D375 A-3

GEN00054-04
Field Assembly Instruction
BULLDOZER D375A -5E0

SERIAL NUMBERS 50001 and up
Preface
Since this machine is large in size, it is divided into some units to meet
the transportation conditions and regulations applied to the transporta-
tion route when shipped from our factory.
This manual describes how to assemble the units into the complete
machine in the field. We hope that this machine will display its quality
and you will use it safely according to the operation manual.
Many units are large in size and heavy in weight and may be handled
in a dangerous place or posture and many workers may have to work
together to sling them with cranes.
Accordingly, before starting the assembly work, the work supervisor is
required to hold a safety meeting to oblige the workers to put on pro-
tective gear and appoint a work leader and a crane work signal man
and allot roles to all the workers for safe work.
In particular, the above meeting is more important when worker of dif-
ferent languages and customs work together.
The following is a reference supervision system diagram.
(Instruction system)
Work leader
Director
Work supervisor Crane director and
deputy director
Operator for assembly

Liaison man
Mechanics Sharing of work

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

Accordingly, before installing the work equipment, inspect and main-
tain the machine thoroughly.
Note that this manual does not describe the whole specification of the
machine but describes only the basic specification.
CONTENTS
Specifications ..................................................................................................................................................... 1
Precautions for field assembly............................................................................................................................ 2
Disposal of removed parts.................................................................................................................................. 3
Assembly procedure, necessary equipment, and schedule ............................................................................... 4
Layout of kit ........................................................................................................................................................ 5
Style for transportation ....................................................................................................................................... 6
Table of tools for field assembly ....................................................................................................................... 11
Tightening torque ............................................................................................................................................. 16
Coating materials list ........................................................................................................................................ 21
Selection of wire ropes used for assembly ....................................................................................................... 24
A. Assembly procedure.................................................................................................................................. 25
A-1 Installation of chassis ....................................................................................................................... 26
A-2.1 Installation of engine air inlet hood................................................................................................... 29
A-2.2 Installation of engine air pre-cleaner (if equipped) ........................................................................... 30
A-3 Installing direction of exhaust pipe ................................................................................................... 31
A-4 Installation of undercover ................................................................................................................. 32
A-5 Installation of pivot shaft................................................................................................................... 33
A-6 Installation of undercarriage............................................................................................................. 35
A-7 Adding oil to recoil chamber and pivot chamber .............................................................................. 62
A-8 Installation of blade lift cylinder ........................................................................................................ 63
A-9 Check fuel, coolant and lubricants ................................................................................................... 65
A-10 No-injection cranking of engine........................................................................................................ 67
A-11 Bleeding air from hydraulic cylinders ............................................................................................... 70
A-12 Installation of ripper ......................................................................................................................... 71
A-13 Installation of track ........................................................................................................................... 78
A-14 Assembly of blade............................................................................................................................ 80
A-15 Installation of blade .......................................................................................................................... 96
A-16 Installation of operator's cab .......................................................................................................... 104
A-17 Installation of ROPS....................................................................................................................... 121
A-18 Installation of VHMS, ORBCOMM antenna ................................................................................... 123
A-19 Check track tension........................................................................................................................ 124
A-20 Lubricating...................................................................................................................................... 126
A-21 Installation of fuel quick charge piping (if equipped) ...................................................................... 130
M. Check and maintenance procedures after completion of assembly........................................................ 131
M-1 Check and adjustment of operator's cab........................................................................................ 132
M-2 Inspection of machine monitor ....................................................................................................... 139
M-3 Checking operation of dual tilt mechanism (If equipped) ............................................................... 153
M-4 Setting procedure for USER ADJUST MODE................................................................................ 154
APPENDIX 1. Installation procedure for spill guard (Installation by welding)................................................ 157
APPENDIX 2. Precautions for initialization procedures for VHMS controller ................................................ 167
Field assembly inspection report
Specifications
Semi U-tiltdozer Full U-tiltdozer Semi U-tiltdozer Full U-tiltdozer
Item Unit
+ Giant ripper + Giant ripper + Multi-ripper + Multi-ripper
Operating weight
kg 69,560 71,070 70,800 72,320
(excluding operator's weight)
Blade weight
kg 10,910 12,420 10,910 12,420
(including cylinders)
Ripper weight
kg 5,470 6,720
(including cylinders)
Engine name — Komatsu SAA6D170E-5 diesel engine
Rated engine output kW/rpm {HP/rpm} 391/1,800 {532/1,800}
Overall length mm 10,410 10,825 10,120 10,535
Overall height (with ROPS) mm 4,265 (4,285)
Overall width mm 4,695 5,140 4,695 5,140
Travel speed Forward km/h 3.5/6.8/11.8
(1st/2nd/3rd) Reverse km/h 4.6/9.2/15.8
• Semi U-tiltdozer + variable multi ripper
• Fell U-tiltdozer + variable giant ripper
1
Precautions for field assembly
1. Selection of work place
1) When selecting a work place, consider the following.
• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout draw-
ing.)
• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
• Is the ground flat? (The ground surface must not be uneven or sloping.)
• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read
and understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the
work place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools

