to work
together to sling them with cranes.
Accordingly, before starting the assembly work, the work supervisor is
required to hold a safety meeting to oblige the workers to put on pro-
tective gear and appoint a work leader and a crane work signal man
and allot roles to all the workers for safe work.
In particular, the above meeting is more important when worker of dif-
ferent languages and customs work together.
The following is a reference supervision system diagram.
(Instruction system)
Work leader
Director
Work supervisor Crane director and
deputy director
Operator for assembly

Liaison man
Mechanics Sharing of work

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

Accordingly, before installing the work equipment, inspect and main-
tain the machine thoroughly.
Note that this manual does not describe the whole specification of the
machine but describes only the basic specification.
If you have any question when dividing and transporting the machine
by yourself in future, ask one of our distributors.
CONTENTS
SPECIFICATIONS ....................................................................................................................................... 1
PRECAUTIONS FOR FIELD ASSEMBLY ................................................................................................... 3
DISPOSAL OF REMOVED PARTS ............................................................................................................. 4
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE ............................................. 5
LAYOUT OF KIT ......................................................................................................................................... 6
STYLE FOR TRANSPORTATION .............................................................................................................. 7
TOOLS LIST FOR FIELD ASSEMBLY ........................................................................................................ 13
TIGHTENING TORQUE .............................................................................................................................. 17
COATING MATERIALS .............................................................................................................................. 21
A. ASSEMBLY PROCEDURE ..................................................................................................................... 23
A-1 Installation of undercarriage ................................................................................................... 24
A-2 Installation of ripper ................................................................................................................ 37
A-3 Installation of tracks ................................................................................................................. 42
A-4 Adding oil to pivot chamber ................................................................................................... 44
A-5 Installation of ripper shank ..................................................................................................... 45
A-6 Installation of blade lift cylinder ............................................................................................. 46
A-7 Installation of trunnion ............................................................................................................ 48
A-8 Assembly of blade ................................................................................................................... 49
A-9 Installation of blade ................................................................................................................. 55
A-10 Adjustment of arm joint (U-blade) ......................................................................................... 58
A-11 Installation of counterweight .................................................................................................. 59
A-12 Installation of operator’s cab .................................................................................................. 60
A-13 Installation of ROPS ................................................................................................................. 76
A-14 Adjustment of potentiometer rod ........................................................................................... 77
A-15 Procedure for adjusting blade tilt angle limit ........................................................................ 78
A-16 Method of checking auto-reset system (Superdozer) ........................................................... 87
A-17 Check track tension .................................................................................................................. 88
A-18 Check of oil and coolant levels ............................................................................................... 90
A-19 Greasing of greasing point ..................................................................................................... 92
A-20 Installation of ORBCOMM antenna and wiring harness ....................................................... 95
A-21 Replacement of return filter
(Replacement of standard filter with Special flushing parts) ............................................... 96
A-22 Installing direction of exhaust pipe ........................................................................................ 99
A-23 Bleeding air from hydraulic cylinders .................................................................................... 100
A-24 Installing lunchbox band (if equipped) .................................................................................. 101
M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY ..................... 103
M-1 Check and adjustment of operator’s cab ............................................................................... 104
M-2 Inspection of machine monitor ............................................................................................... 111
M-3 No-injection cranking of engine ............................................................................................. 124
M-4 Setting procedure of user adjust mode ................................................................................. 127
M-5 Flushing of hydraulic circuit .................................................................................................... 130
APPENDIX 1
INSTALLATION OF SPILL GUARDS
APPENDIX 2
PRECAUTIONS FOR INITIALIZATION PROCEDURES FOR VHMS CONTROLLER
FIELD ASSEMBLY INSPECTION REPORT (U-DOZER SPECIFICATION)
FIELD ASSEMBLY INSPECTION REPORT (SUPERDOZER SPECIFICATION)
SPECIFICATIONS
Semi-U-tiltdozer Full U-tiltdozer Superdozer
Item Unit + Variable giant ripper + Variable giant ripper + Counterweight
Operating weight
(excluding operator's weight) kg 108,310 (*1) 113,120 (*2)
Blade weight
(including cylinders) kg 16,500 18,800 20,900
Ripper weight
(including cylinders) kg 7,360 –
Counterweight kg – 6,040
Engine model – Komatsu SAA12V140E-3 diesel engine
Rated engine output kW/rpm {HP/rpm} 664/2,000{890/2,000}
Overall length mm 11,560 11,950 10,525
Overall height (with ROPS) mm 4,546 (4,646)
Overall width mm 5,265 6,205 6,465
Travel speed Forward km/h 3.5/6.3/10.9
(1st/2nd/3rd) Reverse km/h 4.7/8.4/14.3
*1: Blade + ripper + ROPS cab + air conditioner
*2: Superdozer + counterweight + ROPS cab + air conditioner
• Semi-U-tiltdozer + variable giant ripper
• Full U-tiltdozer + variable giant ripper
1
• Superdozer + counterweight
2
PRECAUTIONS FOR FIELD ASSEMBLY
1. Selection of work place
1) When selecting a work place, consider the following.
• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout draw-
ing.)
• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
• Is the ground flat? (The ground surface must not be uneven or sloping.)
• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read
and understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the
work place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools

The work supervisor or the work leader must perform the following checks about protective gear, slings and
tools.
1) Are all the workers wearing helmets and other protective gear which they are obliged to wear?
If special protective gear is necessary, check that it is prepared and can be used without problem.
2) Are all the slings and tools prepared? Check in advance that they are ready to be used without prob-
lem. In particular, check wooden blocks for internal decay and cracking.
4. k Check during actual work

The work supervisor or the work leader must check the following items constantly and make all the workers
observe them.
1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with
chocks during work? Are outriggers, if installed, used securely?
2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during
work?
3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked
that work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel
control lever) is in the low idle position?
4) Is the balance of the slung item checked extremely during sling work with the crane?
5) Is entry prohibition for outsiders to the work place observed?
5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe
work.
6. Precautions for starting engine

When the engine is started for the first time after assembled in the field, its inside must be lubricated
with engine oil. Lubricate according to “M-3 No-injection cranking of engine” in this manual.
3
DISPOSAL OF REMOVED PARTS
As described in "Preface", when this machine is transported, it is divided into some units such as the
body, undercarriage, cab, work equipment, etc. according to the transportation measure, regulations,
etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the
hydraulic devices, and parts which must not be damaged are plugged or covered to prevent oil leakage,
entry of dirt and dust, and damage during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation
and to facilitate loading, unloading and crane work.
The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after
completion of the machine. Since they are useful when the machine needs to be transported in future,
however, we recommend you to keep them as long as possible.
4
Schedule
No. 1st day 2nd day 3rd day 4th day 5th day
Item
Unloading
• Installation of track
1 • Installation of stand
• Installation of chassis
• Unloading of other parts
2 Installation of blade lift cylinder fl
3 Installation of track frame
4 Replacement with flushing filter
5 Installation of ripper (Installation of counterweight)
6 Installation of track
Blade
• Welding of spill guard (If equipped)
7
• Assembly of blade
• Installation of blade
8 Installation of operator’s cab
5
9 Installation of ROPS
10 Installation of exhaust pipe
11 Adjustment of blade tilt limit rod
The special work in the field shall be adjusted separately.
12 Adjustment of tilt limit angle

13 Check of oil level and addition of oil
A change of the schedule caused by weather is not considered.
14 Greasing
15 Adjustment of track tension
Final assembly inspection
1) Bleeding air from hydraulic circuit
16 2) Flushing of hydraulic circuit
3) Pm clinic
4) Initialization of VHMS
5) Check of cab pressurization
Workers Assembly 4 4 4 3 3
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE
Welding 2
45ton × 2 45ton × 1 45ton × 1 45ton × 1
Crane (Hydraulic type with operator)
1. Arrangement before work 1. Removal of stand

Remarks
2. Starting of assembly 2. Starting of engine
fl The blade lift cylinder may have been installed.
LAYOUT OF KIT
• When selecting the work field, see “Before assembling in field”.
• The dimensions in the drawings are reference dimensions for installation in the following space (30
m x 30 m).
• If a wider work field is available, the shown dimensions should be increased.
Approx. 30 m
Blade
Right straight frame

Left straight frame
Right track
Left track
Track
Track
Wrecker truck
Approx. 30 m
Chassis
Wrecker truck
Accessories
Ripper parts CAB assembly
ROPS guard
6
STYLE FOR TRANSPORTATION
Since the machine can be divided for transportation, ask us or our service shop before transportation.
■ Style of each KIT.
• Body
A Overall length (mm) 6,600

B Overall height (mm) 3,300
C Overall width (mm) 3,320
Weight (kg) 43,000
Note: The blade lift cylinder may
be installed before delivery.
• Track frame

C Overall width (mm) 982
Weight (kg) 12,200
• WORK EQUIPMENT
(1) U-blade

Weight (kg) 14,000
7
(2) Semi U-blade

Weight (kg) 13,000
• Super blade

Weight (kg) 14,000
fl Refer to the Appendix 1 for

welding of spill guard.
• Track shoe
Shoe width 810

A (mm) 4,500
B (mm) 1,400
Weight (kg) 6,770 (1/2)
8
• Straight frame
Semi-U, U Super
A Overall length (mm) 4,857 5,020
B Overall height (mm) 674 682
C Overall width (mm) 638 681
Weight (kg) 1,770 1,868
• Hydraulic cylinder
(1) Pitch, tilt cylinder
Semi-U, U Super
Weight (kg) 504 508
(2) Blade lift cylinder

B Overall height (mm) 630
Weight (kg) 500
Note: May be installed to chassis

before delivery.
(3) Ripper cylinder
Lift Tilt
Weight (kg) 389 394
9
• Giant ripper beam

Weight (kg) 2,400
• Giant ripper arm, multi ripper arm

B Overall height (mm) 580
Weight (kg) 1,750
• Giant ripper shank
A Overall length (mm) 115

Weight (kg) 1,000
10
• Multi ripper beam

Weight (kg) 3,450
• Multi ripper shank
A Overall length (mm) 115

Weight (kg) 740
Q’ty 3
• Cab

Weight (kg) 500
11
• ROPS

Weight (kg) 918
• Counterweight

C1 1,361
Overall width (mm)
C2 1,290
Weight (kg) 7,300
12
TOOLS LIST FOR FIELD ASSEMBLY
No. Tool name Q’ty Remarks

1 Wrecker truck Capacity: 441kN {45 tons} 2
2 Air compressor 0.7 MPa {7.0 kg/cm2}, 15 m3/min 1
Used to weld spill guard (if equipped) to work
3 Welder 2 equipment blade.
See data at end of this manual.
4 Lever block (Chain block) 15 kN {1.5 ton}, 30 kN {3 ton} each 2
12 mm ✕ 2 m 4
16 mm ✕ 2 m 4
20 mm ✕ 5 m 4
5 Wire 20 mm ✕ 6 m 2
30 mm ✕ 3 m 2
36 mm ✕ 5 m 2 For slinging body
36 mm ✕ 10 m 1 For slinging body
25 mm wide ✕ 3 m 2
6 Nylon sling
50 mm wide ✕ 3 m 2
7 Hydraulic wrench Min. 5,890 Nm {600 kgm} 1 For master link bolt of track
8 16 : 1 torque multiplier Min. 4,400 Nm {450 kgm} 1
Min. 2,940 Nm {300 kgm} 1
Min. 980 Nm {100 kgm} 1
9 Air impact wrench Min. 315 Nm {32 kgm} 1
Min. 160 Nm {16 kgm} 1
Min. 140 Nm {14 kgm} 1
Min. 2,060 Nm {210 kgm} 1
Min. 1,375 Nm {140 kgm} 1 Select torque wrenches which can use air
impact wrench sockets.
10 Torque wrench Min. 590 Nm {60 kgm} 1
If such torque wrenches are not available, pre-
Min. 412 Nm {42 kgm} 1 pare sockets for torque wrenches separately.
Min. 180 Nm {18 kgm} 1
Size must match to driver unit of pneumatic

11 Air impact wrench sockets 50, 46, 41, 36, 32, 30 each 1
impact wrench.
27, 24, 22, 19
12 16:1 torque multiplier socket 50, 46, 41, 36 each 1
13 Hydraulic wrench socket 50 1
L = 600 mm 1 Sockets matched to insertion angle of air
14 Extension bar
L = 300 mm 1 impact wrench driver
4
15 Eyebolt
2 For blade center link
For 3 ton 4
16 Shackle For 8 ton 2
For 20 ton 1
17 Sledge hammer 10P 1
18 Crowbar 1m 1
M 33 ✕ P 2 1 For master link
19 Taps (tapping tool) M 30 ✕ P 3 1
M 24 ✕ P 3 1
20 Jack 147 kN {15 ton} 2 For assembling track frame
13
No. Tool name Q’ty Remarks
17 mm
19 mm
22 mm
24 mm
27 mm
21 Wrench (Spanner type) 30 mm each 2 For tightening hydraulic hose adapter
32 mm
36 mm
41 mm
46 mm
50 mm
Use suitable coupler with compressor and
22 Air hose for air impact wrench #04 #06 each 30 m
impact wrench
23 Oil Refer to section A-18.
For master link
24 Lubricant Molybdenum disulphide lubricant 1
Refer to "COATING MATERIALS"
25 Detergent 40 ¬
26 Paint remover 5
27 Paint for repair Refer to "COATING MATERIALS"
28 Glass cleaner 1
29 Cloth Bunch 5
30 Angle meter 1 For dual tiltdozer and superdozer
31 Grease pump Air type 1
32 Oil pump Manual or air type 1
33 Oil jack 5¬ 1
Approx. 1,000 mm ✕ 700 mm ✕ 150 mm
34 Waste oil receiving pan Approx. 700 mm ✕ 400 mm ✕ 150 mm each 2
Approx. 300 mm ✕ 300 mm ✕ 100 mm
35 Step Height: 2 m With ladder 1
Stand Front 1 See attached tool drawing

36
(Chassis stand) Rear 1 See attached tool drawing
350 mm ✕ 750 mm 4
37 Wood block 350 mm ✕ 400 mm 4
100 mm ✕ 750 mm 4
38 Vinyl hose (Transparent) O.D. 10 mm ✕ 3 m 1 For measuring air pressure in cab
39 Cloth adhesive tape 1
Steel plate
40 500 mm ✕ 100 mm ✕ 16 t 4 Weld lifting hooks to corners.
(for installation of chassis stands)
41 Safety belt For arerial work Per person
42 Protective goggle For welding and grinding work Per person for each work
43 Safety rope Do-not-enter board, rope As necessary For securing working area
14
Sketch of tools
Chassis stand (Front side)
15
Material t12
No. Material Q‘ty Remarks

01 SS400C 4 C150 x 75 x t9–1332
02 SS400C 2 C150 x 75 x t9–829
03 SS400C 2 C150 x 75 x t9–829
Only 04 SS400C 2 C150 x 75 x t9–510
movable
part 05 SS400C 2 C150 x 75 x t9–548
06 SS400C 2 C150 x 75 x t9–453
07 SS400C 2 C150 x 75 x t9–355
Only movable
part 08 SS400B 4 M50–500
09 SS400 4 t25 x 180 x 250
10 SS400 4 t12 x 200 x 655
11 SS400 10 t12 x 60 x 128
12 SS400 2 t16 x 124 x 130
13 SS400 2 t25 x 70 x 85
Note) We are not liable for any result of use of tools manufactured according to these drawings.
Chassis stand (Rear side)
16
No. Material Q‘ty Remarks
01 SS400C 4 C150 x 75 x t9–1282
02 SS400C 2 C150 x 75 x t9–829
03 SS400C 2 C150 x 75 x t9–829
04 SS400C 2 C150 x 75 x t9–510
05 SS400C 2 C150 x 75 x t9–548
06 SS400C 2 C150 x 75 x t9–453
07 SS400C 2 C150 x 75 x t9–355
08 SS400B 4 M50–500
09 SS400 4 t25 x 180 x 250
10 SS400 4 t12 x 200 x 655
11 SS400 10 t12 x 60 x 128
12 SS400 2 t16 x 124 x 130
13 SS400 2 t25 x 70 x 85
TIGHTENING TORQUE
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt TTTTT-TTTTT

Part No. of washer EEEEE-EEEEE
Bolt specification Thread diameter × Bolt length
Tool (Socket) Applicable socket size
Tightening torque Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 26
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension c in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. cor-
respond to dimension b in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ – www or QQQ ± RR. If the target tightening torque
is set, expression of QQQ ± RR is applied.
Fig. 1
a : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt
17
Table 1 Tightening torque for bolts not specified in text
Unit: Nm {kgm}
Nominal size of thread Width across flats Tightening torque
✕ pitch (= Socket size)

a (mm) b (mm) Unit : Nm Unit : {kgm}
6 ✕ 1 10 11.8 Ð 14.7 {1.2 Ð 1.5}
8 ✕ 1.25 13 27 Ð 34 {2.8 Ð 3.5}
10 ✕ 1.5 17 59 Ð 74 {6 Ð 7.5}
12 ✕ 1.75 19 98 Ð 123 {10 Ð 12.5}
14 ✕ 2 22 153 Ð 190 {15.5 Ð 19.5}
16 ✕ 2 24 235 Ð 285 {23.5 Ð 29.5}
18 ✕ 2.5 27 320 Ð 400 {33 Ð 41}
20 ✕ 2.5 30 455 Ð 565 {46.5 Ð 58}
22 ✕ 2.5 32 610 Ð 765 {62.5 Ð 78}
24 ✕ 3 36 785 Ð 980 {80 Ð 100}
27 ✕ 3 41 1150 Ð 1440 {118 Ð 147}
30 ✕ 3 46 1520 Ð 1910 {155 Ð 195}
33 ✕ 3 50 1960 Ð 2450 {200 Ð 250}
36 ✕ 3 55 2450 Ð 3040 {250 Ð 310}
39 ✕ 3 60 2890 Ð 3630 {295 Ð 370}
18
2. Tightening torque for pipe threads
Proper tightening torque for pipe threads depends on combination of the materials of the male screw and
female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of
the material of the male screw. If tightening torque is specified specially in explanation, however, apply that
tightening torque.
2.1 If the male screw is made of mild steel or cast iron, apply Table 2.
Table 2
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size
3.9 – 6.9 2.9 – 5.9 2.0 – 3.9
1/8
{0.4 – 0.7} {0.3 – 0.6} {0.2 – 0.4}
5.9 – 11.8 4.9 – 9.8 3.9 – 7.8
1/4
{0.6 – 1.2} {0.5 – 1.0} {0.4 – 0.8}
16.7 – 26.5 13.7 – 21.6 9.8 – 16.7
3/8
{1.7 – 2.7} {1.4 – 2.2} {1.0 – 1.7}
32.3 – 52.9 26.5 – 43.1 19.6 – 32.3
1/2
{3.3 – 5.4} {2.7 – 4.4} {2.0 – 3.3}
51.0 – 85.3 42.1 – 70.6 31.4 – 52.9
3/4
{5.2 – 8.7} {4.3 – 7.2} {3.2 – 5.4}
86.2 – 173.5 72.5 – 146.0 54.9 – 111.7
1
{8.8 – 17.7} {7.4 – 14.9} {5.6 – 11.4}
2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size
16.7 – 29.4 9.8 – 19.6 6.9 – 14.7
1/8
{1.7 – 3.0} {1.0 – 2.0} {0.7 – 1.5}
19.6 – 44.1 16.7 – 37.2 12.7 – 28.4
1/4
{2.0 – 4.5} {1.7 – 3.8} {1.3 – 2.9}
44.1 – 93.1 37.2 – 77.4 27.4 – 58.8
3/8
{4.5 – 9.5} {3.8 – 7.9} {2.8 – 6.0}
98.0 – 188.2 83.3 – 157.8 60.8 – 115.6
1/2
{10.0 – 19.2} {8.5 – 16.1} {6.2 – 11.8}
170.5 – 316.5 141.1 – 247.0 105.8 – 186.2
3/4
{17.4 – 32.3} {14.4 – 25.2} {10.8 – 19.0}
367.5 – 612.5 309.7 – 514.5 235.2 – 392.0
1
{37.5 – 62.5} {31.6 – 52.5} {24.0 – 40.0}
19
3. Tightening torque for hydraulic hose connecting nut
For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply
tightening torque in Table 4.
Table 4
Unit: Nm {kgm}
Outside diameter Width across Tightening torque

of hose flatse.
(mm) (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}

Approx. 10
24 59 – 98 {6.0 – 10.0} 78 {8.0}
Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}
Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}
Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}
Note : When connecting hoses, take care not to twist them.
20
COATING MATERIALS
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used to prevent rubber gaskets, rub-
LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 1 kg al, glass and plastic.
LT-3 (Set of adhesive Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-
MH 705 790-126-9120 75 g Tube pairing engine.
• Quick hardening type adhesive
Three bond 790-129-9140 50 g Polyethylene • Cure time: within 5 sec. to 3 min.
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha 790-129-9130 2g Polyethylene 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite 79A-129-9110 50 cc Polyethylene • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
LG-5 790-129-9080 1 kg Can pipe joints, flanges.
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil pan, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
1211 790-129-9090 100 g Tube pairing engine.
• Features: Silicone type, heat resist-
Three bond ant, vibration resistant, and impact
1207B 419-15-18131 100 g Tube resistant sealing material
• Used as sealing material for transfer
case
21
Category Komatsu code Part No. Q'ty Container Main applications, features
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
disulphide SYG2-400M 400 g × 10 Bellows type
Grease grease SYG2-400M-A 400 g × 20 Bellows type
LM-G (G2-M) SYGA-16CNM 16 kg Can
• Seizure resistance and heat resist-

