D475a-5gen00051 Fa-03

GEN00051-03
Field Assembly Instruction
BULLDOZER
-5E0
D475A
D475ASD -5E0
SERIAL NUMBERS
D475A30001
and up
D475ASD- 30001
Preface
Since this machine is large in size, it is divided into some units to meet
the transportation conditions and regulations applied to the transportation route when shipped from our factory.
This manual describes how to assemble the units into the complete
machine in the field. We hope that this machine will display its quality
and you will use it safely according to the operation manual.
Many units are large in size and heavy in weight and may be handled
in a dangerous place or posture and many workers may have to work
together to sling them with cranes.
Accordingly, before starting the assembly work, the work supervisor is
required to hold a safety meeting to oblige the workers to put on protective gear and appoint a work leader and a crane work signal man
and allot roles to all the workers for safe work.
In particular, the above meeting is more important when worker of different languages and customs work together.
The following is a reference supervision system diagram.
(Instruction system)
Work leader
Work supervisor
Crane director
Director
and
deputy director
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 maintain 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 ...........................................................................................................................
PRECAUTIONS FOR FIELD ASSEMBLY .......................................................................................
DISPOSAL OF REMOVED PARTS.................................................................................................
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE.................................
KIT LAYOUT DIAGRAM ..................................................................................................................
STYLE FOR TRANSPORTATION...................................................................................................
TOOLS LIST FOR FIELD ASSEMBLY ............................................................................................
SKETCH OF TOOLS .......................................................................................................................
TIGHTENING TORQUE ..................................................................................................................
COATING MATERIALS ...................................................................................................................
1
3
4
5
6
7
13
16
25
29
A. ASSEMBLY PROCEDURE ......................................................................................................... 31

A- 1. Setting of track shoe ........................................................................................................... 32
A- 2. Setting of the machine ........................................................................................................ 33
A- 3. Installation of blade lift hydraulic cylinder ........................................................................... 36
A- 4. Installation of undercarriage ............................................................................................... 42
A- 5. Replacement of return filter
(Replacement of standard filter special flushing parts)................................................... 58
A- 6. Adding oil to pivot chamber ................................................................................................ 60
A- 7. Check of oil and coolant levels ........................................................................................... 61
A- 8. Installation of ripper ............................................................................................................ 63
A- 9. Installation of trunnion......................................................................................................... 68
A-10. Installation of track shoe ..................................................................................................... 69
A-11. Check track tension ............................................................................................................ 72
A-12. Assembly of blade .............................................................................................................. 74
A-13. Installation of blade............................................................................................................. 94
A-14. Installation of operator's cab............................................................................................... 102
A-15. Installation of ROPS ........................................................................................................... 122
A-16. Installing direction of exhaust pipe ..................................................................................... 123
A-17. Installation of giant ripper shank ......................................................................................... 124
A-18. Adjustment of arm joint (U-blade) ....................................................................................... 125
A-19. Installation of counterweight ............................................................................................... 126
A-20. Procedure for adjusting blade tilt angle limit....................................................................... 127
A-21. Method of checking auto-reset system (Superdozer)......................................................... 136
A-22. Installation of ORBCOMM antenna and wiring harness ..................................................... 137
A-23. Installing lunchbox band (if equipped) ................................................................................ 138
A-24. Greasing each part of work equipment............................................................................... 140
A-25. Bleeding air from hydraulic cylinders .................................................................................. 143
A-26. Air bleeding from work equipment pump and fan pump ..................................................... 144
M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY................... 145
M- 1. Check and adjustment of operators cab............................................................................ 146
M- 2. Inspection of machine monitor ........................................................................................... 153
M- 3. No-injection cranking of engine .......................................................................................... 166
M- 4. Setting procedure of user adjust mode .............................................................................. 169
M- 5. Flushing of hydraulic circuit ................................................................................................ 172
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
Item
Unit
Semi-U-tiltdozer
+ Variable giant ripper
Full U-tiltdozer
+ Variable giant ripper
Superdozer
+ Counterweight
Operating weight
(excluding operator's weight)
kg
Blade weight
(including cylinders)
kg
Ripper weight
(including cylinders)
kg
Counterweight
kg
Engine model
Komatsu SAA12V140E-3 diesel engine
kW/rpm {HP/rpm}
664/2,000{890/2,000}
Rated engine output

Overall length
mm
Overall height (with ROPS)
mm
Overall width
mm
108,310
(*1)
16,500
11,560
113,120 (*2)
18,800
20,900
7,360
6,040
11,950
10,525
4,546 (4,646)
5,265
6,205
Travel speed
Forward
km/h
3.5/6.3/10.9
(1st/2nd/3rd)
Reverse
km/h
4.7/8.4/14.3
*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
6,465
Superdozer + counterweight
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 drawing.)
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 problem. 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.
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.
Setting of track shoe

Setting of the machine
(Unloading of other parts)
Installation of blade lift hydraulic cylinder

Installation of undercarriage
Replacement of return filter
Adding oil to pivot chamber
Check of oil and coolant levels
Installation of ripper
Installation of trunnion
Installation of track shoe
Check track tension
Assembly of blade
Installation of blade
Installation of operator's cab
Installation of ROPS
Installation of exhaust pipe
Installation of giant ripper shank
Adjustment of arm joint (U-blade)
Installation of counterweight
Procedure for adjusting blade tilt angle limit
Method of checking auto reset system
Installation of ORBCOMM antenna and wiring harness
Installing lunchbox band
Greasing each part of work equipment
Bleeding air from hydraulic cylinders
Air bleeding from work equipment pump and fan pump
Inspection
Assembly
Workers
Welding
Crane (With operator)
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
Schedule
5
4
45 ton 1
45 ton 2
2nd day
1st day
4
(2)
45 ton 1
3rd day
45 ton 1
4th day
45 ton 1
5th day
1
2
No. Item
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE

A change of the schedule caused by weather is not considered.
The special work in the field shall be adjusted separately.
KIT LAYOUT DIAGRAM
Approx. 30 m
Accessories
CAB assembly
ROPS guard
Approx. 30 m
Chassis
Ripper parts
Right straight frame

Truck crane (45 ton)
Left straight frame
Right track
Track
Track
Blade
Left track
When selection the work site, see "Precautions for field assembly", too.
The delivered kits (components) should be arranged as shown in the layout below after unloaded from the trailer and
truck.
However, since the layout below is a reference image of a work site about 30 m by 30 m, decide the actual layout according to the area and land form of the work site, considering the transportation packaging of each kit (component) explained
later.
Truck crane (45 ton)
STYLE FOR TRANSPORTATION

Since the machine can be divided for transportation, ask us or our service shop before transportation.
Style of each KIT.
Body
Overall length (mm)
6,600
Overall height (mm)
3,300
Overall width (mm)

Weight (kg)
3,320
43,000
Note: The blade lift cylinder may

be installed before delivery.
Track frame
a 2 sets of the shoes are prepared for each machine.
Overall length (mm)
4,800
Overall height (mm)
1,500
Overall width (mm)
982
Weight (kg)
12,200
WORK EQUIPMENT
(1) U-blade
Overall length (mm)
6,205
Overall height (mm)
2,615
Overall width (mm)
2,170
Weight (kg)
14,000
(2) Semi U-blade
Overall length (mm)
5,263
Overall height (mm)
2,610
Overall width (mm)
1,760
Weight (kg)
13,000
Overall length (mm)
6,465
Overall height (mm)
2,690
Overall width (mm)
Super blade
Weight (kg)
2,180
14,000
Refer to the Appendix 1 for

welding of spill guard.
Track shoe
a 2 sets of the shoes are prepared for each machine.
Shoe width
810
A (mm)
4,500
B (mm)
1,400
Weight (kg)
6,770 (1/2)
Straight frame
a Right and left straight frames are prepared for each machine.
A
B
C
Overall length (mm)

Overall height (mm)
Overall width (mm)
Weight (kg)
Semi-U, U
4,857
674
638
1,770
Super
5,020
682
681
1,868
A
C
Overall length (mm)

Overall width (mm)
Weight (kg)
Semi-U, U
1,930
351
504
Super
1,754
351
508
Hydraulic cylinder
(1) Pitch, tilt cylinder
a One set of this part is used for single tilt-dozer and two
sets for dual tilt-dozer.
(2) Blade lift cylinder
A
B
C
Overall length (mm)

Overall height (mm)
Overall width (mm)
Weight (kg)
2,900
630
435
500
Note: May be installed to chassis

before delivery.
(3) Ripper cylinder
a Both for lifting and tilting, each one set of this part is used
on both left and right sides.
A
C
Overall length (mm)

Overall width (mm)
Weight (kg)
Lift
1,748
304
389
Tilt
1,698
304
394
Giant ripper beam
A
B
C
Overall length (mm)

Overall height (mm)
Overall width (mm)
Weight (kg)
1,545
1,930
1,535
2,400
A
B
C
Overall length (mm)

Overall height (mm)
Overall width (mm)
Weight (kg)
2,290
580
1,781
1,750
Giant ripper arm, multi ripper arm
a Connecting pin with the beam is

attached in this part in advance.
10
Giant ripper shank assembly
A
B
C
Overall length (mm)

Overall height (mm)
Overall width (mm)
Weight (kg)
115
2,800
940
1,000
a Protector and point is attached

in this part in advance.
Multi ripper beam
A
B
C
Overall length (mm)

Overall height (mm)
Overall width (mm)
Weight (kg)
1,210
1,930
3,065
3,450
Overall length (mm)

Overall height (mm)
Overall width (mm)
Weight (kg)
Qty
115
2,170
775
740
3
Multi ripper shank assembly (machine with multi ripper specification only)
A
B
C
a Protector and point is attached

in this part in advance.
11
Operator cab assembly
A
B
C
Overall length (mm)

Overall height (mm)
Overall width (mm)
Weight (kg)
1,875
1,680
1,740
500
A
B
C
Overall length (mm)

Overall height (mm)
Overall width (mm)
Weight (kg)
2,100
1,411
585
918
ROPS
a For ROPS, see "Specifications".
Counterweight
A
B
C1
C2
Overall length (mm)

Overall height (mm)
Overall width (mm)
Weight (kg)
12
1,950
1,300
1,361
1,290
7,300
TOOLS LIST FOR FIELD ASSEMBLY

No.
Specification
Q'ty
Truck crane
Maximum lifting capacity: 441 kN {45 t}
Air compressor
Discharge pressure: 0.69 MPa {7 kg/cm2}

Discharge flow: 15 m3/min
Welding machine
(see remarks)
It is used when spill guard (if equipped)

Determine the specification and quantity in
is to be added to the blade of work
accordance with the drawings mentioned in the
equipment.
remarks.
For drawing see "Attached sheet".
Chain lever hoist (Chain block)
Part name
Wire rope sling
Belt sling:
(Made by synthetic fibers)
Rated load: 15.7 kN {1.6 t}
Rated load: 31.4 kN {3.2 t}
12 mm 2 m (11 kN {1.2 t})
12 mm 4 m (11 kN {1.2 t})
16 mm 2 m (21 kN {2.1 t})
20 mm 5 m (32 kN {3.3 t})
20 mm 6 m (32 kN {3.3 t})
24 mm 2 m (47 kN {4.8 t})
32 mm 5 m (84 kN {8.56 t})
4
2
For lifting the machine
For lifting the machine
Width: 25 mm 1.5 m (4.9 kN: {0.5 t})
Width: 25 mm 3 m (4.9 kN: {0.5 t})
Width: 50 mm 3 m (9.8 kN: {1 t})
Width: 50 mm 4 m (9.8 kN: {1 t})
Width: 100 mm 4 m (19.6 kN: {2 t})
Wire diameter: 12.5 mm 1.5 m (49 kN: {5 t})
Hydraulic wrench
Tightening capacity (torque):

5890 Nm {600 kgm} or more
Hydraulic wrench socket
10
16-times power wrench
11
Socket for 16-times power

wrench
12
Pneumatic impact wrench
15
Vertical lifting capacity is

shown in parentheses.
JIS B8817 or equivalent
The rope is 24A of JIS
G3525 or equivalent
52 mm 3 m (238 kN {24.3 t})
Load chain
14
65 mm 5 m (373 kN {38 t})
13
Remarks
Nominal width across flats: 50 mm

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

Socket
50, 46, 41, 36, 32
(for pneumatic impact wrench)
30, 27, 24, 22, 19
600 mm long
Extension bar
300 mm long
Torque wrench
1
1
1
1
1
1
Spanner
Nominal width across flats (mm) :

17, 19, 22, 24, 27, 30
32, 36, 41, 46, 50
17
Pneumatic hose and coupler

(for pneumatic tools)
Inner diameter 6 to 10 mm length 30 m

Service pressure: 0.69 MPa {7 kg/cm2}
13
For tightening master link bolts of the

track shoes
1 each
16
Vertical lifting capacity is shown in

parentheses.
Class I, type E of JIS B8818 or
equivalent
2 each
Extending bar for pneumatic impact

wrench
Prepare torque wrench so that the
socket for air impact wrench could
be used commonly.
If torque wrench is not available,
prepare the socket for torque wrench.
The width across flats is the same
with the socket for pneumatic
impact wrench.
For tightening hydraulic hose
mouthpiece nut
The size of couplers on both sides
are to be same as that of air
compressor, pneumatic impact
wrench, grease pump and oil
feeding pump.
No.
18
19
20
21
22
Part name
Eyebolt
Shackle for sling
Master link for lifting
Pinch bar (lever bar)
Sling bar (steel rod)
23
Sledge hammer
24
Jack
25
Tap (for repairing thread)
Specification
Adaptable screw: M12
Using load: 2.16 kN {220 kg}
Adaptable screw: M16
Suitable screw: M24
SD16-M, using load 9.8 kN {1 t}
Q'ty
4
2
SD22-M, using load 19.6 kN {2 t}
SB28-S, using load 78.5 kN {8 t}
SD34-M, using load 49 kN {5 t}
SB36-S, using load 122.6 kN {12.5 t}
SB50-S, using load 245.2 kN {25 t}
BB24-M, using load 35.3 kN {3.6 t}
BB28-S, using load 78.5 kN {8 t}
SB50-V, using load 392 kN {40 t}
O type, using load 80 kN {8.16 t}
2
1
25 mm 700 mm
19 mm 300 mm
Double-headed: 4.5 kg (10 lbs)

Thread type
Using load: 147.1 kN {15 t}
M24 pitch 3
M30 pitch 3
M33 pitch 2
For master link of track shoes

For adjusting the tilt limit angle of
the blade
(see A-25 in assembly procedure)
27
Grease pump
Pneumatic supplying type
30
Drain oil receiver

(made of steel sheet)
Manual type or pneumatic supplying

type
Capacity: Approx. 5 l
JCMAS P018 or equivalent

See Fig. 9 for the shapes
S53C (JIS G4051) or equivalent is
suitable for its material.
For assembly of the undercarriage
Oil jack
O type of JIS B8817 or equivalent

See Fig. 3 and Fig. 5 for the using
positions.
25 mm 1 m
With leveler with a smallest scale of one

degree
29

Symbols show the type, nominal
size and class in order. (See Fig. 8.)
Diameter of grip full length of tool

13 mm 400 mm or equivalent
25 mm 900 mm or equivalent
Angle meter
Oil feed pump

The using load is the load for
vertical lifting
26
28
Remarks
1
1
Height width depth (mm)

Approx. 1000 700 150
Approx. 700 400 150
2 each
Approx. 300 300 100

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

Thickness height width (mm)
16 1000 500
t25 T300 (mm)
t25 300 600 (mm)
See Fig. 3 and Fig. 4
31
Chassis stand
(for fixing the machine body)
32
Floor plate made by steel

(for setting chassis stand)
33
Steel plate
34
Sling jig A
35
Sling jig B
36
Sling jig C
14
Weld lifting hook to the corner
1
For slinging track frame assembly
For slinging final drive assembly
and pivot shaft
For slinging final drive assembly
No.
37
Part name
Wooden bar
Specification
Height width depth (mm)
350 350 750
350 350 670
Q'ty
Remarks
4
2
350 350 400
300 300 600
100 100 750
95 95 180 to 200
350 350 800
38
Stand for high lift work
Height 2 m with stairs and handrail
39
Safety belt
Trunk belt type
40
Goggles
41
Safety rope and "No Entrance"

board
42
Resin tube (Vinyl tube)
43
Lubricating oil and grease
See A-13 of assembly procedure
44
Seizure preventing agent
Molybdenum disulfide grease (LM-P)
45
Cleaning oil
For removing of preservative
40 l
46
Paint remover
5l
47
Repair paint
For removing of phthalic acid coating

materials
See the list of coating materials.
48
Glass cleaner
Liquid cleaner
49
Waste cloth
50
Adhesive cloth tape
Width Length Color

50 mm 25 m Not specified
1 wrap
51
Wire (metal wire)
3.2 mm length approx. 2 m
For the number

For high lift works
of workers
For welding
For protecting from spray
Rope of yellow ground color with black
stripes
Standing signboard
Inner diameter 8 mm thickness 1 mm
length 3 m
Soft and transparent
Necessary
quantity
Necessary
quantity
1
For preventing outsiders

from entering the working
area
For checking air tightness
(internal pressure) of
operator's cab
200 g
See the list of coating

materials.
3 each
For cleaning of the
Proper quantity windshield glass of
operators cab
1 kg
JIS G3532 #10 or

equivalent
a General tools for manual works (such as box wrench, driver, pliers, etc.) are not listed in this list.
Prepare general tools if necessary.
15
Only movable
part
Only
movable
part
No.
01
02
03
04
05
06
07
08
09
10
11
12
13
16
Material
SS400C
SS400C
SS400C
SS400C
SS400C
SS400C
SS400C
SS400B
SS400
SS400
SS400
SS400
SS400
Q'ty
4
2
2
2
2
2
2
4
4
4
10
2
2
Material t12
Remarks
C15075t9-1332
C15075t9-829
C15075t9-829
C15075t9-510
C15075t9-548
C15075t9-453
C15075t9-355
T50-500
t25180250
t12200655
t1260128
t16124130
t257085
Fig.1
SKETCH OF TOOLS
For jigs that are not available from the market, see jig drawings (Fig. 1 to Fig. 7) and make them in the field.
a But Komatsu does not take the responsibility of manufacturer for the jigs made in accordance with Fig. 1 to Fig. 7
1. Chassis stand (Front side)
17
Only movable
part
Only
movable
part
No.
01
02
03
04
05
06
07
08
09
10
11
12
13
Material
SS400C
SS400C
SS400C
SS400C
SS400C
SS400C
SS400C
SS400B
SS400
SS400
SS400
SS400
SS400
Total weight
Material t12
Q'ty
4
2
2
2
2
2
2
4
4
4
10
2
2
Remarks
C15075t9-1282
C15075t9-829
C15075t9-829
C15075t9-510
C15075t9-548
C15075t9-453
C15075t9-355
T50-500
t25180250
t12200655
t1260128
t16124130
t257085
Fig.2
2. Chassis stand (Rear side)
Track frame assembly
Crane
18
Straight shackle
04
Bow shackle
Master link
03
06
Bow shackle
02
Master link
Sling jig A
01
05
Material
No.
Fig. 3 shows the example of using of sling jig A.

Bow shackle (Fig No.06) in Fig. 3 is for installing the leveling sling of the lifting object (track frame assembly).
See Fig. 4 for the details of sling jig A (Fig No.01).
1
Q'ty
Using load: 35.3 kN {3.6 t}

BB24 (M level) of JIS B2801 or equivalent
Using load: 125 kN {12.7 t}

Using load: 122.6 kN {12.5 t}

SB36 (S level) of JIS B2801 or equivalent

Using load: 157 kN {16 t}

BB36 (T level) of JIS B2801 or equivalent
Remarks
Fig.3
3. Sling jig A (Track frame assembly)
19
2 places
2-36 drill
Weight: Approx. 345 kg

The scale is indefinite.
2 places
2 places
2-44 drill
Plate
Plate
Plate
02
03
Part name
01
44 drill
SS400
SS400
SS400
Material
Qty
t36
t36
t36
Remark
Fig.4
3.1 Details of sling jig A
4. Sling jig B (final drive assembly and pivot shaft)

Fig. 5 shows the example of slinging of final drive assembly.
Fig.5
Crane
Master link
Sling jig B
Bow shackle
BB28 (S level) of JIS B2801
or equivalent
Straight shackle
BB28 (S level) of JIS B2801
or equivalent
Sling jig C
Final drive assembly
a For details of sling jigs B and C, see Fig. 6 and 7.

a For example of slinging pivot shaft, see "Assembly procedure A-5".
20
Apply chamfering on
the ridges and corners
so that they would not
hurt hands.
21
Plate
Plate
02
Part name
01
No.
Weight: Approx. 175 kg
36 drill
2-36 drill
SS400
SS400
Material
Qty
t22
t28
Remark
Fig.6
4.1 Details of sling jig B
2-33 drill
2-36 drill
22
Part name
Plate
Boss
01
02
SS400
SS400
Material
Weight : Approx. 14.5 kg
No.
Qty
Before welding
Apply chamfering on the ridges so that

they would not hurt hands.
56
t32
Remark
Fig.7
4.2 Details of sling jig C
5. Selecting table of shackles (extracted from JIS B2801-1996)
Fig.8
Straight shackle
Type SB
Type Nominal
Type SD
Dimension (Unit: mm)
Using load
d1
M level
S level
T level
16
16
32
16
36
64
20
9.8 kN {1 t}
22
22
44
22
50
88
27
19.6 kN {2 t}
28
28
43
28
70
112
34
47.1 kN {4.8 t}
78.5 kN{8 t}
98.1 kN {10 t}
36
36
54
36
90
144
42
78.5 kN {8 t}
122.6 kN {12.5 t}
156.9 kN {16 t}
50
50
75
50
125
200
60
156.9 kN {16 t}
245.2 kN {25 t}
308.9 kN {31.5 t}
SD
SB
Bow shackle
Type BB
Type Nominal
BB
Using load
d1
B1
M level
S level
24
24
39
28
62
126
30
70
35.3 kN {3.6 t}
61.8 kN {6.3 t}
28
28
43
32
70
144
34
80
47.1 kN {4.8 t}
78.5 kN {8 t}
36
36
54
42
90
190
42
105
78.5 kN {8 t}
23
T level
98.1 kN {10 t}
122.5 kN {12.5 t} 156.9 kN {16 t}
6. Pinch bar
Fig.9

Type
L (Overall length)
d (Outer diameter of grip)

[For round ones]
Small
400
13
Big
900
25
a This tool is equivalent to P018-1978 (pinch bar) of JCMAS (Japan Construction Mechanization Association Standard).
Similar parts are acceptable if the quality is not below this tool.
P019-1978 (ply bar) of JCMAS is also acceptable for tools of smaller type.
a You can read the information about JCMAS on the website.
24
TIGHTENING TORQUE
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt
TTTTT-TTTTT
Part No. of washer
EEEEE-EEEEE
Bolt specification
Thread
Bolt
length
Thread
sizediameter
(Diameter,
pitch,
length)
Applicable socket size
Tool (Socket)
Tightening torque
Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 20
26
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension c in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. correspond to dimension b in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ www or QQQ RR. If the target tightening torque
is set, expression of QQQ RR is applied.
Fig. 1
a
b
c
d
: Bolt thread diameter (Nominal diameter)

: Width across flats of bolt head
: Bolt length
: Threaded part of bolt
25
Table 1 Tightening torque for bolts not specified in text