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

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

When the engine is started for the first time after assembled in the field, its inside must be lubricated with
engine oil. Lubricate according to “A-10 No-injection cranking of engine” in this manual.
2
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 hydrau-
lic 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 com-
pletion 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.
3
•
•
•
1st day 2nd day 3rd day 4th day
8:00 10:00 12:00 14:00 16:00 18:00 8:00 10:00 12:00 14:00 16:00 18:00 8:00 10:00 12:00 14:00 16:00 18:00 8:00 10:00 12:00 14:00 16:00 18:00
Schedule
Trailer must Unloading trailer
arrive at Installing pivot shaft and
field before blade lift cylinder
8:00.
Installing under cover
Assembling blade sub-assembly

Installing T/F
Adding and checking oil
Installing ripper sub-assembly

Installing tracks
Special field work shall be arranged separately.
Installing blade
Connecting hoses
4
Installing cab
Test operation
Installing ROPS guard and adjustment
Any change of the schedule caused by weather is not included.
Washing, touching
up, painting
Wrecker 45-ton wrecker × 2 units 45-ton wrecker × 2 units 45-ton wrecker × 1 unit Unnecessary
Working
The F/D assembly and pivot shaft are assumed to be installed to the body beforehand.
8H 8H 8H 8H
hours
Number of
workers 4 workers 4 workers 3 workers 3 workers
Total
Assembly procedure, necessary equipment, and schedule
man-hours 32H 32H 24H 24H
Grand total 112H

Layout of kit
• When selection the work site, see "Before 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.
Approx. 30 m
Blade
Right track
Left track
Ttrack
Ttrack
Approx. 30 m
Chassis
Crane
Crane
Ripper parts CAB assembly

ROPS guard
Accessories
5
Style for transportation
Since the machine can be divided for transportation, ask us or our service shop before transportation.
t Style of each KIT.

• Tractor (Body)
A Overall length (mm) 5,848

B Overall height (mm) 3,091
C Overall width (mm) 3,060
Weight (kg) 27,000
• Track frame
With full
STD
roller guard
A Overall length (mm) 4,194 4,200
B Overall height (mm) 1,280 1,280
C Overall width (mm) 840 840
Weight (kg) 7,940 8,690
2 sets of the shoes are prepared for each
machine.
• Track shoe
Shoe wide 610 710

Number of shoes 41
A (mm) 2,500
B (mm) 2,500
Weight (kg) 4,300 4,650
2 sets of the shoes are prepared for each
machine.
6
• Work equipment Blade
(1) Reinforced U-blade

Weight (kg) 6,500
• Semi-U blade

Stan- Rein-
Weight (kg) dard forced
6,400 6,800
• Work equipment Straight frame

B Overall height (mm) 640
C Overall width (mm) 490
Weight (kg) 1,346
2 sets of the shoes are prepared for
each machine.
7
• Work equipment Blade lift cylinder

Weight (kg) 270
2 sets of the shoes are prepared
for each machine.
• Pivot shaft
A Overall length (mm) 770