Hyper White SYG2-400T-A ance higher than molybdenum di-
Grease G2-T SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type
*: For high less effects on microorganisms,
SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Expiration date: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Expiration date: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
• "S" is used for high-tempera-
SUNSTAR ture season (April - October)
Adhesive for cab glass
PENGUINE Polyethylene and "W" for low-temperature

SEAL 580 320 ml container season (November - April) as
Adhesive SUPER "S" or adhesive for glass.
"W" (Expiration date: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Expiration date: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container
SEAL No. 2505 (Expiration date: 4 months)
SEKISUI • Used to seal front window.

Caulking Polyethylene (Expiration date: 6 months)
material SILICONE 20Y-54-55130 333 ml container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.

SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Expiration date: 12 months)
Natural yellow SYPA-U03PNY – Spray can

Paint
Black gray SYPA-U03PBG – Spray can
22
A. Assembly
Remarks
1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---,
but indicated by (1), (2), (3) --- in the tables and texts.
Example:
(1) Plate
(2) Collar
(3) Washer
(4) Bolt
(5) Bolt
(6) Washer
2. In some places of this manual, the words of front, rear, right hand and left hand
of machine are used. Those words indicate the directions seen from the opera-
tor's seat with the sprocket at the rear as shown below, unless otherwise speci-
fied.
Front
Left hand Right hand
Operator's seat
Sprocket
Rear
23
Assembly procedure
Installation of undercarriage (1/13)
A-1
1. Setting of tracks
• Spread the right and left tracks on the work
ground.
fl Spread the right and left tracks in parallel, while
setting their front ends flush with each other.
Their mutual relational dimensions are shown in
the figure.
fl When the tracks are spread on the ground, the

abutment joints of the master links at the front
ends must be directed down.
At the front ends of the spread tracks, the
abutment joints of their master links are directed
down.
Abutment joints
Left track
Parallel Front
Right track
Front end
Symbol Dimension (mm) Remarks

W 2,770
A 2,060 When shoe width is B
B 710
N 13,066 Number of shoes: 41
24
Assembly procedure
A-1
2. Installation of chassis stand

Place the steel plates between the tracks spread in parallel on the ground and install the chassis
stands on them.
fl Arrange the chassis stands and steel plates as shown in the figure.
fl The chassis stands for the front side and rear side are different from each other.
fl The steel plates are required when the ground is soil. They are not required when the ground
is covered with steel plates.
Chassis stand (rear) Chassis stand (front) Track (Left)
Steel plate
Track (Right)
Front end
Chassis stand (rear)
Steel plate Steel plate Chassis stand (front)
Ground
Symbol Dimension (mm) Remarks

H1 1,105
H2 1,020
t 16 Recommended thickness of steel plate
L1 2,800
3,300
L2
2,450
25
Assembly procedure
A-1
3. Installation of chassis
1) Using the front towing hook and ripper top pin, sling the chassis with 2 cranes (45 ton).
Lifting load Lifting load
Ripper pin
Equalizer bar
Front towing hook Front towing hook
Rear chassis stand Front chassis stand
2) Using the front towing hook installed to the

undercover, sling the front portion as shown in
the figure.
• Wire: 36 mm ✕ 5 m (Safety factor: 5)
• Shackle: For 20 ton
fl Apply pads (felt, rubber, etc.) to the chassis

bottom to prevent the lifting wires from
damaging the chassis.
Shackle
Use corner pad
3) Using the cylinder pins (both right and left) for

installation of the upper ripper cylinders, sling the
rear portion as shown in the figure.
• Wire: 30 mm ✕ 3 m ✕ 2 pieces
26
Assembly procedure
A-1
4. Preparation for installation of track frame
1) To keep the chassis horizontally, put blocks (A) between the equalizer bar and main frame.
( 95 mm or ø95 mm, Length 94 – 102 mm)
fl To remove the block, refer to the section 9-8).
27
Assembly procedure
A-1
2) Removal of accessories
Remove the following 10 parts (the bolts are not
counted in) from the track frame as shown in the photo.
No. Part No. Part name
1 198-30-69830 Cover
198-30-61360 Cover (L.H.)
2
198-50-61370 Cover (R.H.)
3 198-50-61150 Shaft
198-30-69460 Cover (L.H.)
4
198-30-69470 Cover (R.H.)
198-30-62311 Cover (L.H.)
5
198-30-62321 Cover (R.H.)
6 198-50-51390 Cover
198-30-51430 Cover (L.H.)
7
198-30-51440 Cover (R.H.)
198-50-31270 Spacer
8
198-50-51220 Cover A’ssy
9 195-30-31260 Cover
198-30-69850 Cover (L.H.)
10
198-30-69860 Cover (R.H.)
fl Be sure to support the track frame, which has been

installed, to prevent it from falling down.
3) Maintenance of track frame pivot and application

of grease
Apply grease to the O-ring groove and fit the O-
ring to the groove.
O-ring
4) Check of seal for damage, maintenance of shaft,

and application of grease
O-ring
28
Assembly procedure
A-1
5. Installation of track frame

1) Slinging method
When using wires

• Diameter: 24 mm✖✕✖Length: 2 m ✕ 1 piece
When using wires • Lever block 6t ✕ 1 piece
• Diameter: 24 mm ✕ Length: 6 m ✕ 1 piece • Lever block 3t ✕ 1 piece
Rear Front
100 mm
Center of gravity is 100 mm

Hook for working before machining hook end.
Rear carrier roller
Rear view Front view
fl When slinging the rear portion, direct the carrier roller out.
29
Assembly procedure
A-1
2) Sling the track frame horizontally and insert it,

aligning it to the pivot shaft.
fl The workers must not stand between the
chassis and track frame. Doing so is
dangerous.
fl Push in the track frame so that the lifting

wires will not touch the fenders.
If the chassis seems to interfere with the
lifting wires, insert blanket etc. between
them for protection.
3) Install jacks or wooden blocks under the installed track frame assembly so that the track
frame assembly will be kept level after it is released from the crane.
Jack
fl For the jacks, see "Field assembly tool list".
30
Assembly procedure
A-1
4) Install the thrust plate to the end face of the

track frame.
Part name Part No.

Thrust plate 198-50-31270
5) Fix the shaft and track frame with the twisted

seal plate (for fixing).
fl If you use a long bolt as an installation guide,
you can assemble easily.
fl As for the seal plate, refer to the previous item
4-1). "Removal of accessories", part No. 8.
6. Insertion of equalizer bar side pin
1) Adjusting with the crane, align the pin holes

accurately.
fl The pin must be inserted in the correct directly.
Direct its cut part in.
There is UP mark
Part name Part No.

Pin 198-50-61150
2) Connect the grease tube.

Grease tube
Mudguard for pin

3) Install the attached cover.
4) Install the pin fixing bolt.
fl Insert the pin fixing bolt from below and
install the nut to the upper side.
198-50-61410
Part No. of bolt
(2 pieces on each side)
01643-33380
Part No. of washer
(4 piece on each side)
19M-09-12890
Part No. of washer
Length of bolt 320 mm
Necessary socket 50 mm
2,574 ± 123 Nm
Tightening torque
{262.5 ± 12.5 kgm}
31
Assembly procedure
A-1
7. Installation of pivot shaft inside twisted seal cover

1) Install the inside twisted seal cover with the
notch down.
01010-81640
Part No. of bolt
01643-31645
Part No. of washer
fl When fixing the cover, set the track frame

horizontally.
8. Work on pivot shaft ends

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

Left side of machine Right side of machine
Single tiltdozer Not installed Installed
Dual tiltdozer Installed Installed
Super dozer Installed Installed
2) Work when tilt hose piping is installed

2-1) If the tilt hose piping is installed, 2 tilt hoses
are projected from the pivot shaft end as
shown in the figure.
32
Assembly procedure
A-1
2-2) Install the unions, elbows and plugs for the

tilt piping to the pivot shaft end cover.
fl1. Take care not to forget to set the

O-rings.
fl2. Direct the elbows to the rear.
fl3. If these parts have been installed when

delivered, the above work is not
necessary.
No. Part name Part No. Q'ty
1 Cover 198-50-51390 2 pcs. (common to right and left)
2 Union 02781-00628 2 pcs. (for each cover)
3 Plug 07040-12412 2 pcs. (for each cover)
4 Elbow 02782-1062A 2 pcs. (for each cover)
5 O-ring 07002-22434 6 pcs. (for each cover)
Tightening torque of union, plug and elbow 128 Ð 186 Nm {13 Ð 19 kgm}
2-3) Install hoses (2) and (3) to the elbows of the

cover assembly described in step (2) to
connect to the work equipment piping.
fl1. Take care not to forget to set the O-

rings.
fl2. Install the red-banded hose to the elbow

that will be on the upper side when the
cover assembly is installed to the
machine and the blue banded hose to
the elbow that will be on the lower side.
fl3. Set the opposite side of each hose free.
No. Part name Part No. Q'ty Remarks
1 Cover assembly Assembly in step (2) Ñ
2 Hose 198-71-62171 1 Red-banded
3 Hose 198-71-62270 1 Blue-banded
4 O-ring 02896-21018 2
Tightening torque of hydraulic hose 177 Ð 245 Nm {18 Ð 25 kgm}
(The quantity is for 1 cover assembly)
33
Assembly procedure
A-1
2-4) Remove the plugs from the tilt hoses

projected from the pivot shaft end (2 places).
Reference
Plug 07376-70628
O-ring 02896-11018
2-5) Install the tilt hoses projected from the pivot

shaft end to the cover assembly described
in step 2-2).
fl1. Take care not to forget to set the O-

rings.
O-ring 02896-21018 2 pcs.
fl2. Install the red-banded hose to the union

that will be on the upper side when the
cover assembly is installed to the
machine and the blue banded hose to
the union that will be on the lower side.
2-6) Install the cover assembly described in step

2-5) together with the large washers of the
twist seal assembly installed in steps 5-4)
and 5-5).
No. Part name Part No. Q’ty Remarks

2 Bolt 01010-81695 9
For tightening torque of bolts, see
3 Bolt 01011-81625 1
Table 1 on page 18.
4 Washer 01643-31645 10
1 Cover assembly in step 2-5)
5 Hose in step 2-3)
6 Hose in step 2-3)
7 Trunnion mounting seat (see A-7)
Note) The quantity is for 1 cover assembly.
34
Assembly procedure
A-1
2-7) Pass hoses (5) and (6) through the track

frame and pull them out of the hole of the
trunnion mounting seat.
2-8) Install the mud cover to the front of cover

assembly (1) described in step 2-6).
The covers for the right and left sides of the
machine have different part Nos.

1 Cover (Right) 198-30-51440 1
2 Cover (Left) 198-30-51430 1 For tightening torque of bolts, see
3 Bolt 01010-81635 3 Table 1 on page 18.
4 Washer 01643-31645 3
fl The quantity of the bolts and washers is for 1 cover assembly.
3) Work when tilt hose piping is not installed
3-1) As described in 8.1), the tilt hose is not

installed to the left end of the pivot shaft of
the single tiltdozer specification. (Part A in
the figure)
3-2) Install cover (1) together with the large

washers of the twist seal assembly installed
in steps 5-4) and 5-5).
3-3) Close the square hole at the front of cover

(1) with plate (4).

1 Cover 198-50-51220 1
2 Bolt 01010-81695 10
3 Washer 01643-31645 10 For tightening torque of bolts, see
4 Plate 198-30-51330 1 Table 1 on page 18.
5 Bolt 01010-81635 3
6 Washer 01643-31645 3
35
Assembly procedure
A-1
9. Installation of whole chassis to tracks
1) Sling the front portion of the track frame assembly

with the crane, remove the jacks or wooden blocks
installed in 5-3), and release the track frame
assembly from the crane.
2) Sling the front portion of the chassis according

to the procedure in "3. Installation of chassis" and
remove the chassis stand (front). (Pull out the
chassis stand from under the chassis.)
3) Lower the front portion of the chassis slowly to

place the idler treads of the track frame assembly
onto the track links.
4) Ensure that all the load of the front portion of the

chassis is applied to the tracks and then release
the chassis.
5) Sling the rear portion of the chassis according to

the procedure in "3. Installation of chassis" and
remove the chassis stand (rear).
6) Lower the rear portion of the chassis slowly to

place the roller treads onto the track links.
7) Ensure that the whole chassis is on the tracks and

then release it.
L
8) Remove the block between the equalizer bar and
the main frame that was installed in Step 4-1).
9) Remove the bogie fixing plate (special jig L fixing

the track roller and idler) and keep it for the next
modification.
10) Return the rear carrier roller reversed in 5-1).

fl The above work order may be changed
properly. Tap holes
11) Install cork plugs 07049-02734 to the tap holes of

the track frame.
36
Assembly procedure
Installation of ripper (1/5)
A-2
1. Preparation
1) Before installing the ripper, replace the hydraulic
oil return filter with flushing filter referring to
section A-21.
2) Removal of paint and rust prevention oil from

mounting parts
Style
3) Do not remove the arm pin but pull it out to the

state shown in the photo.
4) Arm pin lock bolt

Part No. of bolt 01010-82040 (2 pieces on each side)
Part No. of washer 01643-32060 (2 pieces on each side)
Tightening torque 549 ± 59 Nm {56 ± 6 kgm}
2. Installation of arm
• Sling the arm by 3 points. Set its right and left
parts in parallel accurately.
• Set a wood block under the arm as shown in the
photo.
3. Installation of lift cylinder

• Lift cylinder connecting pin lock bolt Block
37
Assembly procedure
A-2
4. Installation of tilt cylinder

• Tilt cylinder connecting pin lock bolt
5. Installation of right and left lift hoses and tilt hoses

• Direct the hoses as shown in the photo.
• Part No. of hose : 07097 – 01012
(Common to 8 hoses on right and left sides)
Straight openings
L-adapters
6. Sub beam
• Assemble the right and left grease hoses

and elbows before installing them to
cylinder head pin.
7. Installation of beam assembly

• Sling the beam assembly by the 3 points of the
shank pin and cylinder pin.
• Beam connecting pin lock bolt
38
Assembly procedure
A-2
• Set a block (Height: 670 mm) under the beam so

that the arm will be horizontal.
8. Procedure for connecting cylinder
1. Installation of lift cylinder

3. Check of hydraulic oil level and addition of
new oil
• Connecting pin lock bolt on cylinder rod side

Note) If the engine is started for the first time in this work, lubricate it before starting according to
"M-3 No-injection cranking of engine".
39
Assembly procedure
A-2
9. Installation of pin puller hoses

• Clamping positions of hoses
1. Between clamp on side of beam

and cylinder: 990 mm
2. Between connecting part of
chassis and clamp A: 1,060 mm A
3. Between clamp A and clamp on
side of beam: 1,370 mm
• Detail of installation of pin puller hoses
40
Assembly procedure
A-2
10. Installation of grease supply hoses

fl If unnecessary plugs or fittings are set in pin lubrication hole, ✬✴✳#✴✫✯ ✫✬✫✭✯
remove them. ✯✭✳✫ ✳✬✫✭✫
✣✯✤ ✣✯✤
✬✴✳#✲✴
✬✴✮✬✫
✣✯✤
✫✬✰✳✮ ✭✫✰#✲✫
✬✭✭✬✮ ✰✬✮✲✫
✣✯✤ ✣✭✤
✭✫✴#✲✭
✬✱✰✰✫
✣✭✤
✬✴✳#✲✴
✬✴✭✱✫
✫✬✫✭✯
✳✬✭✭✰
✫✬✫✭✯
✳✬✭✱✫
✫✲✫✭✫
✫✫✫✫✫
✣✭✤
✬✴✳#✲✴
✬✴✮✬✫ ✬✴✳#✴✫✯ ✫✬✫✭✯
✫✬✰✳✮ ✣✭✤ ✯✭✳✫ ✳✬✫✭✫
✣✭✤ ✣✭✤
✬✭✭✬✮
✣✭✤
✬✴✳#✲✴ ✬✴✳#✲✴ ✫✲✫✭✫ ✬✴✳#✲✴
✬✴✭✰✫ ✬✴✮✰✫ ✫✫✫✫✫ ✬✴✮✯✬
✣✭✤ ✣✭✤ ✣✭✤
✫✬✫✭✯
✳✬✭✭✰ ✭✬❏#✲✭
✬✲✱✴✫
✫✬✫✭✯ ✣✭✤
✳✬✭✱✫
• Method of installing centralized greasing unit on

mount side
• After completing assembly, check the operation
and confirm that the hose is not abnormally
slackened or tensed.
41
Assembly procedure
Installation of tracks (1/2)
A-3
1. Installation of track link
fl Wind the front end of each track up to the top

of the idler.
2. While rotating the sprockets forward, discharge

the grease from the cylinder and retract the cyl-
inder to the stroke end.
Wooden block 300 ✕ 300 ✕ 600
fl Keep the grease plug open. Master link
3. Push up the machine with the ripper and disen-

gage the link from the sprocket so that the ma- Wire 24 ø ✕ 2 m
chine body will not run on the track.
Inserted
fl Put a steel plate on the block Steel plate 25
mm thick
to protect the block.
Wooden block 300 ✕ 300 ✕ 600