Unit: Nm {kgm}
Tightening torque
Nominal size of thread

pitch
a (mm)
Width across flats

(= Socket size)
b (mm)
Unit : Nm
Unit : {kgm}
61
10
12
{1.2}
8.8 14.7
{0.9 1.5}
8 1.25
13
25
{2.5}
14.7 34
{1.5 3.5}
10 1.5
17
54
{5.5}
34 74
{3.5 7.5}
12 1.75
19
89
{9}
54 123
{5.5 12.5}
14 2
22
137
{14}
84 196
{8.5 20}
16 2
24
230
{23.5}
147 309
{15 31.5}
18 2.5
27
315
{32}
201 427
{20.5 43.5}
20 2.5
30
460
{47}
319 608
{32.5 62}
22 2.5
32
650
{66.5}
471 829
{48 84.5}
24 3
36
810
{82.5}
588 1030
{60 105}
27 3
41
1180
{120}
883 1470
{90 150}
30 3
46
1520
{155}
1130 1910
{115 195}
33 3
50
1960
{200}
1470 2450
{150 250}
36 3
55
2450
{250}
1860 3040
{190 310}
39 3
60
2940
{300}
2260 3630
{230 370}
a For symbols a and b in the table, see Fig. 1.
26
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
1/8
3.9 6.9
{0.4 0.7}
2.9 5.9
{0.3 0.6}
2.0 3.9
{0.2 0.4}
1/4
5.9 11.8
{0.6 1.2}
4.9 9.8
{0.5 1.0}
3.9 7.8
{0.4 0.8}
3/8
16.7 26.5
{1.7 2.7}
13.7 21.6
{1.4 2.2}
9.8 16.7
{1.0 1.7}
1/2
32.3 52.9
{3.3 5.4}
26.5 43.1
{2.7 4.4}
19.6 32.3
{2.0 3.3}
3/4
51.0 85.3
{5.2 8.7}
42.1 70.6
{4.3 7.2}
31.4 52.9
{3.2 5.4}
86.2 173.5
{8.8 17.7}
72.5 146.0
{7.4 14.9}
54.9 111.7
{5.6 11.4}
Nominal size (in)
2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Unit: Nm {kgm}
Material of female thread
Steel
Cast iron
Light alloy
1/8
16.7 29.4
{1.7 3.0}
9.8 19.6
{1.0 2.0}
6.9 14.7
{0.7 1.5}
1/4
19.6 44.1
{2.0 4.5}
16.7 37.2
{1.7 3.8}
12.7 28.4
{1.3 2.9}
3/8
44.1 93.1
{4.5 9.5}
37.2 77.4
{3.8 7.9}
27.4 58.8
{2.8 6.0}
1/2
98.0 188.2
{10.0 19.2}
83.3 157.8
{8.5 16.1}
60.8 115.6
{6.2 11.8}
3/4
170.5 316.5
{17.4 32.3}
141.1 247.0
{14.4 25.2}
105.8 186.2
{10.8 19.0}
367.5 612.5
{37.5 62.5}
309.7 514.5
{31.6 52.5}
235.2 392.0
{24.0 40.0}
Nominal size (in)
27
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
Tightening torque (Nm {kgm})
Outside diameter
of hose
(mm)
Width across
flatse.
(mm)
Range
Target
Approx. 6
19
35 63 {3.5 6.5}
44 {4.5}
22
54 93 {5.5 9.5}
74 {7.5}
24
59 98 {6.0 10.0}
78 {8.0}
Approx. 13
27
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}
Approx. 10
Note : When connecting hoses, take care not to twist them.
4. Proper socket sizes for bolts of M39 and larger (Reference)

For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and
larger, see Table 5.
Table 5
Unit: mm
Thread diameter
Proper sizes of sockets or spanners
M42
65
M45
70
M48
75
M52
80
M56
85
M60
90
M64
95
28
COATING MATERIALS
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
Main applications, features
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cock plug from
coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber,
metal and non-metal.
LT-2
09940-00030
50 g
Polyethylene
container
Features: Resistance to heat and

chemicals
Used for anti-loosening and sealant
purpose for bolts and plugs.
LT-3
790-129-9060
(Set of adhesive
and hardening
agent)
Adhesive:
1 kg
Hardening
agent:
500 g
Can
LT-4
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Used as heat-resisting sealant for repairing engine.
Three bond
1735
790-129-9140
50 g
Polyethylene
container
Quick hardening type adhesive

Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals,
rubbers, plastics and woods.
Adhesives
Used as adhesive or sealant for metal, glass and plastic.
Used as sealant for machined holes.
Aron-alpha
201
790-129-9130
2g
Polyethylene
container
Quick hardening type adhesive

Quick cure type (max. strength after
30 minutes)
Used mainly for adhesion of rubbers,
plastics and metals.
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
Resistance to heat, chemicals

Used at joint portions subject to high
temperatures.
LG-1
790-129-9010
200 g
Tube
Used as adhesive or sealant for gaskets and packing of power train case,
etc.
LG-5
790-129-9080
1 kg
Can
Used as sealant for various threads,

pipe joints, flanges.
Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
Tube
Features: Silicon based, resistance

to heat, cold
Used as sealant for flange surface,
tread.
Used as sealant for oil pan, final
drive case, etc.
LG-6
790-129-9020
200 g
Gasket
sealant
LG-7
790-129-9070
1 kg
Tube
Features: Silicon based, quick hardening type

Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Three bond
1211
790-129-9090
100 g
Tube
Used as heat-resisting sealant for repairing engine.
Tube
Features: Silicone type, heat resistant, vibration resistant, and impact

resistant sealing material
Used as sealing material for transfer
case
Three bond
1207B
419-15-18131
100 g
29
Category
Molybdenum
disulphide
lubricant
Grease
Komatsu code
Part No.
Q'ty
Container
Main applications, features
LM-G
09940-00051
60 g
Can
Used as lubricant for sliding portion

(to prevent from squeaking).
Tube
Used to prevent seizure or scuffling

of the thread when press fitting or
shrink fitting.
Used as lubricant for linkage, bearings, etc.
LM-P
09940-00040
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Molybdenum
disulphide
grease
LM-G (G2-M)
SYG2-400M
SYG2-400M-A
SYGA-16CNM
Hyper White
Grease G2-T
G0-T (*)
*: For use in cold
district
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
SYG0-16CNT (*)
Biogrease G2B
G2-BT (*)
*: For high
temperature
and large load
SYG2-400B
SYGA-16CNB
SYG2-400BT (*)
SYGA-16CNBT (*)
200 g
General purpose type

Various
Various
Various
Various
400 g 10 Bellows type

400 g 20 Bellows type
16 kg
Can
400 g
16 kg
400 g
16 kg
Used for normal temperature, light

load bearing at places in contact
with water or steam.
Used for heavy load portion
Seizure resistance and heat resistance higher than molybdenum diBellows type
sulfide grease
Can
Since this grease is white, it does
not stand out against machine
body.
Since this grease is decomposed
by bacteria in short period, it has
Bellows type
less effects on microorganisms,
Can
animals, and plants.
SUNSTAR
PAINT PRIMER
580 SUPER
20 ml
Glass
container
SUNSTAR
GLASS PRIMER
580 SUPER
20 ml
Glass
container
Used as primer for cab side

(Expiration date: 4 months)
Primer
Caulking
material
SUNSTAR
PENGUINE
SEAL 580
SUPER "S" or
"W"
320 ml
Polyethylene
container
Adhesive for cab glass
Adhesive
417-926-3910
Used as primer for glass side

"S" is used for high-temperature season (April - October)
and "W" for low-temperature
season (November - April) as
adhesive for glass.
Used as adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Cartridge
Natural yellow
SYPA-U03PNY
Spray can
Black gray
SYPA-U03PBG
Spray can
Used to seal joints of glass

parts.
Used to seal front window.
Used to seal joint of glasses.
Translucent white seal.
Paint
30
A. Assembly
Remarks
1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---,
but indicated by (1), (2), (3) --- in the tables and texts.
Example:
(1)
(2)
(3)
(4)
(5)
(6)
2.
Plate
Collar
Washer
Bolt
Bolt
Washer
In some places of this manual, the words of front, rear, right hand and left hand
of machine are used. Those words indicate the directions seen from the operator's seat with the sprocket at the rear as shown below, unless otherwise specified.
Front
Left hand
Right hand
Operator's seat
Sprocket
Rear
31
Assembly procedure
Setting of track shoe
A-1
1. Place two sets of track shoes to the place planned in the kit layout above, and expand one set on the left side of the machine
while the other set on the right side as shown in Fig. 1.
Left track
Parallel
Front
Right track
Front end
Symbol Dimension (mm)

W
2,770
2,060
710
13,066
Remarks
When shoe width is B
a Only master shoes are removed previously (one piece

on each side, i.e. two pieces for each machine).
Number of shoes: 40
a When the track shoes are placed, they are folded as the
shape in Fig. 2, so pay attention to the front and rear directions when expanding them.
a When the track shoes are placed on the ground, the joint
portion with the master link on the tip of front side shoes
faces to the ground. (Fig. 3)
Abutment joints
Ground
32
Assembly procedure
Setting of the machine (1/3)
A-2
1. Installation of chassis stand
Place the steel plates between the tracks spread in parallel on the ground and install the chassis stands on them.
a Arrange the chassis stands and steel plates as shown in the figure.
a The chassis stands for the front side and rear side are different from each other.
a The steel plates are required when the ground is soil. They are not required when the ground is covered with steel
plates.
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
H1
H2
t
L1
L2
Dimension (mm)
1,105
1,020
16
2,800
3,300
2,450
Remarks
Recommended thickness of steel plate
33
Assembly procedure
A-2
2. Setting of the machine
(1) Front tow hook (hole diameter : 70 mm)

(installed on the machine previously )
(7) Wire rope sling

(52 mm 3 m 2 pieces)
(2) Shackle (equivalent to JIS SB50 [class 5])
(8) The second crane

(45 t specification)
(3) Damage preventing pad (rubber or felt plate)
(9) Equalizer bar

(installed on the machine previously)
(4) Wire rope sling (36 mm 5 m 1 piece)

(5) The first crane (45 t specification)
(10) Hull frame

(main frame of the machine)
(6) Tilt cylinder mounting pin for the ripper

(installed on the machine previously)
(11) Front chassis stand

(12) Rear chassis stand
a See the part of machine itself in above-mentioned "Style for transportation" for the machine weight.
34
Assembly procedure
A-2
As shown in Fig. 4, set wire rope sling on the machine, one in the front and two in the rear, lift the machine up with two cranes
together (one sling by one crane in the front, two slings by another crane in the rear), put down the machine from the trailer,
and set it on the chassis stand on the ground.
a Install the front wire rope sling by using tow hook on the under cover installed on the machine with suitable shackle.
At this time, set rubber or felt pad in the portions that the machine and the sling interfere with each other to prevent damage
of the machine.
a Install the rear wire rope sling to the tilt cylinder mount of the ripper attached on the machine previously.
There is one pin on each right and left side of the mount, so set one sling to each pin.
a Set the equalizer bar, attached on the machine previously, on the front chassis stand, and set the hull frame (main frame
of the machine ) on the rear chassis stand.
At this time, set the machine while confirming that the chassis stand is at the center of the width of the machine.
a Before releasing the lift, set wooden bars (13) on left and right sides in the clearance between equalizer bar (9) and main
frame (10) of the machine as shown in Fig. 5.
<Specification of wooden bar>
Section: 95 mm, square
Length: 180 to 200 mm
a Steel bar of the same shape can be used instead of
wooden bar.
(9) Equalizer bar

(10) Main frame of the machine
(11) Front chassis stand
(13) Wooden bar
35
Assembly procedure
A-3
Installation of blade lift hydraulic cylinder (1/6)
1. Make the counter mark from cylinder stay yoke (1) on the
front top of the machine to cap (2), then remove them.
(Fig.1)
a Specification of bolt (3)
M30, length 140 mm
a Remove bushings (5) and (6) held by cap (2) at the same
time. At this time, disconnect greasing hose connected to
the elbow of bushing (5).
(1) Cylinder stay yoke

(2) Cap
(3) Bolt
(4) Washer
(5) Bushing (top)
(6) Bushing (bottom)
2. To sling and install hydraulic cylinder horizontally (Fig. 3),

turn cylinder stay yoke to keep its posture as shown in
Fig. 2.
a Set the mounting side of greasing hose connected to the
bushing to the rear side.
Greasing hose
3. Lift up hydraulic cylinder with belt sling as shown in Fig.

3, and set it on the mounting portion of cylinder stay yoke.
a Lifting load: 4.9 kN {500 kg}
a Adjust the posture of hydraulic cylinder to be horizontal
during lifting.
a Set the rod side of hydraulic cylinder to the front side.
a Tubes of hydraulic cylinder (A) on both left and right sides
are on the outer and lower side of cylinder.
36
Assembly procedure
A-3
4. Insert bushing (5) [Sealing welded plate on which the elbow connecting greasing hose is attached] into the trunnion shaft that becomes top of hydraulic cylinder.
a Dust seal is embedded in the end of inserting port on
bushing side. Carefully insert the bushing after applying
grease (G2-LI), etc. in order to prevent damaging the lip
of this seal.
Trunnion shaft
5. After that, install it to cylinder stay yoke by using bolts (3)

and washers (4) so that bushing (5) is pressed by cap (2).
a Align the dowel pin (knock pin) installed previously on the
cap with the hole on bushing side.
a Temporarily tighten the bolts at this time.
6. Insert bushing (6) (Sealing welded plate on which greasing nipple is attached) into trunnion shaft under hydraulic
cylinder from the bottom, press it with cap (2) on the top
in the same way, and install it to cylinder stay yoke by using bolts (3) and washers (4).
(2) Cap
(3) Bolt (M30)
(4) Washer
(5) Bushing (top)
(6) Bushing (bottom)
(7) Blade lift hydraulic cylinder
7. Tighten bolts (3) on top and bottom firmly.

Bolt specification
M30, length 140 mm
Necessary socket
46 mm
Tightening torque
Refer to Table 1, "Tightening

Torques" in this manual.
37
Assembly procedure
A-3
8. Loosen bolt (9), and remove fixing jig (8) installed on hydraulic cylinder (7). (Fig. 5)
M16, length 35 mm
a Fixing jig (8):
It is a special jig for supporting hydraulic cylinder when
front work equipment (blade) is not installed, and is mainly used when the machine is operated as a tractor.
9. After that, change the direction of fixing jig (8), reinstall

hydraulic cylinder (7), and install the other side to the machine body by using bolts (11) and washers (12) as
shown in Fig. 6.
Then hydraulic cylinder is fixed at nearly horizontal posture.
Rotating center of cylinder stay yoke
a Bolts (11) and washers (12) are installed on the machine

in advance, and the part numbers are listed below as a
reference.
No.
11
12
Part No.
01010-81630
21T-09-11330
Part Name
Bolt
Washer
Q'ty
1
1

M16, length 30 mm
10. Release the slinging.
11. Reconnect greasing hose disconnected in Item 1 to the
elbow of bushing (5).
38
Assembly procedure
A-3
12. Installation of hydraulic hoses
1) Confirm the necessary quantity of parts by Fig. 7 and

the table below.
a The quantity shown in the table below is for one machine, and the necessary quantity for left and right hydraulic cylinder are both one half of the quantity for
one machine.
a Reuse flange (16) and sems bolt (17) of the cover part
(see Fig. 8) removed in 2).
Piping on machine side
a This figure shows left

hydraulic cylinder.
Right hydraulic cylinder
is laterally symmetric
with this figure.
No.
13
14
15
16
17
Part No.
07098-01218
07098-01219
07000-F3038
07371-51260
07375-21250
Part Name
Hose
Hose
O-ring
Flange
Sems bolt
Q'ty
2
2
8
16
32
Remarks
Length: 1,800 mm
Length: 1,900 mm
Bolt with washer
a Specification of sems bolt (17)

M12, length 50 mm
Width across flats of bolt head: 17 mm (Special dimension)
39
Assembly procedure
A-3
2) Remove cover parts (16 to 19) installed on hydraulic

hose mounting portion of hydraulic cylinder and hydraulic hose mounting portion of machine piping for
preventing oil leak during transportation and dust entrance into hydraulic circuit. (Fig.8)
a But flange (16) and sems bolt (17) are to be reused
for installing hydraulic hose.
Piping on machine side
No.
18
19
Part No.
07378-11210
07000-F3038
Part Name
Head
O-Ring
3) Install hydraulic hoses (13) (14) to hydraulic cylinder.

a See Fig. 7 and Fig. 9 for mounting position and direction
of left hydraulic cylinder.
For right hydraulic cylinder, install the parts laterally symmetrically as shown in Fig. 10.
Bolt specification
M12, length 50 mm
Necessary socket
17 mm
Tightening torque

(Bottom)
(Head)
a This figure shows View Y in Fig.

8 for left hydraulic cylinder.
40
Q'ty
1
1
Assembly procedure
A-3
a Reference
As shown in Fig. 9 and Fig. 10, the installation of hydraulic
hose is laterally symmetric for left and right cylinders, but
the hydraulic flow of left and right cylinders is different as
shown in the following table.
Hydraulic
cylinder
Left
Right
Hydraulic
hose No.
13
Hydraulic cylinder
connecting port
Head
14
Bottom
13
Bottom
14
Head
(Head)
(Bottom)
4) Connect the other side of hydraulic hose with piping

parts on machine side (see Fig. 7 or Fig. 8).
Connecting procedures, such as tightening torque of
bolts, etc. are the same with 3).
a Avoid interference between hydraulic hoses or between
hydraulic hose and machine during installation.
13. Items 1 to 12 are mainly described on left hydraulic cylinder. Install right hydraulic cylinder with the same procedure.
Avoid interference
41
Assembly procedure
Installation of undercarriage (1/16)
A-4
1. Preparations
1) Removal of accessories
Remove the following 10 parts (the bolts are not
counted in) from the track frame as shown in the photo.
No.
1
2
3
4
5
6
7
8
9
10
Part No.
198-30-69530
198-30-61360
198-50-61370
198-50-61150
198-30-69460
198-30-69470
198-30-62311
198-30-62321
198-50-51390
198-30-51430
198-30-51440
198-50-31270
198-50-51220
195-30-31260
198-30-69850
198-30-69860
Part Name
Cover
Cover (L.H.)
Cover (R.H.)
Shaft (Side pin)
Cover (L.H.)
Cover (R.H.)
Cover (L.H.)
Cover (R.H.)
Cover
Cover (L.H.)
Cover (R.H.)
Spacer
Cover assembly
Cover
Cover (L.H.)
Cover (R.H.)
2) Maintenance of track frame pivot and application of

grease
Apply grease (G2-LI) to the O-ring groove and fit the
Oring to the groove.
No.
11
Part No.
07000-15355
Part Name
O-ring
3) Check of seal for damage, maintenance of shaft, and

application of grease
Apply grease (G2-LI) to the (P) and (Q) surfaces.
Torsion seal
42
Assembly procedure
A-4
2. Sling work of track frame assembly

Chain lever hoist
Lifting jig A
Crane
Crane
Lifting jig A
Lifting jig A
Chain lever hoist

Hook
Pivot shaft hole
Hook
Horizontally sling track frame assembly by using sling jig A and chain lever hoist (referred as chain block hereafter) as shown
in Fig. 5, and move it close to machine.
a See "Tools list for field assembly" for lifting jig A and chain block.
Use two chain blocks with rated capacity of 31.4 kN (3.2 t).
a U-hook is welded to the lifting portion of track frame assembly in advance.
The center hook (for slinging jig A) is set to a position a little backward (approximately 100 mm) to the center of gravity of
track frame assembly, so adjust track frame assembly to be horizontal by chain block.
a Lifting load: approximately 124 kN (12.65 t)
(Track frame assembly + lifting jig A + chain block (2 sets))
43
Assembly procedure
A-4
3. Installation of track frame assembly (moving close to machine)

1) Keep track frame assembly horizontally slung, move
it close to machine, and insert pivot shaft installed on
the machine into the pivot shaft hole in track frame assembly.
a At this time, keep away from the space between machine body and track frame assembly.
2) Keep track frame assembly horizontally slung, move

it closer to machine (Fig. 6) until the pin holes of side
pin of equalizer bar are aligned. (Fig. 7)
Pin holes
Equalizer bar
44
Assembly procedure
A-4
3) Confirm that the track frame assembly is completely

moved to the machine, and confirm that inner thread
seal (12) pressed and fixed into pivot shaft in advance
contacts with the mounting surface of O-ring (11) on
track frame described in 1-2). (Fig. 8)
Pivot shaft
Track frame
Machine
(11) O-ring
(12) Inner torsion seal
(13) Seal pressing cover
4. Insertion of equalizer bar side pin

1) Adjusting with the crane, align the pin hole of equalizer bar side
pin and track frame side pin accurately, and insert side pin (3).
a The pin must be inserted in the correct directly. (Fig. 9)
Head side faces the front of the machine and head UP mark
faces up.
There is UP mark
(3) Side pin

2) Connect the grease tube.
Grease tube
Mudguard for pin
3) Install the side pin fixing bolt.