Weight (kg) 210
2 sets of the shoes are prepared
for each machine.
a This part may be delivered installed to the machine.
• Under cover
(1) Front

Weight (kg) 250
a This part may be delivered installed to the machine.
8
(2) Side

Weight (kg) 231
(3) Rear

Weight (kg) 256
• Cab

Weight (kg) 500
9
• ROPS

Weight (kg) 703
* ROPS is an abbreviation for Rollover Protective Structure.
• Mulit-ripper beam

Weight (kg) 2,500
• Giant-ripper beam

Weight (kg) 1,710
10
Table of tools for field assembly
No. Tool name Specification Q'ty Remarks
1 Air compressor Min. 0.69 MPa – 15 m³/min 1
2 Pneumatic hose and cou- Hose length: 30 m 1 set For air compressor
pler (for pneumatic tools) Coupler must fit impact wrench
and oil feed pump.
3 Crane truck Lifting load: 25 ton 2
4 Welder 2 For welding blade spill guard
(If equipped)
5 Chain lever hoist Rated load 1.5 ton 1 JIS B8819 or equivalent
(Chain block) Rated load 3.2 ton 1
Rated load 6.3 ton 1
6 Wire rope sling ø 36 × 6 m 4 Specification: JIS B8817 or equivalent
ø 24 × 5 m 4
ø 20 × 5 m 2
ø 20 × 3 m 1
ø 20 × 2 m 4
ø 12 × 2 m 4
7 Belt sling 25 mm wide × 3 m 2 Specification: JIS B8818 or equivalent
(made of synthetic fibers) 50 mm wide × 4 m 2
8 Hydraulic wrench Min 5,890 Nm {600 kgm} 1 Mainly for master link bolt
9 Hydraulic wrench socket Width across flats: 46 1 unit For master link bolt
each
10 Extension bar T 38.1 × L300 1
11 Air impact wrench See No. 43
12 Socket for impact wrench Width across flats: 19, 22, 24, 27, 1 unit Must fit impact wrench No. 43.
30, 32, 36, 41, 46, 50 each
13 Torque wrench Tightening capacity 1 Impact wrench socket may be used if it
588 Nm {60 kgm} fits.
Tightening capacity 1
1,370 Nm {140 kgm}
Tightening capacity 1
2,060 Nm {210 kgm}
14 Soket for torque wrench Width across flats: 32, 36, 41, 46 1 unit
each
15 Eyebolt M12, Using load: 220 kg 4
M16, Using load: 450 kg 2 For blade center link
16 Shackle SD22 4 Specification symbols are quoted from
BC36 2 JIS B2801
SA60 1
17 Sledge hammer Double-headed: 4.5 kg (10 lbs) 1
Double-headed: 2.25 kg (5 lbs) 2
18 Pinch bar (Lever) ø 25 × 900 mm 1 JCMAS P018 or equivalent, Note 1)
19 Thread repair tap M33 × Pitch 2 1 For master link
M30 × Pitch 3 1
M24 × Pitch 3 1
20 Jack Screw type, Using load: 15 ton 2 For assembling track frame
21 Single ended wrench Nominal width across flats (mm) 2 units For tightening hydraulic hose mouthpiece
17, 19, 22, 24, 27, 30, 32, 36, 41, each nut
46, 50
22 Lubricating oil and grease See assembly procedures A-7 —
and A-9.
23 Anti-seize compound Molybdenum disulphide grease 200 g See coating material list.
(LM-P)
11
No. Tool name Specification Q'ty Remarks
24 Cleaning oil For removing preservative 40 l
25 Paint remover For removing phthalate resin 5l
coating
26 Paint for repair See coating material list 3 units
each
27 Glass cleaner Cleaning liquid 1 For cleaning operator cab windshield
(commercially available) glass
28 Cloth Bunch 1 kg
29 Adhesive cloth tape Width × Length × Color 1 roll
50 mm × 25 mm × Not specified
30 Angle meter (with level) Min. division: 1 deg. 1 For dual tiltdozer