Floated
fl Carry out this work on a level place.
4. Sling the forward end of the track with a crane
and wind the track link up to the top of the
sprocket as shown in the photo.
5. Wind the track onto the sprocket. While slinging

the forward end of the track with the crane, ro-
tate the sprocket to move only the upper part of
the track forward.
fl The signal person must stand at a position

where the bulldozer operator and crane
operator can see him/her easily and must give
signals. Before starting the work, confirm the
signals.
6. Clean the mating faces of the master link.
7. Engage the master links and clamp them and

shoe plates together with the bolts.
fl Set the master link above the idler (a little
behind the center).
fl Tighten all the 4 bolts with the fingers until
the master link mating faces are fitted.
fl If the bolts are tightened forcibly before the
master link mating faces are fitted, the threads
of them and those of the master link may be
damaged.
42
Assembly procedure
Installation of tracks (2/2)
A-3
8. Control of bolt tightening torque
fl Retightening method
1. Tighten the bolts to torque of 980 ± 98 Nm {100

± 10 kgm} first and check that the mating faces
of the link are fitted.
2. Make a match mark (indicated with the arrow).
3. After checking, retighten the bolt by an angle

of 180° ± 10°.
fl Tightening order
Tighten the bolts in the order shown at right.
2 Shoe mounting bolt: LM-P

Anti-seize compound (MARUZEN MOLYMAX
No. 2 or equivalent)
fl Adjust the track tension when adding grease

at last.
(Refer to the section A-17.)
43
Assembly procedure
Adding oil to pivot chamber
A-4
• Pivot chamber
Add engine oil through the hole of plug (1).
fl Quantity of oil: 26 ¬/each side
fl Oil level (B): 10 – 30 mm from oil level (2)
44
Assembly procedure
Installation of ripper shank
A-5
1) Ride over the blocks to raise the rear of the machine.
2) Raise the ripper arm to the highest position and hold

the ripper beam to the position that the shank hole
is perpendicular to the floor.
3) Lay down the ripper shank to the floor. The ring for
the sling is just below the shank hole of ripper beam
at this time.
Block
4) Pass the sling wire of the crane through the shank

hole of the ripper beam and connect it to the ring
for the sling on the floor.
fl Use the shackle for 3 tons referring to the ''Tools

list for field assembly''.
Multi ripper shank: 740 kg/each

Giant ripper shank: 1,000 kg/each
5) Sling the shank with crane and pass the shank

through shank hole of the ripper beam.
fl Never operate the ripper at this time.

fl Be careful of the direction of the shank.
6) Align the shank pin hole and ripper beam pin hole.
Then, insert the shank installation pin and fix them.
Precautions Necessary tools Necessary equipment

Name Q’ty Name Q’ty
Other remarks
45
Assembly procedure
Installation of blade lift cylinder (1/2)
A-6
fl The blade lift cylinder may be installed before delivery.
1. Remove the yoke cap and bushing.
2. Installation of cylinder
• Install the cylinder with the right and left tubes
out down.
• Install the upper cap and bushing to the cylinder
first. After tightening the bolts temporarily, install
the lower cap and bushing, lifting them up.
Install the upper cap first.
Keep the lower cap removed.
• Cap mounting bolts

Tightening torque 1,716 ± 196 Nm {175 ± 20 kgm}
Installation angle
3. Installation of hoses
• Install the hoses so that they will not interfere with
each other as shown in the photo.
Hoses must be free from interference.
46
Assembly procedure
Installation of blade lift cylinder (2/2)
A-6
• Install the upper and lower hoses correctly.

Upper hose (1): 07098-01219 (Right and left)
Lower hose (2): 07098-01218 (Right and left)
Bottom
Head
• Blade lift cylinder connecting ports

Hose
Cylinder Upper hose Lower hose
Left lift Bottom side Head side
Right lift Head side Bottom side
47
Assembly procedure
Installation of trunnion
A-7
• Sling and install the trunnion.
• Remove the paint from both trunnion

mounting faces.
• Remove the paint from the trunnion, too.
• Trunnion mounting bolts Track frame

Trunnion
Washer
Tightening torque For tightening torque of bolts,
see Table 1 on page 18. Bolt
• If there are tilt hoses, pull them out of the center of

the trunnion as shown in the figure.
Trunnion Tilt hose
48
Assembly procedure
Assembly of blade (1/6)
A-8
1. Erect the blade.

• Using the main hook and auxiliary hook of the
crane simultaneously, erect the blade.
fl Since the blade is heavy, set the crane as near
the blade as possible.
Auxiliary hook
Main hook
• Set blocks at 4 places to prevent the blade from

falling down.
Joint
Correct Wrong
Remove all paint from joint side face.

(Clearance in blade insertion part is narrow)
2 places on right and left side
• Pull out the straight frame mounting pins inward.
2 places on right and left side
49
Assembly procedure
A-8
2. Installation of right and left straight frames

Caution
• Sling the straight frames horizontally in each
direction.
Sling straight frames with 2 nylon slings.
• Set the straight frames to a low position so that

you can install the tilt cylinder easily.
• Set the straight frames a little open so that you

can install the arm rod easily.
• Using a chain block, pull up the center link in

parallel with the back of the blade.
(Between trunnion centers)
3. Installation of arm rod

Caution
• Install the center link side first and support it with
a block.
• Sling the straight frames with the crane, move

them in, and connect the joints.
• Tighten both sides of the arm temporarily.
50
Assembly procedure
A-8
4. Adjustment of clearance in arm ball joint (Adjust ➞
both inside and outside similarly) ➞ AB
Standard: 4.5 mm
Procedure
(1) Pull the flange with the bolt and seat the joint end
without inserting a shim. (Take care since the
frame slips slightly at this time.)
(2) Insert the temporary shim in the clearance and
obtain maximum clearance (A) and minimum
clearance (B). Calculate the proper shim thickness
as (A + B)/2 + 0.5 and insert a shim of that thickness.
fl First, obtain the proper shim thickness on either
side of the arm ball joint. Then, remove the
bolt and obtain the proper shim thickness on
the opposite side according to the same
procedure (to set the arm free).
(3) Apply sufficient amount of grease to the ball joints Part No. of shim Thickness (mm)
at both ends and then insert the shims of proper
thickness and tighten each flange. 198-71-31450 2
(4) Tighten the bolt with an impact wrench, and then 198-71-31460 1
swing the frame and check the clearance visually. 198-71-31470 0.5

Caution
• Install the hoses and cover of the tilt cylinder in
advance.
For superdozer, install the tube, block, hoses and
cover of the tilt cylinder in advance.
• Install the tilt cylinder assembly to the straight
frames.
fl You may insert the pin on the rod side after
starting the engine.
• Tilt cylinder connecting pin lock bolt

51
Assembly procedure
A-8
• Connection of cylinder hose and installation of cover (For dual tiltdozer)
Intermediate cover Step cover

Hose

Step cover

Part No. of washer 01643-32060 (6 pieces on each side) Part No. of bolt 01010-81225 (2 pieces on each side)
Length of bolt 45 mm Part No. of washer 01643-31232 (2 pieces on each side)
Necessary socket 30 mm Intermediate Length of bolt 25 mm
Tightening torque 549 ± 59 Nm {56 ± 6 kgm} cover Necessary socket 19 mm
Tightening torque 110 ± 12 Nm {11.25 ± 1.25 kgm}
Red
Blue
B
Mark Cylinder Color
A Head Red
A B Bottom Blue
fl For single tiltdozer, install only the R.H. cylinder.
52
Assembly procedure
A-8
(For superdozer)
Part No. of bolt 01010-82040 (6 pieces on each side) Part No. of bolt 01011-82025 (1 pieces on each side)
Part No. of washer 01643-32060 (6 pieces on each side) Part No. of washer 01643-32060 (1 pieces on each side)
Length of bolt 40 mm Length of bolt 125 mm
Necessary socket 30 mm Necessary socket 30 mm
Tightening torque 56 ± 6 kgm Tightening torque 56 ± 6 kgm

Tightening torque 56 ± 6kgm
Step cover
53
Assembly procedure
A-8
6. Move the center link and match the straight frames

to the width of the trunnion center.
fl If you sling the straight frames with the crane,
you can move it easily.
3980
(Between trunnion centers)
7. Match the straight frames trunnion to the height of

the chassis trunnion center.
fl Sling the frame with the crane and adjust its
height.
980
54
Assembly procedure
Installation of blade (1/3)
A-9
Caution
• Checking the inside clearance between the track
and straight frame on the right and left sides,
move the chassis forward until it touches the
trunnion.
• When connecting the tilt hose, check the marks

(red and blue).
q Red Head side Upper side
w Blue Bottom side Lower side
• Pass the bolts through the cap and install wires

to them.
• Cap mounting bolts
Part No. of bolt 198-61-11250 (4 pieces on each side)
• Hose cover mounting bolts

• Sling the blade cylinder with the crane and

remove the blade cylinder fixing plate of the
transportation jig.
Nylon sling
Blade cylinder
fixing plate
55
Assembly procedure
A-9
• Keep the blade cylinder fixing plate (special jig) fixed to the
cylinder as shown in the photo at right until it is used for the next
modification.
• Connect the cylinders one by one.

• While extending the cylinder, connect the rod.
fl The person in charge of making signs shall
make signs to the operators of the crane and
bulldozer properly to prevent a mistake in
operation.
fl The joint link is installed on the blade side.

• Joint connecting pin lock bolt
Tightening torque 277 ± 32 Nm {28.25 ± 3.25 kgm}
• After installing the cylinders to the blade, install

the right and left tilt control adjustment rods.
fl Standard length of rod : 425 mm

Adjustment rod
Potentiometer
fl Detail of adjusting rod installation

To blade cylinder yoke
No. Part No. Q'ty
1 01010-81055 2
2 01643-31032 2
3 04250-81056 2
4 195-33-11220 2
fl The adjusting rod does not adjust the tilt control
5 01582-11008 2
for the single tiltdozer.
6 04248-31037 2
56
Assembly procedure
A-9
• Adjustment of length of single tiltdozer brace
1) Raise the blade a little.

2) Tilting to the right and left in the operator’s seat, rotate the brace.
3) Adjust the length of the brace so that the tilting distances on both sides will be the same.
Rotate with this lever.
Distance between pins
Check of installed condition of blade cylinder hydraulic hoses

• Operate the blade with the engine at low speed. (Raise, lower and tilt)
• Check the condition of the hydraulic hoses in each position and ensure that an excessive force
is not applied to the caulked parts of the hoses.
If an excessive force is applied to a caulked part of a hose, eliminate it by adjusting the installed
angle of the hose.
Operate the blade and check the hydraulic
hoses for high tension and a twist.
57
Assembly procedure
Adjustment of arm joint (U-blade)
A-10
Check of clearance in arm ball joint
fl If the clearance in arm ball joint is adjusted properl y in Assembly procedure A-8, step 4, following
check is not necessary.
Adjustment of shim
1. Remove shim (1) and tighten bolt (2) until the

play of the ball joint is eliminated. Shim (1)
Bolt (2)
2. Measure clearance “A” and remove bolt (2).
3. Install shim (1) having thickness of “A + (0 to 1)

mm”. Standard thickness of shim: 4.5 mm
4. Tighten bolt (2). Then, check that the ball joint

rotates smoothly.
Adjustment of shim
Adjustment of shim
Adjustment of shim
58
Assembly procedure
Installation of counterweight
A-11
(1) Sling the counterweight assembly and set it to the Fig. 1

mounting position of the main frame.
Weight of counterweight: 7,300 kg

Lifting wire: ø20 mm ✕ 6 m ✕ 2 pieces
(2) Install the mounting pins as shown in Fig. 2.
Fig. 2
No. Part name Part No. Q ty

1 Counterweight assembly 1
2 Main frame —
3 Lifting wire 2
4 Pin 198-78-21180 2
5 Plate 205-70-61560 2
6 Bolt 01010-82045 4
7 Washer 01643-32060 4
8 Pin 198-78-21140 2
9 Plate 195-78-21171 2
10 Bolt 01010-82040 4
11 Washer 01643-32060 4
59
Assembly procedure
Installation of operator’s cab (1/16)
A-12
fl Remove the power supply wiring harness for the

cab (Refer Fig. 10) and install it again after
assembling the cab.
1. Installation of open lock striker

Install right and left open lock striker mounting
brackets (1) and (2) with bolts (3) and washers (4)
as shown in Fig. 1.
fl Strikers (5), nuts (6), washers (7), stopper
rubbers (8), and nuts (9) are installed to the
bracket when delivered.
After mounting the operator’s cab on the chassis,
check the inspection items.
2. Installation of cab mounting L-plate

Install indoor L-plate (10) and outdoor L-plate (11)
temporarily with bolts (12) and washers (13) as
shown in Fig. 2. (3 pieces on each side)
Before installing the cab, loosen bolts (12).
Fig. 1
No. Part No. Q'ty

1 198-Z11-3341 1
2 198-Z11-3351 1
3 01010-D1230 10
4 01643-71232 10
5 14X-911-1921 2
6 01580-11008 8
7 01643-31032 8
8 09453-00002 2
9 01580-01210 2
10 198-Z11-3571 1
11 198-Z11-3581 1
Fig. 2 12 01010-D1230 12
13 01643-71232 12

Other remarks
60
Assembly procedure
A-12
3. Installation of seals to dashboard bracket

(1) Apply the sealant to the joints of the Photo 1
dashboard bracket and floor as shown in
Photo 1.
Apply sealant (packed separately).
(2) Fit seal (14) to the guide plate of the dashboard

bracket and apply liquid sealant (55) as shown Photo 2
in Photo 2.
Apply sealant (packed separately).
(3) Apply grease (G2-LI) to the outside of the seal

(14) (cab and sealing face) as shown in Photo 3. Photo 3
(14) Apply grease
Remark 1: Apply grease so that the cab will slip Cover

well and the seal will not be moved
or deformed when the cab is lowered.
No. Part No. Q'ty
Remark 2: If the covers (both the right and left 14 198-Z11-3540 1
ones) are removed, the cab can be
installed easily since it does not
interfere with them.
61
Assembly procedure
A-12
4. Installation of seals of operator’s cab mating faces

(1) Sling the operator’s cab assembly.
fl Sling the operator’s cab to stick the seal to its mating faces.
4 Operator’s cab assembly: 455 kg
(2) Remove dirt, oil, and grease from the seal sticking faces.
(3) Remove the release paper from seals (15), (16), and (17), and then stick the seals, referring
to Fig. 4 on the next page.
-1 (L.H.)
-2 (R.H.)
No. Part No. Q'ty
Fig. 3 15 14X-911-5911 3
16 198-Z11-7420 2
17-1 198-Z11-7410 1
17-2 198-Z11-7430 1

Since the seals are longer than the necessary Name Q’ty Name Q’ty
length, cut them properly when sticking.
Other remarks
62
Assembly procedure
A-12
Apply sealant to clearance.
Stick seals so that it will

project about 10 mm.
Front 10
Apply sealant before

Part P
assembling cab.
(On both sides)
(For how to stick (16)

and (17), see photos 1
and 2 on page 5/15)
Overlap here.

(See Photo 3 on page 5/15)
Sealing sponge Spacer plate (t2.3)

Do not place sealing sponge
over spacer plate.
Fig. 4 How to stick seals (View from bottom of operator’s cab)
63
Assembly procedure
A-12
Photo 1 Photo 2
Photo 3

Other remarks
64
Assembly procedure
A-12
5. Installation of operator’s cab

(1) Lower the operator’s cab assembly slowly onto
the floor frame.
fl Lower the operator’s cab carefully since the
reaction force of the sealing sponge is large.
fl Take care not to move or damage the seals. After installing cab, check
fl Check that the seal of the air conditioner duct that there is not clearance at
on the cab side is fitted tightly to the air each corner.
conditioner duct on the dashboard side.
fl Lower the operator’s cab carefully since the
clearance between the air conditioner duct on
the cab side and monitor is narrow.
(2) Tighten bolts (18) and (20) and washers (19)
temporarily. (See Fig. 10) Lower cab in direction
fl Note that the bolt length and washer at the of arrow.
door are different.
(3) Check that there is not clearance in the joint (a)
of the seal and floor frame.
(4) As a result of check step (3) above, if there is
clearance, reinstall the operator’s cab. If the
clearance is narrow, however, seal it with sealant
(55).
Flange
Cab body
After installing cab, check

that there is not clearance at
Dashboard each corner.
bracket
Fig. 5
No. Part No. Q'ty
18 01010-81275 15
19 124-54-26540 21 Lower cab in direction
of arrow.
20 01010-81245 6
55 198-Z11-3960 1
65
Assembly procedure
A-12
(5) Check that the clearance between the air

Air conditioner duct
conditioner duct on the cab side and monitor is on cab side
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
Clearance
the right and left sides of the air conditioner duct Clearance
on the dashboard side and it is not moved to Monitor
the right or left.
(6) If the clearance between the air conditioner duct
on the cab side and monitor is not even, loosen Dashboard
the air conditioner duct mounting screws on the
Fig. 6
cab side and move the air conditioner duct so
that the clearance will be even. (Fig.8) on cab side
If the duct on the cab side or air conditioner side
is moved to the right or left, adjust it similarly.
(7) Permanently tighten bolts (18) and (20) which
were tightened temporarily in step (2) above .
(8) Permanently tighten mounting bolts (12) of L-
plates (10) and (11) which were installed Monitor
temporarily in step (2) above. Seal Face C
Face C
Dashboard assembly
on dashboard side
Fig. 7
on cab side
Monitor
Dashboard
Duct mounting screw
Fig. 8
66
Assembly procedure
A-12
(9) Install plates (21) with bolts (25) and washers

(26). (2 pieces on each side)
(10) Install right and left foot rests (24) and (25) with
bolts (26) and washers (27). (2 pieces on each
side)
(11) Install pedal caps (28) to the foot rests.
Fig. 9
No. Part No. Q'ty

21 198-Z11-2961 2
22 01010-D1230 4
23 01643-71232 4
24 14X-911-5711 1
25 14X-911-5721 1
26 01010-D1230 4
27 01643-71232 4
28 203-43-56450 2
67
Assembly procedure
A-12
(12) Referring to Fig. 10, bind the windshield washer hoses, windshield washer connector, and
cab power supply wiring harnesses with strings. Pass them through holes (A) and (B), and
then connect the wiring harnesses on the chassis side from the decorative cover above the
left fender.
Marks fl at 15 places
Marks ª at 6 places
Floor frame
assembly
Fig. 19
(B) Hole
Windshield washer hoses

Red ............. Right door
Blue ............. Left door
Black ............. Rear window
– ............. Front window
Part under door
Wiring harness
4-pole connector ............................ Windshield washer
From floor From cab Red (Nominal JIS size: 5) ............... Power supply
Yellow (Nominal JIS size: 0.85) ..... Backup power supply (For radio)
Fig. 10
View X (sean from rear)
fl After connecting the hoses and connectors, fit the grommet on the wiring harness side securely.
For the installed condition of the grommet, see Fig. 19.
68
Assembly procedure
A-12
6. Installation of left parking brake lever knob

(1) Before installing the panel, remove the lever
knob.
(2) After installing the panel, apply adhesive (LT-
2) to the thread part of the knob, and then
install the knob to the lever.
Garnish
Knob
Fig. 11 (Lever)
fl When installing the garnish, be sure to install

the screws shown in the figure.
Screw
Screw
69
Assembly procedure
A-12
7. Installation of bellows bracket

(1) Pull and remove bellows (1) and bellows
bracket (2) of blade lever as shown in the
photo.
(2) Similarly, remove bellows (3) and bellows
bracket (4) of ripper lever.
(3) Install cover (33).
(4) Install the bellows bracket to fixing spring (5).
• Installing condition of cover (33)
Correct Wrong
Fig. 16

Other remarks
70
Assembly procedure
A-12
8. Installation of interior parts

(1) Install floor covers (29), (30), and (31) with
screws (34) (14 pieces).
(2) Install covers (32), (33), and (35) with button
(37). (16 places)
(3) Install cup holder (40) with screws (41) to plate
(36). Then, install ashtray (38) and cigarette
lighter (39) to plate (36) with screws (41) and
washers (42).
(4) Install grille (44).
(5) Install rubber chutes (45) and (46).
Fig. 12
No. Part No. Q'ty

29 198-Z11-6170 1
30 198-Z11-6190 1
31 198-Z11-6150 1
32 198-54-61511 1
33 198-54-61531 1
34 01024-D0820 14
35 198-54-61521 1
36 198-Z11-6160 1
37 23D-950-4450 16
38 20Y-06-21751 1
39 20Y-06-2347 1
40 17A-Z11-3180 1
41 01245-00616 4
42 01643-70623 4
43 01370-40408 2
44 201-979-7820 2
45 198-Z11-6230 1
Fig. 13 46 198-Z11-6241 1
A–A
1. Install plate (36) on cover (32) as shown in the Name Q’ty Name Q’ty
photo.
2. Install cover (32) first, and then install plate (36).