Part No. of bolt
Part No. of washer
Part No. of washer
Length of bolt
Necessary socket
Tightening torque
198-50-61410 (2 pieces on each side)

01643-33380 (4 piece on each side)
19M-09-12890 (2 pieces on each side)
M33, Length 320 mm
50 mm
2450 2700 Nm {250 275 kgm}
4) Install the attached cover and tighten the bolt.

a Refer to the Table 1, "Tightening Torques".
45
a Insert the pin fixing bolt from below

and install the nut to the upper side.
Assembly procedure
A-4
5. Assembly of end portion of pivot shaft
1) Set spacer (8) removed in "1. Preparations" on the tip

portion (Fig. 11) of pivot shaft inserted into track
frame assembly. Install smaller O-ring (15) on the tip
side of pivot shaft and larger O-ring (16) on torsion
seal assembly (17) side. Set torsion seal assembly
(17) to press spacer and O-rings. Install inner washer
to pivot shaft by using bolts (18) and washers (19),
and install outer washer to track frame by using bolts
(20) and washers (21).
a Torsion seal assembly (17) is included in parts (8) removed in "1. Preparations".
No.
Part No.
198-50-31270
Spacer
1 each on right and left sides
15
07000-05190
O-ring
07000-05315
O-ring
16
Part Name
198-50-31160
17
198-50-31241
198-50-52171
Q'ty
Remarks

The quantity shows the
number of parts for dual tilt
1 each on right and left sides dozer specification.
1 each on right and left sides For single tilt dozer, the
quantity shows only for one
13 each on right and left sides side (right side).
Inner washer
Torsion seal
Torsion seal
assembly
Outer washer
18
01010-81665
Bolt
19
01643-31645
Washer
20
01011-82005
Bolt
21
01643-32060
Washer
2) Tightening bolts
Bolt
Specifications
18
M20, length 105 mm
Nominal size of socket

wrench to be used
30 mm
20
M16, length 65 mm
24 mm
a Set the track frame parallel with the machine.
46
Tightening torque
Refer to Table 1, "Tightening Torques" in
this manual.
Assembly procedure
A-4
6. Fixing of torsion seal on the larger diameter side of pivot shaft
Seal pressing cover

Torsion seal
Track frame
O-ring
Machine
Pivot shaft
Fix torsion seal on the larger diameter side (inner side of track frame assembly) of pivot shaft by using the seal pressing cover
at the further portion (inner side).
Set the cutting portion of seal pressing cover downwards (to the ground), and install it to the track frame by using bolts (25)
and washers (26).
No.
25
26
Part No.
01010-81640
01643-31645
Part Name
Bolt
Washer
Q'ty
6 each on left and right sides
6 each on left and right sides
Bolt specification
M16, length 40 mm
Necessary socket
24 mm
Tightening torque

47
Assembly procedure
A-4
7.
1) The right and left sides of the pivot shaft are different, depending on the machine specification.
Structure
Specification
Tilt hose piping

Left side of machine
Right side of machine
Not installed
Installed
Dual tiltdozer
Installed
Installed
Super dozer
Installed
Installed
Single tiltdozer
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.
2-2) Install the unions, elbows and plugs for the tilt
piping to the pivot shaft end cover.
a1. Take care not to forget to set the O-rings.
a2. Direct the elbows to the rear.
a3. If these parts have been installed when delivered, the above work is not necessary.
No.
31
32
33
34
35
Part Name
Cover
Union
Plug
Elbow
O-ring
Part No.
198-50-51390
02781-00628
07040-12412
02782-1062A
07002-22434
Tightening torque of union, plug and elbow
Q'ty
2 pcs. (common to right and left)
2 pcs. (for each cover)
128 186 Nm
{13 19 kgm}
a Parts (31) to (35) are components of (6) and (7) removed in "1. Preparations".
48
Assembly procedure
A-4
3) Install hoses (36) and (37) to the elbows of the cover

assembly described in step 2) to connect to the work
equipment piping.
a1. Take care not to forget to set the Orings (38).
a2. 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.
a3. Set the opposite side of each hose free.
No.
6
36
37
38
Part Name
Part No.
Cover
Assembly in step 2.2)
Hose
198-71-62171
Hose
198-71-62270
O-ring
02896-21018
Tightening torque of hydraulic hose
(The quantity is for 1 cover assembly)
4) Remove the plugs from the tilt hoses projected from
the pivot shaft end (2 places).
Reference
Plug
07376-70628
O-ring
02896-11018
49
Q'ty
1
1
2
Remarks
Red-banded
Blue-banded
177 245 Nm {18 25 kgm}
Assembly procedure
A-4
5) Install the tilt hoses projected from the pivot shaft end
to the cover assembly described in step 2).
a1. Take care not to forget to set the O-rings.
O-ring
02896-21018
2 pcs.
a2. 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.
6) Tighten cover assembly in item 5) together with the

large washer of torsion seal assembly installed in 5)
and install it.
(41) Cover assembly in 5)
(45) Hose in 3)
(46) Hose in 3)
(47) Mounting seat of trunnion (see A-9)
P: Hydraulic hose with identification color mark
Q: Hydraulic hose without identification color mark
No.
Part Name
Part No.
42 Bolt
01010-81695
43 Bolt
01011-81625
44 Washer
01643-31645
Note) The quantity is for 1 cover assembly.
Q'ty
9
1
10
Remarks
For tightening torque of bolts, see
refer to Table 1, "Tightening Torques"
in this manual.
7) Installation of plug to the tilt hose end.

Install the oil stopper plugs to the tilt hose end (P, Q in Fig. 19) from the trunnion mounting portion.
50
Assembly procedure
A-4
Figure No.
Part Name
Qty
Part No.
For single tilt dozer
For dual tilt dozer
77
Plug
07376-70522
Only two for the right side
Two each on left and right sides
78
O-ring
02896-11015
Only two for the right side
Two each on left and right sides
a Be sure to install this plug in advance.

It is because that hydraulic oil pressure of work equipment may apply on the hose before front work equipment (blade assembly) is installed when rear work equipment (ripper) is reused in "A-10 Installation of track shoe" below.
a Plugs (77) removed in step 4.1.1) can be reused.
8) Pass hoses (45) and (46) through the track frame and
pull them out of the hole of the trunnion mounting
seat.
9) Install the mud cover to the front of cover assembly
(41) described in step 6).
The covers for the right and left sides of the machine
have different part Nos.
No.
51
52
53
54
Part Name
Cover (Right)
Cover (Left)
Bolt
Washer
Part No.
198-30-51440
198-30-51430
01010-81635
01643-31645
Q'ty
1
1
3
3
Remarks
in this manual.
Note) The quantity of bolts and washers shows for each one cover.
51
Assembly procedure
A-4
10) Work when tilt hose piping is not installed

10.1) As described in 1), the tilt hose is not installed to
the left end of the pivot shaft of the single tiltdozer
specification. (Part A in Fig. 22)
Install the cover described in 10.2) and 10.3) (Fig. 23)
10.2) Install cover (61) together with the outer washers of
the twist seal assembly installed in steps 5).
10.3) Close the square hole at the front of cover (61) with
plate (64).
No.
61
62
63
64
65
66
Part Name
Cover
Bolt
Washer
Plate
Bolt
Washer
Part No.
198-30-51220
01010-81695
01643-31645
198-30-51330
01010-81635
01643-31645
Q'ty
1
10
10
1
3
3
Remarks

in this manual.
52
Assembly procedure
A-4
8. Release of slinging
If the works in 7 are completed, loosen and remove the sling.

a When the installation of track frame assembly on one side is completed, and the installation on the other side is to be
started, set jack or wooden bar under the installed track frame assembly in order to prevent dropping when the slinging
by crane is finished. (Fig.24)
Jack
Set two or more jacks or wooden bars to keep the track frame assembly to be
longitudinally horizontal.
9. Lowering of the machine (removing chassis stand)

1) Sling only the front of the machine by crane in accordance with the same procedure in "A-2 Setting of the
Machine", and draw out the front chassis stand from
under the machine. (Fig.25)
a Lifting load: Approximately 343 kN {35 t}
2) After that, draw out the wooden bar set between the
equalizer bar described in Fig. 5 of the same procedure and the machine.
3) Slowly lower the front side of the machine, and place
the idler of track frame assembly on the track shoes.
4) Release the slinging works for front side of the machine.
53
Assembly procedure
A-4
5) After that, lift only the rear side of the machine by

crane in accordance with the same procedure of "A-2
Setting of the machine", and draw out the rear chassis
stand from under the machine.
Wire rope sling
a Lifting load: Approx 343 kN {35 t}

6) In order to keep enough working space for the works
in 7), insert the wooden bar put between steel plates,
between rear track roller and track shoes on the
ground.
a Set wooden bars for the track rollers in the same positions on left and right sides.
a Wooden bars: T300 600 (mm) 2 pieces
Steel plates: t25 300 600 (mm) 4 pieces
54
Assembly procedure
A-4
7) Sling the rear of the machine again, and draw out

wooden bars and steel plates.
8) After that, slowly lower the rear of the machine, and
set all track rollers on track shoe links. (Fig. 27)
9) Release the slinging of the rear side of the machine.
10. Removal of bogie fixing jig
1) Remove the bogie fixing jig (L) for track frame assembly. (Fig. 28)
2) As shown in Fig. 29 (the next page), the fixing jigs are
installed on four places on the outer side of left and
right track frame assemblies. (Among the four places,
only one jig has the different size.)
a Removal is to be performed after lowering the machine on the track shoes.
If the machine is remained on chassis stand, the track
roller will hang down, interfering the following works.
a This fixing jig is used for transporting, preventing the
track roller from hanging down when track frame assembly is placed on trailer, etc. or lifted up by using
crane when unloading.
a Follow the intention of the customer or the judgment
of service department for the storage of removed jigs.
Necessary socket
50 mm
55
Assembly procedure
A-4
Figure No. Part Name
Part No.
Qty
75
Plate
198-30-69280
76
Collar
198-30-66190
77
Washer
19M-54-11770
78
Bolt
01011-62710
79
Bolt
01010-62765
80
Washer
01643-32780
81
Plate
198-30-68950
82
Collar
198-30-68960
83
Washer
19M-54-11770
84
Bolt
01011-62710
Remarks
Removal parts
Reinstall them in different places.
Removal parts
a The quantity shows the number of parts for each one side of left and right track frame assemblies.
56
Assembly procedure
A-4
3) For the portions without bolts and washers after fixing

jigs are removed, supply mounting bolts and washers
(79), (80), (85), (86) to triangle cover and install it.
(Fig. 30)
a Among the supplied bolts and washers, reuse bolts
(79) and washers (80) for mounting fixing jigs on triangle covers (3 places) in track roller bogie assembly.
(See Fig. 29)
Necessary socket
41 mm
Tightening torque
883 1,470 Nm
{90 150 kgm}
Figure No.
79
80
85
86
Part Name
Bolt
Washer
Bolt
Washer
Part No.
01010-62765
01643-32780
01010-62765
01643-32780
Q'ty
3
3
2
2
Remarks
Reuse
Reuse
Newly supply
Newly supply
a The quantity shows the number of parts for each one side of left and right track frame assemblies.
4) For the portions without bolts and washers after fixing

jigs are removed, knock cork plug (87) into thread
holes without the following installation to protect
them. (Fig. 31)
Figure No.
Part Name
87
Plug
Part No.
07049-02734
Q'ty
3
a The quantity shows the number of parts for each one side
of left and right track frame assemblies.
57
Assembly procedure
A-5

(Replacement of standard filter special flushing parts) (1/2)
1. The machine requires flushing of work equipment hydraulic oil after assembly, so in this procedure, replace the element of
hydraulic oil return filter with flushing element in advance.
Replace the element of hydraulic oil return filter with exclusive flushing element (1), and replace valve and strainer with
plate (2).
a Avoid entrance of dirt when removing installed standard element.
Remove the dirt remaining inside the case by hands, and replace it with exclusive flushing element.
a Confirm the installing condition of the element in accordance with "2. Installing Condition of Element".
a When the atmospheric temperature is below 15C, do not use (2). Replace only the element and flush the circuit while
running the engine at low idle.
No.
1
2
Part Name
Element
Plate
Part No.
208-60-71170
21T-60-13730
Q'ty
1
1
Exclusive flushing element
a Removed standard element (208-60-71120), strainer (07069-25400) and valve (208-60-71160) will be used again after
flushing is finished. Accordingly, clean and keep them so that they will not be damaged.
a For the flushing procedure, see "Check and maintenance procedures after completion of assembly M-5".
58
Assembly procedure
A-5

(Replacement of standard filter special flushing parts) (2/2)
2. Installing condition of element
Element
Fig. 1 Good condition
Fig. 2 Bad condition
a Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig. 2.
Particularly when the filter case is filled with oil, it is difficult to see if the element is installed normally. In this case, turn the
installed element with the hand.
If you can turn the element smoothly, it is installed normally.
59
Assembly procedure
A-6
Adding oil to pivot chamber
Pivot chamber
Add engine oil through the hole of plug (1).
a Quantity of oil: 26 l/each side

a Oil level (B): 10 30 mm from oil level (2)
a For using oil type, see "A-7 Check of oil and coolant
levels" in assembly procedure.
60
Assembly procedure
A-7
Check of oil and coolant levels (1/2)
61
Assembly procedure
Check of oil and coolant levels (2/2)
A-7
Precautions
Tools required
Name
Others
.If any oil level or coolant level is low, add oil

or coolant.
62
Equipment required
Qty
Name
Qty
Assembly procedure
Installation of ripper (1/5)
A-8
1. Preparation
Removal of paint and rust prevention oil from mounting parts
Do not remove the arm pin but pull it out to the state
shown in the photo.
Arm pin lock bolt
Part No. of washer
01010-82040
(2 pieces on each side)
01643-32060
Bolt specification
M20, Length 40 mm
Necessary socket
30 mm
Tightening torque

Part No. of bolt
Style
It is necessary to start the engine to perform the following step "8. Connection of cylinder", so prepare to
start the engine.
2. Installation of arm
Sling the arm by 3 points. Set its right and left parts in
parallel accurately.
Set a wood block under the arm as shown in the

photo.
3. Installation of lift cylinder
Lift cylinder connecting pin lock bolt
Block
Part No. of washer
01010-82045
01643-32060
Bolt specification
M20, Length 45 mm
Necessary socket
30 mm
Tightening torque

Part No. of bolt
63
Assembly procedure
A-8
4. Installation of tilt cylinder
Tilt cylinder connecting pin lock bolt
Part No. of washer
01010-82045
01643-32060
Bolt specification
M20, Length 45 mm
Necessary socket
30 mm
Tightening torque

Part No. of 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.
a Connect the pin portion after the installation.
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
Part No. of washer
01010-82040
01643-32060
Bolt specification
M20, Length 40 mm
Necessary socket
30 mm
Tightening torque

Part No. of bolt
64
Assembly procedure
A-8
Set a block (Height: 670 mm) under the

beam so that the arm will be horizontal.
8. Connection of cylinder
1) Start the engine in low idle, and confirm the movement of the lift cylinder rod and the tilt cylinder rod.
If the movement of rods is abnormal, confirm the

amount of hydraulic oil and fill oil.
2) Install lift cylinder while adjusting by moving the rod of

the cylinder.
3) Install tilt cylinder while adjusting by moving the rod of
the cylinder.
Connecting pin lock bolt on cylinder rod side
Bolt specification
01010-82045
01643-32060
M20, Length 45 mm
Necessary socket
30 mm
Tightening torque

Torques" in this mannual.
Part No. of bolt

Part No. of washer
Note) If the engine is started for the first time in this work, lubricate it before starting according to "M-3 No-injection cranking
of engine".
65
Assembly procedure
A-8
9. Installation of pin puller hoses
Clamping positions of hoses
1. Between clamp on side of beam

and cylinder: 990 mm
2. Between connecting part of
chassis and clamp A: 1,060 mm
3. Between clamp A and clamp on

side of beam: 1,370 mm
Detail of installation of pin puller hoses
66
Assembly procedure
A-8
10. Installation of grease supply hoses
Method of installing centralized greasing unit on

mount side
After completing assembly, check the operation and

confirm that the hose is not abnormally slackened or
tensed.
67
Assembly procedure
Installation of trunnion
A-9
Sling and install the trunnion.
Remove the paint from both trunnion mounting faces.
a Weight of trunnion: 1.37 kN {140 kg}
Trunnion mounting bolts
Track frame
Part No. of washer
01011-83005
01643-33080
Bolt specification
M30, Length 105 mm
Necessary socket
46 mm
Tightening torque

Part No. of bolt
Trunnion
Washer
Bolt
If there are tilt hoses, pull them out of the center of

the trunnion as shown in the figure.
Trunnion
68
Tilt hose
Assembly procedure
A-10
Installation of track shoe (1/3)
The cooperation of crane operator, machine operator and signal worker is required for installing track shoes.
Therefore, make communication between the three persons to clarify the signals.
The signaler should give out signals at a position where he could be clearly seen by the operators of the machine and the crane.
1. Sling the front end of track shoes by crane, and roll the
track shoes on the idler. (Fig. 1)
After that, set wooden bar on the grouser of track shoes
to prevent the track shoes from rewinding, and loosen the
sling.
Wire rope
slings
Slinging bar
Wooden
bars
a Slinging bar: steel rod 25 mm 1 m (one piece)

a Wire rope slings: 24 mm 2 m (2 pieces)
a Wooden bars: T300 mm 600 mm (2 pieces)
a Properly set steel plates between track shoes and
grouser to slightly adjust the height of wooden bar.
2. Start the engine, operate the ripper to vertically raise ripper beam a little, and set wooden bar under ripper beam.
Then set steel plate on the top of wooden bar, and set ripper beam onto it. (Fig. 2)
Steel plate
Wire rope
slings
a Steel plate: t25 mm T300 mm

a Wooden bar: T300 mm 600 mm (1 piece)
Inserted
3. Move ripper beam downwards to raise the rear side of

machine until the sprocket completely falls off the track
shoes. (Fig. 2)
Floated
Wooden bars
4. Sling one side of the front end of the rear of track shoes
(sprocket side) as shown in Fig. 3, and move it close to
the sprocket.
Crane.
Main hoisting
a Slinging bar: steel rod 25 mm 700 mm (one piece)

a Load chain: wire diameter 12.5 mm 1.5 m (one piece)
Using load: 49 kN {5 t}
Load chain
Outside
Inside
Sling bar
5. As shown in Fig. 4, connect the belt sling with track shoes

by using the subsidiary crane, and pull the track shoes
until it goes beyond the sprocket.
a Sling bar: steel rod 25 mm 700 mm (one piece)
a Belt sling: width 75 mm 5 m
Crane.
Main hoisting
Belt sling
Sling bar
Sprocket
Track shoes
69
Carrier roller
Crane.
Subsidiary
hoisting
Assembly procedure
A-10
6. After that, move it forward until the fifth link pin interlocks
with sprocket, completely set track shoes on the sprocket,
and then loosen the sling on subsidiary crane to lower the
track shoes.
7. Clean the mating surface of master link to remove all
harmful sand, metal scraps, etc.
a Also clean the master link on the idler described in
item 1.
8. Start the engine, and rotate the sprocket to slowly move

the track shoes forward.
After that, make the master links on the front end and on
the idler interlock with each other. (Fig. 6)
Interlocking of master links
a In this work, be sure to keep cooperation between

crane operator, machine operator and signaler.
Wooden bar
9. The lifting of track shoes is finished when the master links

interlock with each other.
10. Set the interlocked master link on master shoe (1), install
and temporarily tighten four master bolts (3) to make the
master links firmly contact with each other.
a If the shoe bolts are tightened forcibly before the contact surfaces of the master link are fitted, the threads
of them and master link may be damaged.
11. Confirm that the interlock surface is firmly contacted, and
then loosen master bolts (3) to remove master shoe (1).
12. Apply seizure preventing agent (LM-P) on the thread portion of shoe bolts.
a See "Coating materials".
No.
1
2
3
Part No.
198-32-31483
19M-32-11450
198-32-31341
Part Name
Master shoe
Key
Master bolt
Q'ty
70
Assembly procedure
A-10
13. Control of bolt tightening torque

1) Install master shoe (1) and key (2) to the master link
again, and screw-in the master bolt (3).
2) Tighten the bolts to torque of 980 98 Nm {100 10
kgm} first and check that the mating faces of the link
are fitted.
3) Make counter marks to bolt head and shoe with white
paint, etc., so that the original position of the bolt head
is identified.
4) After making counter marks, further tighten them by
using impact wrench to set the angle between counter
marks 180 10 from the original position.
a Tightening order
Tighten the bolts in the order shown in Fig. 9.
a To adjust the track tension, refer to the section A-11.
14. Remove the wooden bars set in steps 1 and 2.
71
Assembly procedure
Check track tension (1/2)
A-11
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.
Precautions
Name
Others
NOTICE
Grease inside the adjusting mechanism is under
high pressure.
Grease coming from plug (4) under pressure can
penetrate the body causing injury or death. For this
reason, do not loosen plug (4) more than one turn.
Do not loosen any part other than plug (4).
Furthermore, do not bring your face in front of the
grease fitting.
If the track tension is not relieved by this
procedure, please contact your Komatsu
distributor.
When removing cover (2), be careful not to let any
dirt get inside.
There is a safety label stuck to the back of cover
(2). Be careful not to damage the safety label.
Tools required
72
Equipment required
Qty
Name
Qty
Assembly procedure
Check track tension (2/2)
A-11
INSPECTION
Stop the machine on level ground (stop with the
transmission in FORWARD while applying the brake
slowly). Then place a straight bar on the track shoes
between the carrier roller and the idler as shown in the
figure, and measure the clearance is 20 to 30 mm, the
tension is standard.
If the track tension is not at the standard value, adjust it
in the following manner.
a Set the track tension to 30 mm for the first 100
operating hours to fit the bushings and pins.
Precautions
Tools required
Others
Name
73
Equipment required
Qty
Name
Qty
Assembly procedure
A-12
Assembly of blade (1/20)
1. Installation of blade
Stand the delivered blade vertically on the assembly
ground according to the following procedure.
a Stand the blade means to set the back of the blade at
90 to the ground as shown in (Fig. 1).
[1] Sling the blade with the crane. While operating the main
and auxiliary hoists, stand the blade gradually as shown
in (Fig. 2) and (Fig. 3) until it stands vertically on the object position (ground).
Auxiliary
hoist side
Main hoist side
a Install the rope slings of the main hoist to the blade lift
hydraulic cylinder mounting pin.
a Install the rope slings of the auxiliary hoist to the lifting
holes at both ends of the blade top through shackles.
Weight of semi U-blade
Weight of full U-blade
Weight of Super dozer
Wire rope sling
Shackle
13 t
14 t
12 t
32 mm 5 m (4 pieces)
SD34 (2 pieces)
a Use rope slings of JIS B8817 or equivalent having the

lifting capacity of at least 84 kN {8.56 t}.
a Use shackles of JIS B2801 or equivalent having the
lifting capacity of at least 49 kN {5 t}.
Reference: Additionally weld spill guard on the blade before setting the blade vertical.
See "Appendix: Installation of Spill Guard" for the installing (welding) procedure.
74
Assembly procedure
A-12
2. Measures to prevent blade from falling

(Set the blade so that it will stand vertically and stably even
after the slings are loosened.)
[1] Set wooden blocks under the center link brackets. (Fig. 4)
a Wooden block:
T350 mm length 400 mm 2 pieces
[2] Set wooden blocks under the straight frame brackets on
both sides. (Fig. 5)
2 parts
a Wooden block:
T350 mm length 400 mm 2 pieces
[3] If it is difficult to stand the blade vertically with only the
wooden blocks in steps [1] and [2], add plates to adjust
finely. (Fig. 5)
[4] After confirming that the blade stands stably, loosen and
remove the slings.
Plate
[5] Install eye bolts (2) to center link (1).
Wooden block
(Insert on both sides)
a Remove cork plugs knocked into the thread holes in

advance, and then install eye bolts.
[6] Turn center link (1) by using eye bolts (2) and crane, and
set it to a position as shown in Fig. 6 (upwards).
Set bar (4) on the top of mud cover (5) welded on the back
surface of the blade on top of center link. Connect eye
bolt and bar with wire (3), and twist the wire to fix the center link.
No.
1
Part Name
Center link
Eyebolt
Wire (metal wire)
Sling bar
Mud cover
Shackle
Remarks
Components of blade assembly
M24, using load: 9.32 kN {950 kg}
(JIS B1168 or equivalent)
#10 wire, 3.2 mm approximate length 2 m
(JIS G3532 or equivalent)
SS400B, 19 mm 300 mm
(JIS G3532 or equivalent)
Welded on the back surface of the blade already
SD16, using load: 9.81 kN {1 t}
(JIS B2801).
To be used for slinging by crane
75
Assembly procedure
A-12
3. Connection of straight frames to right and left of blades

Joint
[1] Check that the joints at the ends of the straight frames
are installed in the correct directions. (Fig. 7)
a If the joints are installed in wrong directions, correct their directions.
Good
[2] Remove the connecting pins installed to the straight

frame brackets on the blade. (Fig. 8)
No.
81
84
85
86
Part Name
Pin
Lock
Bolt
Washer
Part No.
198-72-51810
09257-11219
01010-82455
01643-32460
Q'ty
2
2
8
8
Bolt specification
M24, Length 55 mm
Tool (Socket)
36 mm
a The quantity is the number of parts necessary to

1 machine (1 blade).
76
Wrong
Assembly procedure
A-12
[3] Sling the straight frame horizontally with belt slings.