31 Plastic tube (Vinyl tube) 8 mm inside diameter × 1 mm 1 For checking airtightness (internal pres-
thick × 3 m long, soft, transparent sure) of operator cab
32 Oil feed pump Manual or pneumatic 1
33 Oil jack Capacity: Approx. 5 l 1
34 Drain oil receiver 1,000 × 700 × 150 (mm) 2 units
(made of steel sheet) 700 × 400 × 150 each
300 × 300 × 100
35 Stand for high lift work 2 m high, with stair and handrail 2
36 Safety belt Waist belt type Same as
number of
workers
37 Safety glasses Same as
number of
workers
38 Stand For attached tool drawing 1 Front
(for setting machine) For attached tool drawing 1 Rear
39 Steel plate liner (for install- 1,000 × 500 (mm) 4 With lifting hook
ing support stand No. 38) 16 mm thick
40 Sling for track fame For attached tool drawing 1
41 Wood block T 350 mm × 750 mm high 4
T 350 mm × 400 mm high 4
T 300 mm × 800 mm high 1
T 300 mm × 700 mm high 1
T 300 mm × 600 mm high 1
T 300 mm × 400 mm high 2
T 100 mm × 750 mm high 4
42 Steel plate T 300 mm × 25 ton 1
43 Pneumatic impact wrench Objective bolt thread diameter 1 Note 2)
Tightening capacity
Unit: Nm {kgm}
– 200 {20.4} M10 – M14 1 Socket No. 12 must fit this impact
– 600 {61.2} M16 – M20 1 wrench.
– 1,000 {102} M22 – M24 1
– 3.000 {306} M27 – M38 1
– 6,500 {663} Min. M39 1
44 Common tools Note 3)
Note 1) Pinch bar (Lever) No. 18 is P018-1978 (Pinch bar) of JCMAS (Japan Construction Mechanization
Association) or equivalent.
You can read the information about JCMAS on the website.
Note 2) Hydraulic wrench No. 8 may be used instead of pneumatic impact wrench No. 43 having tightening
capacity of 1,000 – 6,500 Nm {102 – 663 kgm} (suitable for tightening M27 bolt or larger), as long as
the sockets are adaptable.
Note 3) This list does not contain general hand tools (box wrenches, screwdrivers, pliers, etc.) Prepare them
separately as required.
12
Sketch of jigs
Stand (Front side)
13
SYM. Part name Material Q'ty/set Mass Remarks
01 Channel SS400C 2 C100 × 65 × 6T × 747L
02 Channel SS400C 2 C125 × 65 × 6T × 970L
03 Channel SS400C 2 C125 × 65 × 6T × 378L
04 Channel SS400C 2 C100 × 100 × 5T × 400L
05 Channel SS400C 2 C100 × 100 × 5T × 351L
06 Angle SS400C 2 65 × 65 × 6T × 970L
07 Angle SS400 2 65 × 65 × 6T × 200L
08 Plate SS400 2 50 × 300L
09 Plate SS400 4 9T × 150B × 500
10 Plate SS400 10 12T × 55 × 102
11 Plate SS400 2 9T × 50 × 40
12 Plate SS400 4 32T × 180 × 250
Note) We are not liable for any result of use of jigs manufactured according to these drawings.
Stand (Rear side)
14
01 Channel SS400C 2 C100 × 65 × 6T × 747L
02 Channel SS400C 2 C125 × 65 × 6T × 970L
03 Channel SS400C 2 C125 × 65 × 6T × 378L
04 Channel SS400C 2 C100 × 100 × 5T × 400L
05 Channel SS400C 2 C100 × 100 × 5T × 351L
06 Angle SS400C 2 65 × 65 × 6T × 970L
07 Angle SS400 2 65 × 65 × 6T × 200L
08 Plate SS400 2 50 × 300L
09 Plate SS400 4 9T × 150B × 500
10 Plate SS400 10 12T × 55 × 102
11 Plate SS400 4 32T × 180 × 250
Sling (Track frame assembly)
Sling (Track frame assembly)
1p
iec
e
es
ec
pi
2
Idler SYM. Part name Q'ty/set Remarks