Match the mounting holes of cover (32) before
installing plate (36). After plate (36) is installed,
the position of cover (32) cannot be adjusted.
3. If the band to fix the optional lunch box is se-

lected, see also A-24.
Other remarks
71
Assembly procedure
A-12
Correct installation
Wrong installation
Plate (36) is installed

under cover (32).

Other remarks
72
Assembly procedure
A-12
(6) Install sensor (52) to cover (51), and then install them with screws (53) and washers 54.
(4 pieces)
(7) Install plates (47) and (48) with screws (49) and washers (50). (8 pieces)
(8) Install cab door plate (56). (On both sides).
(9) After installing cab door plate (56), apply liquid sealant (55) all around the plate. (On both
sides) Before opening and closing the door, wait until the sealant dries up.
CN-SLS is fixed to dashboard

wiring harness with band.
Cut band and connect.
No. Part No. Q'ty

47 198-Z11-2941 1
48 198-Z11-2951 1
Fig. 14 49 01245-00616 8
50 01643-70623 8
Sensor 51 198-Z11-6280 1
52 20Y-979-6161 1
53 01245-00616 4
54 01643-70623 4
55 198-Z11-3960 1
56 198-Z11-6410 2
65 01010-D0645 6
66 01643-70623 6
Section of central part of cab
73
Assembly procedure
A-12
(10) Install cushion (57) and install mat (58) on it.

(11) Install mat (59).
(12) Install plate (56). (On both sides)
No. Part No. Q'ty

57 198-54-75681 1
58 198-54-15791 1
59 198-54-75770 1
60 198-54-75620 1
61 198-54-75610 1
62 198-54-74950 1
63 198-54-74941 1
Fig. 15 64 198-54-74862 1

Other remarks
74
Assembly procedure
A-12
9. Installation of rearview mirror
10. Change of antenna mounting angle

When delivered, the antenna is directed down for
packing and transportation of the operator’s cab
(Fig. 17). After mounting the operator’s cab, set
the antenna at the correct angle (Fig. 18).
Antenna (198-Z11-4610)
Left window
Directed down when delivered
Rear window
Fig. 17
• Loosen the wing bolt at part (b) near the
antenna mounting part and direct the antenna Antenna
up. Then, tighten the wing bolt.
b
Left window Rear window
Fig. 18
75
Assembly procedure
Installation of ROPS
A-13
• Sling the ROPS with the crane and install it to the

mounting position.
4 ROPS: 918 kg
3 Mounting bolt (1):

1,960 – 2,450 Nm {200 – 250 kgm}
Set stamp F on the front side.
No. Part No. Q'ty

1 01011-83310 16
2 01643-33380 16

Torque wrench
1
(2,059 Nm {210 kgm})
Socket 50 mm
1
(38.1 )
Other remarks
76
Assembly procedure
Adjustment of potentiometer rod
A-14
Length of rod : 425 mm
Reference: See the A-15 PROCEDURE FOR ADJUSTING

BLADE TILT ANGLE LIMIT.

Other remarks
77
Assembly procedure
Procedure for adjusting blade tilt angle limit (1/9)
A-15
1. Dual-tiltdozer
1-1 Set the machine under the standard condition.
• Set the potentiometer rod to 425 mm.
• Keep the machine horizontally.
1-2 Run the engine at low idling and set the blade
in the following standard position.
1) Set the tilt angle to 0°.
2) Set the pitch angle to the maximum pitch Pitch back
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.
Tilt switch
Dual tilt

Other remarks
78
Assembly procedure
A-15
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 Mode and operation

1) Hold buzzer cancel switch (3) in the position
for 2.5 seconds, and the maintenance mode is
displayed. Then, set the buzzer cancel switch
to information switch (2), and the adjustment
mode is selected.
2) Set the buzzer cancel switch in the position,
and the adjustment mode selecting screen is
displayed.
3) Operate the information switch to
display the tilt limit setting screen.
4) Set the buzzer cancel switch in the select
position ( ) to enter the tilt limit adjustment
mode (User adjustment mode). If the pitch-
back button (lower button) of the work
equipment control lever is pressed, the buzzer
sounds and the reference position is saved.
5) Set the buzzer cancel switch in the cancel
position ( ) to leave the adjustment mode
temporarily.

Other remarks
79
Assembly procedure
A-15
1-5 Raise the blade tip to about 1 m above the

ground.
1-6 Tilt the blade to the left with the blade control
lever and set the left tilt angle to 12°. (User
adjustment mode)
fl Since the tilt limiting function does not work,
operate slowly so that the tilt angle will not
increase too much.
fl Adjust the tilt angle accurately with angle
gauge.
1-7 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 left tilt limit Tilt switch
in the system.
fl When the saving operation is finished, the
buzzer sounds.
Single tilt
Dual tilt

Other remarks
80
Assembly procedure
A-15
1-8 Set buzzer cancel switch (3) in the cancel

position ( ) once to leave the adjustment
mode.
1-9 Set the blade in the maximum pitch type

position. (Set the work equipment horizontally.)
1-10 Set buzzer cancel switch (3) in the select

position ( ) again to enter the tilt limit
adjustment mode.

Other remarks
81
Assembly procedure
A-15
1-11 Tilt the blade to the right with the blade control
lever and set the right tilt angle to 12°.
increase too much.
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.
fl When the saving operation is finished, the buzzer sounds.
1-13 The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( )
to leave the adjustment 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.

Other remarks
82
Assembly procedure
A-15
2. Superdozer
2-1 Set the machine under the standard condition.
• Set the potentiometer rod to 425 mm.
• Keep the machine horizontally.
2-2 Run the engine at low idling and set the blade
in the following standard position.
1) Set the tilt angle to 0°.
2) Set the pitch angle to the maximum pitch Pitch back
back.
3) Lower the blade to the ground and then raise
it about 100 mm.
2-3 Adjust mounting dimension “a” of rod (1) and

connect the rod to potentiometer lever (2) and
yoke (3).
• Mounting dimension “a”: 425 mm

Other remarks
83
Assembly procedure
A-15
2-4 Mode and operation

1) Hold buzzer cancel switch (3) in the position
for 2.5 seconds, and the maintenance mode is
displayed. Then, set the buzzer cancel switch
to information switch (2), and the adjustment
mode is selected.
2) Set the buzzer cancel switch in the position,
and the adjustment mode selecting screen is
displayed.
3) Operate the information switch to
display the tilt limit setting screen.
4) Set the buzzer cancel switch in the select
mode (User adjustment mode). If the pitch-
back button (lower button) of the work
equipment control lever is pressed, the buzzer
sounds and the reference position is saved.
5) Set the buzzer cancel switch in the cancel
position ( ) to leave the adjustment mode
temporarily.
2-5 Operate the blade according to the following

procedure so that it can be tilted.
1) Raise the blade tip to 200 – 300 mm above
the ground.
2) Set the blade angle to 52°.
fl Adjust the blade angle accurately with
angle gauge.

Other remarks
84
Assembly procedure
A-15
2-6 Set the buzzer cancel switch in the select

mode (User adjustment mode).
2-7 Raise the work equipment about 1,000 mm without

changing the blade pitch angle adjusted in step 2-5
and tilt it 7° to the left. Under this condition, press
the pitch-dump button (upper button), and the
buzzer sounds and the left limit position is saved.
increase too much.
gauge.
2-8 Tilt the work equipment 7° to the right. Under
this condition, press the pitch-dump button
(upper button), and the buzzer sounds and the
right limit position is saved.
increase too much.
gauge.

Other remarks
85
Assembly procedure
A-15
2-9 The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( )
to leave the adjustment 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 and check that the blade stops
tilting to the right and left in the following range automatically, regardless of its height.
• Automatic tilt stopping angle: 7 ± 1°

Other remarks
86
Assembly procedure
Method of checking auto-reset system
A-16 (Superdozer)
System to return the blade to the digging position

automatically
Pitch dump
1. Pitch the blade forward.
Pitch back
2. Set the gear speed in R1 or R2.
3. Press the pitch-back button.
4. The blade is fully pitched back.
5. The blade returns to the digging position.
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.
Tilt forward Digging posture
Controller
Valve
Pitch back solenoid

Other remarks
87
Assembly procedure
Check track tension (1/2)
A-17
WHEN INCREASING TENSION

1. First remove both bolts (1) and then remove the
cover (2).
2. Pump in grease through the grease fitting (3) with a
grease pump.
3. To check that the correct tension has been achieved,
move the machine backwards and forwards.
4. Check the track tension again, and if the tension is
not correct, adjust it again.
WHEN LOOSENING TENSION

1. Remove both bolts (1), then remove cover (2).
2. Loosen plug (4) gradually to release the grease.
3. Turn plug (4) a maximum of one turn.
4. If the grease does not come out smoothly, move the
machine backwards and forwards a short distance.
5. Tighten plug (4).
6. To check that the correct tension has been achieved,
move the machine backwards and forwards.
7. Check the track tension again, and if the tension is
not correct, adjust it again.

NOTICE Name Q’ty Name Q’ty
• 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 Other remarks
careful not to damage the safety label.
88
Assembly procedure
Check track tension (2/2)
A-17
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.
fl Set the track tension to 30 mm for the first 100

operating hours to fit the bushings and pins.

Other remarks
89
Assembly procedure
Check of oil and coolant levels (1/2)
A-18
90
Assembly procedure
Check of oil and coolant levels (2/2)
A-18

If any oil level or coolant level is low, Name Q’ty Name Q’ty
add oil or coolant.
Other remarks
91
Assembly procedure
Greasing of greasing point (1/3)
A-19
1. Blade Center ball joint
Center link pin
Left ball joint
Right ball joint
2. Blade lift cylinder support yoke
Cap upper side
Cap lower side
92
Assembly procedure
A-19
3. Blade lift cylinder support shaft
Support shaft
LH and RH
4. Ripper
Cylinder bottom LH and RH
LH & RH LH & RH
LH & RH
Arm bottom LH and RH
93
Assembly procedure
A-19
5. Equalizer bar side pin
Equalizer bar side pin

LH and RH
6. Equalizer bar both end.
Remove cover and

lubricate both end.
7. Suspension
(Equalizer bar center shaft)
(1 place)
(Right side of engine room)
94
Assembly procedure
Installation of ORBCOMM antenna and wiring harness
A-20
1. Remove left cover (6) (above the left fender).
2. Install the wiring harness and antenna (3) as shown

in the following figure.
3. Install left cover (6).
No. Part No. Q'ty

1 01024-81220 5
2 04434-50612 5
3 8A13-10-2100 1
4 21N-54-38450 1
5 01024-81225 1

Other remarks
95
Assembly procedure Replacement of return filter
(Replacement of standard filter ➞ special flushing parts)
A-21 (1/3)
When flushing the work equipment hydraulic circuit (Check and maintenance procedure "M-5"), replace
hydraulic oil return filter element (3) with flushing element (1) and replace valve (5) and strainer (4)
with plate (2).
fl When taking out the existing standard element, take care not to drop dirt in.
Remove the dirt remaining in the case with the hand before installing the flushing element.
fl Check the installed condition of the element according to (3/3)
fl When the atmospheric temperature is below -15°C, do not use (2). Replace only the element
and flush the circuit while running the engine at low idle.

1 Element 208-60-71170 1
2 Plate 21T-60-13730 1
fl 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.
fl For the flushing procedure, see “Check and maintenance procedures after completion of
assembly M-3”.
96
(Replacement of special flushing parts ➞ standard filter)
A-21 (2/3)
After flushing the work equipment hydraulic circuit with oil, replace the flushing parts installed in (1/
3) with kept standard element (3), strainer (4) and valve (5).
fl When taking out the flushing element, take care not to drop sticking dirt in.
Remove the dirt remaining in the case with the hand before installing the flushing element.
fl Check the installed condition of the element according to (3/3)
fl When the atmospheric temperature is below -15°C, the valve and strainer are not replaced
with the plate. Take care.

1 Element 208-60-71120 1
2 Strainer 07069-25400 1
3 Valve 208-60-71160 1
fl Check and discard the used flushing element according to "Check and maintenance procedure
M-5". When discarding, observe the local regulations.
fl It is recommended to keep the plate replaced with the strainer and valve since it can be used
for the next flushing.
97
(Replacement of standard filter special flushing parts)
A-21 (3/3)
Installing condition of element
Element
Fig. 1 Good condition Fig. 2 Bad condition
fl 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.

Other remarks
98
Assembly procedure
Installing direction of exhaust pipe
A-22
• After installing the exhaust pipe, connect komaclone tube (4), using gasket (1), bolt (2), and
washer (3).
Right of chassis
Install rain caps

20¡ rotated.
Left of chassis
Front of chassis
No. Part No. Q'ty

1 6162-13-5611 2
2 01010-81025 4
3 01643-51032 4

Other remarks
99
Assembly procedure
Bleeding air from hydraulic cylinders
A-23
fl 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.
fl Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the
circuit under any circumstance.
3) Keeping the engine at low idling, extend the cylinder to a point approx. 100 mm before the 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.
fl Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the
circuit under any circumstance.
3) Repeat this operation with the engine at full throttle, then run the engine at low idling 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.

Other remarks
100
Assembly procedure
Installing lunchbox band (if equipped) (1/2)
A-24
Note) When performing the following procedure, refer to A-12 Installing operator's cab, too.
1. After installing plate (1) to the operator's cab, pass the band through the rear U-hook as shown
below.
2. Install cover (3).

Slide and position cover (3) to the rear U-hook as shown in the figure of part P, and then fix it.
No. Part No. Q'ty

1 198-Z11-6170 1
P 2 198-911-7350 2
3 198-54-61511 1

Other remarks
101
Assembly procedure
Installing lunchbox band (if equipped) (2/2)
A-24
3. Referring to A-12 Installing operator's cab, install the lining and rubber plate.
4. Install the band as shown below.
After installing cover (3), pass

band through front and side
U-hooks.
Lining
Front
Rubber plate

Other remarks
102
M. CHECK AND MAINTENANCE PROCEDURES
AFTER COMPLETION OF ASSEMBLY
103
Assembly procedure
Check and adjustment of operator’s cab (1/7)
M-1
1. Measuring pressure in cab

(1) Measure the pressure in the cab.
• Criterion: Measured value ≥ 98.1 Pa {10 mmH2O}
• Testing condition : Run the engine at full throttle and set the engine fan to 100%.
: Max. cooling fan speed.
: Set the blower to the high (Hi).
fl Set the maximum cooling fan speed of the USER ADJUST MODE of the machine monitor.
Use the USER ADJUST MODE according to Assembly procedure M-4.
fl Operate the blower according to the following procedure.
1) Depress air outlet selector switch (2) on the air Front-Rear-Foot area
conditioner control panel to select the front-rear- (including defroster)
foot area mode (shown at right).
<Indication on LCD and air flow>
2) Select the fresh air mode with the RECIRC/FRESH
air selector switch (3). Indication on LCD Air flow
Low
3) Depress fan switch (1) to set the blower to the
high (Hi). Medium 1
Medium 2
Medium 3
Medium 4
Blower
High
at high (Hi)
fl If the standard pressure is not obtained, check the
seals around the dashboard and the seals of the
fitting faces of the cab and floor for an opening.
(Run water over outside to see if it enters the cab.)
If there is an opening, fill it with liquid seal.
104
Assembly procedure
M-1
(2) Outlined below is a simplified method for the internal

pressure measurement of the operator’s cab: 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.
(c) Remove the sliding windshield lock lever located
on the side panel of the operator’s cab to insert
one end of the vinyl hose before fastening an
adjacent part of the hose to the top end of the
back seat using packing tape.
(d) Seal the gap occurring between the lock-lever
hose and the outer periphery-of the hose.
10 mm or more
(e) Match the water levels of the beginning part and
the ending part of the water cloumn inside the
transparent vinyl hose at the outside of the
operator’s cab.
(f) Start the engine and run it at full speed to read
the difference between the two water levels.
Inside the Outside

operator‘s cab (Atmospheric pressure)
Remove lock lever and insert vinyl hose.
Fix vinyl hose to top end of back seat
Vinyl hose
105
Assembly procedure
M-1
2. Shower test for water-tightness
(1) Close all the opening sections of the operator’s cab.