(Fig. 9)
Belt sling
Lifting load : Approx. 1770 kg for each side

: Approx. 1850 kg for each side
(for super dozer)
Belt sling: Both ends eye type
100 mm wide, 4 m long (2 pieces)
Connection
a If the straight frame slants to the right or left, the

joint described in [1] will not be inserted in the
bracket yoke easily.
Accordingly, keep the straight frames horizontally.
Wooden block
Reference: A belt sling means a belt made of

synthetic fibers used to sling heavy
things.
It is used to prevent damage on the
products and protect the paint during sling work.
[4] While slinging the straight frame, insert the joint at its
end in the bracket yoke on the blade and align the
connecting pin holes. (Fig. 9)
[5] Insert pin (81) removed in step [2] and fix it to the
bracket on the blade with lock (83), bolt (84) and
washer (85). (Fig. 9)
Belt sling
a For tightening torque of bolt, see Table 1, "Tightening Torque".

[6] Set a wooden block under the rear end of the straight
frame (on the opposite side to the joint) and adjust the
height (H) of the trunnion mounting portion (center) of
the machine above the ground to approx. 1,085 mm.
(Fig. 10)
Wooden block
a Wooden block:
T350 mm length 800 mm 1 piece
[7] Perform steps [1] [6] on both right and left sides.
[8] Sling the straight frames again and set the right and
left straight frames symmetrically about the blade and
adjust the distance between both straight frames (dimension W) to approx. 3,810 mm. (Fig. 11)
a Clean each connecting part.
77
Assembly procedure
A-12
4. Installation of center brace
4.1 Temporary installation

[1] Remove the shims, bolts and washers installed temporarily in advance to part (F) (spherical seat) of the
center link and part (G) (spherical seat) of the straight
frame. (Fig. 12)
No.
1
2
3
4
5
Part Name
Bolt
Washer
Shim (2 mm)
Shim (1 mm)
Shim (0.5 mm)
Part No.
01011-83335
01643-33380
198-71-31450
198-71-31460
198-71-31470
Q'ty
8
8
2
4
4
a "Q'ty" in above table indicates the number for each

spherical seat.
Each machine has 2 parts (F) and 2 parts (G), 4 parts
in total.
a For the "Part No." in above table, see (Fig. 13).
a The kinds and numbers of the removed shims are so
combined that the thickness at each place will be 4.5
mm. Accordingly, the shims removed from part (F)
should not be mixed with those removed from part
(G).
Detail P
a When adjusting the thickness of 4.5 mm, keep each

combination of (A) and (B). (Fig. 14)
View Z
[2] Install the belt sling to the center of center brace (90).
While slinging the center brace with the crane, put the
balls of the ball joints respectively to the spherical
seat (part F) of the center link and that (part G) of the
straight frame. (Fig. 12)
No.
90
Part Name
Center brace
Part No.
198-72-51350
Q'ty
2
a "Q'ty" in above table indicates the number for

each machine.
a Weight of center brace: Approx. 340 kg/piece
a Belt sling: Both ends eye type
50 mm wide, 4 m long (2 pieces)
78
Assembly procedure
A-12
[3] Temporarily install the ball caps of center brace (90)

to the spherical seats of the center link and straight
frame (parts (F) and (G) in (Fig. 12)) with bolts (1) and
washers (2) removed in step [1], while inserting shims
(3), (4) and (5) removed in step [1] in parts A. (Fig. 15)
and (Fig. 16)
Bolt specification
M33, Length 135 mm
Tool (Socket)
50 mm
Ball cap
a Insert the sets of shims 4.5 mm thick in total (One

2-mm shim, Two 1-mm shims and One 0.5-mm
shim) in the Two upper and lower places.
a Tighten the bolts until the spherical seat, shims
and ball cap are fitted to each other, although they
are being installed temporarily.
[4] Install the center brace on the opposite side similarly

(according to steps [1] [3]).
a To perform the same procedure for the opposite
side, remove the eye bolts, washers and bar already installed in step 2-[6].
Knock the cork plug into the thread hole to which
the eye bolt is installed.
Part Name
Plug
Part No.
07049-02430
Q'ty
1
[5] Supply a little amount of grease through part (M) (1

place) and parts (N) (1 place each on the right and left
sides). (Fig. 16)
a Use grease G2-LI (See the coating material list).
[6] Install the belt sling to either of the right and left
straight frames and move the straight frame end up
and down slowly for several times with the crane as
shown in (Fig. 17). (Stroke: 300 400 mm)
While moving up and down, check the ball joints of
the center brace for abnormal sound and ensure that
the ball joints move smoothly (check the balls for internal interference).
Perform this check on both right and left straight
frames.
Belt sling
a If no problem is detected, go to step 4.2. If any

problem is detected, adjust the shims again (add
new shims) according to step 4.3.
79
Assembly procedure
A-12
4.2 Permanent installation

[1] If no problem is detected in step 4.1-[6], tighten the
ball cap bolts at both ends of the center brace (1) in
(Fig. 15) permanently.
Necessary socket
41 mm
Tightening torque

a Tighten all the bolts evenly in the diagonal order.

[2] After tightening permanently, go to step 4.4.
4.3 Shim adjustment (Addition of shims)
[1] If any problem is detected (interference of the ball is
felt) in step 4.1-[6], remove bolts (1) and washers (2)
which are fixing the ball caps temporarily at both ends
of the center brace and add 0.5-mm thick shim (5) to
the shim set in part (A), and then install the ball caps
temporarily with bolts (1) and washers (2) according
to step 4.1-[3]. (Fig. 18)
Shim
Bolt
Washer
Ball joint
No.
5
Part Name
Shim (0.5 mm)
Part No.
198-71-31470
Q'ty
2
a Numbers in above fig. show the quantity required

for each spherical seat.
a When adjusting the thickness of 4.5 mm, keep
each combination of (A) and (B). (Fig. 14)
View Z
4.4 Adjustment of distance between tilt cylinder mounting
pin holes
[1] Sling the straight frame again with the belt sling as
shown in (Fig. 19) and adjust the distance between
the mounting pin holes of the tilt cylinder (dimension
K) (or the brace assembly on the left side in step 6 for
the single tilt dozer specification) to about 1,845 mm.
Then, adjust the position of the wooden block under
the straight frame so that the distance between the
holes will be stabilized and then remove the sling.
a Perform this adjustment on the right and left
sides.
Belt sling
Wooden block
80
Assembly procedure
A-12
5. Installation of tilt hydraulic cylinders
5.1 In case of dual tiltdozer specification

[1] Install hydraulic hoses and hose protection covers to
the right and left hydraulic cylinders. (Fig. 20)
No.
6
7
8
9
10
11
12
13
14
15
Part Name
Hydraulic cylinder
Hydraulic hose
(Overall length: 1,650 mm)
Hydraulic hose
O-ring
Flange
Bolt
Washer
Cover
Bolt
Washer
Part No.
707-01-0X760
Q'ty
2
198-71-62131
198-71-62121
07000-23025
07371-30640
07372-21035
01643-51032
198-71-62211
01010-82045
01643-32060
4
8
16
16
2
12
12
Bolt specification
Tool (Socket)
M10
17 mm
M20
30 mm
Tightening torque

a Flange (10), bolt (11) and washer (12) are installed to each hydraulic cylinder in advance.
(Marked )
However, do not reuse the sleeve head (oil stop
cover) installed to the hydraulic cylinder with (10),
(11) and (12) when installing the hydraulic hoses.
a Replace O-ring (9) with new one, as a rule.
When assembling, make sure that the

shorter hose (bottom side) has been
located on R.H. side of the cylinder
(both R.H. and L.H. cylinders).
81
Assembly procedure
A-12
[2] Remove the covers and hydraulic cylinder mounting

pins installed to the hydraulic cylinder mounting sections of the right and left straight frames. (Fig. 21)
(Same as super dozer specification)
Bolt specification
Tool (Socket)
M12
19 mm
M20
30 mm
[3] While slinging hydraulic cylinder (6) with belt sling

(20), with the cover side (hydraulic hose side) up,
align the mounting pin hole on the bottom side (clevis
side) with that of the straight frame.
Then, insert mounting pin (16) removed in step [2]
and fix it to the straight frame with lock (17), bolt (18)
and washer (19). (Fig. 21)
Sling weight (Weight of hydraulic cylinder assembly)

R.H. and L.H. sides, approx. 510 kg each
Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque

Belt sling: The same with 4.1-[2]
[4] Set a wooden block between hydraulic cylinder (hydraulic hose protection cover) and straight frame so
that hydraulic cylinder (6) will be positioned as shown
in (Fig. 22), and then loosen and remove the sling.
Wooden block TIE
a Do not connect the head side of hydraulic cylinder

(6) (part (R) in Fig. 22) at this time.
Connect it after installing the blade assembly to
the machine. See "assembly procedure A-13"
82
Assembly procedure
A-12
[5] Connect the free ends of hydraulic hoses (7) and (8)
installed to hydraulic cylinder (6) in step [1] to the elbows of flange (21) installed to the straight frame.
(Fig. 23)
Connect according to the letters stamped on the
flange.
Stamp
H
B
Hose to be connected
Longer hydraulic hose
(Head side)
Shorter hydraulic hose
(Bottom side)
a Take care not to forget to install O-rings (22).

No.
22
Part Name
O-ring
Part No.
02896-11018
Q'ty
4
a When connecting the hydraulic hoses, remove the oil

plugs (Part No.: 02789-00628) installed to the elbows
of the flange in advance.
83
Assembly procedure
A-12
5.2 In case of single tiltdozer specification

a For the single tiltdozer specification, install the tilt
hydraulic cylinder to only the right side.
[1] Install the hydraulic hoses and hose protection cover
to the hydraulic cylinder. (Fig. 24)
No.
31
32
33
34
35
36
37
38
39
40
Part Name
Hydraulic cylinder
Hydraulic hose
Hydraulic hose
O-ring
Flange
Bolt
Washer
Cover
Bolt
Washer
Part No.
707-01-0X760
Q'ty
2
198-71-62121
198-71-62131
07000-23025
07371-30640
07372-21035
01643-51032
198-71-62211
01010-82045
01643-32060
4
8
16
16
2
12
12
Bolt specification
Tool (Socket)
M10
17 mm
M20
30 mm
Tightening torque

a Flange (35), bolt (36) and washer (37) are installed to hydraulic cylinder (31) in advance.
(Marked )
However, do not reuse the sleeve head (oil stop
cover) installed to the hydraulic cylinder with (35),
(36) and (37) when installing the hydraulic hoses.
a Replace O-ring (34) with new one, as a rule.
When assembling, make sure that

the shorter hose (bottom side) has
been located on R.H. side of the
cylinder
84
Assembly procedure
A-12
[2] Remove the covers and hydraulic cylinder mounting

pin (41) installed to the tilt hydraulic cylinder mounting
section of the right straight frame. (Fig. 25)
Bolt specification
Tool (Socket)
M12
19 mm
M20
30 mm
[3] While slinging tilt hydraulic cylinder (31) with belt sling
(20), with the hydraulic hose cover side down, align
the mounting pin hole on the bottom side (clevis side)
with that of the straight frame.
and fix it to the straight frame with lock (42), bolt (43)
and washer (44). (Fig. 25)
Sling weight (Weight of hydraulic cylinder assembly):

Approx. 510 kg each
Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque

Belt sling: The same with 4. 1-[2]
[4] Set a wooden block between hydraulic cylinder (hydraulic hose protection cover) and straight frame so
that the hydraulic cylinder (31) will be positioned as
shown in (Fig. 26), and then loosen and remove the
sling.
Wooden block TIE
a Do not connect the head side of the hydraulic cylinder (31) (part (R) in Fig. 26) at this time.
the machine.
(See "Assembly procedure A-13")
85
Assembly procedure
A-12
[5] Connect the free ends of hydraulic hoses (32) and

(33) installed to the hydraulic cylinder (31) in step [1]
to the elbows of flange (46) installed to the straight
frame. (Fig. 27)
Connect according to the letters stamped on the
flange.
Stamp
Hose to be connected
Longer hydraulic hose
(Head side)
Shorter hydraulic hose
(Bottom side)
H
B
a Take care not to forget to fit O-rings (47).

No.
47
Part Name
O-ring
Part No.
02896-11018
Q'ty
4

plugs (Part No.: 02789-00628) installed to the elbows
of the flange in advance.
[6] Reinstall the covers removed in step [2].
Bolt specification
Tool (Socket)
Tightening torque
M12
Length 25 mm
19 mm
M20
Length 40 mm
30 mm
Refer to Table 1, "Tightening Torques"

in this manual.
86
Assembly procedure
A-12
5.3 For super dozer specification
[1] Install tube and tube protection covers to the right and
left hydraulic cylinders.
No.
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
Part Name
Hydraulic cylinder
(For super dozer)
Tube (L.H.)
Tube (R.H.)
O-ring
Bolt
Washer
Bolt
Washer
Block (L.H.)
Block (R.H.)
Bolt
Washer
Bolt
Washer
Cover
Bolt
Bolt
Washer
Hose
O-ring
Part No.
Q'ty
707-01-0X990
198-72-62570
198-72-62580
07000-F3030
07372-21045
01643-51032
07372-21060
01643-51032
198-72-62550
198-72-62560
07372-21035
01643-51032
01010-81095
01643-51032
198-72-62590
01011-82025
01010-82040
01643-32060
198-72-52110
07000-F3025
1
1
6
4
4
4
4
1
1
8
8
8
8
2
2
12
14
4
4
Bolt specification
Tool (Socket)
M10
17 mm
M20
30 mm
Tightening torque

87
Assembly procedure
A-12
[2] Set the cover side of hydraulic cylinder (88) facing upwards, lift the cylinder up by using belt sling (20), and
align the mounting pin holes on the bottom side (Clevis side) of the cylinder and on straight frame.
and fix it to the blade with lock (111), bolt (108) and
washer (109).
Sling weight (Weight of hydraulic cylinder assembly)

R.H. and L.H. sides, approx. 510 kg each
Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque

[3] Set a wooden block between hydraulic cylinder and

straight frame so that hydraulic cylinder (88) will be
positioned as shown in (Fig. 26), and then loosen and
remove the sling.
a Do not connect the head side of hydraulic cylinder
(88) (part (R) in Fig. 26) at this time.
the machine.
(See "assembly procedure A-13")
88
Assembly procedure
A-12
[4] Connect flange (114), bolt (115) and washer (116) to

joint of flange (113), which the free side of hose (112)
is installed to hydraulic cylinder (88) in step [1].
a Take care not to forget to fit O-rings (117).
No.
117
Part Name
O-ring
Part No.
07000-F3025
Bolt specification
Tool (Socket)
M10
17 mm
Q'ty
4

head (Part No.: 07378-10600) installed to the joint in
advance.
[5] Reinstall the covers removed in step [2].
Bolt specification
M12
M20
Tool (Socket)
19 mm
30 mm
Tightening torque

in this manual.
89
Assembly procedure
A-12
6. Installation of brace assembly
a The brace assembly is applied to the single tilt dozer

specification in the portion shown in Fig. 28.
Not necessary for super dozer
[1] Remove covers (51 54) and brace assembly mounting pins (55 58) installed to the brace assembly
mounting section of the left straight frame in advance.
(Fig. 29)
Bolt specification of 53, 57
M20
Tool (Socket)
30 mm
[2] Remove brace assembly mounting pins (59 62) installed to the brace assembly mounting section of the
blade in advance. (Fig. 30)
90
Assembly procedure
A-12
[3] The brace assembly consists of the following parts.

(Fig. 31)
No.
63
64
65
66
67
68
69
70
71
72
Part Name
Brace
Fitting
Seal
Screw
Screw
Bushing
Ring
Handle
Bolt
Washer
Part No.
198-72-53260
07020-00000
2989-01-2580
198-71-21280
198-71-21272
195-71-51254
195-71-52360
198-71-32150
01010-81660
01643-31645
Q'ty
1
2
1
1
1
1
1
1
2
2
[4] Supply grease (See step [9]) through fitting (64) installed to brace (63) and rotate brace (63) with attached lever (73) to adjust dimension (L) between the
holes at both ends of brace assembly to approximately 1,850 mm. (Fig. 32)
Reference
If brace (63) is rotated with lever (73) while screws
(66) and (67) at both ends are fixed, dimension (L) increases or decreases by 12.7 mm performance turn.
Accordingly, if only one side screw in the both end
screws is rotated by a half turn, dimension (L) can be
adjusted by 3.175 mm.
91
Assembly procedure
A-12
[5] While slinging brace assembly with the belt sling, with
the handle (70) up, align the mounting pin hole of the
brace assembly with that of the straight frame. Then,
insert mounting pin (55) removed in step [1] and fix it
to the straight frame with lock (56), bolt (57) and
Sling weight (Weight of brace assembly):

Approx. 280 kg
Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque

[6] While still slinging the brace assembly with the belt
sling (21), align the mounting pin hole on the opposite
side of step [5] with the mounting pin hole of the brace.
a At this time, if the mounting pin holes cannot be
aligned because of dimension (L) adjusted in step
[4], rotate screw (67) one half by one to adjust dimension (L) finely while locking brace (63).
If brace (63) is rotated with lever (73)

to adjust dimension (L), the direction
of handle (70) changes. According,
do not apply this method.

and fix it to the blade with lock (60), bolt (61) and
Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque

[7] Loosen and remove the sling.
92
Assembly procedure
A-12
[8] Reinstall covers (51) (54) removed in step [1].

No.
53
57
Tool (Socket)
M20
M20
Length 40 mm
Length 50 mm
30 mm
Tightening torque

in this manual.
Bolt specification
[9] Greasing
Single tiltdozer
After finishing installation, supply grease to the 5 places indicated with the arrows in (Fig. 34) until it comes
out.
Single tiltdozer
Dual tiltdozer
Super dozer
6 places indicated by arrows

a G2-LI in "Coating material list" in this manual is

recommended as grease for the above purpose.
Dual tiltdozer, Super dozer
93
Assembly procedure
A-13
Installation of blade (1/8)
Condition 1) Before starting the following work, complete "Assembly procedure A-12".
2) Before starting the following work, set the engine so that it can run to move the machine.
1) Posture of blade assembly before installation
Adjust the posture of the blade assembly before installation with wooden blocks (E) and (F) as shown in (Fig. 1) and (Fig. 2).
Dimension (b)
(Disconnect between sphere centers)
Approx. 1,085 mm
Approx. 3,810 mm
Dimension (a)
a Dimension (a) in the table is set on the assumption that the machine is used on a hard ground where the track shoe grousers will not sink. If the machine is used on a ground where the grousers sink, the trunnion height decreases by the sinking
distance. Accordingly, dimension (a) must be lowered by the decrease of the trunnion height.
a If the center link falls, dimension (b) increases. To prevent this, set wooden block (F) under the center link or arm.
a Leave wooden block (G) set to erect the blade vertically in "assembly procedure A-12" as it is.
2) Connection of blade assembly and machine
2.1)
Peel off the paint from the spherical part of the trunnion and clean its surface.
a Apply grease [G2-LI] to the spherical part of the trunnion.

G2-LI : See [Coating materials]
Seat
2.2)
Set the machine within dimension (b) of the blade assembly and move it forward so that the right and left clearances
will be the same.
2.3)
Move and press the machine forward until the trunnion is seated in the trunnion holder (bushing) of the blade assembly (straight frame). (Fig. 3)
94
Assembly procedure
A-13
a If the trunnion and trunnion holder are different in height, trunnion holder bushing (2) in (Fig. 4) may move when the
trunnion is pressed.
If the trunnion and trunnion holder are different in height, sling the straight frame of the blade assembly with a crane
etc. and adjust their heights.
2.4)
No.
1
2
3
4
5
6
7
Set the trunnion parts (Fig. 4) and tighten the bolts.
Part Name
Straight frame
Bushing
Plate
Cap
Nut
Bolt
Washer
Part No.
198-71-51340
198-72-00110
198-71-51390
195-71-11510
198-61-11250
01643-33380
Q'ty
2
4
1
4
4
4
Bolt specification
M33, Length 305 mm
Tool (Socket)
50 mm
Tightening torque

Remarks
See "assembly procedure A-12"
2.5) Remove wooden block (E) set under the straight frame in step 1).
95
Assembly procedure
A-13
3) Connection of hydraulic hoses for tiltdozer and super dozer

3.1)
Remove the plug at the tip of the hydraulic hose

coming out from the center hole of trunnion.
a Take care not to lose the "O-rings".

3.2)
Remove the upper and lower plugs from the nipples of the flange (7) in (Fig. 5) on the blade assembly side.
3.3)
Connect the hydraulic hoses to the nipples of the

above flange. (Fig. 5)
a When connect it, certainly assemble O-ring (02896-11018) removed in step 3.1).
a Connect the hydraulic hoses according to the following table.
Hose indentification
Color identification mark
(red) at the tip of hose
Color identification mark
(blue) at the tip of hose
Selection of connecting nipple

Connect to upper nipple.
Connect to lower nipple.
a The part Nos. of the plug and nut removed from the nipple of the flange in step 2) are shown below for reference.
Part name/Part No.
Plug
02789-00628
Dual tiltdozer
Q'ty
2 pieces each on
right and left
Single tiltdozer
Q'ty
2 pieces on only
right
Super dozer
Q'ty
2 pieces each on
right and left
This part is not necessary any more after the blade assembly is installed to the machine.
Keeping this part is recommended, however, since it is necessary again when the blade assembly is removed from
the machine and stored.
a When the front work equipment is the single tiltdozer, perform this work only on the right side.
96
Assembly procedure
A-13
4) Installation of tiltdozer hydraulic hose protection cover

Install tiltdozer hydraulic hose protection cover (8) (Fig. 6) connected in step 3).
No.
1
4
8
9
10
Part Name
Blade assembly
Trunnion cap
Cover
Bolt
Washer
Part No.
198-71-21240
01010-82050
01643-32060
Q'ty
1 each on right and left

Bolt specification
M20, Length 50 mm
Tool (Socket)
30 mm
Tightening torque

Remarks
See 2.4) of this procedure
a Before installing the protection cover, check the operation of the tilt cylinder in the blade adjustment work described
later and confirm that there is not oil leakage or another problem in the tilt hose connection.
97
Assembly procedure
A-13
5) Connection of blade assembly and blade lift cylinders

5.1)
Sling the hydraulic cylinder with the belt sling and

remove the transportation sling bracket.
(Fig. 7), (Fig. 8)
Belt sling
Sling bracket
a Connect the hydraulic cylinders one by one.
5.2)
Start the engine and operate the blade control lever

to extend/retract the hydraulic cylinder rod and
align it with the connecting hole (joint link) of the
blade assembly. Part (A) in (Fig. 9)
a The work shall be performed by the machine operator, crane operator, and "signalman". The signalman must arrange the signaling method in
advance and give proper directions to both operators.
5.3)
Insert the connecting pin in part (A). (Fig. 9)
5.4)
Stop the engine.
5.5)
Set the lock to the connecting pin head and bolt it

to the joint link. (Fig. 9)
Connecting pin part No.