Install to carrier roller.
1 Frame 1
2 Master link 1
3 Shackle 1 SB32
4 Shackle BB32
For weight of track frame assembly, see 5 Chain lever hoist 2 For 5 ton
transportation posture. 6 Chain lever hoist 1 For 6.3 ton
15
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 size (Diameter, pitch, length)
Tool (Socket) Applicable socket size
Tightening torque Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 26
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension c in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. cor-
respond to dimension b in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ – www or QQQ ± RR. If the target tightening torque
is set, expression of QQQ ± RR is applied.
Fig. 1
a : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt
16
Table 1 Tightening torque for bolts not specified in text
Unit: Nm {kgm}
Nominal size of thread Width across flats Tightening torque

× pitch (= Socket size)
a (mm) b (mm) Target Range
12 8.8 – 14.7
M6 × 1 10
{1.2} {0.9 – 1.5}
25 14.7 – 34
M8 × 1.25 13
{2.5} {1.5 – 3.5}
54 34 – 74
M10 × 1.5 17
{5.5} {3.5 – 7.5}
89 54 – 123
M12 × 1.75 19
{9} {5.5 – 12.5}
137 84 – 196
M14 × 2 22
{14} {8.5 – 20}
230 147 – 309
M16 × 2 24
{23.5} {15 – 31.5}
315 201 – 427
M18 × 2.5 27
{32} {20.5 – 43.5}
460 319 – 608
M20 × 2.5 30
{47} {32.5 – 62}
650 471 – 829
M22 × 2.5 32
{66.5} {48 – 84.5}
810 588 – 1030
M24 × 3 36
{82.5} {60 – 105}
1180 883 – 1470
M27 × 3 41
{120} {90 – 150}
1520 1130 – 1910
M30 × 3 46
{155} {115 – 195}
1960 1470 – 2450
M33 × 3 50
{200} {150 – 250}
2450 1860 – 3040
M36 × 3 55
{250} {190 – 310}
2940 2260 – 3630
M39 × 3 60
{300} {230 – 370}
a For symbols “a” and “b” in the table, see Fig. 1.
17
2. Tightening torque for pipe threads
Proper tightening torque for pipe threads depends on combination of the materials of the male screw and
female screw. In this manual, however, select tightening torque from Table 2 and Table 3 on the basis of
the material of the male screw. If tightening torque is specified specially in explanation, however, apply that
tightening torque.
2.1 If the male screw is made of mild steel or cast iron, apply Table 2.
Table 2
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size
3.9 – 6.9 2.9 – 5.9 2.0 – 3.9
1/8
{0.4 – 0.7} {0.3 – 0.6} {0.2 – 0.4}
5.9 – 11.8 4.9 – 9.8 3.9 – 7.8
1/4
{0.6 – 1.2} {0.5 – 1.0} {0.4 – 0.8}
16.7 – 26.5 13.7 – 21.6 9.8 – 16.7
3/8
{1.7 – 2.7} {1.4 – 2.2} {1.0 – 1.7}
32.3 – 52.9 26.5 – 43.1 19.6 – 32.3
1/2
{3.3 – 5.4} {2.7 – 4.4} {2.0 – 3.3}
51.0 – 85.3 42.1 – 70.6 31.4 – 52.9
3/4
{5.2 – 8.7} {4.3 – 7.2} {3.2 – 5.4}
86.2 – 173.5 72.5 – 146.0 54.9 – 111.7
1
{8.8 – 17.7} {7.4 – 14.9} {5.6 – 11.4}
2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.
Table 3
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size
16.7 – 29.4 9.8 – 19.6 6.9 – 14.7
1/8
{1.7 – 3.0} {1.0 – 2.0} {0.7 – 1.5}
19.6 – 44.1 16.7 – 37.2 12.7 – 28.4
1/4
{2.0 – 4.5} {1.7 – 3.8} {1.3 – 2.9}
44.1 – 93.1 37.2 – 77.4 27.4 – 58.8
3/8
{4.5 – 9.5} {3.8 – 7.9} {2.8 – 6.0}
98.0 – 188.2 83.3 – 157.8 60.8 – 115.6
1/2
{10.0 – 19.2} {8.5 – 16.1} {6.2 – 11.8}
170.5 – 316.5 141.1 – 247.0 105.8 – 186.2
3/4
{17.4 – 32.3} {14.4 – 25.2} {10.8 – 19.0}
367.5 – 612.5 309.7 – 514.5 235.2 – 392.0
1
{37.5 – 62.5} {31.6 – 52.5} {24.0 – 40.0}
18
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 4.1 and 4.2.
Table 4.1 Hydraulic hose of face seal type
Type that uses