(2) Prepare to pour water of a flow of about 19 ¬/min. through a water hose.
(3) Pour water to the area around the hatched section in Fig. for about 10 minutes.
When doing this, it is not necessary to use pressurized water.
(4) Pour water horizontally to the sealed surface according to the “Cross-section A-A”.
(5) Carefully check the area around the dashboard, in particular.
fl When any water leakage is found, apply due caulking before re-checking the section if the
water leakage still occurs.
(Sealed surface)
Shower test for water-tighteness

Other remarks
106
Assembly procedure
M-1
3. Checking the door lock

Check the correlation between the operator’s cab structure and the door when the door is opened
and closed. When anything is found abnormal, make due adjustment to correct it.
3.1 Checking the current statuses

(1) Check the mounted elevation of the damper rubber. (Located at 4 places per a side and
check them on both L.H and R.H sides.)
Applying a packing tape strip over the contact surfaces of the damper rubber, open and
close the door for 2 to 3 times. After finishing this opening and closing cycles of the
door, check the contact surface of the packing tape with the operator’s cab structure.
Normal: The back surface of the packing tape comes in light contact the operator’s
cab structure when the door is being closed.
Abnormal: The back surface of the packing tape does not come in contact with the
operator’s cab structure when the door is being closed, or if the two sections
come in a harsh contact such as peeling off the applied packing tape.
Damper rubber (14X-911-1690)

Mounting screw (01023-20616)
Packing tape strip

Door
Shim (14X-911-1761)
(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
Make the observation to Center of the striker
check the engagement from Center of the latch
this side.
Striker
Check if the center of the striker and the

center of the latch are not deviated.
107
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
Door structure t1.2

The shape of the shim
(14X-911-1761)
(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.
When the grease adhering over the latch surface dries Name Q’ty Name Q’ty
out, the turning effort for the knob will become heavier.
Therefore, apply grease sufficiently in order not to allow
it to become dried up.
Other remarks
108
Assembly procedure
M-1
4. Checking the open-locked state of the door

Check the correlation between the operator’s cab structure and the door when the door is in
open-locked state. When anything is found abnormal, make due adjustment to correct it.
4.1 Checking the current statuses

(1) Check the correlation between the open -lock latch and the striker.
(Check them on both L.H and R.H sides.)
Move the door toward the opening direction to observe the engaging state between the
latch and the striker.
Check if the claw of the latch is
not riding over the bent section
of the striker.
Releasing lever
The status is normal if the latch
is not riding over the bent
Shake the door section of the striker.
back and forth.
Latch (20Y-54-36380)
Bolt (01435-30820)
Make the
Striker (14X-911-1921)
observation
through this Nut (01580-11008)
direction 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.

Other remarks
109
Assembly procedure
M-1
4.2 Adjustment
(1) Adjusting the correlation between the latch and the striker
Loosen the striker mounting nut and adjust the position of the striker so that it does 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.
(2) Adjusting the elevation of the stopper rubber

(a) Loosen the stopper rubber fastening nut.
(b) When ratting exists, bring out the stopper rubber until the clearance disappears.
However, in case the lock is hard to engage for the turning effort for the releasing
lever is too heavy, bring back the stopper rubber within the range where ratting of
the door does not occur.
(c) Tighten the fasting nut back to the original state.

Other remarks
110
Assembly procedure
Inspection of machine monitor (1/13)
M-2
Machine monitor
There are the following 2 designs in the machine monitor, the functions of which are the same.
• Serial No. 30001 – 30070
• Serial No. 30071 and up
111
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. 1 Front panel
(1) Machine monitor

(2) Upper display unit
• Gear speed is displayed on this unit in
normal mode (operator mode).
(3) Lower display unit (Multi-information unit)
• Transmission shift mode and service
meter are displayed on this unit in nor-
mal mode (operator mode).
(4) Starting switch
(5) Buzzer cancel switch
(6) Information switch
(7) Lower cover
(8) Service switch
Note: The "Service mode" is used in "Initialization of VHMS controller" of the VHMS specification de-
scribed later in "Attached material 2". Accordingly, understand the operating procedure thor-
oughly.
112
Assembly procedure
M-2
1) Setting in "Service mode"
1.1) Remove cover (7) under the front panel so that you can operate service switch (8).
1.2) Turn starting switch (4) "ON".
1.3) While pressing service switch (8), turn and hold buzzer cancel switch (5) toward the [U] mark 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 ser-
vice 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
Upper display unit (2)

Upper display unit (2)
Lower display unit (3)

Lower display unit (3)
2) Display check of "Failure code"

In the service mode, a trouble that occurred in the machine can be displayed by a classification code
named the "Failure code" on lower display unit (3) of machine monitor (1). With this function, the
operator can grasp the cause of the trouble precisely and repair the machine quickly.
The "Failure codes" are classified into the electrical system failure codes and mechanical system
failure codes, which are displayed on lower display unit (3) by setting the service mode code of
upper display unit (2) to "EE (Electrical system failure code display mode)" or "bE (Mechanical sys-
tem failure code display mode)".
113
Assembly procedure
M-2
2.1) Check of "Electrical system failure code

display mode"
-1) Set upper display unit (2) in the service

mode and turn information switch (6)
toward the > mark or < mark to display
service mode code "EE". (See Fig. 3)
Remark:Operation of information switch

(6)
• Toward > mark: Next code
• Toward < mark: Previous code
-2) After service mode code "EE" is dis-

played, turn buzzer cancel switch (5) to
the <> mark to settle "EE".
-3) If "EE" is settled, the "failure code" of the

electrical system is displayed on lower
display unit (3).
-4) For the contents of display on lower dis-

play unit (3), see step 2.3).
2.2) Check of "Mechanical system failure code

display mode"
-1) Turn buzzer cancel switch (5) to the t

mark to cancel the "EE" mode.
-2) Turn information switch (6) toward the >

mark or < mark to display service mode
code "bE". (See Fig. 4)
-3) Turn buzzer cancel switch (5) to the U

mark to settle "bE".
-4) If "bE" is settled, the "failure code" of the

mechanical system is displayed on lower
display unit (3).
-5) For the contents of display on lower dis-

play unit (3), see step 2.3).
114
Assembly procedure
M-2
2.3) Contents of display on lower display unit
The "failure codes" of both "EE (Electrical system failure code display mode)" and "bE (Electrical
system failure code display mode" are displayed in the same format on lower display unit (3) as
shown below.
-1) When the assembly work is completed, no past

trouble is recorded and no trouble is detected cur-
rently, thus the display is as shown in Fig. 5 in
both modes.
-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. 6.
(1): Record No. (up to 20 Nos.)

(2): Failure code (Code of trouble occurring at
present blinks)
(3): Number of occurrence up to now
(4): Elapsed time by service meter after first oc-
currence
(5): Elapsed time by service meter after last oc-
currence
-3) If a trouble occurs after this machine is put in

operation or if there is the record of a past
trouble, the display of (bE) becomes as shown
in Fig. 7.
(1): Record No. (up to 15)

(2): Failure code (Code being output currently is
flashing)
(3): Number of past occurrences
(4): Time tested by service meter after first
occurrence
(5): Time tested by service meter after last
occurrence
2.4) Failure code
As described above, the "failure codes" are classified and displayed into the "electrical system
failure codes" and "mechanical system failure codes". For the details of each code, see "Testing
and adjusting volume" or "Troubleshooting volume of the shop manual.
The major "failure codes" are listed on the following pages.
115
Assembly procedure
M-2
Error codes list (Related to machine controller)
116
Assembly procedure
M-2
117
Assembly procedure
M-2
118
Assembly procedure
M-2
119
Assembly procedure
M-2
Error codes list (Related to VHMS controller)
120
Assembly procedure
M-2
Error codes list (Related to engine controller)
121
Assembly procedure
M-2
122
Assembly procedure
M-2
123
Assembly procedure
No-injection cranking of engine (1/3)
M-3
When starting the engine for the first time, perform its no-injection cranking to lubricate it in 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.
Fig. 1 Front panel

(1) Machine monitor

• Gear speed is displayed on this
unit in normal mode (operator
mode).
(3) Lower display unit (Multi-infor-

mation unit)
• Transmission shift mode and
service meter are displayed on
this unit in normal mode
(operator mode).
(4) Starting switch
124
Assembly procedure
M-3
2. Procedure
Fig. 2
(1) Turn the starting switch "ON". The machine

monitor is turned ON.
(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.
Fig. 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 multi-
information 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.
Fig. 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 multi-
information 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 multi-
information section returns to the state in step
(1).
125
Assembly procedure
M-3
(5) Turn information switch again to the [ ]

Fig. 5
information section to NO INJECTION (Fig. 5).
(6) Turn the buzzer cancel switch to the [ ]

position (left side) to settle NO INJECTION.
Reference: In step (5), each time the 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.
Fig. 6
(7) In about 3 seconds after NO INJECTION is

settled, the display of the lower line of the multi-
information section changes from "WAIT" to
"ACTIVE" (Fig. 6) and the mode becomes
effective.
(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
Fig. 7
°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.
(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 (1) where the
starting switch is turned "ON".
(10) Turn the starting switch "OFF".
126
Assembly procedure
Setting procedure of user adjust mode (1/3)
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 operator’s 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.
Fig. 1 Front panel

(1) Machine monitor

• Gear speed is displayed on this
unit in normal mode (operator
mode).
(3) Lower display unit (Multi-infor-

mation unit)
• Transmission shift mode and
service meter are displayed on
this unit in normal mode
(operator mode).
(4) Starting switch
127
Assembly procedure
M-4
2. Procedure
Fig. 2
(1) Turn the starting switch "ON". The machine

monitor is turned ON.
(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.
Fig. 3
(3) Turn information switch ((6) in Fig. 2) to the [ ]
information 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.
Fig. 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 multi-
information 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 multi-
information section returns to the state in step
(1).
128
Assembly procedure
M-4
(5) Turn information switch again to the [ ]

position (left side) or [ ] position (right side) Fig. 5
information section to NO INJECTION (Fig. 5).
(6) Turn the buzzer cancel switch to the [ ]

position (left side) to settle NO INJECTION.
Reference: In step (5), each time the 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.
(7) If the engine is started under this condition, the

cooling fan speed is kept controlled to about
100% of the maximum speed.
fl (7) is effective only in this mode. It becomes

ineffective if the system is set out of this mode.
(8) 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 (1) where the
starting switch is turned "ON".
129
Assembly procedure
Flushing of hydraulic circuit
M-5
After finishing assembly, flush the work equipment hydraulic circuit with oil.
The purpose of flushing is to collect dirt in the hydraulic oil in advance and protect the circuit by
circulating the hydraulic oil in the circuit through the flushing filter element.
(1) Preparation
• The hydraulic oil return filter element must be replaced with the flushing element according to
"Assembly procedure A-21".
• Each hydraulic cylinder must be bled according to "Assembly procedure A-23".
• The oil level must be proper.
(2) Execution
(2-1) Run the engine at low idle with each lever in neutral for 30 minutes.
(2-2) Run the engine at medium speed (about 1,000 rpm) with each lever in neutral for 30 minutes.
(2-3) Increase the engine speed to about 1,700 rpm and operate each work equipment control
lever in the following pattern. Keep the lever in each operation position for 1 – 1.5 minutes.
Raise blade ➞ Lower blade ➞ Tilt blade to left ➞ Tilt blade to right
➞ Raise ripper ➞ Lower ripper ➞ Tilt ripper in ➞ Tilt ripper back
Repeat this pattern 4 times.
fl If the atmospheric temperature is below -15°C, ensure that the replacement parts of the hydraulic
oil return filter element are in accordance with "Assembly procedure A-21", (1/3), and then
perform above steps (3) and (4) while running the engine at low idle.
(3) Confirmation
After finishing flushing, replace the flushing parts with the standard parts according to "Assem-
bly procedure A-21", (2/3).
At this time, check that the dirt captured in the flushing element does not indicate any problem.
If it indicates any problem, consult your Komatsu distributor.
130
APPENDIX 1.
INSTALLATION OF SPILL GUARDS
1. Introduction ...................................................................................................................................... 1
2. Additional parts ................................................................................................................................ 1
3. Spill guard fabrication drawings ..................................................................................................... 2
3-1. For semi-U blade ....................................................................................................................... 2
3-2. For full-U blade .......................................................................................................................... 6
3-3. For superdozer blade ................................................................................................................ 10
4. Installation procedure ...................................................................................................................... 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 Part No. Part Name Q‘ty Weight (kg) Remarks

198-71-61710 Spill guard (center) 1 134.6
Semi-U 198-71-61720 Spill guard (left) 1 49.6
198-71-61730 Spill guard (right) 1 49.6
198-72-63910 Spill guard (center) 1 171 Refer to the fabrication
Full-U 198-72-63920 Spill guard (left) 1 56 drawing
198-72-63930 Spill guard (right) 1 56
198-72-63810 Spill guard (center) 1 224
Superdozer 198-72-63820 Spill guard (left) 1 34
198-72-63830 Spill guard (right) 1 34
1
3. Spill guard fabrication drawings
3-1. For semi-U blade
(1) Spill guard
2
3
(2) Spill guard (for semi-U, center) 198-71-61710 fabrication drawing
1. This drawing shown CO-gas welding groove

dimensions and leg length for manual welding
per KES 04.351
2. Flatness of surface A in drawing to be within 2.
Sym. Part Name Material Q‘ty Weight (kg) Remarks
01 PLATE SS400F 2 24.5 t 19 ✕ 65
02 PLATE SS400F 11 2.55 t 19 ✕ 65
03 PLATE SS400P 10 5.75 t 19

4
per KES 04.351
2. Flatness of surfaces A, B, C, D and E in drawing
to be within 2.
01 PLATE SS400F 1 12.6 t 19 ✕ 65

(3) Spill guard (for semi-U, left) 198-71-61720 fabrication drawing
02 PLATE SS400F 1 11.9 t 19 ✕ 65
03 PLATE SS400F 1 2.30 t 19 ✕ 65
04 PLATE SS400F 1 2.15 t 19 ✕ 65
05 PLATE SS400F 1 1.90 t 19 ✕ 65
06 PLATE SS400F 1 1.75 t 19 ✕ 65
07 PLATE SS400F 1 1.45 t 19 ✕ 65
08 PLATE SS400F 1 1.35 t 19 ✕ 65
09 PLATE SS400P 1 5.10 t 19
10 PLATE SS400P 1 3.95 t 19
11 PLATE SS400P 1 2.80 t 19
12 PLATE SS400P 1 2.30 t 19

5
per KES 04.351
to be within 2.
(4) Spill guard (for semi-U, right) 198-71-61730 fabrication drawing

01 PLATE SS400F 1 12.6 t 19 ✕ 65
02 PLATE SS400F 1 11.9 t 19 ✕ 65
03 PLATE SS400F 1 2.30 t 19 ✕ 65
04 PLATE SS400F 1 2.15 t 19 ✕ 65
05 PLATE SS400F 1 1.90 t 19 ✕ 65
06 PLATE SS400F 1 1.75 t 19 ✕ 65
07 PLATE SS400F 1 1.45 t 19 ✕ 65
08 PLATE SS400F 1 1.35 t 19 ✕ 65
09 PLATE SS400P 1 5.10 t 19
10 PLATE SS400P 1 3.95 t 19
11 PLATE SS400P 1 2.80 t 19
12 PLATE SS400P 1 2.30 t 19
3-2 For full-U blade
(1) Spill guard
6
7
(2) Spill guard (for full-U, center) 198-72-63910 fabrication drawing

per KES 04.351
to be within 2.
01 PLATE SS400F 2 29.0 t 19 ✕ 65
02 PLATE SS400F 12 2.54 t 19 ✕ 65
03 PLATE SS400P 13 6.16 t 19
04 PLATE SS400F 4 0.66 t 19 ✕ 65

8
per KES 04.351
to be within 2.
01 PLATE SS400F 1 14.2 t 19 ✕ 65
(3) Spill guard (for full-U, left) 198-72-63920 fabrication drawing
02 PLATE SS400F 1 13.5 t 19 ✕ 65

03 PLATE SS400F 1 2.42 t 19 ✕ 65
04 PLATE SS400F 1 2.23 t 19 ✕ 65
05 PLATE SS400F 1 1.99 t 19 ✕ 65
06 PLATE SS400F 1 1.84 t 19 ✕ 65
07 PLATE SS400F 1 1.55 t 19 ✕ 65
08 PLATE SS400F 1 1.41 t 19 ✕ 65
09 PLATE SS400F 1 1.11 t 19 ✕ 65
10 PLATE SS400F 1 0.98 t 19 ✕ 65
11 PLATE SS400P 1 5.28 t 19
12 PLATE SS400P 1 3.98 t 19
13 PLATE SS400P 1 2.76 t 19
14 PLATE SS400P 1 2.40 t 19
15 PLATE SS400F 1 0.40 t 16 ✕ 32
9
per KES 04.351
to be within 2.
01 PLATE SS400F 1 14.2 t 19 ✕ 65
02 PLATE SS400F 1 13.5 t 19 ✕ 65
(4) Spill guard (for full-U, right) 198-72-63930 fabrication drawing
03 PLATE SS400F 1 2.42 t 19 ✕ 65

04 PLATE SS400F 1 2.23 t 19 ✕ 65
05 PLATE SS400F 1 1.99 t 19 ✕ 65
06 PLATE SS400F 1 1.84 t 19 ✕ 65
07 PLATE SS400F 1 1.55 t 19 ✕ 65
08 PLATE SS400F 1 1.41 t 19 ✕ 65
09 PLATE SS400F 1 1.11 t 19 ✕ 65
10 PLATE SS400F 1 0.98 t 19 ✕ 65
11 PLATE SS400P 1 5.28 t 19
12 PLATE SS400P 1 3.98 t 19
13 PLATE SS400P 1 2.76 t 19
14 PLATE SS400P 1 2.40 t 19
15 PLATE SS400F 1 0.40 t 16 ✕ 32
3-3 For superdozer blade
(1) Spill guard
10
11
(2) Spill guard (for superdozer, center) 198-72-63810 fabrication drawing

per KES 04.351
to be within 2.
01 PLATE SS400F 2 34.3 t 19 ✕ 65
02 PLATE SS400P 1 74.0 t9
03 PLATE SS400P 4 6.55 t 19
04 PLATE SS400P 7 7.95 t 19

12
per KES 04.351
to be within 2.
(3) Spill guard (for superdozer, left) 198-72-63820 fabrication drawing
01 PLATE SS400F 1 1.65 t 19 ✕ 65
02 PLATE SS400P 1 2.05 t 19
03 PLATE SS400F 1 1.75 t 19 ✕ 65
04 PLATE SS400P 1 3.05 t 19
05 PLATE SS400F 1 2.05 t 19 ✕ 65
06 PLATE SS400P 1 3.20 t 19
07 PLATE SS400F 1 2.35 t 19 ✕ 65
08 PLATE SS400F 1 9.35 t 19 ✕ 65
09 PLATE SS400F 1 6.50 t 19 ✕ 65