Part No. of lock
Part No. of bolt
Part No. of washer
Bolt specification
Tool (Socket)
Tightening torque
5.6)
198-72-62140
(1 piece each on right and left)
198-72-62170
(1 piece each on right and left)
01010-81635
(2 pieces each on right and left)
01643-31645
(2 pieces each on right and left)
M16, Length 45 mm
24 mm
Install blade cylinder holdfast (11) on the upper side of the cylinder facing inside of cylinder to fix the cylinder.
98
Assembly procedure
A-13
6) Connection of blade assembly and blade tilt hydraulic cylinder

6.1)
Remove the pins from the right and left of the cylinder connecting side (blade). (Fig. 11)
a For the single tiltdozer, remove the pin from only

the right side. For the left side, see "assembly procedure A-12" Installation of brace assembly.
No.
12
13
14
15
Part Name
Pin
Lock
Bolt
Washer
Part No.
09255-06295
09257-09014
01010-82045
01643-32060
Q'ty
1 each
1 each
4 each
4 each
Bolt specification
M20, Length 45 mm
Tool (Socket)
30 mm
For super dozer
No.
12
13
14
15
Part Name
Pin
Lock
Bolt
Washer
Part No.
198-72-51720
09257-09014
01010-82045
01643-32060
Q'ty
1 each
4 each
4 each
4 each
6.2)
The bottom side (clevis side) of the hydraulic cylinder has been connected to the straight frame already. See "assembly procedure A-11".
Raise one end of this hydraulic cylinder with the
belt sling and remove the wooden block placed under it. (Fig. 12)
6.3)
With the hydraulic cylinder raised, start the engine

and operate the blade control lever to extend/retract the hydraulic cylinder rod and align its pin hole
(P) with the pin hole (Q) of the blade. (Fig. 12)
cylinder
a The work shall be performed by the machine operator, crane operator, and "signalman". The signalman must arrange the signaling method in
advance and give proper directions to both operators.
99
Assembly procedure
A-13
6.4)
After aligning the pin holes, stop the engine and insert pin (12) removed in step 6.1) and fix it to the
blade with lock (13), bolt (14) and washer (15).
(Fig. 13)
a Perform the work from step 6.2) to step 6.4) on

the right and left sides.
However, perform on only the right side for the
single tiltdozer.
a For the tightening torque of bolt (14), see "Tightening torque", Table 1 in this manual.
6.5)
Loosen and remove the slings of the hydraulic cylinder.
6.6)
Start the engine again and operate the blade control lever to raise the whole blade assembly.
Then, remove all the wooden blocks placed under
the blade.
6.7)
Lower the blade to the ground and stop the engine.
7) Confirmation of operation of blade assembly

7.1)
Check of hydraulic oil level and supply of new oil
[1] Check the hydraulic oil level again and supply new oil,
if necessary.
a Confirm the oil level after lowering the ripper
shank and blade to the ground and set the back of
the blade perpendicular to the ground.
a About the kind of used fluids refer to "Assembly
procedure A-7" Check on the amount of lubricants
and coolant.
7.2)
Check of each part for interference
[1] Move the blade slowly and check that each part does
not make interference or abnormal sound.
If abnormal sounds seem to come from the ball joints
at both ends of the center brace, see step 7.5).
[2] Confirm that the blade does not interfere with the machine (radiator guard) when it is tilted to the maximum
(or dual-tilted to the maximum for the dual tiltdozer) at
the maximum lifting height.
[3] Confirm that there is sufficient clearances between
the straight frames of the blade assembly and the
tracks of the undercarriage when the blade is tilted to
the maximum (or dual-tilted to the maximum for the
dual tiltdozer).
100
Assembly procedure
A-13
7.3)
Confirmation of operation of blade
[1] Confirm that the blade is "raised" and "lowered" according to the operation of the blade control lever.
(Fig. 14)
[2] Confirm that the blade is "right-tilted" and "left-tilted"
according to the operation of the blade control lever.
(Fig. 15)
[3] Inspect according to the "Field assembly inspection
check sheet" attached to the end of this manual.
a If the lateral balance or the clearance between
blade assembly and machine needs to be adjusted and the brace assembly length must be adjusted consequently as a result of the check, return to
"assembly procedure A-12" Assembly of blade, 6.
Installation of brace assembly, and readjust those
items.
Confirmation of operation of dual tiltdozer
[4] In addition to [1] and [2] of the single tiltdozer specification, ensure that the blade is "pitched back" and
"pitched forward" according to the operation of the
blade control lever. (Fig. 16)
[5] Furthermore, confirm that the blade is "left-dual-tilted"
and "right-dual-tilted" according to the operation of
the blade control lever.
[6] Inspect according to the "Field assembly inspection
check sheet" attached to the end of this manual.
a For super dozer, this corfirmation of operation of
dual tiltdozer is not necessary.
7.4)
Readjustment of ball joint shims at both ends of center brace

When the blade is tilted to the right or left, if abnormal sound comes from either of the ball joints at both ends of the
center brace, remove the ball cap of the ball joint which produces the abnormal sound and add the thinnest shim (0.5
mm) according to "assembly procedure A-12" Assembly of blade, step 4, and tilt the blade again to check.
101
Assembly procedure
A-14
Installation of operator's cab (1/20)
1) Installation of open lock striker

Install right and left open lock striker mounting brackets
(1) and (2) with sems bolts (3), washers (4) as shown in
(Fig. 1). (5 pieces on each side)
a Strikers (5), nuts (6), washers (7), stopper rubbers
(8), and nuts (9) are installed to the bracket when delivered.
After mounting the operator's cab on the chassis, check
the inspection items.
2) Installation of cab mounting bracket (L-shaped plate)
Temporarily tighten the bracket (10) (L-shaped plate for
indoor use) and bracket (11) (for outdoor use) to the position shown in [Fig. 2] by using sems bolts (12) and
washers (13) (3 pieces on each side).
Loosen the sems bolts (12) before installation of the cab.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Part Name
Bracket (L.H.)
Bracket (R.H.)
Bolt
Washer
Striker
Nut
Washer
Stopper
Nut
Bracket
Bracket
Bolt
Washer
Part No.
198-Z11-3341
198-Z11-3351
01010-D1230
01643-71232
14X-911-1921
01580-11008
01643-31032
09453-00002
01580-01210
198-Z11-3571
198-Z11-3581
01010-D1230
01643-71232
Q'ty
1
1
10
10
2
8
8
2
2
1
1
12
12
Remarks
Left
Right
102
Assembly procedure
A-14
3) Installation of rubber seals (14) to dashboard bracket

3.1)
Apply paste seal (55) to the mating faces of the

dashboard bracket and floor as shown in (Fig. 3).
3.2)
Fit rubber seal (14) to the guide plate of the dashboard bracket and apply paste seal (55) as shown
in (Fig. 4).
3.3)
Apply grease (G2-LI) to the outside of rubber seal

(14) (joint face to the cap) as shown in (Fig. 5).
Remark 1: Apply grease so that the cab and rubber seal

(14) will slip well against each other and rubber seal (14) will not be shifted or deformed
when the cab is installed.
Remark 2: For the ease of assembly, remove both of
right and left covers (A) before installing the
cab and reinstall them after installing the cab.
Apply G2-LI
No.
14
55
Part Name
Rubber seal
Paste seal
Part No.
198-Z11-3540
198-Z11-3960
Q'ty
1
1
Remarks
Sponge rubber
103
Assembly procedure
A-14
4) Installation of rubber seals to mating face of operator cab bottom (Fig. 6)

4.1)
Weight of operator cab assembly: Approx. 500 kg
4.2)
Remove dirt, oil and grease from the rubber seal sticking faces of operator cab bottom.
4.3)
Peel off the release paper of rubber seals (15), (16) and (17) and stick those seals, referring to (Fig. 7) on the next
page.
Remark : Since the rubber seals are made a little longer than required, cut them properly when sticking.
No.
15
16
17-1
17-2
Part Name
Rubber seal
Rubber seal
Rubber seal
Rubber seal
Part No.
14X-911-5911
198-Z11-7420
198-Z11-7410
198-Z11-7430
Q'ty
3
2
1
1
104
Assembly procedure
A-14
Fig. 7 How to stick seals (View from bottom of operator's cab)
17
17
16
17
20
16
16
20
15
Remark : For the base seal shown in the figure, see the next page.
105
Assembly procedure
A-14
Apply paste seal

(55) to clearance
Apply paste seal

(55) to clearance
No.
55
Part Name
Paste seal
Part No.
198-Z11-3960
Q'ty
1
106
Assembly procedure
A-14
5) Installation of operator cab (hereinafter referred to as cab)

5.1)
Lower the operator's cab assembly slowly onto the

floor frame.
After installing cab, check

that there is not
clearance at each corner.
a Since the clearance between the air conditioner duct

on the cab side and the machine monitor (instrument
panel) is narrow, lower the cab carefully, taking care
not to hit it.
a Since the rubber seal has high reaction force, take
care that the cab will not swing or move laterally.
a Take care that the rubber seal will not be moved or
damaged.
Lower cab in direction of

arrow.
a Eliminate the clearance between the rubber seal of

the air conditioner duct on the cab side and the air
conditioner duct on the dashboard side.
Remark: For the machine monitor, see "assembly procedure M-2".
5.2)
Tighten bolts (18) and (20) and washers (19) temporarily. See (Fig. 15)
a The bolts at the cab door inlet have different length.

Take care.
After installing cab, check

that there is not
clearance at each corner.
Lower cab in direction of

arrow.
5.3)
Confirm if there is a clearance between the mating

part (a) of the rubber seal and floor frame. (Fig. 14)
a If there is a clearance as a result of the confirmation,

sling the cab again and repeat the procedure from
step 5.1).
If the clearance is very narrow, however, fill it with
paste seal (55).
Flange
Cab
Dashboard
Bracket
107
Assembly procedure
A-14
Operator cab assembly
15 parts
6 parts
Floor frame assembly

Lower part of door
No.
18
19
20
55
Part Name
Bolt
Washer
Bolt
Paste seal
Part No.
01010-81275
124-54-26540
01010-81245
198-Z11-3960
108
Q'ty
15
21
6
1
Assembly procedure
A-14
5.4)
Check that the clearance between the air conditioner duct on the cab side and monitor is even on
the right and left sides. At the same time, check
that the air conditioner duct seal on the cab side is
fitted to faces (C) on the right and left sides of the
air conditioner duct on the dashboard side and it is
not moved to the right or left.
5.5)
If the clearance between the air conditioner duct on

the cab side and monitor is not even, loosen the air
conditioner duct mounting screws on the cab side
and move the air conditioner duct so that the clearance will be even.
If the duct on the cab side or air conditioner side is
moved to the right or left, adjust it similarly.
5.6)
Permanently tighten bolts (10), (18) and (20) which

were tightened temporarily in step 5.2) above .
5.7)
Permanently tighten mounting bolts (12) of Lplates (11) which were installed temporarily in step
5.4 above.
109
Assembly procedure
A-14
5.8)
Install plates (21) with bolts (22) and washers (23). (2 pieces on each side)
5.9)
Install right and left foot rests (24) and (25) with bolts (26) and washers (27).
5.10) Install pedal caps (28) to the foot rests.
Part P
No.
21
22
23
24
25
26
27
28
Part Name
Plate
Bolt
Washer
Foot rest (left)
Foot rest (right)
Bolt
Washer
Pedal cap
Part No.
198-Z11-2961
01010-D1230
01643-71232
14X-911-5711
14X-911-5721
01010-D1230
01643-71232
203-43-56450
110
Q'ty
2
4
4
1
1
4
4
2
Assembly procedure
A-14
5.11) The bundle of window washer tubes and the power

supply wiring harness for cab (A) in (Fig. 20) come
out of the bottom of the cab left side pillar (pillar at
the left door hinge) into the cab. Take them out of
the cab through the hole on the floor frame (B) in
(Fig. 20).
Operator cab
5.12) Fit the grommet of the rubber boot protecting

above bundle (A) to hole (B) and connect the boot
to the cab and floor frame. (Fig. 21)
5.13) Connect bundle of the window washer tubes and
power supply wiring harness for cab (A) pulled out
in step 5.11) to the window washer tubes and power supply wiring harness for cab installed to the machine in advance at a place out of hole (B)
indicated with Xo in (Fig. 20). (Fig. 22), (Fig. 23)
Floor frame
a The window washer tubes and power supply wiring harness for cab have connector No. indicating
rings at their ends as shown in (Fig. 22).
Connect the tubes having the same color marks
and the connectors having the same Nos. together respectively.
Grommet
111
Assembly procedure
A-14
Identification color marks

Red
Blue
Black

For right door

For left door
For rear window
For front window
Window washer tubes
Connectors No.
1 Phase
1 Phase
3 Phase
Wiring harness connectors
4 Phase
Connector No. indicating ring
Window washer tubes
Wiring harness
for cab power source
No.
29
30
31
Part Name
Clip
Clip
Sems bolt
Part No.
198-Z11-2961
01010-D1230
01643-71232
112
Q'ty
1
1
1
Assembly procedure
A-14
6. Installation of left parking brake lever knob

6.1)
Before installing the garnish, remove the lever knob.
6.2)
After installing the garnish, apply adhesive (LT-2) to

the thread part of the knob, and then install the knob
to the lever.
Garnish
Knob
(Lever)
a When installing the garnish, be sure to install the screws shown in the figure.
Screw
Screw
113
Assembly procedure
A-14
7. Installation of bellows bracket

7.1)
Pull and remove bellows (101) and bellows bracket

(102) of blade lever as shown in the photo.
7.2)
Similarly, remove bellows (103) and bellows bracket (104) of ripper lever.
7.3)
Install cover (33).
7.4)
Install the bellows bracket to fixing spring (105).
Installing condition of cover (33) (Fig. 30)
Fig. 30
Correct
Wrong
114
Assembly procedure
A-14
8) Installation of interior parts

8.1)
Install floor covers (35), (36), and (37) with screws

(40) (14 pieces).
8.2)
Install covers (38), (39), and (41) with button (43). (16
places)
8.3)
Install cup holder (46) with screws (47) to plate (42).

Then, install ashtray (44) and cigarette lighter (45) to
plate (42) with screws (47) and washers (48).
8.4)
Install grille (50).
8.5)
Install rubber chutes (51) and (52).
No.
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Precautions
Tools required
Name
1. Install plate (42) on cover (38) as shown in

the photo.
2. Install cover (38) first, and then install
plate (42).
Match the mounting holes of cover (38)
before installing plate (42). After plate
(42) is installed, the position of cover (38)
cannot be adjusted. (Fig. 33, Fig. 34)
Others
3. If the band to fix the optional lunch box is

selected, see also A-23.
115
Part No.
198-Z11-6170
198-Z11-6190
198-Z11-6150
198-54-61511
198-54-61531
01024-D0820
198-54-61521
198-Z11-6160
23D-950-4450
20Y-06-21751
20Y-06-23472
17A-Z11-3180
01245-00616
01643-70623
01370-40408
201-979-7820
198-Z11-6230
198-Z11-6241
Q'ty
1
1
1
1
1
14
1
1
16
1
1
1
4
4
2
2
1
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-14
Correct installation
Wrong installation
Plate (42) is installed

under cover (38).
116
Assembly procedure
A-14
8.6)
Install sensor (62) to cover (61), connect CN-SLS, and then install them with screws (63) and washers (64). (4 pieces)
8.7)
Install plates (57) and (58) with screws (59) and washers (60). (8 pieces)
8.8)
Install cab door plate (65). (On both sides).
8.9)
After installing cab door plate (65), apply liquid sealant (55) all around the plate. (On both sides)
Before opening and closing the door, wait until the sealant dries up.
CN-SLS is fixed to dashboard

wiring harness with band.
Cut band
and connect.
Sensor
Section of central part of cab
117
No.
55
57
58
59
60
61
62
63
64
65
75
76
Part No.
198-Z11-3960
198-Z11-2941
198-Z11-2951
01245-00616
01643-70623
198-Z11-6280
20Y-979-6161
01245-00616
01643-70623
198-Z11-6410
01010-D0645
01643-70623
Q'ty
1
1
1
8
8
1
1
4
4
2
6
6
Assembly procedure
A-14
8.10) Install cushion (67) and install mat (68) on it.

8.11) Install mat (69).
8.12) Install plate (65). (On both sides, See Fig. 36)
No.
67
68
69
70
71
72
73
74
Precautions
Tools required
Others
Name
118
Part No.
198-54-75681
198-54-15791
198-54-75770
198-54-75620
198-54-75610
198-54-74950
198-54-74941
198-54-74862
Q'ty
1
1
1
1
1
1
1
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-14
8) Install floor mat (74) while holding down its right and left ends with plates (81) and (82) attached to the bottom of the operator cab doorway. (See Fig. 39)
Section A-A
No.
81
82
Part Name
Plate (Left)
Plate (Right)
Part No.
198-Z11-6410
198-Z11-6410
119
Q'ty
1
1
Remarks
Assembly procedure
A-14
10) Installation of rear view mirror (if equipped)
No.
91
92
93
94
Part Name
Mirror
Bracket
Bolt
Washer
Part No.
14X-911-6140
198-Z11-3670
01010-D0845
01643-70823
Q'ty
1
1
2
2
Remarks
10.1) Install rear view mirror (91) to bracket (92).

10.2) Install bracket (92) to the front duct top of the operator cab with bolts (93) and washers (94).
a The rear view mirror is an optional part, which is not installed to the operator cab of the standard specification.
a Each operator cab to be equipped with the rear view mirror is delivered with the rear view mirror installed, as a rule.
Accordingly, this work is required only when the rear view mirror is delivered uninstalled.
120
Assembly procedure
A-14
11) Change of installed angle of radio antenna
Loosen the wing bolt at the center of rotation of the radio antenna, rotate the antenna from position (T) indicated with the broken
line to position (P) indicated with the solid line, and stand it vertically.
Tighten the wing bolt again to fix the antenna.
a Loosen and tighten the wing bolt with the hand.
a The radio antenna is set to position (T) indicated with the broken line for packing when the operator cab is transported from
the factory to the field.
121
Assembly procedure
Installation of ROPS
A-15
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.
Precautions
Tools required
Name
122
T)
No.
Part No.
Q'ty
01011-83310
16
01643-33380
16
Equipment required
Qty
Torque wrench (2,059 Nm {210 kgm})

Socket 50 mm (38.1
Others
1
1
Name
Qty
Assembly procedure
A-16
Installing direction of exhaust pipe
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
Precautions
Tools required
Others
Name
123
No.
Part No.
Q'ty
6162-13-5611
01010-81025
01643-51032
Equipment required
Qty
Name
Qty
Assembly procedure
A-17
Installation of giant ripper shank
1. Operate the machine to make the distance from the bottom of ripper beam to the ground as dimension (H) shown
in Fig. 1.
a (H): 2700 mm or more
a Make the hole for shank holder of ripper beam to be
vertical to the ground.
The following is an example of the method. Choose proper method according to the conditions in the field.
1) Set the rear of the machine on blocks, etc. to raise it
as shown in Fig. 1.
2) Raise ripper arm to the highest position, operate ripper beam, and set the hole for shank holder vertical to
the ground.
2. Set ripper shank on the ground under ripper beam. At this
time, the sling ring on the top of ripper shank should be
right under the hole for shank holder of ripper beam.
3. Set lifting rope sling on the crane, and insert the rope sling
into the hole for shank holder of ripper beam from the top
to leave the front end of the rope sling on the ground.
Crane
Rope sling
Ripper
a Rope sling: 12 mm 4 m
See "Tools list for field assembly"
4. Connect the rope sling and the lifting ring of ripper shank
with shackle.
a Shackle: SD22-M
See "Tools list for field assembly"
a Weight of shank assembly: approx. 9.8 kN {1000 kg}
5. Sling ripper shank by using crane, and insert it into the
hole for shank holder of ripper beam.
6. Align the pin holes of ripper shank and ripper beam, and
insert shank mounting pin to fix it.
Reference: The procedure for multi-ripper specification is almost the same.
124
Shackle
Shank assembly
Assembly procedure
Adjustment of arm joint (U-blade)
A-18
Check of clearance in arm ball joint

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.
2. Measure clearance A and remove bolt (2).
3. Install shim (1) having thickness of A + (0 to 1)
mm.
Shim (1)
Bolt (2)
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
125
Assembly procedure
A-19
Installation of counterweight
(1) Sling the counterweight assembly and set it to the

mounting position of the main frame.
Fig. 1
Weight of counterweight: 7,300 kg

Lifting wire: 20 mm 6 m 2 pieces
(2) Install the mounting pins as shown in Fig. 2.
Fig. 2
No.
Part name
Part No.
Q ty
Counterweight assembly
Main frame
Lifting wire
Pin
198-78-21180
Plate
205-70-61560
Bolt
01010-82045
Washer
01643-32060
Pin
198-78-21140
Plate
195-78-21171
10
Bolt
01010-82040
11
Washer
01643-32060
126
Assembly procedure
A-20
Procedure for adjusting blade tilt angle limit (1/9)
1. Dual-tiltdozer
1-1 Set the machine under the standard condition.
Set the potentiometer rod to 425 mm.
Keep the machine horizontally.
Run the engine at low idling and set the blade in the
following standard position.
1) Set the tilt angle to 0.
2) Set the pitch angle to the maximum pitch back.
3) Lower the blade to the ground and then raise it
about 100 mm.
4) Set the toggle switch of the blade lever to the
dual tilt position.
Pitch back
Tilt switch
Dual tilt
Precautions
Tools required
Name
Others
1-2
127
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
1-3
Adjust mounting dimension "a" of rod (1) and connect the rod to potentiometer lever (2) and yoke (3).
Mounting dimension "a": 425 mm
1-4
Mode and operation "Note 1"

1) Hold buzzer cancel switch (3) in the
position for 2.5 seconds, and the maintenance
mode is displayed.
2) Set the buzzer cancel switch to information
switch (2), and the adjustment mode is selected.
3) Set the buzzer cancel switch in the
position,
and the adjustment mode selecting screen is
displayed.
4) Operate the information switch
to display
the tilt limit setting screen.
5) Set the buzzer cancel switch in the select position (
) to enter the tilt limit adjustment mode
(User adjustment mode). If the pitchback button (lower button) of the work equipment control lever is pressed, the buzzer sounds and the
reference position is saved.
6) Set the buzzer cancel switch in the cancel position (
) to leave the adjustment mode temporarily.
Precautions
Tools required
Name
Others
Note 1) For buzzer cancel switch and

information switch, see "Assembly
procedure M-2".
128
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
1-5
Raise the blade tip to about 1,000 mm 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)
a Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase
too much.
a Adjust the tilt angle accurately with angle gauge.
1-7
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 in the system.
a When the saving operation is finished, the buzzer
sounds.
Tilt switch
Single tilt
Dual tilt
Precautions
Tools required
Others
Name
129
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
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.
Precautions
Tools required
Others
Name
130
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
1-11 Tilt the blade to the right with the blade control lever
and set the right tilt angle to 12.
a Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase too much.
a Adjust the tilt angle accurately with angle
gauge.
1-12 Set the toggle switch of the blade control lever in the single tilt position, and then set it in the dual tilt position again
to save the right tilt limit in the system.
a When the saving operation is finished, the buzzer sounds.
1-13 The adjustment work is finished. Set the buzzer cancel switch in the cancel position (
mode, and then lower the work equipment to the ground and stop the engine.
) to leave the adjustment
1-14 Start the engine again and tilt the blade to the right and left and check that the blade does not interfere with the track
shoe, regardless of its height.
Precautions
Tools required
Others
Name
131
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
2. Superdozer
2-1 Set the machine under the standard condition.
Set the potentiometer rod to 425 mm.
Keep the machine horizontally.
2-3
Run the engine at low idling and set the blade in the
following standard position.
1) Set the tilt angle to 0.
2) Set the pitch angle to the maximum pitch back.
3) Lower the blade to the ground and then raise it
about 100 mm.
Pitch back
Adjust mounting dimension "a" of rod (1) and connect the rod to potentiometer lever (2) and yoke (3).
Mounting dimension "a": 425 mm
Precautions
Tools required
Name
Others
2-2
132
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
2-4
Mode and operation "Note 2"

1) Hold buzzer cancel switch (3) in the
position for 2.5 seconds, and the maintenance
mode is displayed.
2) Set the buzzer cancel switch to information
switch (2), and the adjustment mode is selected.
3) Set the buzzer cancel switch in the
position,
and the adjustment mode selecting screen is
displayed.
4) Operate the information switch
to display
the tilt limit setting screen.
5) Set the buzzer cancel switch in the select position (
) to enter the tilt limit adjustment mode
(User adjustment mode). If the pitchback button (lower button) of the work equipment control lever is pressed, the buzzer sounds and the
reference position is saved.
6) 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 300 mm above the
ground.
2) Set the blade angle to 52.
a Adjust the blade angle accurately with angle
gauge.
Precautions
Tools required
Name
Others
Note 1) For buzzer cancel switch and

information switch, see "Assembly
procedure M-4".
133
Equipment required
Qty
Name
Qty
Assembly procedure
A-20
2-6
Set the buzzer cancel switch in the select position

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

changing the blade pitch angle adjusted in step 25 and tilt it 8 1 to the left. Under this condition,
press the pitch-dump button (upper button), and
the buzzer sounds and the left limit position is
saved.
a Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase too much.
gauge.
134
Assembly procedure
A-20
2-8
Operate the work equipment control lever to tilt the

work equipment to the right. Under this condition,
press the pitch-dump button (upper button), and
the buzzer sounds and the right limit position is
saved.
a Since the tilt limiting function does not work, operate slowly so that the tilt angle (a) becomes
the following angle in the chart.
gauge.
Shoe width
810 mm
910 mm
2-9
Tilt angle (a)

8 1
9 1
The adjustment work is finished. Set the buzzer cancel switch in the cancel position (
mode, and then lower the work equipment to the ground and stop the engine.
) to leave the adjustment
2-10 Start the engine again and tilt the blade to the right and left, operate the blade following the procedure in section 25 and raise the blade about 1,000 mm, and check that the blade stops tilting to the right and left in the following range
automatically.
Automatic tilt stopping angle: 8 1
Precautions
Tools required
Others
Name
135
Equipment required
Qty
Name
Qty
Assembly procedure
A-21
Method of checking auto-reset system (Superdozer)
System to return the blade to the digging position automatically

1.
2.
3.
4.
5.
6.
Auto pitch back switch
Auto pitch back switch : ON

Pitch the blade forward.
Set the gear speed in R1 or R2.
Press the pitch-back button.
The blade is fully pitched back.
The blade returns to the digging position and horizontal
position.
Pitch dump
Pitch back
The auto-reset system is used to set the blade in the digging position automatically (to lower the blade to the ground and set
its angle to 52). To reset this system, press the pitch button.
Digging posture
Tilt forward
Controller
Valve
Pitch back solenoid
Precautions
Tools required
Others
Name
136
Equipment required
Qty
Name
Qty
Assembly procedure
A-22
Installation of ORBCOMM antenna and wiring harness
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.
1
2
3
4
5
Precautions
Tools required
Name
Others
ORBCOMM:
The ORBCOMM terminal system is a
communication system to use the satellite
communication service of ORBCOMM Co.,
Ltd. (USA).
137
Part No.
01010-81220
04434-50612
8A13-10-2100
21N-54-38451
01010-81225
Q'ty
5
5
1
1
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-23
Installing lunchbox band (if equipped) (1/2)
Note) This part is optional. If not ordered, this part is not equipped.
a When performing the following procedure, refer to A-14 Installing operator's cab, too.
1. After installing plate (1) to the operator's cab, pass the band through the rear U-hook as shown below.
2. Install cover (3).