13
per KES 04.351
to be within 2.
(4) Spill guard (for superdozer, right) 198-72-63830 fabrication drawing
01 PLATE SS400F 1 1.65 t 19 ✕ 65
02 PLATE SS400P 1 2.05 t 19
03 PLATE SS400F 1 1.75 t 19 ✕ 65
04 PLATE SS400P 1 3.05 t 19
05 PLATE SS400F 1 2.05 t 19 ✕ 65
06 PLATE SS400P 1 3.20 t 19
07 PLATE SS400F 1 2.35 t 19 ✕ 65
08 PLATE SS400F 1 9.35 t 19 ✕ 65
09 PLATE SS400F 1 6.50 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 Do not use anti-spatter agents.
4-3-4 Use coated welding rods specified by JIS 4316 (Low-hydrogen welding rod for mild steel)
or welding wires specified by JIS YGW11.
4-3-5 Before using coated welding rods, dry them at 300 - 350°C for 30 - 60 minutes.
4-3-6 Preheat the area about 50 mm from the beat to be laid at 150 - 200°C. When the ambient
temperature is below 10°C, post-heat the same area, too, at 150 - 200°C.
4-3-7 Set the welding current to the lower limit of the current range specified for the diameter
of the welding rod or wire.
4.3.8 When performing multi-layer welding, weave the welding rod.
4.3.9 Do not weld by letting the melted metal flow, but weld from below to above with 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. Precautions for initialization of VHMS controller and ORBCOMM terminal (optional) ............................... 2
2. Initialization procedures for VHMS controller............................................................................................. 11
1
PRECAUTIONS FOR INITIALIZATION OF VHMS CONTROLLER
AND ORBCOMM TERMINAL (OPTIONAL)
When a machine equipped with VHMS controller is delivered to a customer,
Delivery of machine equipped with VHMS controller
Step 1) Notify the machine information for registration in WebCARE.
Application for registration in WebCARE
If you have not registered an ID for reading WebCARE,
Application for registration of WebCARE user
Step 2) When installing an ORBCOMM communication terminal optionally, notify the

terminal information.
Request for opening ORBCOMM (optional) terminal
Step 3) Initialize the VHMS controller.
Step 4) Initialize the ORBCOMM communication terminal.
Step 5) Send the check sheet after initialization.
Check sheet for VHMS controller initialization
Check sheet for ORBCOMM initialization
Step 6) Send the first downloaded data by E-mail.
2
1. Registration of WebCARE machine information
• Fill the attached "Application for registration in WebCARE" and send it to VHMS/WebCARE Global Support
Center.
• The model name, serial No., customer information, etc. will be registered in the WebCARE server of the sup-
port center.
a If you have not obtained an ID and a password for reading WebCARE, fill the attached "Application for reg-
istration of WebCARE user" and send it to VHMS/WebCARE Global Support Center.
After you are registered, your ID and password will be sent you.
Komatsu’s distributor
Application for Komatsu Server

registration VHMS/WebCARE
in WebCARE Application Support center Registration
Model
Serial No.
User
etc.
3
2. Application for opening ORBCOMM terminal (Optional)
• If the ORBCOMM is installed optionally, an application for opening a communication terminal is necessary.
• The "Request for opening ORBCOMM terminal" and "terminal part No. seal" (which is the same as one stuck
to the terminal) are packed together with the terminal or the machine.
• Stick the seal to the request and fill it, and then send it to KOMTRAX Service Hot Line.
• After a contract is made with ORBCOMM Co., Ltd., the date of opening the terminal will be notified.
IMPORTANT: It takes 1 – 2 weeks to make a contract with ORBCOMM Co., Ltd. after the application is
received. Keep the antenna removed and do not set the terminal until the date of opening the
terminal is notified.
Komatsu’s distributor
ORBCOMM terminal
Komatsu Solution Division
Seal having serial No. of controller

Request for opening
ORBCOMM terminal
Komatsu KOMTRAX
Service Hot Line
Making of contract with 1 to 2 weeks

ORBCOMM Co., Ltd.
4
• Set the ORBCOMM terminal after the date of opening the terminal.
Case 1: Procedure for operating the machine before opening the terminal
Step 1) Initialize only the VHMS controller.
VHMS controller
Remove the antenna and

fit the cap to the connector.
Never set the communication

system before making contract
with ORBCOMM.
Step 2) After receiving notification of date of opening the terminal (After that date), set ORB-
COMM.
Connection of antenna
ORBCOMM terminal
Case 2:Procedure for operating the machine after opening the terminal
Initialize of both VHMS controller and ORBCOMM simultaneously.
VHMS controller ORBCOMM terminal
5
3. Preparation of tools and items to be executed after initialization (IMPORTANT)
a A cable to connect a personal computer and the VHMS controller is necessary for setting VHMS/ORB-
COMM. Purchase and prepare it.
a A setting program to be installed to the personal computer is also necessary. (This program is contained in
the VHMS analysis tool software.) Purchase the VHMS analysis tool software.
Service kit 799-608-3101
Components
• Analysis tool CD & FD 799-608-3211
• Cable 799-608-3220
1) For initialization of VHMS, see Procedure for initializing VHMS controller.

2) Keep the check sheet filled when the VHMS controller is initialized.
If the system does not work normally, enter the trouble in the check sheet and send it to the following
address.
3) Attach the machine information sheet to the first setting downloaded data and them to the following
address by E-mail.
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)
[email protected]
6
To: VHMS / WebCARE Support Center SEKN5051-1
FAX : 81-3-5561-4766 Attached Sheet
VHMS / WebCARE Basis Information Sheet

For Machine Registration into WebCARE Please describe clearly.
<<DB information>>
Distributor name / Branch /
Person in charge
e-mail address
DB code(GCPS code)
<<Customer information>>
Customer name / Site name /
<<Machine information>>
Model - type
Serial No.
Engine Serial No.
/
(Enter both of two engines if mounted.)
Transmission Serial No.
Unit No.
Date of Orbcomm activation
For initial download data check Result

(Note 1)
The new machine delivery or Retro - Fit
Reason for VHMS setting
(Note 1)
*Check the reason on the right. Replace the VHMS controller.
*For replacement,enter the serial No.of the replaced (Note 2 or 3)
component below each column (Note). Replace the component.
(engine or transmission)
Setting date (mm:dd:yyyy) ( : : )

Setting time (Checked by watch) (HH :MM: SS) ( : : )
Person in charge of setting
Service Meter Reading
(Note1)
New VHMS controller serial number.
(Note2) No.1 Engine ( )
New engine serial number.
Enter both of two engines if mounted. No.2 Engine ( )
(Note3)
New transmission serial number.
GCC code(If Orbcomm is equipped)
Time difference (GMT) (Time Zone offset : 00)
Summer time (Daylight Savings Time) ON / OFF
Did you initialize VHMS as described in the shop
YES
manual ?
***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]
7
PLACE TO STORE DOWNLOADED DATA
1. Open the "VHMS_DATA" icon in drive C (or the drive specified when the software was installed).
2. Open the icon of the applicable model. Next, open the icon of the serial No., and then open the icon of the
date and time of downloading.
Example: D475 Example: Example:

Serial No.20002 Sept. 4, 2003
Caution:
All of the files downloaded
today are stored in the icons.
The icon of the largest number
has the latest file.
3. After finishing initialization and downloading the data, send all the files in this icon by E-mail.
8
METHOD OF INSTALLING VHMS SETTING TOOL
1. Insert the CD-ROM in the CD drive, and installation of the analysis tool is started automatically. Perform the
shown procedures, and the analysis tool icon is made on the desktop.
Now, installation of the analysis (including download and FTP) tool is completed.
2. Insert the CD-ROM again, and installation of the analysis tool is started automatically again. When the fol-
lowing screen is displayed, click "Cancel" and interrupt the operation by clicking "Exit Setup".
9
3. Select the drive of the CD-ROM by "My computer" (or "Explorer") and click "Open".
a Do not double-click.
4. Select and open the "Setting Tool" icon.
5. Click "Set up.EXE".
6. Installation of the setting tool is started automatically and the icon is made on the desktop. Now, installation
of the setting tool is completed.
10
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER 1
a Initialization tools for VHMS controller 1. Check of machine information, engine
information and controller information
Symbol Part No. Part name
a This step is a work performed on the
1 799-608-3211 Diskette whole machine.
2 799-608-3220 Wiring harness Check and record the machine information,
engine information, VHMS controller informa-
Z Notebook type personal com-
tion and ORBCOMM terminal information.
Commercially puter (OS: Windows98/2000/
3
available NT/Me/XP Terminal No. Information to be checked
"RS232C" is with it)
1 Machine model
a Before starting full operation after completion 2 Machine serial No.
of local assembly or before resuming operation 3 Current service meter reading
after storage for a long period, initialize the
4 Engine serial No.
VHMS controller according to the following
procedure. 5 Transmission serial No.
a Machine data collected with the VHMS control- 6 VHMS controller serial No.
ler are stored and managed in WebCARE
ORBCOMM terminal serial No.
database. To process the data smoothly on the 7
[For ORBCOMM specification only]
WebCARE, it is necessary to set the VHMS
controller consistently. If it is not set correctly,
a The VHMS controller and ORBCOMM ter-
data will not be taken into the WebCARE and
minal are in the VHMS controller box
data in the VHMS controller may not be uti-
under the left side cover of the floor.
lized. Accordingly, be sure to carry out the ini-
tialization.
a For the method of installing the VHMS Initial-
ization Program to the personal computer,
refer to the Operation and Maintenance Man-
ual contained in the package of diskette Z1.
a Since the service menu of the monitor panel
will be used in the following procedure, read
“Special functions of monitor panel” and under-
stand the operating procedure in advance.
a The initialization procedures cover both “ORB-
COMM Specification” and “ORBCOMMLESS
Specification”. In case of “ORBCOMMLESS”
Specification”, omit the procedures necessary
for “ORBCOMM Specification” only.
a During the initialization work, confirm each
2. Connection of personal computer
work according to the “VHMS Initialization
1) Make sure that the starting switch is in the
Work Checklist”.
OFF position.
k Be sure to connect and disconnect
the personal computer while start-
ing switch is in the OFF position.
2) Connect personal computer Z3 and down-
load connectors VDW and DL1 by wiring
harness Z2.
a The download connectors are
installed to the following places.
q VDW: Inside of cab (Left rear
lower part)
q DL1: Rear side of chassis (Hull
frame)
a Connect the personal computer to the
RS232C terminal.
11
2) Select “Service mode” and “Real-time
monitoring mode” in order on the monitor
panel.
3) Input ID = 20301.
4) If the central part of the lower line of the
multi-information display unit counts up,
the VHMS controller is normal.
a Execute initialization of VHMS from

the connector in the cab.
a Use the ground download connector
for only downloading.
5) Judge the operation of the ORBCOMM

controller by the state of the dot at the
right bottom of the LED digit of the VHMS
controller.
6) The dot at the right bottom of the LED digit
of the VHMS controller can be checked in
the multi-information display unit of the
monitor by the following method.
1] Set the starting switch in the ON posi-
tion.
2] For monitor panel specification:
Referring to 10. “Real-time monitoring
mode” or 11. “Dual display monitoring
mode”, input ID = 20301.
3. Check of operation and satellite capturing

condition of VHMS controller
a This step is a work performed in the oper-
ator's cab. 7) At least 3 minutes after starting the VHMS,
a Check of satellite capturing condition is check the decimal point at the right bottom
necessary o only [ORBCOMM specifica- of the LED of the VHMS controller or the
tion]. decimal point at the right bottom of the
1) Set the starting switch in the ON position. central part of the lower line of the multi-
information display unit.
12
9) Watch the decimal point LED on the right
of the right-hand 7 segments of the VHMS
controller to check that the ORBCOMM
controller is capturing the satellite [ORB-
COMM specification].
a Check the communication satellite
capturing condition of the ORBCOMM
controller on the VHMS controller
side.
a If the ORBCOMM controller is nor-
mal, the decimal point LED of the
right-hand 7 segments flashes.
Right decimal
Display
point
• Power is not supplied to ORB-
COMM controller.
OFF
• Communication line to VHMS
controller is abnormal.
• Satellite is not captured.
• Power is supplied to ORB-
ON COMM controller.
• Communication line to VHMS
controller is normal.
• Power is supplied to ORB-
4. Startup of VHMS initialization tool
COMM controller.
Blinking • Communication line to VHMS
controller is normal. ator's cab (on the personal computer).
• Satellite is captured. 1) Turn on the personal computer and start
the OS.
2) Click the icon of [VHMS Initialization Tool]
8) Check the controller for normal operation on the personal computer screen to start
referencing 7-segment LED of VHMS con- the VHMS initialization tool.
troller. a The setting screen varies with the
a VHMS controller is fed with switch version No. of the VHMS setting tool.
power supply. Thus, its operation is a When using a tool before Ver. 3.5.2.1
judged normal if its 7-segment LED (CD-ROM), set the VHMS in step 5.
starts flashing while rotating as the a When using an updated tool (Ver.
starting switch is turned on and then if 3.5.2.1 or after), set the VHMS in step
the controller starts counting in the 6.
ascending order. a It is recommended to download the
latest VHMS setting tool from the
WebCARE and update your tool.
(Related material: Servicemate SMP-
623)
3) Input the 10-digit service ID in [Service
ID].
a Service ID: 7826146000
4) Select [Data clear and Set up] in the
[Select Function] column.
5) Press the [OK] button to go to the setup
screen.
13
3) If information in the [Date/Time] box is not
correct, change it according to the follow-
ing procedures:
1] Press [Edit] button (1) on the right
lower part of the [Date/Time] box to
display the correction screen.
2] Correct the information and press the
[OK] button.
4) If information in the [Machine information]

box is not correct, change it according to
the following procedures:
1] Press the [Edit] button (2) on the right
lower part of the [Machine informa-
tion] box to display the correction
5. Initialization of VHMS controller (Tool screen.
before Ver. 3.5.2.1) 2] Correct the information and press the
a This step is a work performed in the oper- [OK] button.
ator's cab (on the personal computer).
a When initializing, do not change the data
of service meter [SMR].
[Machine information]
1) Open the [Machine information] tab.
a The [Machine information] tab is dis-
played first in the [Data clear and Set
up] menu.
2) Check all the data.
14
5) After checking/changing all the data in [Communication Setting] [For ORBCOMM spec-
[Machine information], press [Apply] but- ification only]
ton (3) to settle the setting. a Execute this setting after requesting for open-
a Press the [Apply] button (3), and the ing of the ORBCOM terminal and finishing the
screen for checking the setting will opening procedure.
appear. Check the setting again and 6) Open the [Communication Setting] tab.
press the [OK] button if the setting is 7) Check all the data.
correct.
a In case of the ORBCOMM Specifica-
tion, execute [Communication Set-
ting] first and then settle the setting.
8) To change the setting in [SHORT FAULT

HISTRY], follow the procedure below:
1] Select [SHORT FAULT HISTRY] on
the screen and press [Edit] button (5)
on the left lower part of the [File
Transfer Setting] block to display the
setting screen.
2] Change the setting and then press
the [OK] button.
a At initialization, select [Occur-
rence] at [Timing] and set the
function to [ON].
15
9) To change setting in [SHORT TREND 11) After checking/changing all the data in
ANALYSIS], follow the procedures below: [Communication Setting], press [Apply]
1] Select [SHORT TREND ANALYSIS] button to settle the setting.
on the screen and press [Edit] button a If the [Apply] button is pressed, the
on the left lower part of the [File s c r ee n fo r c he c k i n g t he s e tt in g
Transfer Setting] block to display the appears. Check the setting again and
setting screen. press the [OK] button if the setting is
2] Change the setting and then press correct.
the [OK] button.
a At initialization, input [20h] to
[SMR] and set the function to
[ON].
10) To change the setting of [Satellite Setting],

follow the procedure below. 12) After checking/changing the data of
1] Press the [Edit] button in the [Satellite [Machine Information] and [Communica-
Setting] block to display the setting tion Setting], press the [Exit] button at the
screen. right lower part of the screen to finish
2] Set the GCC Code to the applicable [VHMS Initialization Tool].
area and then press the [OK] button.
GCC codes and applicable areas

Applicable Applicable
Code Code
Area Area
U.S.A. 121 Malaysia
1
Brazil 122 Korea
120 Italy 130 Japan
16
6. Initialization of VHMS controller (Ver. 3.5.2.1 3) Check the machine information. If it does
or after) not need to be corrected, press the “Next”
a This step is a work performed in the oper- button.
a When initializing, do not change the data
of service meter [SMR].
1) Select [VHMS Setting] and press the
“Next” button.
a If the VHMS was installed addition-

ally, the information of [Serial No.] etc.
must be input.
2) Select [Set up & All clear] and press the

“Next” button.
17
4) Select the time zone. 8) The contents of the setting are displayed
5) Input the local time. finally. If there is not a problem, press the
6) If the DST (Daylight Saving Time) is used “Apply” button.
now, select it and press the “Next” button.
a If the DST is selected, the clock is
advanced 1 hour automatically, thus
the time must be corrected again.
9) The system asks you if you save the data

before changing the setting. If you do not
need to save, select “NO”.
7) Set the GCC Code to the applicable area

and then press the “Next” button.
GCC codes and applicable areas

Applicable Applicable
Code Code
Area Area
U.S.A. 121 Malaysia
1
Brazil 122 Korea
120 Italy 130 Japan
10) After finishing the work of changing the

contents of initialization, press the “OK”
button to finish the program.
18
7. Procedures for executing Quick Pm 2] Set the buzzer cancel switch in the
a The Quick Pm means the Pm Clinic exe- [U] position.
cuted with the manual snap shot function 3] “READY” is displayed and the system
of the monitor panel. is ready to start.
a Data in 7 minutes 30 seconds are saved in a On the lower line, 15 pieces of “-”
the VHMS controller. are displayed.
k Stop the machine on a flat place.
1) Start the engine.

2) Set the monitor panel to display the ser-
vice menu.
a For the operating method, see “Spe-
cial functions of monitor panel”.
3) Selection and execution of mode.
1] Select “Snap shot mode” on the mode
selection screen.
a If the mode is selected, code (55)
is displayed in gear speed dis-
play unit (1) and the title is dis-
played in multi-information unit
(2).
Serial numbers: 30001 – 30070
4] Set the buzzer cancel switch in the
[U] position, and the snap shot oper-
ation starts.
a After the snap shot operation
starts, the elapsed time is dis-
played on the upper line.
a On the lower line, 1 “ ” is added
every 30 seconds. While multiple
“ ” are displayed, the one at the
right end blinks.
a To interrupt the snap shot opera-
tion, set the buzzer cancel switch
in the [t] position.
Serial numbers: 30071 and up
19
5] After starting the snap shot operation,
operate the machine according to
Table 1.
a Check that the engine coolant
temperature and torque con-
verter oil temperature are in the
operating range.
a After 10 “ ” are displayed (After 5
minutes), “#” is added up to 5.
a “ ”: The data sampling interval is
10 seconds.
a “#”: The data sampling interval is
1 second.
20
Table 1 Operations of machine to be executed while snap shot is operated
Operation of machine
Time (sec)
Finish
Start
Fuel
No.
State of machine Steer- Decelera- Brake Parking

Transmission Work equipment control
ing tor pedal pedal brake
dial
1 0:00 0:25 25 N LH N LOW HI Released Released
Low idle
2 0:25 0:50 25 N RH N LOW HI Released Released
3 0:50 1:40 50 High idle N N N HI HI Released Released
4 1:40 2:30 50 Deceleration slow N N N HI LOW Released Released
High-pressure Right tilt (or
5 2:30 3:00 30 N N HI HI Released Released
relief & high idle pitch back in
High-pressure case of dual tilt
6 3:00 3:30 30 N N model) LOW HI Released Released
relief & low idle
Port relief &
7 3:30 4:00 30 N N Left tilt (or pitch HI HI Released Released
high idle
dump in case of
Port relief & dual tilt model)
8 4:00 4:30 30 N N LOW HI Released Released
low idle
NoF1oF2oF
Torque converter
9 4:30 5:10 40 3oNoR1oR2 N N LOW HI ON Released
stall & low idle
oR3oN
NoF3 (Shift to
Torque converter LOWo
F3, then run
10 5:10 6:00 50 stall (F3) & high N N HI Shift to F3, ON Released
engine at full
idle (Note 1) then HI
throttle)
11 6:00 6:30 30 High idle N N N HI HI Released Released
NoF3 (Shift to
Torque converter Left tilt (or pitch LOWo
F3, then run
12 6:30 7:10 40 stall + High-pres- N dump in case of HI Shift to F3, ON Released
engine at high
sure relief dual tilt model) then HI
idle)
High idleo HIo
13 7:10 7:30 20 N N N HI Released ON
Low idle (Note 2) LOW
(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.)
21
6] The screen shown below appears 7 q Blowby Press
minutes 30 seconds after the snap q Exhaust Temp RB (Exhaust tem-
shot is started, and then the initial perature of right bank: 1, 2, 3, 4,
screen appears 5 seconds after. (End 5, 6)
of snap shot) q Exhaust Temp LB (Exhaust tem-
perature of left bank: 1, 2, 3, 4, 5,
6)
q Engine Oil Press
q Engine Oil Temp
q Eng Coolant Temp
q Ambient Temp
q Demand Eng Speed
(Engine speed demanded by
controller)
q T/C Oil Temp
(Torque converter oil tempera-
ture)
q T/M Main Press
(Transmission main relief pres-
Important sure)
The data of the Quick Pm is recorded only q T/M Output Speed
once. If the Quick Pm is executed again, (Transmission output speed)
the current data are overwritten. Accord- q Shift Position
ingly, be sure to save the data in the per- ( Tr a n s m i s s i o n , t r a v e l , g e a r
sonal computer after executing the Quick speed)
Pm, referring to “8. Downloading of set q S/T Clutch Pos.
data”. (Steering clutch position)
q S/T Brake Pos. (Steering brake
7] Using the analysis tool, read the data position)
of the Quick Pm. q Hydr Oil Temp
a For the usage of the analysis tool, (Hydraulic oil temperature)
see the operation manual. q Pump 1 Press
8] Open the data of the Quick Pm and (Work equipment pump 1 oil
translate them into a graph. pressure)
a Set the time to the X-axis and set the q Pump 2 Press
following items to the Y-axis. (Work equipment pump 2 oil
q Engine Speed pressure)
q Fuel Inject q Body Pitch Angle (Pitch angle)
22
9] Check “Click position graphic value
display”.
23
10] Click a point in the graph, and the
value of each measurement item at
that point on the X-axis is displayed
under the graph.
(Example of displayed graph: This is
different from the actual graph.)
24
11] Enter the above value in the Pm Clinic Inspection Sheet.
a The relationship between the data necessary for the Pm Clinic and the measurement condi-
tions is as follows.
Measurement items
Transmission main relief pressure
Steering right clutch fill switch
Steering right brake fill switch

Steering left clutch fill switch
Steering left brake fill switch
Work equipment pump (FR)

Front clutch fill switch
Rear clutch fill switch

Exhaust temperature
State of machine
2nd clutch fill switch
3rd clutch fill switch

Engine oil pressure
1st clutch fill switch

Blow-by pressure
Engine speed
Engine at low idle Q Q Q Q Q Q Q

Engine at high idle Q Q Q
Deceleration slow Q
High-pressure relief & engine at full throttle Q Q
High-pressure relief & engine at slow Q
Port relief & engine at full throttle Q Q
Port relief & engine at slow Q
Torque converter stall & engine at slow Q Q Q Q Q Q Q Q
Torque converter stall (F3) & engine at full
Q Q Q
throttle
Engine at full throttle
Torque converter stall & high-pressure relief Q
Engine at high idle o Engine at low idle Q Q
a The stall speed measured with Snapshot is not the exact value. If measuring the stall speed exactly, set
stall mode "0530" and measure it.
25
8. Downloading of set data
1) Connect personal computer Z3 and down-
load connectors VDW in the cab or ground
download connector DL1 by wiring har-
ness Z2.
2) When using download connector VDW in

the cab, set the starting switch in the ON
position.
3) When using ground download connector
DL1, turn switch (2) ON.
a Download connector VDW in the cab a The green LED lights up.
is installed to the left rear lower part of 4) Operate the icon of [VHMS Technical
the operator's seat. Analysis Tool] on the personal computer to
start the VHMS technical analysis tool.
a Input [User Name] and [Password].

a For the operation procedures, see the
Operation and Maintenance Manual
a Ground download connector DL1 is for VHMS Technical Analysis Tool.
installed in frame (1) at the rear of the
machine.
26
5) Use the [Download] function to download 10. Disconnection of Personal Computer
the data recorded in the VHMS controller 1) Make sure that the starting switch is in the
to the personal computer. OFF position.
a For the operation procedures, see the k Be sure to turn off the starting
Operation and Maintenance Manual switch before connecting or dis-
for VHMS Technical Analysis Tool. connecting the personal computer.
a Make sure that downloading has 2) Finish the OS of the personal computer
completed before proceeding to the and then turn the personal computer OFF.
next step.
9. Check of downloaded data

1) Check the set data with the [View] func- 3) If the data was downloaded in the cab,
tion. disconnect wiring harness Z2 from down-
a For the operation procedures, refer to load connector VDW.
the Operation and Maintenance Man-
ual for VHMS Technical Analysis Tool.
a Make sure that the [MFA0] code at
the time when the snapshot was
operated is displayed in [Fault His-
tory].
a Make sure that the snap shot data is
recorded.
4) If the data was downloaded on the

ground, turn switch (2) OFF and discon-
nect wiring harness Z2 from download
connector DL1.
2) After checking the set data, terminate
[VHMS Technical Analysis Tool].
27
11. Communication to Komatsu
After completing steps 1 to 9 successfully,
send the “VHMS/WebCARE setting notification
form” to VHMS/WebCARE Support Center of
Komatsu, Tokyo.
a Since Komatsu has to set the receiving
side of the satellite communication, be
sure to inform Komatsu of the completion
of the setting.
a Send the VHMS data by Notes (LAN) or
E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: [email protected]
28
(Objective model: D475A-5E0 Bulldozer)
29
(Objective model: D475A-5E0 Bulldozer)
30
U-dozer or Semi U-dozer specification 1/8
Report No.
FIELD ASSEMBLY INSPECTION REPORT

(For Full U-dozer or Semi U-dozer)
After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.
Model-Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
D475A-5E0 SAA12V140E-3
Service Meter Reading (Hr): Date of Inspection Inspector's name: Location of Machine at Inspection:
Distributor's Name: Specification
Blade U Semi U. (Dual Single)
Customer's name:
Ripper or counterweight VGR VMR CW ( Ton)
(Country)
Shoe width 910 mm 810 mm 710 mm
Address: Cab With cab, Without cab
Others Enter specification of optional/local

(Optional/Local procurement part) procurement part, if there is any
Delivery Report No. attached:
Inspector's comments:
KOMATSU USE ONLY:

Sheet Receiving Date: By: Remark:
Check sheets filling instruction:
1. Use following indexes for entry of judgement
Normal Correction made on abnormal point
Abnormal Not applied
2. Enter actually measured values in parenthese, [ ].
Note:
Criteria are based on the standards when the machine is shipped out of the factory
Category Inspection Item Inspection Criteria
Above the bottom Radiator
Main radiator coolant level
surface Strainer
Reserve tank coolant level Low – Full
Engine oil level EO15W40-DH (H+L)/2 – (H+20) Engine : Stopped

Engine : Low idle
Power train oil level TO30 L – (H+20)
(After 3 to 5 minutes)
Damper case oil level TO30 (H+L)/2 – (H+10) Engine : Stopped
Center to upper Pitch back on the ground.
Hydraulic tank oil level
TO10 level of sight Ripper point on the ground.
• Between H – L
gauge Engine : stopped
COOLANT AND OIL LEVEL
LH See operation manual.

Final drive oil level GO85W-140 H – (H–20)
RH Engine : stopped
Oil level
LH
TO30 (H+10) – (H+30)
Pivot shaft oil level See operation manual.
EO30-CD from shaft end
RH
LH
TO30
Recoil spring oil level a=100 ± 10 See operation manual.
EO30-CD
RH
Battery electrolyte level Between L and H
UPPER LEVEL Must be no adhesion of grease, loosened

Check battery
LOWER LEVEL terminal, or crack
Window washer tank water level Full
Fuel tank Full (1670 l)
Draining of fuel tank Drain fuel tank (Drain water, foreign matter, etc.)
Horn Must be of no beat sound or sound deterioration.
Backup alarm must sound when the PCCS lever
Backup alarm is at the back position.
(Starting engine)
Must be of no beat sound or sound deterioration.
Monitor must be turned on with buzzer sound,
Monitor display then go off after 3 seconds. After that all gauge
lamps must come on.
No error code indicated in the service meter.
Operation of service meter
(Engine: Low idle) Before engine start, meter must not operate
when the key switch turned on.
INSPECTION
Charge lamp (Engine: Low idle) Must not light up when all lamps are turned on.
Lamp ON (Head lamp, tail lamp and work lamp) Must light up when turned on.
Preheating switch (Auto preheating when at ON position)
Preheating lamp (green) must light up
(Manual preheating when turned to left)
Corrosion resistor valve Must be fully open.
Winter: Open valve fully
Heater hose valve
(Close valve fully in summer)
Controller error code indication (make sure that error does not recur) Clear error code after confirming it.
Flushing Execute flushing

(Before starting engine, replace standard filter with flushing filter. After flushing, replace flushing filter with standard
After flushing, replace flushing filter with standard filter.) filter
Air bleeding of the hydraulic cylinder Perform air bleeding of the hydraulic cylinder
Max. 0.10 kPa {10 mm Aq.}

Measurement of cab pressurization (If pressure is below standard value, adjust it,
referring to M-1, pages 4/7 – 7/7.)
Confirmation of VHMS controller initialization Must be done.

Parking lever
The engine must not be started when the parking
lever is free.
The machine must not be moved when the

parking lever is locked.
Operability of the travel lever

Must be of no pinching or abnormal sound.
• Gear change
Notch must not be released.
• Forward-reverse
• Steering (right/left)
Play of the lever at “N" position Must be of no pinching or abnormal sound.
Must return to the N position smoothly.
Play: Max. 5 mm
FUNCTION / OPERATION
Check of the gear speed indication on the monitor panel. N, F1, F2, F3, R1, R2 and R3 are indicated.
• Must be able to be shifted to any position with the engine at low
idle and the brake turned on. Must be no indication error.
Check of front/rear adjustment of the travel lever box

• 10-level position adjustment Must be adjustable.
• Check of the box lock (up/down)
Must not move after locking.
Free
Case
Lock
Case
Must work smoothly.

Check of the brake pedal operation
• Full stroke: 60 to 88 mm
Check of the deceleration pedal operation Must work smoothly.
• Set the fuel dial to high idle position.
• Check the deceleration RPM High idle: 2,000 ± 50 rpm
Low idle: 900 ± 50 rpm
Check of the fuel dial operation Must move smoothly.

Check of tilt direction
Blade must move to left
RH tilt LH tilt
(RH tilt cylinder is lengthened)
RH tilt
SINGLE
LH tilt
Blade must move to right

LH tilt RH tilt
(RH tilt cylinder is retracted)
Check of dual tilt and pitch direction

Blade must move backward. D + B
Pitch back
Pitch dump Blade must move forward. D + A
LH dual tilt Blade must move to left (both cylinders move) a + B
RH dual tilt Blade must move to right (both cylinders move) a + A
LH tilt Blade must move to left (LH cylinder retracted) B + b
Blade must move to right (LH cylinder lengthened) A + b
DUAL
RH tilt
Check of tilting restriction adjustment Note: See manual of tilting restriction.

• Measure tilting angle at the top of the cutting edge
LH tilt 12 ± 1°
when the tilting limit switch is turned on.
RH tilt 12 ± 1°
Difference of LH and RH is max. 30 mm (Measure
Check of the clearance between frame and track on flat ground)
(Difference of LH and RH) Move blade up and down and stop 100 mm
above ground, and then measure.
No actuator must work when the work equipment
lock lever is at ON position
Check of the work equipment lock lever lock function
(Lever can move but work equipment must not
move)
Must be of no hydraulic drift (Engine: Low idle)
Check of the blade lever floating
Engine stops at floating, then notch must be
WORK EQUIPMENT
Check of the blade lever floating notch release

released.
At the engine full, set the blade lever at down
Check of the quick drop valve operation
position. When the lever is set at the N position
• Quick dropping of the blade from top position.
after the blade drops by 1000 mm, it must stop.
Must be bridged with the blade and the ripper
Main relief valve function (Engine: Low idle)
(Chassis)
Must function immediately after the engine stops
Check of the accumulator function (blade, ripper)
then drop from the top to the ground.
Blade cylinder oil leakage

• Leakage from U-packing, damaged rod, quick drop valve, LH Must be none.
tube, flange or dust seal
RH
Tilt cylinder/pitch cylinder oil leakage

• Leakage from U-packing, damaged rod, tube, flange or LH Must be none.
dust seal
RH
• Tense a string or a bar between

Track tension adjustment the first carrier roller and the idler
• With the gear at F1 and the engine at low idle, travel on flat LH 20 – 30 mm to measure distance between the
place for about 10 m, and when the grouser comes over string (bar) and the grouser.
the first carrier roller, stop the machine by depressing the RH 20 – 30 mm (Difference between LH and RH :
brake pedal. Max. 20 mm)
UNDERCARRIAGE
• Target is 30 mm when new.
Carrier roller alignment

• Travel on flat place with the gear at F1 and R1 for about
10 m, repeatedly about 3 or 4 times, then gradually apply LH Flanges must be free from contact with links at
brake to stop. RH all times.
* Check only when track frame is installed in field
(Check is not necessary if track frame has been installed)
Undercarriage oil leakage

• Leakage from idler, carrier roller, bogie, pivot shaft, LH Must be none.
adjustment cylinder, and lubricated track (plug, seal)
RH
Beat noise inside the cab, beat noise of the outer cover Must be none.
Must work smoothly to securely lock the doors by
Opening/closing and locking effect of the cab doors.
door-locking or key-locking.
Lever must operate smoothly and unlock
securely.
Cab door-open lock release lever
(Unlock: Door is pushed out of stopper rubber
section.)
Opening/closing and locking effect of the left/right side slide glass Must work smoothly to securely lock.
Lighting of the room lamp Must come on/go off by turning the switch on/off.
Must be on/off by turning the switch on/off.
CAB
Operation of the window wiper and the window washer Wiper: Must operate smoothly (without beat
noise)
Operation of the radio and cassette system
Must operate correctly
(Volume, tuning, AM/FM switching, cassette)
Operation of the cigar lighter Must be red-heated.
Ash tray installation Must be installed.
Cold and warm air must be able to be switched
Operation of the air conditioner by monitor operation.
Air flow amount must be able to be adjusted
Air flow amount must be able to be adjusted (Hi, Mid or Lo)
Air comes out from each blowout port.
• Louver must be smoothly switched
Portions to be lubricated Q'ty Example: U blade
• Equalizer bar side pin shaft 2
LUBRICATION
• Equalizer bar center pin shaft 1

• Blade lift cylinder support shaft and yoke 6
• Blade center pin 1
• Blade oblique arm ball joint 3
• Brace screw (Single tiltdozer) 2
BLADE
Interference and twist of blade lift cylinder hoses When blade is tilted up, down and to right and
(Check through operation range) left, hoses must not interfere or twist.
Check of ripper direction

a Raise
c Lower
A Tilt in
B Tilt out
Ripper lift cylinder oil leakage

• U-packing, damaged rod, tube, flange, dust seal LH Must be none
loosing
RH
Ripper tilt cylinder oil leakage

• U-packing, damaged rod, tube, flange, dust seal LH Must be of no contact.
loosing
RH
Interference and twist of hoses during ripper operation
When ripper is raised, lowered and tilted in and
(Ripper lift and tilt hoses, pin-puller hoses)
out, hoses must not interfere or twist.
(Check through operation range)
Creak of the ripper link pin Must be of no creak.
Check of the pin puller switch direction Must be the same as the pin puller cylinder
A: Pin out
RIPPER
operation direction
B: Pin in
Check of the pin puller cylinder hose clamp position Must be of no contact
(Entire operation area must be checked) Must be of no excess hose tension.
Pin puller cylinder oil leakage
Must be none
• Leakage from U-packing, damaged rod, tube or flange
LH
Check of ripper lubricated hose installation Must be no contact or no excess bend.
RH
(Add grease)
Grease must not leak
Portions to be lubricated Q'ty Must be lubricated (right and left)
• Ripper lift cylinder head 8 2
• Ripper lift cylinder bottom 6 2
• Ripper tilt cylinder head 7 2
• Ripper tilt cylinder bottom 5 2
• Ripper arm pin (front) 9 2
• Ripper arm pin (rear) 0 2
<Precautions for measurement>
Measure each performance value after each oil temperature has increased.
(Reference) Engine coolant temperature: Within operating range
Power train oil temperature: 75 – 85°C
Hydraulic oil temperature: 45 – 55°C
Engine speed
Category Item Condition Unit Standard Result
Engine speed Run engine at low idle (low speed). rpm 600 – 700
Engine
Run engine at high idle (Engine high and decelerator cut mode). *2 rpm 2100 – 2200
Set decelarator at low speed. rpm 850 – 950
Stall torque converter. *1 rpm 1640 – 1740
*1: Measure stall speed 1 segment before red range of torque converter oil temperature gauge.
Measure with ID "0530" in adjustment mode of monitor.
*2: Measure high idle speed with adjustment mode ID "0007" of monitor.
Power train oil pressure

Main relief pressure *3 Run engine at low speed and set transmission in N. MPa 2.35 – 2.89
Transmission
{kg/cm2} {24.0 – 29.5}

Run engine at full throttle and set transmission in N. MPa 2.65 – 2.98
{kg/cm2} {27.0 – 30.4}
*3: Measure main relief pressure with monitoring mode ID "43000" of monitor.
Work equipment oil pressure