Slide and position cover (3) to the rear U-hook as shown in the figure of part (P), and then fix it.
No.
1
2
3
Precautions
Tools required
Others
Name
138
Part No.
198-Z11-6170
198-911-7350
198-54-61511
Q'ty
1
2
1
Equipment required
Qty
Name
Qty
Assembly procedure
A-23
Installing lunchbox band (if equipped) (2/2)
3. Referring to A-14 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
Precautions
Tools required
Others
Name
139
Equipment required
Qty
Name
Qty
Assembly procedure
A-24
Greasing each part of work equipment (1/3)
a For using oil type, see "A-7 Check of oil and coolant
levels" in assembly procedure.
a
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
140
Assembly procedure
A-24
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
141
Assembly procedure
A-24
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)
142
Assembly procedure
A-25
Bleeding air from hydraulic cylinders
After disassembling for transpotation, changing the oil in the hydraulic tank, or removing the
hydraulic cylinders or work equipment piping, bleed the air from the hydraulic circuit as follows.
1. Blade lift cylinder (with piston valve)
1) Start the engine and run at low idling for approx. 5 minutes.
2) With the engine at low idling, extend and retract the cylinder four or five times without operating
it to the end of its stroke.
Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the
circuit under any circumstance.
3) Keeping the engine at low idling, extend the cylinder to a point approx. 100 mm before the end
of the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of
stroke. Hold it in this position for 3 minutes.
4) With the engine at high idling, extend the cylinder to a point approx. 100 mm before the end of
the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of its
stroke. Hold it in this position for 1 minute.
2. Blade tilt cylinder (without piston valve)
1) Start the engine and run at low idling for approx. 5 minutes.
2) With the engine at low idling, raise and lower the blade four or five times without operating
the cylinder to the end of its stroke.
Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the
circuit under any circumstance.
3) Repeat this operation with the engine at full throttle, then run the engine at low idling and
operate the piston rod to the end of its stroke to relieve the circuit.
If from the beginning the engine is run at full throttle; or the cylinders are operated to the end of
their stroke, the piston packing may be damaged, so never operate in this way.
Check the oil level, and add oil to the specified level if necessary.
Precautions
Tools required
Others
Name
143
Equipment required
Qty
Name
Qty
Assembly procedure
A-26
Air bleeding from work equipment pump and fan pump
1. Bleeding air from pumps

Procedure: Loosen air bleeding plug before starting the engine.
Start the engine, and leave the pump opened until no bubbles are found in the oil flowing out.
After that, tighten the plug.
1) Bleeding air from fan pump

(1 place)
Tighten after air is bled
2) Bleeding air from work equipment pump
Precautions
Tools required
Name
Others
Stop the engine before tightening work

equipment pump.
Or there is danger of being caught into the
universal joint.
144
Equipment required
Qty
Name
Qty
M. CHECK AND MAINTENANCE PROCEDURES

AFTER COMPLETION OF ASSEMBLY
145
Assembly procedure
M-1
Check and adjustment of operators cab (1/7)
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).
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.
Operate the blower according to the following procedure.
1) Depress air outlet selector switch (2) on the air

conditioner control panel to select the front-rearfoot area mode (shown at right).
2) Select the fresh air mode with the RECIRC/FRESH
air selector switch (3).
3) Depress fan switch (1) to set the blower to the
high (Hi).
Front-Rear-Foot area
(including defroster)
<Indication on LCD and air flow>
Indication on LCD
Air flow
Low
Medium 1
Medium 2
Medium 3
Medium 4
High
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.
146
Blower
at high (Hi)
Assembly procedure
M-1
(2) Outlined below is a simplified method for the internal

pressure measurement of the operators 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.
10 mm or more
c) Remove the sliding windshield lock lever located on

the side panel of the operators 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. (See photo.)
d) Seal the hole of lock lever with tape.
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 operators cab.
f)
Start the engine and run it at full speed to read the difference between the two water levels.
Inside the
operators cab
Outside
(Atmospheric pressure)
a Before measuring inner pressure, confirm that the

grommet at the position shown in Fig. A is firmly
locked.
Remove lock lever and insert vinyl hose.
Fig. A is the same with Fig. 21

in "Assembly Procedure A-14".
Fix vinyl hose to top end of back seat
Vinyl hose
147
Assembly procedure
M-1
2. Shower test for water-tightness

(1) Close all the opening sections of the operators 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.
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
Precautions
Tools required
Others
Name
148
Equipment required
Qty
Name
Qty
Assembly procedure
M-1
3. Checking the door lock

Check the correlation between the operators 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 operators cab structure.
Normal:
The back surface of the packing tape comes in light contact the operators
cab structure when the door is being closed.
Abnormal: The back surface of the packing tape does not come in contact with the
operators 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

check the engagement from
this side.
Center of the striker

Center of the latch
Striker
Check if the center of the striker and the

center of the latch are not deviated.
149
Assembly procedure
M-1
3.2
Adjustments
(1) Adjusting the elevation of the damper rubber
When adjusting the elevation of the damper rubber, supplement or reduce the shims
being inserted below the damper rubber to adjust the elevation of the damper rubber
properly.
Damper rubber
Shims
t1.2
Door structure
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.
Precautions
Tools required
Name
Others
When the grease adhering over the latch

surface dries out, the turning effort for the
knob will become heavier.
Therefore, apply grease sufficiently in order
not to allow it to become dried up.
150
Equipment required
Qty
Name
Qty
Assembly procedure
M-1
4. Checking the open-locked state of the door

Check the correlation between the operators 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
section of the striker.
Shake the door

back and forth.
Latch (20Y-54-36380)
Bolt (01435-30820)
Striker (14X-911-1921)
Make the
observation
through this
direction
Nut (01580-11008)
Washer (01643-31032)
Bracket
(198-Z11-3341)
(198-Z11-3351)
Check and make sure that
the body of the latch and the
striker are not interfering.
The correlation is normal
if they are not interfering.
(2) Check the mounted elevation of the stopper rubber. (At 2 places each on one side. Check
them on both L.H and R.H sides.)
(a) Shaking the door back and forth in open-locked state, check for rattling.
(b) Check if the turning effort for the releasing lever is too heavy.
Precautions
Tools required
Others
Name
151
Equipment required
Qty
Name
Qty
Assembly procedure
M-1
Adjustment
(1) Adjusting the correlation between the latch and the striker
Loosen the striker mounting nut and adjust the position of the striker so that it does not
interfere with the latch nor the overriding over the bent section occurs before tightening
the nut back to its original state.
When the interference cannot be corrected by the adjustment on the striker side, loosen
the latch side mounting bolts to make the adjustment from the latch side.
Latch
Clearence
Striker
Door structure
Striker
Stopper rubber
Latch
Depress the door and if it moves
until the clearance disappears,
bring out the stopper rubber
toward the depressed side.
(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.
Precautions
Tools required
Name
Others
4.2
152
Equipment required
Qty
Name
Qty
Assembly procedure
M-2
Inspection of machine monitor (1/13)
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
153
Assembly procedure
M-2
Check that the "machine monitor" on the front panel can be set in the "service mode" with its special
function and the "failure codes" can be displayed normally in that mode.
Fig. 13 Front panel
(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 normal 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 described later in "Attached material 2". Accordingly, understand the operating procedure thoroughly.
154
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 service mode codes among the 8 of 1C, EE, bE, Cb, Ld, 5R, dR and 55. For details of the service
mode codes, see "Testing and adjusting volume" of the shop manual.
Fig. 2
Fig. 4
Upper display unit (2)
Upper display unit (2)
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 system failure code display mode)".
155
Assembly procedure
M-2
2.1)
Check of "Electrical system failure code

display mode"
Fig. 5
-1) Set upper display unit (2) in the service

2.1.1)
mode and turn information switch (6)
toward the > mark or < mark to display
service mode code "EE". (See Fig. 5
3)
Remark:Operation of information switch
(6)
Toward > mark: Next code
Toward < mark: Previous code
2.1.2)
-2) After service mode code "EE" is displayed, turn buzzer cancel switch (5) to
the <> mark to settle "EE".
-3) If "EE" is settled, the "failure code" of the
2.1.3)
electrical system is displayed on lower
display unit (3).
-4) For the contents of display on lower dis2.1.4)
play unit (3), see step 2.3).
2.2)
Check of "Mechanical system failure code

display mode"
Fig. 6
2.2.1)
-1) Turn buzzer cancel switch (5) to the t
mark to cancel the "EE" mode.
-2) Turn information switch (6) toward the >
2.2.2)
mark or < mark to display service mode
code "bE". (See Fig. 4)
6
-3) Turn buzzer cancel switch (5) to the U
2.2.3)
mark to settle "bE".
-4) If "bE" is settled, the "failure code" of the
2.2.4)
mechanical system is displayed on lower
display unit (3).
2.2.5)
-5) For the contents of display on lower display unit (3), see step 2.3).
156
Assembly procedure
M-2
2.3)
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.
2.3.1)
-1) When the assembly work is completed, no past
trouble is recorded and no trouble is detected currently, thus the display is as shown in Fig. 75 in
both modes.
2.3.2)
-2) If a trouble occurs after this machine is put in
operation or if there is the record of a past
trouble, the display of (EE) becomes as shown
in Fig. 8
6.
Fig. 7
Fig. 8
(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 occurrence
(5): Elapsed time by service meter after last occurrence
-3) If a trouble occurs after this machine is put in
2.3.3)
operation or if there is the record of a past
trouble, the display of (bE) becomes as shown
in Fig. 9
7.
Fig. 9
(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.
157
Assembly procedure
M-2
Error codes list (Related to machine controller)
158
Assembly procedure
M-2
159
Assembly procedure
M-2
160
Assembly procedure
M-2
161
Assembly procedure
M-2
Error codes list (Related to VHMS controller)
162
Assembly procedure
M-2
Error codes list (Related to engine controller)
163
Assembly procedure
M-2
164
Assembly procedure
M-2
165
Assembly procedure
M-3
No-injection cranking of engine (1/3)
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).
Transmission shift mode and
service meter are displayed on
this unit in normal mode
(operator mode).
(4) Starting switch
166
Assembly procedure
M-3
2. Procedure
2.1
(1) Turn the starting switch "ON". The machine
monitor is turned ON.
2.2
(2) Turn buzzer cancel switch ((5) in Fig. 2) to the
[
] position (left side) and hold it for 2 3
seconds.
The display of multi-information section ((3) in
Fig. 1) changes to OIL, FILTER MAINTENANCE
MODE (Fig. 3).
After the display changes, release the switch,
and it returns to the neutral position.
2.3
(3) Turn information switch ((6) in Fig. 2) to the [
]
position (left side) or [
] position (right side)
several times to change the display of the multiinformation section to USER ADJUST MODE
(Fig. 4).
Reference: Each time the information switch is
turned, the 4 modes of OIL, FILTER
MAINTENANCE MODE, PM CLINIC
MODE, FAULT CODE DISPLAY MODE
and USER ADJUST MODE are selected
in either order repeatedly.
2.4
(4) After the display of the multi-information section
changes to USER ADJUST MODE, turn the
buzzer cancel switch to the [ ] position (left
side) again to settle USER ADJUST MODE. Once
this mode is settled, it does not change to
another mode described in step (3) even if the
information switch is turned, and the multiinformation section changes to the variation
selection screen in USER ADJUST MODE.
Note: If the buzzer cancel switch is turned to the [ ]
position (right side) by mistake, the multiinformation section returns to the state in step
2.1.
(1).
167
Assembly procedure
M-3
2.5
(5) Turn information switch again to the [ ]
position (left side) or [ ] position (right side)
several times to change the display of the multiinformation section to NO INJECTION (Fig. 5).
2.6
(6) Turn the buzzer cancel switch to the [ ]
position (left side) to settle NO INJECTION.
Reference: In step (5), each time the information
switch is turned, the 7 variations of LCD
BRIGHTNES, DSP BRIGHTNES, DSP
CONTRAST, FAN 100% SPEED, NO
INJECTION, TILT LIMIT and PRE-LUB ON
are selected in either order repeatedly.
2.7
(7) In about 3 seconds after NO INJECTION is
settled, the display of the lower line of the multiinformation section changes from "WAIT" to
"ACTIVE" (Fig. 6) and the mode becomes
effective.
2.8
(8) Under this condition, turn starting switch ((4)
in Fig. 1) to the START position to rotate the
starting motor and perform no-injection
cranking.
Perform no-injection cranking for about 10
seconds at the normal temperature (about 20
C), depending on the ambient temperature.
Note 1: Do not perform no-injection cranking
continuously for more than 20 seconds.
Note 2: This function does not work while the
engine is running. During this period, "NOT
AVAILABLE" is displayed (Fig. 7) on the
lower line of the multi-information section
to indicate that this mode is not available.
2.9
(9) To reset this mode, turn the buzzer cancel
switch to the [ ] position (right side).
The display of the multi-information section
returns to the state after step 2.1
(1) where the
starting switch is turned "ON".
2.10
(10) Turn the starting switch "OFF".
168
Assembly procedure
M-4
Setting procedure of user adjust mode (1/3)
When setting the cooling fan speed to about 100% of the maximum speed forcibly for measurement
of the pressure inside the cab in [M-1: Check and adjustment of operators cab], operate the machine
monitor to display USER ADJUST MODE in the multi-information section according to the following
procedure.
1. Use multi-information section (3) of the machine monitor, starting switch (4), buzzer cancel switch
(5) and information switch (6) to set the user adjust mode.
Fig. 1 Front panel

(1) Machine monitor
Gear speed is displayed on this
unit in normal mode (operator
mode).
Transmission shift mode and
service meter are displayed on
this unit in normal mode
(operator mode).
(4) Starting switch
169
Assembly procedure
M-4
2. Procedure
2.1
(1) Turn the starting switch "ON". The machine
monitor is turned ON.
2.2
(2) Turn buzzer cancel switch ((5) in Fig. 2) to the
[
] position (left side) and hold it for 2 3
seconds.
The display of multi-information section ((3) in
Fig. 1) changes to OIL, FILTER MAINTENANCE
MODE (Fig. 3).
After the display changes, release the switch,
and it returns to the neutral position.
2.3
(3) Turn information switch ((6) in Fig. 2) to the [
]
position (left side) or [
] position (right side)
several times to change the display of the multiinformation section to USER ADJUST MODE
(Fig. 4).
Reference: Each time the information switch is
turned, the 4 modes of OIL, FILTER
MAINTENANCE MODE, PM CLINIC
MODE, FAULT CODE DISPLAY MODE
and USER ADJUST MODE are selected
in either order repeatedly.
2.4
(4) After the display of the multi-information section
changes to USER ADJUST MODE, turn the
buzzer cancel switch to the [ ] position (left
side) again to settle USER ADJUST MODE. Once
this mode is settled, it does not change to
another mode described in step (3) even if the
information switch is turned, and the multiinformation section changes to the variation
selection screen in USER ADJUST MODE.
Note: If the buzzer cancel switch is turned to the [ ]
position (right side) by mistake, the multiinformation section returns to the state in step
2.1.
(1).
170
Assembly procedure
M-4
2.5
(5) Turn information switch again to the [ ]
position (left side) or [ ] position (right side)
several times to change the display of the multiinformation section to NO INJECTION (Fig. 5).
(6) Turn the buzzer cancel switch to the [ ]
2.6
position (left side) to settle NO INJECTION.
Reference: In step 2.5
(5), each time the information
switch is turned, the 7 variations of LCD
BRIGHTNES, DSP BRIGHTNES, DSP
CONTRAST, FAN 100% SPEED, NO
INJECTION, TILT LIMIT and PRE-LUB ON
are selected in either order repeatedly.
2.7
(7) If the engine is started under this condition, the
cooling fan speed is kept controlled to about
100% of the maximum speed.
(7)
2.7 is effective only in this mode. It becomes
ineffective if the system is set out of this mode.
(8) To reset this mode, turn the buzzer cancel

2.8
switch to the [ ] position (right side).
The display of the multi-information section
returns to the state after step 2.1
(1) where the
starting switch is turned "ON".
171
Fig. 5
Assembly procedure
Flushing of hydraulic circuit (1/3)
M-5
1. After assembly, flush the hydraulic pressure circuit of work equipment in accordance with the following procedures.
a According to "A-5 Replacing Return Filter" in Assembly Procedure, return filter element is already replaced from standard
element to exclusive flushing element for the flushing.
1) Set the levers in neutral and run the engine at low idle for 30 minutes.
2) Set the levers in neutral and run the engine at medium speed for 30 minutes.
3) While running the engine at speed of about 1,700 rpm, repeat the following lever operation pattern 4 times (Keep each
operation for 1 minute to 1 minute 30 seconds).
The operation patterns are as follows.
Raise blade
Raise ripper
Lower blade
Tilt blade to left
Lower ripper
Tilt ripper in
Tilt blade to right

Tilt ripper back
4) After 1) to 3) are finished, remove the installed exclusive flushing element, replace it with stored current standard element. See Item 2 for replacing procedure.
Reference: Flushing is a cleaning method to remove dirt in hydraulic oil, which works by forcibly circulate hydraulic oil through
flushing filter installed to collect and filter the early dirt in the circuit.
Precautions
Tools required
Name
Others
When atmospheric temperature is at -15C or

lower, install the valve and strainer (Do not
install the oil stopper plate) then perform flushing at low idle.
172
Equipment required
Qty
Name
Qty
Assembly procedure
M-5
2. Replacement of exclusive flushing element with standard element

1) After the flushing is finished for work equipment circuit, replace the exclusive flushing parts with stored original element
(3), strainer (4) and valve (5).
a Avoid entrance of dirt when removing exclusive flushing element.
a When atmospheric temperature is at -15C or lower, pay attention that the valve and the strainer are not replaced with
the plate.
a Keep accordance with the element installing condition in 2) as the element capacity will be lower if the installing condition is wrong.
No.
3
4
5
Part Name
Element
Strainer
Valve
Part No.
208-60-71120
07069-25400
208-60-71160
Q'ty
1
1
1
Standard element
a Scrap the used flushing element. Keep accordance with the local laws for scraping.
a Strainer, valve and replaced plate are reusable, so it is recommended to store them for the next flushing work.
173
Assembly procedure
M-5
2) Installing condition of element
Element
Fig. 1 Good condition
Fig. 2 Bad condition
a Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig. 2.
Particularly when the filter case is filled with oil, it is difficult to see if the element is installed normally. In this case, turn the
installed element with the hand.
If you can turn the element smoothly, it is installed normally.
Precautions
Tools required
Name
Others
174
Equipment required
Qty
Name
Qty
APPENDIX 1.
INSTALLATION OF SPILL GUARDS
1. Introduction ......................................................................................................................................
2. Additional parts ................................................................................................................................
3. Spill guard fabrication drawings .....................................................................................................
3-1. For semi-U blade .......................................................................................................................
3-2. For full-U blade ..........................................................................................................................
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
Semi-U
Full-U
Superdozer
Part No.
Part Name
Qty
Weight (kg)
198-71-61710
Spill guard (center)
134.6
198-71-61720
Spill guard (left)
49.6
198-71-61730
Spill guard (right)
49.6
198-72-63910
171
198-72-63920
Spill guard (left)
56
198-72-63930
Spill guard (right)
56
198-72-63810
224
198-72-63820
Spill guard (left)
34
198-72-63830
Spill guard (right)
34
Remarks
Refer to the fabrication

drawing
3. Spill guard fabrication drawings

3-1. For semi-U blade
(1) Spill guard
3
Part Name
PLATE
PLATE
PLATE
Sym.
01
02
03
SS400P
SS400F
SS400F
Material
10
11
Qty
5.75
2.55
24.5
t 19
t 19 65
t 19 65
Weight (kg) Remarks
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.
(2) Spill guard (for semi-U, center) 198-71-61710 fabrication drawing
PLATE
PLATE
PLATE
PLATE
09
11
12
PLATE
08
10
PLATE
PLATE
06
PLATE
05
07
PLATE
PLATE
PLATE
02
03
PLATE
01
04
Part Name
Sym.
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
Material
Qty
2.30
2.80
3.95
5.10
1.35
1.45
1.75
1.90
2.15
2.30
11.9
12.6
t 19
t 19
t 19
t 19
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
Weight (kg) Remarks

per KES 04.351
2. Flatness of surfaces A, B, C, D and E in drawing
to be within 2.
(3) Spill guard (for semi-U, left) 198-71-61720 fabrication drawing
5
PLATE
PLATE
PLATE
PLATE
09
10
11
12
PLATE
PLATE
07
08
PLATE
PLATE
05
06
PLATE
PLATE
PLATE
02
03
PLATE
01
04
Part Name
Sym.
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
Material
Qty
2.30
2.80
3.95
5.10
1.35
1.45
1.75
1.90
2.15
2.30
11.9
12.6
t 19
t 19
t 19
t 19
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
Weight (kg) Remarks

per KES 04.351
to be within 2.
(4) Spill guard (for semi-U, right) 198-71-61730 fabrication drawing
3-2 For full-U blade