Work equipment pump Only machine Ripper lift Run engine at MPa 26.0 – 28.8
F pump
relief pressure *4 with ripper low speed and {kg/cm2} {266 – 294}
set transmission MPa 26.0 – 28.8
in N. R pump
{kg/cm2} {266 – 294}
Run engine at MPa 26.0 – 28.8
F pump
full throttle and {kg/cm2} {266 – 294}
in N. R pump
{kg/cm2} {266 – 294}
Single tilt Blade left tilt Run engine at MPa 21.6 – 24.4
F pump
specification low speed and {kg/cm2} {221 – 249}
in N. R pump
{kg/cm2} {221 – 249}
F pump
set transmission
Oil pressure
MPa 23.1 – 25.9

in N. R pump
{kg/cm2} {236 – 264}
Blade right tilt Run engine at MPa 26.0 – 28.8
F pump
low speed and {kg/cm2} {266 – 294}
in N. R pump
{kg/cm2} {266 – 294}
F pump
in N. R pump
{kg/cm2} {266 – 294}
Dual tilt Blade single Run engine at MPa 26.0 – 28.8
F pump
specification left tilt low speed and {kg/cm2} {266 – 294}
in N. R pump
{kg/cm2} {266 – 294}
F pump
in N. R pump
{kg/cm2} {266 – 294}
Work equipment pump Dual tilt Blade single Run engine at MPa 21.6 – 24.4
F pump
relief pressure *4 specification right tilt low speed and {kg/cm2} {221 – 249}
in N. R pump
{kg/cm2} {221 – 249}
F pump
in N. R pump
{kg/cm2} {236 – 264}
Blade dual Run engine at MPa 19.7 – 22.5
F pump
left tilt low speed and {kg/cm2} {201 – 229}
in N. R pump
{kg/cm2} {266 – 294}
F pump
in N. R pump
{kg/cm2} {266 – 294}
Blade dual Run engine at MPa 26.0 – 28.8
F pump
right tilt low speed and {kg/cm2} {266 – 294}
set transmission
Oil pressure
MPa 19.7 – 22.5

in N. R pump
{kg/cm2} {201 – 229}
F pump
in N. R pump
{kg/cm2} {231 – 259}
Pitch dump Run engine at MPa 19.7 – 22.5
F pump
in N. R pump
{kg/cm2} {201 – 229}
F pump
in N. R pump
{kg/cm2} {236 – 264}
Pitch back Run engine at MPa 26.0 – 28.8
F pump
in N. R pump
{kg/cm2} {266 – 294}
F pump
in N. R pump
{kg/cm2} {266 – 294}
*4: Measure work equipment relief pressure of F pump with monitoring mode ID "70700" of monitor.
Measure work equipment relief pressure of R pump with monitoring mode ID "70702" of monitor.
Work equipment speed

Blade lift RAISE Run engine at full throttle. sec 4.5 – 5.5
Ripper Blade
LOWER Run engine at full throttle. sec 1.5 – 2.1

Ripper tilt Tilt IN Run engine at full throttle. sec 4.7 – 5.7
Tilt BACK Run engine at full throttle. sec 2.8 – 3.8
Hydraulic drift of work equipment

Blade lift Engine stopped, Cutting edge height: 500 – 800 mm. mm/min Max. 50/5
Ripper lilt Engine stopped, Ripper point height: 300 – 600 mm. mm/min Max. 30/5
Check sheet for tightening torque for bolts of ROPS
Sketch Record
1. Tightening torque of ROPS

From right to left of machine rear A – H
From right to left of machine front I – P
(rear 8 + front 8, total 16)
Position Location Record Standard tightening torque
Machine backward
C
H 1960 – 2450 Nm
I {200 – 250 kgm}
J
Machine forward
P
Superdozer specification 1/8
Report No.
FIELD ASSEMBLY INSPECTION REPORT

(For Superdozer)
After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.
Model-Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
D475ASD-5E0 SAA12V140E-3
Service Meter Reading (Hr): Date of Inspection Inspector's name: Location of Machine at Inspection:
Distributor's Name: Specification
Blade Super
Customer's name:
Ripper or counterweight VGR CW ( Ton)
(Country)
Shoe width 910 mm 810 mm
Address: Cab With cab, Without cab
Others Enter specification of optional/local

(Optional/Local procurement part) procurement part, if there is any
Delivery Report No. attached:
Inspector's comments:
KOMATSU USE ONLY:

Sheet Receiving Date: By: Remark:
Check sheets filling instruction:
1. Use following indexes for entry of judgement
Normal Correction made on abnormal point
Abnormal Not applied
2. Enter actually measured values in parenthese, [ ].
Note:
Criteria are based on the standards when the machine is shipped out of the factory
Above the bottom Radiator
Main radiator coolant level
surface Strainer
Reserve tank coolant level Low – Full
Engine oil level EO15W40-DH (H+L)/2 – (H+15) Engine : Stopped

Engine : Low idle
Power train oil level TO30 L – (H+20)
(After 3 to 5 minutes)
Damper case oil level TO30 (H+L)/2 – (H+10) Engine : Stopped
Center to upper Pitch back on the ground.
Hydraulic tank oil level
TO10 level of sight Ripper point on the ground.
• Between H – L
gauge Engine : stopped
COOLANT AND OIL LEVEL
LH See operation manual.

Final drive oil level GO85W-140 H – (H–20)
RH Engine : stopped
Oil level
LH
TO30 (H+10) – (H+30)
Pivot shaft oil level See operation manual.
EO30-CD from shaft end
RH
LH
TO30
Recoil spring oil level a=100 ± 10 See operation manual.
EO30-CD
RH
Battery electrolyte level Between L and H
UPPER LEVEL Must be no adhesion of grease, loosened

Check battery
LOWER LEVEL terminal, or crack
Window washer tank water level Full
Fuel tank Full (1670 l)
Draining of fuel tank Drain fuel tank (Drain water, foreign matter, etc.)
Horn Must be of no beat sound or sound deterioration.
Backup alarm must sound when the PCCS lever
Backup alarm is at the back position.
(Starting engine)
Must be of no beat sound or sound deterioration.
Monitor must be turned on with buzzer sound,
Monitor display then go off after 3 seconds. After that all gauge
lamps must come on.
No error code indicated in the service meter.
Operation of service meter
(Engine: Low idle) Before engine start, meter must not operate
when the key switch turned on.
INSPECTION
Charge lamp (Engine: Low idle) Must not light up when all lamps are turned on.
Lamp ON (Head lamp, tail lamp and work lamp) Must light up when turned on.
Preheating switch (Auto preheating when at ON position)
Preheating lamp (green) must light up
(Manual preheating when turned to left)
Corrosion resistor valve Must be fully open.
Winter: Open valve fully
Heater hose valve
(Close valve fully in summer)
Controller error code indication (make sure that error does not recur) Clear error code after confirming it.
Flushing Execute flushing

(Before starting engine, replace standard filter with flushing filter. After flushing, replace flushing filter with standard
After flushing, replace flushing filter with standard filter.) filter
Air bleeding of the hydraulic cylinder Perform air bleeding of the hydraulic cylinder
Max. 0.10 kPa {10 mm Aq.}

Measurement of cab pressurization (If pressure is below standard value, adjust it,
referring to M-1, pages 4/7 – 7/7.)
Confirmation of VHMS controller initialization Must be done.

Parking lever
The engine must not be started when the parking
lever is free.
The machine must not be moved when the

parking lever is locked.
Operability of the travel lever

Must be of no pinching or abnormal sound.
• Gear change
Notch must not be released.
• Forward-reverse
• Steering (right/left)
Play of the lever at “N" position Must be of no pinching or abnormal sound.
Must return to the N position smoothly.
Play: Max. 5 mm
Check of the gear speed indication on the monitor panel. N, F1, F2, F3, R1, R2 and R3 are indicated.
• Must be able to be shifted to any position with the engine at low
idle and the brake turned on. Must be no indication error.
Check of front/rear adjustment of the travel lever box

• 10-level position adjustment Must be adjustable.
• Check of the box lock (up/down)
Must not move after locking.
Free
Case
Lock
FUNCTION / OPERATION
Case
Must work smoothly.

Check of the brake pedal operation
• Full stroke: 60 to 88 mm
Check of the deceleration pedal operation Must work smoothly.
• Set the fuel dial to high idle position.
• Check the deceleration RPM High idle: 2,000 ± 50 rpm
Low idle: 900 ± 50 rpm
Check of the fuel dial operation Must move smoothly.

Check of pitch direction
Pitch backward Pitch
Pitch dump Blade must move to forward smoothly.
dump
Pitch forward
Pitch back
Pitch
Blade must move to backward smoothly.
back

RH tilt LH tilt Blade must move to left
RH tilt
LH tilt
LH tilt RH tilt Blade must move to right
Check of tilting restriction adjustment Note: See manual of tilting restriction.

• Measure tilting angle at the top of the cutting edge
LH tilt 7 ± 1°
when the tilting limit switch is turned on.
RH tilt 7 ± 1°
Check of auto pitch back operation 52 ± 3°

• After pitch dumping, move backward with the speed gear at R1, Blade should be horizontal after pitch back to the
then turn the pitch back switch on. stroke end, and pitch dumping is performed to
return to the digging posture.
Difference of LH and RH is max. 30 mm (Measure
Check of the clearance between frame and track on flat ground)
(Difference of LH and RH) Move blade up and down and stop 100 mm
above ground, and then measure.
No actuator must work when the work equipment
lock lever is at ON position
Check of the work equipment lock lever lock function
(Lever can move but work equipment must not
move)
Must be of no hydraulic drift (Engine: Low idle)
Check of the blade lever floating
Engine stops at floating, then notch must be
WORK EQUIPMENT
Check of the blade lever floating notch release

released.
At the engine full, set the blade lever at down
Check of the quick drop valve operation
position. When the lever is set at the N position
• Quick dropping of the blade from top position.
after the blade drops by 1000 mm, it must stop.
Must be bridged with the blade and the ripper
Main relief valve function (Engine: Low idle)
(Chassis)
Must function immediately after the engine stops
Check of the accumulator function (blade, ripper)
then drop from the top to the ground.
Blade cylinder oil leakage

• Leakage from U-packing, damaged rod, quick drop valve, LH Must be none.
tube, flange or dust seal
RH
Tilt cylinder/pitch cylinder oil leakage

• Leakage from U-packing, damaged rod, tube, flange or LH Must be none.
dust seal
RH
• Tense a string or a bar between

Track tension adjustment the first carrier roller and the idler
• With the gear at F1 and the engine at low idle, travel on flat LH 20 – 30 mm to measure distance between the
place for about 10 m, and when the grouser comes over string (bar) and the grouser.
the first carrier roller, stop the machine by depressing the RH 20 – 30 mm (Difference between LH and RH :
brake pedal. Max. 20 mm)
UNDERCARRIAGE
• Target is 30 mm when new.
Carrier roller alignment

• Travel on flat place with the gear at F1 and R1 for about
10 m, repeatedly about 3 or 4 times, then gradually apply LH Flanges must be free from contact with links at
brake to stop. RH all times.
* Check only when track frame is installed in field
(Check is not necessary if track frame has been installed)
Undercarriage oil leakage

• Leakage from idler, carrier roller, bogie, pivot shaft, LH Must be none.
adjustment cylinder, and lubricated track (plug, seal)
RH
Beat noise inside the cab, beat noise of the outer cover Must be none.
Must work smoothly to securely lock the doors by
Opening/closing and locking effect of the cab doors.
door-locking or key-locking.
Cab door-open lock release lever Must work smoothly to securely lock.
Opening/closing and locking effect of the left/right side slide glass Must work smoothly to securely lock.
Lighting of the room lamp Must come on/go off by turning the switch on/off.
Must be on/off by turning the switch on/off.
Operation of the window wiper and the window washer Wiper: Must operate smoothly (without beat
CAB
noise)
Operation of the radio and cassette system
Must operate correctly
(Volume, tuning, AM/FM switching, cassette)
Operation of the cigar lighter Must be red-heated.
Ash tray installation Must be installed.
Cold and warm air must be able to be switched
Operation of the air conditioner by monitor operation.
Air flow amount must be able to be adjusted
Air flow amount must be able to be adjusted (Hi, Mid or Lo)
Air comes out from each blowout port.
• Louver must be smoothly switched
Portions to be lubricated Q'ty Example: Super blade
• Equalizer bar side pin shaft 2
LUBRICATION
• Equalizer bar center pin shaft 1

• Blade lift cylinder support shaft and yoke 6
• Blade center pin 1
• Blade oblique arm ball joint 3
BLADE
Interference and twist of blade lift cylinder hoses When blade is tilted up, down and to right and
(Check through operation range) left, hoses must not interfere or twist.
Check of ripper direction

a Raise
c Lower
A Tilt in
B Tilt out
Ripper lift cylinder oil leakage

• U-packing, damaged rod, tube, flange, dust seal LH Must be none
loosing
RH
Ripper tilt cylinder oil leakage

• U-packing, damaged rod, tube, flange, dust seal LH Must be of no contact.
loosing
RH
Interference and twist of hoses during ripper operation
When ripper is raised, lowered and tilted in and
(Ripper lift and tilt hoses, pin-puller hoses)
out, hoses must not interfere or twist.
(Check through operation range)
Creak of the ripper link pin Must be of no creak.
Check of the pin puller switch direction Must be the same as the pin puller cylinder
A: Pin out
RIPPER
operation direction
B: Pin in
Check of the pin puller cylinder hose clamp position Must be of no contact
(Entire operation area must be checked) Must be of no excess hose tension.
Pin puller cylinder oil leakage
Must be none
• Leakage from U-packing, damaged rod, tube or flange
LH
Check of ripper lubricated hose installation Must be no contact or no excess bend.
RH
(Add grease)
Grease must not leak
Portions to be lubricated Q'ty Must be lubricated (right and left)
• Ripper lift cylinder head 8 2
• Ripper lift cylinder bottom 6 2
• Ripper tilt cylinder head 7 2
• Ripper tilt cylinder bottom 5 2
• Ripper arm pin (front) 9 2
• Ripper arm pin (rear) 0 2
<Precautions for measurement>
Measure each performance value after each oil temperature has increased.
(Reference) Engine coolant temperature: Within operating range
Power train oil temperature: 75 – 85°C
Hydraulic oil temperature: 45 – 55°C
Engine speed
Engine speed Run engine at low idle (low speed). rpm 600 – 700
Engine
Run engine at high idle (Engine high and decelerator cut mode). *2 rpm 2100 – 2200
Set decelarator at low speed. rpm 850 – 950
Stall torque converter. *1 rpm 1640 – 1740
*1: Measure stall speed 1 segment before red range of torque converter oil temperature gauge.
Measure with ID "0530" in adjustment mode of monitor.
*2: Measure high idle speed with adjustment mode ID "0007" of monitor.
Power train oil pressure

Main relief pressure Run engine at low speed and set transmission in N. MPa 2.35 – 2.89
Transmission
*3 {kg/cm2} {24.0 – 29.5}

Run engine at full throttle and set transmission in N. MPa 2.65 – 2.98
{kg/cm2} {27.0 – 30.4}
*3: Measure main relief pressure with monitoring mode ID "43000" of monitor.

Work equipment pump Only machine Ripper lift Run engine at MPa 26.0 – 28.8
F pump
relief pressure *4 with ripper low speed and {kg/cm2} {266 – 294}
in N. R pump
{kg/cm2} {266 – 294}
F pump
in N. R pump
{kg/cm2} {266 – 294}
Superdozer Blade left tilt Run engine at MPa 26.0 – 28.8
F pump
specification low speed and {kg/cm2} {266 – 294}
in N. R pump
{kg/cm2} {266 – 294}
F pump
set transmission
Oil pressure
MPa 26.0 – 28.8

in N. R pump
{kg/cm2} {266 – 294}
Blade right tilt Run engine at MPa 21.6 – 24.4
F pump
in N. R pump
{kg/cm2} {221 – 249}
F pump
in N. R pump
{kg/cm2} {236 – 264}
Pitch dump Run engine at MPa 19.7 – 22.5
F pump
in N. R pump
{kg/cm2} {201 – 229}
F pump
in N. R pump
{kg/cm2} {241 – 269}
Work equipment pump Superdozer Pitch back Run engine at MPa 26.0 – 28.8
F pump
relief pressure *4 specification low speed and {kg/cm2} {266 – 294}
set transmission
Oil pressure
MPa 26.0 – 28.8

in N. R pump
{kg/cm2} {266 – 294}
F pump
in N. R pump
{kg/cm2} {266 – 294}
*4: Measure work equipment relief pressure of F pump with monitoring mode ID "70700" of monitor.
Measure work equipment relief pressure of R pump with monitoring mode ID "70702" of monitor.
Work equipment speed

Blade lift Superdozer RAISE Run engine at full throttle. sec 4.6 – 5.6
Ripper Blade
specification LOWER Run engine at full throttle. sec 1.4 – 2.0

Ripper tilt Tilt IN Run engine at full throttle. sec 4.7 – 5.7
Tilt BACK Run engine at full throttle. sec 2.8 – 3.8
Hydraulic drift of work equipment

Blade lift Engine stopped, Cutting edge height: 500 – 800 mm. mm/min Max. 50/5
Ripper lilt Engine stopped, Ripper point height: 300 – 600 mm. mm/min Max. 30/5
Check sheet for tightening torque for bolts of ROPS
Sketch Record
1. Tightening torque of ROPS

From right to left of machine rear A – H
From right to left of machine front I – P
(rear 8 + front 8, total 16)
Position Location Record Standard tightening torque
Machine backward
C
H 1960 – 2450 Nm
I {200 – 250 kgm}
J
Machine forward
P
GEN00051-02

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GEN00051-02

Field Assembly Instruction

BULLDOZER D475A -5E0

Operator for assembly

Mechanics Sharing of work

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

• Semi-U-tiltdozer + variable giant ripper

• Full U-tiltdozer + variable giant ripper

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

4. k Check during actual work

6. Precautions for starting engine

12 Adjustment of tilt limit angle

1. Arrangement before work 1. Removal of stand

Right straight frame

A Overall length (mm) 6,600

A Overall length (mm) 4,800

A Overall length (mm) 6,205

A Overall length (mm) 5,263

A Overall length (mm) 6,465

ﬂ Refer to the Appendix 1 for

Shoe width 810

(2) Blade lift cylinder

A Overall length (mm) 2,900

Note: May be installed to chassis

(3) Ripper cylinder

A Overall length (mm) 1,545

• Giant ripper arm, multi ripper arm

A Overall length (mm) 2,290

• Giant ripper shank

A Overall length (mm) 115

A Overall length (mm) 1,210

• Multi ripper shank

A Overall length (mm) 115

A Overall length (mm) 1,875

A Overall length (mm) 2,100

A Overall length (mm) 1,950

No. Tool name Q’ty Remarks

Size must match to driver unit of pneumatic

Stand Front 1 See attached tool drawing

Chassis stand (Front side)

No. Material Q‘ty Remarks

Part No. of bolt TTTTT-TTTTT

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

a : Bolt thread diameter (Nominal diameter)

Nominal size of thread Width across flats Tightening torque

✕ pitch (= Socket size)

6 ✕ 1 10 11.8 Ð 14.7 {1.2 Ð 1.5}

8 ✕ 1.25 13 27 Ð 34 {2.8 Ð 3.5}

12 ✕ 1.75 19 98 Ð 123 {10 Ð 12.5}

14 ✕ 2 22 153 Ð 190 {15.5 Ð 19.5}

16 ✕ 2 24 235 Ð 285 {23.5 Ð 29.5}

18 ✕ 2.5 27 320 Ð 400 {33 Ð 41}

20 ✕ 2.5 30 455 Ð 565 {46.5 Ð 58}

22 ✕ 2.5 32 610 Ð 765 {62.5 Ð 78}

24 ✕ 3 36 785 Ð 980 {80 Ð 100}

27 ✕ 3 41 1150 Ð 1440 {118 Ð 147}

30 ✕ 3 46 1520 Ð 1910 {155 Ð 195}

33 ✕ 3 50 1960 Ð 2450 {200 Ð 250}

36 ✕ 3 55 2450 Ð 3040 {250 Ð 310}