(1) Spill guard
7
PLATE
PLATE
PLATE
02
04
PLATE
01
03
Part Name
Sym.
SS400F
SS400P
SS400F
SS400F
Material
13
12
Qty
0.66
6.16
2.54
29.0
t 19 65
t 19
t 19 65
t 19 65
Weight (kg) Remarks

per KES 04.351
to be within 2.
(2) Spill guard (for full-U, center) 198-72-63910 fabrication drawing
PLATE
PLATE
PLATE
13
14
15
PLATE
PLATE
11
12
PLATE
PLATE
09
10
PLATE
PLATE
07
08
PLATE
PLATE
05
06
PLATE
PLATE
PLATE
02
03
PLATE
01
04
Part Name
Sym.
SS400F
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
Material
Qty
0.40
2.40
2.76
3.98
5.28
0.98
1.11
1.41
1.55
1.84
1.99
2.23
2.42
13.5
14.2
t 16 32
t 19
t 19
t 19
t 19
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
Weight (kg) Remarks

per KES 04.351
to be within 2.
(3) Spill guard (for full-U, left) 198-72-63920 fabrication drawing
PLATE
PLATE
PLATE
13
14
15
PLATE
PLATE
11
12
PLATE
PLATE
09
10
PLATE
PLATE
07
08
PLATE
PLATE
05
06
PLATE
PLATE
PLATE
02
03
PLATE
01
04
Part Name
Sym.
SS400F
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
Material
Qty
0.40
2.40
2.76
3.98
5.28
0.98
1.11
1.41
1.55
1.84
1.99
2.23
2.42
13.5
14.2
t 16 32
t 19
t 19
t 19
t 19
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
t 19 65
Weight (kg) Remarks

per KES 04.351
to be within 2.
(4) Spill guard (for full-U, right) 198-72-63930 fabrication drawing
3-3 For superdozer blade

(1) Spill guard
10
11
Part Name
PLATE
PLATE
PLATE
PLATE
Sym.
01
02
03
04
SS400P
SS400P
SS400P
SS400F
Material
Qty
7.95
6.55
74.0
34.3
t 19
t 19
t9
t 19 65
Weight (kg) Remarks

per KES 04.351
to be within 2.
(2) Spill guard (for superdozer, center) 198-72-63810 fabrication drawing
12
PLATE
PLATE
PLATE
PLATE
PLATE
05
06
07
08
09
PLATE
PLATE
PLATE
02
03
PLATE
01
04
Part Name
Sym.
SS400F
SS400F
SS400F
SS400P
SS400F
SS400P
SS400F
SS400P
SS400F
Material
Qty
6.50
9.35
2.35
3.20
2.05
3.05
1.75
2.05
1.65
t 19 65
t 19 65
t 19 65
t 19
t 19 65
t 19
t 19 65
t 19
t 19 65
Weight (kg) Remarks

per KES 04.351
to be within 2.
(3) Spill guard (for superdozer, left) 198-72-63820 fabrication drawing
13
PLATE
PLATE
PLATE
PLATE
PLATE
05
07
08
09
PLATE
04
06
PLATE
PLATE
02
PLATE
01
03
Part Name
Sym.
SS400F
SS400F
SS400F
SS400P
SS400F
SS400P
SS400F
SS400P
SS400F
Material
Qty
6.50
9.35
2.35
3.20
2.05
3.05
1.75
2.05
1.65
t 19 65
t 19 65
t 19 65
t 19
t 19 65
t 19
t 19 65
t 19
t 19 65
Weight (kg) Remarks

per KES 04.351
to be within 2.
(4) Spill guard (for superdozer, right) 198-72-63830 fabrication drawing
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 - 350C for 30 - 60 minutes.
4-3-6
Preheat the area about 50 mm from the beat to be laid at 150 - 200C. When the ambient
temperature is below 10C, post-heat the same area, too, at 150 - 200C.
4-3-7
Set the welding current to the lower limit of the current range specified for the diameter
of the welding rod or wire.
4.3.8
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. Initialization procedures for VHMS controller.......................................................................................... 2
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

a
Initialization tools for VHMS controller
Symbol
Part No.
Part name
799-608-3211
Diskette
799-608-3220
Wiring harness
Commercially
available
Notebook type personal computer (OS: Windows98/2000/

NT/Me/XP Terminal
"RS232C" is with it)
1.
Check of machine information, engine

information and controller information
a This step is a work performed on the
whole machine.
Check and record the machine information,
engine information, VHMS controller information and ORBCOMM terminal information.
No.
Before starting full operation after completion

of local assembly or before resuming operation
after storage for a long period, initialize the
VHMS controller according to the following
procedure.
Machine data collected with the VHMS controller are stored and managed in WebCARE
database. To process the data smoothly on the
WebCARE, it is necessary to set the VHMS
controller consistently. If it is not set correctly,
data will not be taken into the WebCARE and
data in the VHMS controller may not be utilized. Accordingly, be sure to carry out the initialization.
For the method of installing the VHMS Initialization Program to the personal computer,
refer to the Operation and Maintenance Manual contained in the package of diskette Z1.
Since the service menu of the monitor panel
will be used in the following procedure, read
Special functions of monitor panel and understand the operating procedure in advance.
The initialization procedures cover both ORBCOMM Specification and ORBCOMMLESS
Specification. In case of ORBCOMMLESS
Specification, omit the procedures necessary
for ORBCOMM Specification only.
During the initialization work, confirm each
work according to the VHMS Initialization
Work Checklist.
Information to be checked
Machine model
Machine serial No.
Current service meter reading
Engine serial No.
Transmission serial No.
VHMS controller serial No.
ORBCOMM terminal serial No.

[For ORBCOMM specification only]
2.
The VHMS controller and ORBCOMM terminal are in the VHMS controller box
under the left side cover of the floor.
Connection of personal computer

1) Make sure that the starting switch is in the
OFF position.
k Be sure to connect and disconnect
the personal computer while starting switch is in the OFF position.
2) Connect personal computer Z3 and download 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.
2)
3)
4)
a
a
Execute initialization of VHMS from

the connector in the cab.
Use the ground download connector
for only downloading.
5)
6)
3.
Select Service mode and Real-time

monitoring mode in order on the monitor
panel.
Input ID = 20301.
If the central part of the lower line of the
multi-information display unit counts up,
the VHMS controller is normal.
Check of operation and satellite capturing

condition of VHMS controller
a This step is a work performed in the operator's cab.
a Check of satellite capturing condition is
necessary o only [ORBCOMM specification].
1) Set the starting switch in the ON position.
7)
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.
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 position.
2] For monitor panel specification:
Referring to 10. Real-time monitoring
mode or 11. Dual display monitoring
mode, input ID = 20301.
At least 3 minutes after starting the VHMS,

check the decimal point at the right bottom
of the LED of the VHMS controller or the
decimal point at the right bottom of the
central part of the lower line of the multiinformation display unit.
9)
Right decimal
point
Display
OFF
Power is not supplied to ORBCOMM controller.

Communication line to VHMS
controller is abnormal.
ON
Satellite is not captured.

Power is supplied to ORBCOMM controller.
controller is normal.
Blinking
Power is supplied to ORBCOMM controller.

controller is normal.
Satellite is captured.
8)
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 [ORBCOMM specification].
a Check the communication satellite
capturing condition of the ORBCOMM
controller on the VHMS controller
side.
a If the ORBCOMM controller is normal, the decimal point LED of the
right-hand 7 segments flashes.
4.
Check the controller for normal operation

referencing 7-segment LED of VHMS controller.
a VHMS controller is fed with switch
power supply. Thus, its operation is
judged normal if its 7-segment LED
starts flashing while rotating as the
starting switch is turned on and then if
the controller starts counting in the
ascending order.
Startup of VHMS initialization tool

a This step is a work performed in the operator's cab (on the personal computer).
1) Turn on the personal computer and start
the OS.
2) Click the icon of [VHMS Initialization Tool]
on the personal computer screen to start
the VHMS initialization tool.
a The setting screen varies with the
version No. of the VHMS setting tool.
a When using a tool before Ver. 3.5.2.1
(CD-ROM), set the VHMS in step 5.
a When using an updated tool (Ver.
3.5.2.1 or after), set the VHMS in step
6.
a It is recommended to download the
latest VHMS setting tool from the
WebCARE and update your tool.
(Related material: Servicemate SMP623)
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.
5.
Initialization of VHMS controller (Tool

before Ver. 3.5.2.1)
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 displayed first in the [Data clear and Set
up] menu.
2) Check all the data.
3)
If information in the [Date/Time] box is not

correct, change it according to the following 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 information] box to display the correction
screen.
2] Correct the information and press the
[OK] button.
5)
After checking/changing all the data in

[Machine information], press [Apply] button (3) to settle the setting.
a Press the [Apply] button (3), and the
screen for checking the setting will
appear. Check the setting again and
press the [OK] button if the setting is
correct.
a In case of the ORBCOMM Specification, execute [Communication Setting] first and then settle the setting.
[Communication Setting] [For ORBCOMM specification only]

a Execute this setting after requesting for opening of the ORBCOM terminal and finishing the
opening procedure.
6) Open the [Communication Setting] tab.
7) Check all the data.
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 [Occurrence] at [Timing] and set the
function to [ON].
9)
To change setting in [SHORT TREND

ANALYSIS], follow the procedures below:
1] Select [SHORT TREND ANALYSIS]
on the screen and press [Edit] button
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, input [20h] to
[SMR] and set the function to
[ON].
11) After checking/changing all the data in

[Communication Setting], press [Apply]
button to settle the setting.
a If the [Apply] button is pressed, the
s c r ee n fo r c he c k i n g t he s e tt in g
appears. Check the setting again and
press the [OK] button if the setting is
correct.
10) To change the setting of [Satellite Setting],

follow the procedure below.
1] Press the [Edit] button in the [Satellite
Setting] block to display the setting
screen.
2] Set the GCC Code to the applicable
area and then press the [OK] button.
12) After checking/changing the data of

[Machine Information] and [Communication Setting], press the [Exit] button at the
right lower part of the screen to finish
[VHMS Initialization Tool].
GCC codes and applicable areas

Code
1
120
Applicable
Area
Code
Applicable
Area
U.S.A.
121
Malaysia
Brazil
122
Korea
Italy
130
Japan
6.
Initialization of VHMS controller (Ver. 3.5.2.1

or after)
a When initializing, do not change the data
of service meter [SMR].
1) Select [VHMS Setting] and press the
Next button.
3)
Check the machine information. If it does

not need to be corrected, press the Next
button.
2)
Select [Set up & All clear] and press the

Next button.
If the VHMS was installed additionally, the information of [Serial No.] etc.
must be input.
4)
5)
6)
Select the time zone.

Input the local time.
If the DST (Daylight Saving Time) is used
now, select it and press the Next button.
a If the DST is selected, the clock is
advanced 1 hour automatically, thus
the time must be corrected again.
7)
8)
The contents of the setting are displayed

finally. If there is not a problem, press the
Apply button.
9)
The system asks you if you save the data

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

and then press the Next button.
GCC codes and applicable areas
Code
1
120
Applicable
Area
Code
Applicable
Area
U.S.A.
121
Malaysia
Brazil
122
Korea
Italy
130
Japan
10) After finishing the work of changing the

contents of initialization, press the OK
button to finish the program.
7.
Procedures for executing Quick Pm

a The Quick Pm means the Pm Clinic executed with the manual snap shot function
of the monitor panel.
a Data in 7 minutes 30 seconds are saved in
the VHMS controller.
k Stop the machine on a flat place.
2]
3]
Set the buzzer cancel switch in the

[U] position.
READY is displayed and the system
is ready to start.
a On the lower line, 15 pieces of -
are displayed.
1)
2)
Start the engine.

Set the monitor panel to display the service menu.
a For the operating method, see Special 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 display unit (1) and the title is displayed in multi-information unit
(2).
Serial numbers: 30001 30070
4]
Serial numbers: 30071 and up
10
Set the buzzer cancel switch in the

[U] position, and the snap shot operation starts.
a After the snap shot operation
starts, the elapsed time is displayed 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 operation, set the buzzer cancel switch
in the [t] position.
5]
After starting the snap shot operation,

operate the machine according to
Table 1.
a Check that the engine coolant
temperature and torque converter 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.
11
Time (sec)
Finish
Start
No.
Table 1 Operations of machine to be executed while snap shot is operated

Operation of machine
State of machine
0:00 0:25 25
0:25 0:50 25
0:50 1:40 50
1:40 2:30 50 Deceleration slow
2:30 3:00 30
Transmission
Fuel
SteerWork equipment control
ing
dial
Decelerator pedal
Brake
pedal
Parking
brake
LH
LOW
HI
Released Released
RH
LOW
HI
Released Released
HI
HI
Released Released
HI
LOW
Released Released
High-pressure
relief & high idle
HI
HI
Released Released
3:00 3:30 30
High-pressure
relief & low idle
Right tilt (or

pitch back in
case of dual tilt
model)
LOW
HI
Released Released
3:30 4:00 30
Port relief &

high idle
4:00 4:30 30
Port relief &

low idle
4:30 5:10 40
Torque converter
stall & low idle
Torque converter
10 5:10 6:00 50 stall (F3) & high
idle (Note 1)
11 6:00 6:30 30
Low idle
High idle
High idle
Torque converter
12 6:30 7:10 40 stall + High-pressure relief
13 7:10 7:30 20
High idleo
Low idle (Note 2)
HI
HI
Released Released
Left tilt (or pitch

dump in case of
dual tilt model)
LOW
HI
Released Released
NoF1oF2oF
3oNoR1oR2
oR3oN
LOW
HI
ON
Released
NoF3 (Shift to
F3, then run
engine at full
throttle)
HI
LOWo
Shift to F3,
then HI
ON
Released
HI
HI
NoF3 (Shift to
F3, then run
engine at high
idle)
Left tilt (or pitch

dump in case of
dual tilt model)
HI
LOWo
Shift to F3,
then HI
ON
Released
HIo
LOW
HI
Released
ON
Released Released
(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.
(Note 2): Keep running the engine at low idle until the oil temperature is lowered to the normal level.
a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine
speed to high idle.
a After stalling the torque converter, watch the power train oil temperature gauge and take care not to
overheat the power train oil.
(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature
gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the
engine at high idle to lower the oil temperature.)
12
6]
The screen shown below appears 7

minutes 30 seconds after the snap
shot is started, and then the initial
screen appears 5 seconds after. (End
of snap shot)
q
q
q
q
q
q
q
Important
The data of the Quick Pm is recorded only
once. If the Quick Pm is executed again,
the current data are overwritten. Accordingly, be sure to save the data in the personal computer after executing the Quick
Pm, referring to 8. Downloading of set
data.
7]
a
8]
a
q
q
q
q
Using the analysis tool, read the data

of the Quick Pm.
For the usage of the analysis tool,
see the operation manual.
Open the data of the Quick Pm and
translate them into a graph.
Set the time to the X-axis and set the
following items to the Y-axis.
q
Engine Speed
q
Fuel Inject
q
q
13
Blowby Press
Exhaust Temp RB (Exhaust temperature of right bank: 1, 2, 3, 4,
5, 6)
Exhaust Temp LB (Exhaust temperature of left bank: 1, 2, 3, 4, 5,
6)
Engine Oil Press
Engine Oil Temp
Eng Coolant Temp
Ambient Temp
Demand Eng Speed
(Engine speed demanded by
controller)
T/C Oil Temp
(Torque converter oil temperature)
T/M Main Press
(Transmission main relief pressure)
T/M Output Speed
(Transmission output speed)
Shift Position
( Tr a n s m i s s i o n , t r a v e l , g e a r
speed)
S/T Clutch Pos.
(Steering clutch position)
S/T Brake Pos. (Steering brake
position)
Hydr Oil Temp
(Hydraulic oil temperature)
Pump 1 Press
(Work equipment pump 1 oil
pressure)
Pump 2 Press
(Work equipment pump 2 oil
pressure)
Body Pitch Angle (Pitch angle)
9]
Check Click position graphic value

display.
14
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.)
15
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 conditions is as follows.
Engine at high idle
Deceleration slow
High-pressure relief & engine at full throttle
Q
Q
High-pressure relief & engine at slow

Port relief & engine at full throttle
Q
Q
Port relief & engine at slow

Q
Torque converter stall & engine at slow

Torque converter stall (F3) & engine at full
throttle
Work equipment pump (FR)
3rd clutch fill switch
2nd clutch fill switch
1st clutch fill switch
Rear clutch fill switch
Steering right brake fill switch
Steering left brake fill switch
Steering right clutch fill switch
Steering left clutch fill switch
Engine at low idle
Front clutch fill switch
Transmission main relief pressure
Exhaust temperature
Blow-by pressure
Engine speed
State of machine
Engine oil pressure
Measurement items
Engine at full throttle

Torque converter stall & high-pressure relief
Engine at high idle o Engine at low idle
The stall speed measured with Snapshot is not the exact value. If measuring the stall speed exactly, set
stall mode "0530" and measure it.
16
8.
Downloading of set data

1) Connect personal computer Z3 and download connectors VDW in the cab or ground
download connector DL1 by wiring harness Z2.
2)
3)
a
Download connector VDW in the cab

is installed to the left rear lower part of
the operator's seat.
4)
When using download connector VDW in

the cab, set the starting switch in the ON
position.
When using ground download connector
DL1, turn switch (2) ON.
a The green LED lights up.
Operate the icon of [VHMS Technical
Analysis Tool] on the personal computer to
start the VHMS technical analysis tool.
a
a
a
Ground download connector DL1 is

installed in frame (1) at the rear of the
machine.
17
Input [User Name] and [Password].

For the operation procedures, see the
Operation and Maintenance Manual
for VHMS Technical Analysis Tool.
5)
9.
Use the [Download] function to download

the data recorded in the VHMS controller
to the personal computer.
a For the operation procedures, see the
Operation and Maintenance Manual
for VHMS Technical Analysis Tool.
a Make sure that downloading has
completed before proceeding to the
next step.
10. Disconnection of Personal Computer

1) Make sure that the starting switch is in the
OFF position.
k Be sure to turn off the starting
switch before connecting or disconnecting the personal computer.
2) Finish the OS of the personal computer
and then turn the personal computer OFF.
Check of downloaded data

1) Check the set data with the [View] function.
a For the operation procedures, refer to
the Operation and Maintenance Manual for VHMS Technical Analysis Tool.
a Make sure that the [MFA0] code at
the time when the snapshot was
operated is displayed in [Fault History].
a Make sure that the snap shot data is
recorded.
2)
After checking the set data, terminate

[VHMS Technical Analysis Tool].
18
3)
If the data was downloaded in the cab,

disconnect wiring harness Z2 from download connector VDW.
4)
If the data was downloaded on the

ground, turn switch (2) OFF and disconnect wiring harness Z2 from download
connector DL1.
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: webcare@komatsu.co.jp
19
(Objective model: D475A-5E0 Bulldozer)
20
(Objective model: D475A-5E0 Bulldozer)
21
To: VHMS / WebCARE Support Center

FAX : 81-3-5561-4766
SEKN5051-1
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

*Check the reason on the right.
*For replacement,enter the serial No.of the replaced
component below each column (Note).
(Note 1)
Replace the VHMS controller.
(Note 2 or 3)
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)
New engine serial number.
Enter both of two engines if mounted.
(Note3)
New transmission serial number.
GCC code(If Orbcomm is equipped)
No.1 Engine
No.2 Engine
Time difference (GMT)
(Time Zone offset
Summer time (Daylight Savings Time)

Did you initialize VHMS as described in the shop
manual ?
ON
: 00)
OFF
YES
***Important***
*After entering the VHMS/WebCARE Basis Information Form,fax or email it to the following location with the initial
download data.
VHMS / WebCARE support center (Product Support Div. Komatsu LTD.)
TEL : 81-3-5561-2765 *** FAX : 81-3-5561-4766 *** EMAIL : webcare@komatsu.co.jp
22
U-dozer or Semi U-dozer specification 1/7
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
D475A-5E0
Service Meter Reading (Hr):
Engine Serial No.
SAA12V140E-3
Date of Inspection
Inspector's name:
Location of Machine at Inspection:
Distributor's Name:
Specification
Customer's name:
(Country)
Address:
Blade
Semi U.
Ripper or counterweight
VGR
Shoe width
910 mm
Cab
With cab, Without cab
VMR
(Dual
Single)
CW (
810 mm
Ton)
710 mm
Enter specification of optional/local

Others
(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
COOLANT AND OIL LEVEL
Category
Inspection Item
Inspection
Criteria
Main radiator coolant level
Above the bottom Radiator

surface
Strainer
Reserve tank coolant level
Low Full
Engine oil level
EO15W40-DH
(H+L)/2 (H+20)
Engine : Stopped
Power train oil level
TO30
L (H+20)
Engine : Low idle

(After 3 to 5 minutes)
Damper case oil level
TO30
(H+L)/2 (H+10)
Engine : Stopped
Hydraulic tank oil level

Between H L
TO10
Center to upper
level of sight
gauge
Pitch back on the ground.

Ripper point on the ground.
Engine : stopped
Final drive oil level
GO85W-140
H (H20)
See operation manual.

Engine : stopped
(H+10) (H+30)
from shaft end
a=100 10
Oil level
Pivot shaft oil level
LH
RH
LH
TO30
EO30-CD
RH
LH
Recoil spring oil level
TO30
EO30-CD
RH
Battery electrolyte level

Check battery
Between L and H
UPPER LEVEL
LOWER LEVEL
Must be no adhesion of grease, loosened

terminal, or crack
Window washer tank water level
Full
Fuel tank
Full (1670 l)
Draining of fuel tank
Drain fuel tank (Drain water, foreign matter, etc.)
Horn
Must be of no beat sound or sound deterioration.
Backup alarm
(Starting engine)
Backup alarm must sound when the PCCS lever

is at the back position.
Monitor display
Monitor must be turned on with buzzer sound,

then go off after 3 seconds. After that all gauge
lamps must come on.
No error code indicated in the service meter.
INSPECTION
Operation of service meter

(Engine: Low idle)
Before engine start, meter must not operate

when the key switch turned on.
Charge lamp (Engine: Low idle)
Must not light up when all lamps are turned on.
Lamp ON (Head lamp, tail lamp and work lamp)
Must light up when turned on.
Preheating switch (Auto preheating when at ON position)

(Manual preheating when turned to left)
Preheating lamp (green) must light up
Corrosion resistor valve
Must be fully open.
Heater hose valve
Winter: Open valve fully

(Close valve fully in summer)
Controller error code indication (make sure that error does not recur)
Clear error code after confirming it.
Flushing
(Before starting engine, replace standard filter with flushing filter.
After flushing, replace flushing filter with standard filter.)
Execute flushing
Air bleeding of the hydraulic cylinder
Perform air bleeding of the hydraulic cylinder
After flushing, replace flushing filter with standard

filter
Measurement of cab pressurization
Max. 0.10 kPa {10 mm Aq.}

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

Category
Inspection Item
Inspection
Parking lever
Criteria
The engine must not be started when the parking
lever is free.
The machine must not be moved when the
parking lever is locked.
Operability of the travel lever

Gear change
Forward-reverse
Steering (right/left)
Play of the lever at N" position
Must be of no pinching or abnormal sound.

Notch must not be released.
Must return to the N position smoothly.
FUNCTION / OPERATION
Play: Max. 5 mm
N, F1, F2, F3, R1, R2 and R3 are indicated.
Check of the gear speed indication on the monitor panel.

Must be able to be shifted to any position with the engine at low
idle and the brake turned on.
Must be no indication error.
Check of front/rear adjustment of the travel lever box

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

Full stroke: 60 to 88 mm
Check of the brake pedal operation

Check of the deceleration pedal operation
Set the fuel dial to high idle position.
Check the deceleration RPM
Must work smoothly.

High idle: 2,000 50 rpm
Low idle: 900 50 rpm
Check of the fuel dial operation
Must move smoothly.
Check of tilt direction
SINGLE
RH tilt
Blade must move to left

(RH tilt cylinder is lengthened)
RH tilt
Blade must move to right

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

Pitch back
Pitch dump
LH dual tilt
RH dual tilt
DUAL
LH tilt
RH tilt
LH tilt
RH tilt
Check of tilting restriction adjustment

Measure tilting angle at the top of the cutting edge
LH tilt
when the tilting limit switch is turned on.
RH tilt
Blade must move backward. D + B

Blade must move forward. D + A
Blade must move to left (both cylinders move) a + B
Blade must move to right (both cylinders move) a + A

Blade must move to left (LH cylinder retracted) B + b
Blade must move to right (LH cylinder lengthened) A + b
Note: See manual of tilting restriction.

12 1
12 1

Category
Inspection Item
Inspection
Criteria
Check of the clearance between frame and track

(Difference of LH and RH)
Difference of LH and RH is max. 30 mm (Measure

on flat ground)
Move blade up and down and stop 100 mm
above ground, and then measure.
Check of the work equipment lock lever lock function
No actuator must work when the work equipment

lock lever is at ON position
(Lever can move but work equipment must not
move)
WORK EQUIPMENT
Must be of no hydraulic drift (Engine: Low idle)

Check of the blade lever floating
Check of the blade lever floating notch release
Check of the quick drop valve operation
Quick dropping of the blade from top position.
At the engine full, set the blade lever at down

position. When the lever is set at the N position
after the blade drops by 1000 mm, it must stop.
Main relief valve function (Engine: Low idle)
Must be bridged with the blade and the ripper

(Chassis)
Check of the accumulator function (blade, ripper)
Must function immediately after the engine stops

then drop from the top to the ground.
Blade cylinder oil leakage

Leakage from U-packing, damaged rod, quick drop valve,
tube, flange or dust seal
UNDERCARRIAGE
Tilt cylinder/pitch cylinder oil leakage

Leakage from U-packing, damaged rod, tube, flange or
dust seal
Track tension adjustment

With the gear at F1 and the engine at low idle, travel on flat
place for about 10 m, and when the grouser comes over
the first carrier roller, stop the machine by depressing the
brake pedal.
Carrier roller alignment

Travel on flat place with the gear at F1 and R1 for about
10 m, repeatedly about 3 or 4 times, then gradually apply
brake to stop.
* Check only when track frame is installed in field
(Check is not necessary if track frame has been installed)
Undercarriage oil leakage
Leakage from idler, carrier roller, bogie, pivot shaft,
adjustment cylinder, and lubricated track (plug, seal)
CAB
Engine stops at floating, then notch must be

released.
LH
Must be none.
RH
LH
Must be none.
RH
LH
RH
LH
Tense a string or a bar between

the first carrier roller and the idler
20 30 mm to measure distance between the
string (bar) and the grouser.
20 30 mm (Difference between LH and RH :
Max. 20 mm)
Target is 30 mm when new.
RH
Flanges must be free from contact with links at

all times.
LH
Must be none.
RH
Beat noise inside the cab, beat noise of the outer cover
Must be none.
Opening/closing and locking effect of the cab doors.
Must work smoothly to securely lock the doors by

door-locking or key-locking.
Cab door-open lock release lever
Lever must operate smoothly and unlock

securely.
(Unlock: Door is pushed out of stopper rubber
section.)
Opening/closing and locking effect of the left/right side slide glass
Must work smoothly to securely lock.
Lighting of the room lamp
Must come on/go off by turning the switch on/off.
Operation of the window wiper and the window washer
Must be on/off by turning the switch on/off.

Wiper: Must operate smoothly (without beat
noise)
Operation of the radio and cassette system

(Volume, tuning, AM/FM switching, cassette)
Must operate correctly
Operation of the cigar lighter

Ash tray installation
Must be red-heated.
Must be installed.
Operation of the air conditioner
Cold and warm air must be able to be switched

by monitor operation.
Air flow amount must be able to be adjusted
Air flow amount must be able to be adjusted (Hi, Mid or Lo)

Louver must be smoothly switched
Air comes out from each blowout port.

Category
Inspection Item
Inspection
BLADE
LUBRICATION
Portions to be lubricated
Criteria
Q'ty
Equalizer bar side pin shaft
Equalizer bar center pin shaft
Blade lift cylinder support shaft and yoke
Blade center pin
Blade oblique arm ball joint
Brace screw (Single tiltdozer)
Interference and twist of blade lift cylinder hoses

(Check through operation range)
Check of ripper direction
Example: U blade
When blade is tilted up, down and to right and

left, hoses must not interfere or twist.
a Raise
c Lower
A Tilt in
B Tilt out
Ripper lift cylinder oil leakage

U-packing, damaged rod, tube, flange, dust seal
loosing
RIPPER
Ripper tilt cylinder oil leakage

loosing
LH
Must be none
RH
LH
Must be of no contact.
RH
Interference and twist of hoses during ripper operation

(Ripper lift and tilt hoses, pin-puller hoses)
When ripper is raised, lowered and tilted in and

out, hoses must not interfere or twist.
Creak of the ripper link pin
Must be of no creak.
Check of the pin puller switch direction

A: Pin out
B: Pin in
Must be the same as the pin puller cylinder

operation direction
Check of the pin puller cylinder hose clamp position

(Entire operation area must be checked)
Must be of no contact
Must be of no excess hose tension.
Pin puller cylinder oil leakage

Leakage from U-packing, damaged rod, tube or flange
Must be none
LH
Check of ripper lubricated hose installation

(Add grease)
RH
Must be no contact or no excess bend.

Grease must not leak
Q'ty
Ripper lift cylinder head
Ripper lift cylinder bottom
Ripper tilt cylinder head
Ripper tilt cylinder bottom
Ripper arm pin (front)
Ripper arm pin (rear)
Must be lubricated (right and left)

<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 85C

Hydraulic oil temperature: 45 55C
Engine speed
Engine
Category
Item
Condition
Engine speed
Run engine at low idle (low speed).

Run engine at high idle (engine high). *2
Set decelarator at low speed.
Stall torque converter. *1
Unit
Standard
rpm
rpm
rpm
rpm
600 700
2100 2200
850 950
1640 1740
Result
*1: Measure stall speed 1 segment before red range of torque converter oil temperature gauge.
Measure with ID "0530" in adjustment mode of monitor.
*2: Measure high idle speed with adjustment mode ID "0007" of monitor.
Power train oil pressure

Transmission
Category
Item
Condition
Main relief pressure *3 Run engine at low speed and set transmission in N.
Run engine at full throttle and set transmission in N.
Unit
Standard
MPa
{kg/cm2}
MPa
{kg/cm2}
2.35 2.89
{24.0 29.5}
2.65 2.98
{27.0 30.4}
Result
*3: Measure main relief pressure with monitoring mode ID "43000" of monitor.
Work equipment oil pressure *4

Single tilt specification
Work equipment oil pressure
Category
Item
Condition
High pressure relief

pressure
Port relief pressure
Control circuit basic

pressure
Unit
Standard
Run engine at low speed and set

transmission in N.
MPa
{kg/cm2}
26.0 28.8
{266 294}
Run engine at full throttle and set

transmission in N.
MPa
{kg/cm2}
26.0 28.8
{266 294}

transmission in N.
MPa
{kg/cm2}
21.6 24.4
{221 249}

transmission in N.
MPa
{kg/cm2}
23.1 25.9
{236 264}
Lever neutral

transmission in N.
MPa
{kg/cm2}
3.92 4.51
{40 46}
Unit
Standard
Pitch back

transmission in N.
MPa
{kg/cm2}
26.0 28.8
{266 294}

transmission in N.
MPa
{kg/cm2}
26.0 28.8
{266 294}

transmission in N.
MPa
{kg/cm2}
19.7 22.5
{201 229}

transmission in N.
MPa
{kg/cm2}
23.1 25.9
{236 264}

transmission in N.
MPa
{kg/cm2}
3.92 4.51
{40 46}
Blade right tilt
Blade left tilt
Result
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R pump
Dual tilt specification

Category
Item
Condition

pressure

pressure
Pitch dump
Lever neutral
Result
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R pump
*4: Measure work equipment relief pressure of F pump with monitoring mode ID "70700" of monitor.
Measure work equipment relief pressure of R pump with monitoring mode ID "70702" of monitor.
Work equipment speed

Category
Item
Blade lift
Ripper tilt
Condition
Unit
Standard
RAISE

transmission in N.
sec
4.5 5.5
LOWER

transmission in N.
sec
1.5 2.1
Tilt IN

transmission in N.
sec
4.7 5.7
Tilt BACK

transmission in N.
sec
2.8 3.8
Unit
Standard
Result
Hydraulic drift of work equipment

Category
Item
Condition
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
Result

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
B
C
D
E
F
G
H
I
Machine forward
J
K
L
M
N
O
P
1960 2450 Nm
{200 250 kgm}
Superdozer specification 1/7
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
D475ASD-5E0
Service Meter Reading (Hr):
Engine Serial No.
SAA12V140E-3
Date of Inspection
Inspector's name:
Location of Machine at Inspection:
Distributor's Name:
Specification
Customer's name:
(Country)
Address:
Blade
Super
Ripper or counterweight
VGR
Shoe width
910 mm
Cab
With cab, Without cab
CW (
Ton)
810 mm
Enter specification of optional/local

Others
(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
COOLANT AND OIL LEVEL
Category
Inspection Item
Inspection
Criteria
Main radiator coolant level
Above the bottom Radiator

surface
Strainer
Reserve tank coolant level
Low Full
Engine oil level
EO15W40-DH
(H+L)/2 (H+15)
Engine : Stopped
Power train oil level
TO30
L (H+20)
Engine : Low idle

(After 3 to 5 minutes)
Damper case oil level
TO30
(H+L)/2 (H+10)
Engine : Stopped
Hydraulic tank oil level

Between H L
TO10
Center to upper
level of sight
gauge
Pitch back on the ground.

Ripper point on the ground.
Engine : stopped
Final drive oil level
GO85W-140
H (H20)

Engine : stopped
(H+10) (H+30)
from shaft end
a=100 10
Oil level
Pivot shaft oil level
LH
RH
LH
TO30
EO30-CD
RH
LH
Recoil spring oil level
TO30
EO30-CD
RH
Battery electrolyte level

Check battery
Between L and H
UPPER LEVEL
LOWER LEVEL
Must be no adhesion of grease, loosened

terminal, or crack
Window washer tank water level
Full
Fuel tank
Full (1670 l)
Draining of fuel tank
Drain fuel tank (Drain water, foreign matter, etc.)
Horn
Backup alarm
(Starting engine)
Backup alarm must sound when the PCCS lever

is at the back position.
Monitor display
Monitor must be turned on with buzzer sound,

then go off after 3 seconds. After that all gauge
lamps must come on.
No error code indicated in the service meter.
INSPECTION
Operation of service meter

(Engine: Low idle)
Before engine start, meter must not operate

when the key switch turned on.
Charge lamp (Engine: Low idle)
Must not light up when all lamps are turned on.
Lamp ON (Head lamp, tail lamp and work lamp)
Must light up when turned on.
Preheating switch (Auto preheating when at ON position)

(Manual preheating when turned to left)
Preheating lamp (green) must light up
Corrosion resistor valve
Must be fully open.
Heater hose valve
Winter: Open valve fully

(Close valve fully in summer)
Controller error code indication (make sure that error does not recur)
Clear error code after confirming it.
Flushing
(Before starting engine, replace standard filter with flushing filter.
After flushing, replace flushing filter with standard filter.)
Execute flushing
Air bleeding of the hydraulic cylinder
Perform air bleeding of the hydraulic cylinder
After flushing, replace flushing filter with standard

filter
Measurement of cab pressurization
Max. 0.10 kPa {10 mm Aq.}

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

Category
Inspection Item
Inspection
Parking lever
Criteria
The engine must not be started when the parking
lever is free.
The machine must not be moved when the
parking lever is locked.
Operability of the travel lever

Gear change
Forward-reverse
Steering (right/left)
Play of the lever at N" position

Notch must not be released.
Must return to the N position smoothly.
Play: Max. 5 mm
N, F1, F2, F3, R1, R2 and R3 are indicated.
Check of the gear speed indication on the monitor panel.

Must be able to be shifted to any position with the engine at low
idle and the brake turned on.
Must be no indication error.
Check of front/rear adjustment of the travel lever box

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

Full stroke: 60 to 88 mm
Check of the brake pedal operation

Check of the deceleration pedal operation
Set the fuel dial to high idle position.
Check the deceleration RPM
Must work smoothly.

High idle: 2,000 50 rpm
Low idle: 900 50 rpm
Check of the fuel dial operation
Must move smoothly.
Check of pitch direction

Pitch backward
Pitch dump
Pitch forward
Pitch back
Pitch
dump
Blade must move to forward smoothly.
Pitch
back
Blade must move to backward smoothly.
LH tilt
Blade must move to left
RH tilt
Blade must move to right

RH tilt
RH tilt
LH tilt
LH tilt
Check of tilting restriction adjustment

Measure tilting angle at the top of the cutting edge
LH tilt
when the tilting limit switch is turned on.
RH tilt
Note: See manual of tilting restriction.
Check of auto pitch back operation

After pitch dumping, move backward with the speed gear at R1,
then turn the pitch back switch on.
52 3
Blade should be horizontal after pitch back to the
stroke end, and pitch dumping is performed to
return to the digging posture.
7 1
7 1

Category
Inspection Item
Inspection
Criteria
Check of the clearance between frame and track

(Difference of LH and RH)
Difference of LH and RH is max. 30 mm (Measure

on flat ground)
Move blade up and down and stop 100 mm
above ground, and then measure.
Check of the work equipment lock lever lock function
No actuator must work when the work equipment

lock lever is at ON position
(Lever can move but work equipment must not
move)
WORK EQUIPMENT
Must be of no hydraulic drift (Engine: Low idle)

Check of the blade lever floating
Check of the blade lever floating notch release
Check of the quick drop valve operation
Quick dropping of the blade from top position.
At the engine full, set the blade lever at down

position. When the lever is set at the N position
after the blade drops by 1000 mm, it must stop.
Main relief valve function (Engine: Low idle)
Must be bridged with the blade and the ripper

(Chassis)
Check of the accumulator function (blade, ripper)
Must function immediately after the engine stops

then drop from the top to the ground.
Blade cylinder oil leakage

Leakage from U-packing, damaged rod, quick drop valve,
tube, flange or dust seal
UNDERCARRIAGE
Tilt cylinder/pitch cylinder oil leakage

Leakage from U-packing, damaged rod, tube, flange or
dust seal
Track tension adjustment

With the gear at F1 and the engine at low idle, travel on flat
place for about 10 m, and when the grouser comes over
the first carrier roller, stop the machine by depressing the
brake pedal.
Carrier roller alignment

Travel on flat place with the gear at F1 and R1 for about
10 m, repeatedly about 3 or 4 times, then gradually apply
brake to stop.
* Check only when track frame is installed in field
(Check is not necessary if track frame has been installed)
Undercarriage oil leakage
Leakage from idler, carrier roller, bogie, pivot shaft,
adjustment cylinder, and lubricated track (plug, seal)
CAB
Engine stops at floating, then notch must be

released.
LH
Must be none.
RH
LH
Must be none.
RH
LH
RH
LH
Tense a string or a bar between

the first carrier roller and the idler
20 30 mm to measure distance between the
string (bar) and the grouser.
20 30 mm (Difference between LH and RH :
Max. 20 mm)
Target is 30 mm when new.
RH
Flanges must be free from contact with links at

all times.
LH
Must be none.
RH
Beat noise inside the cab, beat noise of the outer cover
Must be none.
Opening/closing and locking effect of the cab doors.
Must work smoothly to securely lock the doors by

door-locking or key-locking.
Cab door-open lock release lever
Opening/closing and locking effect of the left/right side slide glass
Lighting of the room lamp
Must come on/go off by turning the switch on/off.
Operation of the window wiper and the window washer
Must be on/off by turning the switch on/off.

Wiper: Must operate smoothly (without beat
noise)
Operation of the radio and cassette system

(Volume, tuning, AM/FM switching, cassette)
Must operate correctly
Operation of the cigar lighter

Ash tray installation
Must be red-heated.
Must be installed.
Operation of the air conditioner
Cold and warm air must be able to be switched

by monitor operation.
Air flow amount must be able to be adjusted
Air flow amount must be able to be adjusted (Hi, Mid or Lo)

Louver must be smoothly switched
Air comes out from each blowout port.

Category
Inspection Item
Inspection
BLADE
LUBRICATION
Criteria
Q'ty
Equalizer bar side pin shaft
Equalizer bar center pin shaft
Blade lift cylinder support shaft and yoke
Blade center pin
Blade oblique arm ball joint
Interference and twist of blade lift cylinder hoses

Check of ripper direction
Example: Super blade
When blade is tilted up, down and to right and

left, hoses must not interfere or twist.
a Raise
c Lower
A Tilt in
B Tilt out
Ripper lift cylinder oil leakage

loosing
RIPPER
Ripper tilt cylinder oil leakage

loosing
LH
Must be none
RH
LH
Must be of no contact.
RH
Interference and twist of hoses during ripper operation

(Ripper lift and tilt hoses, pin-puller hoses)
When ripper is raised, lowered and tilted in and

out, hoses must not interfere or twist.
Creak of the ripper link pin
Must be of no creak.
Check of the pin puller switch direction

A: Pin out
B: Pin in
Must be the same as the pin puller cylinder

operation direction
Check of the pin puller cylinder hose clamp position

(Entire operation area must be checked)
Must be of no contact
Must be of no excess hose tension.
Pin puller cylinder oil leakage

Leakage from U-packing, damaged rod, tube or flange
Must be none
LH
Check of ripper lubricated hose installation

(Add grease)
RH
Must be no contact or no excess bend.

Grease must not leak
Q'ty
Ripper lift cylinder head
Ripper lift cylinder bottom
Ripper tilt cylinder head
Ripper tilt cylinder bottom
Ripper arm pin (front)
Ripper arm pin (rear)
Must be lubricated (right and left)

<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 85C

Hydraulic oil temperature: 45 55C
Engine speed
Engine
Category
Item
Condition
Engine speed
Run engine at low idle (low speed).

Run engine at high idle (engine high). *2
Set decelarator at low speed.
Stall torque converter. *1
Unit
Standard
rpm
rpm
rpm
rpm
600 700
2100 2200
850 950
1640 1740
Result
*1: Measure stall speed 1 segment before red range of torque converter oil temperature gauge.
Measure with ID "0530" in adjustment mode of monitor.
*2: Measure high idle speed with adjustment mode ID "0007" of monitor.
Power train oil pressure

Transmission
Category
Item
Main relief pressure
*3
Condition
Unit
Standard
Run engine at low speed and set transmission in N.
MPa
{kg/cm2}
MPa
{kg/cm2}
2.35 2.89
{24.0 29.5}
2.65 2.98
{27.0 30.4}
Unit
Standard
Run engine at full throttle and set transmission in N.
Result
*3: Measure main relief pressure with monitoring mode ID "43000" of monitor.
Work equipment oil pressure *4

Superdozer specification
Category
Item
Condition

pressure

pressure
Pitch back
Pitch dump
Lever neutral

transmission in N.
MPa
{kg/cm2}
26.0 28.8
{266 294}

transmission in N.
MPa
{kg/cm2}
26.0 28.8
{266 294}

transmission in N.
MPa
{kg/cm2}
19.7 22.5
{201 229}

transmission in N.
MPa
{kg/cm2}
23.1 25.9
{236 264}

transmission in N.
MPa
{kg/cm2}
3.92 4.51
{40 46}
Result
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R pump
F pump
R pump
*4: Measure work equipment relief pressure of F pump with monitoring mode ID "70700" of monitor.
Measure work equipment relief pressure of R pump with monitoring mode ID "70702" of monitor.
Work equipment speed

Category
Item
Blade lift
Superdozer
specification
Ripper tilt
Condition
Unit
Standard
RAISE
Run engine at full throttle

and set transmission in N.
sec
4.6 5.6
LOWER

sec
1.4 2.0
Tilt IN

sec
4.7 5.7
Tilt BACK

sec
2.8 3.8
Result
Hydraulic drift of work equipment

Category
Unit
Standard
Blade lift
Item
Engine stopped, Cutting edge height: 500 800 mm.
Condition
mm/min
Max. 50/5
Ripper lilt
Engine stopped, Ripper point height: 300 600 mm.
mm/min
Max. 30/5
Result

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
B
C
D
E
F
G
H
I
Machine forward
J
K
L
M
N
O
P
1960 2450 Nm
{200 250 kgm}

D475a-5gen00051 Fa-03

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GEN00051-03

Field Assembly Instruction

Operator for assembly

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

A. ASSEMBLY PROCEDURE ......................................................................................................... 31

Komatsu SAA12V140E-3 diesel engine

Rated engine output

Overall height (with ROPS)

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

Semi-U-tiltdozer + variable giant ripper

Full U-tiltdozer + variable giant ripper

PRECAUTIONS FOR FIELD ASSEMBLY

6. Precautions for starting engine

DISPOSAL OF REMOVED PARTS

Setting of track shoe

Installation of blade lift hydraulic cylinder

ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE

KIT LAYOUT DIAGRAM

Right straight frame

Left straight frame

Truck crane (45 ton)

STYLE FOR TRANSPORTATION

Overall length (mm)

Overall height (mm)

Overall width (mm)

Note: The blade lift cylinder may

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

Overall length (mm)

Overall height (mm)

Overall width (mm)

Overall length (mm)

Overall height (mm)

Overall width (mm)

(2) Semi U-blade

Overall length (mm)

Overall height (mm)

Overall width (mm)

Overall length (mm)

Overall height (mm)

Overall width (mm)

Refer to the Appendix 1 for

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

Overall length (mm)

Overall length (mm)

(2) Blade lift cylinder

Overall length (mm)

Note: May be installed to chassis

(3) Ripper cylinder

Overall length (mm)

Giant ripper beam

Overall length (mm)

Overall length (mm)

Giant ripper arm, multi ripper arm

a Connecting pin with the beam is

Giant ripper shank assembly

Overall length (mm)

a Protector and point is attached

Multi ripper beam

Overall length (mm)

Overall length (mm)

a Protector and point is attached

Operator cab assembly

Overall length (mm)