O-ring at this
position
Unit: Nm {kgm}
Outside diameter Tightening torque (Nm {kgm})
of hose Width across flats
(mm) (mm) Range Target
Approx. 6 19 34 – 54 {3.5 – 5.5} 44 {4.5}
Approx. 10 22 54 – 93 {5.5 – 9.5} 74 {7.5}
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}
Table 4.2 Hydraulic hose of taper seal type
Type that does

not use O-ring
at this position
Unit: Nm {kgm}
Outside diameter Tightening torque (Nm {kgm})
of hose Width across flats
(mm) (mm) Range Target
Approx. 6 19 34 – 63 {3.5 – 6.5} 44 {4.5}
Approx. 10 24 59 – 98 {6.0 – 10.0} 78 {8.0}
Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}
Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}
Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}
Note: When connecting hose, take care not to twist them.
19
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
20
Coating materials list
(Rev. 2009.08)
a The recommended coating materials such as adhesives, liquid gaskets, 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 manual.
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Use to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropylene,

20 g Polyethylene tetrafluoroethylene and vinyl chloride), rubber, met-
LT-1B 790-129-9050
(2 pcs.) container al, and non-metal parts which require immediate
and strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.

LT-2 790-129-9040 50 g
container q Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instantaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instantaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
648-50 container
ture.
q Use to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for hy-
draulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal flange surfaces and threaded portions.
Liquid gasket
q Use to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant, vi-
ThreeBond 419-15-18131 100 g Tube bration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the weld
ThreeBond 790-129-9310 200 g Tube
which must be caulked, etc.
1206D
q Can be coated with paint.
21
Cate- Komatsu
gory code
LG-10 q Use as lubricant/sealant when installing the radiator
ThreeBond 790-129-9320 200 g Tube hoses to the water tubes.
Liquid gasket
1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine.
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulfide
portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
Use to lubricate linkages, bearings, etc.
lubricant
q Spray type
q Thin molybdenum disulphide films are made on
— 09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound
q Feature: Seizure and galling prevention compound

LC-G with metallic super-fine-grain, etc.
Seizure
NEVER- — — Can q Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharger,
etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
num disul- SYG2-400M 400 g × 10 Bellows-type q Do not use this grease for rolling bearings like
fide grease SYG2-400M-A 400 g × 20 container swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can q Use this grease for work equipment pins only
(G2-M) when installing them, but do not use it after-
ward.
SYG2-400T-A
Grease
Hyper White
SYG0-400T-A
G2-T, Bellows-type q Seizure resistance, heat resistance and water re-
(*) 400 g
G0-T (*) container sistance higher than molybdenum disulfide grease.
SYG2-16CNT
*: For cold 16 kg Can q Not conspicuous on machine since color is white.
SYG0-16CNT
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals, and
high temper- SYGA-16CNB
16 kg Can plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable tempera-
G2-S ture range, high resistance to thermal-oxidative
ThreeBond — 200 g Tube degradation and performance to prevent deteriora-
1855 tion of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
22
Cate- Komatsu
gory code
q Feature: Urea (organic system) grease with heat re-
sistance and long life, can be packed into the con-
Grease
G2-U-S
427-12-11871 2 kg Can fined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER tainer (Effective period: four months after date of
580 SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of
For adhered window glass

PRIMER tainer
manufacture)
580 SUPER
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
Primer
22M-54-27230 20 ml
435-95 manufacture)
q Use as primer for black ceramic-coated glass
SUNSTAR
surface and for hard polycarbonate-coated
GLASS
22M-54-27240 150 ml Can surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
GP-402 manufacture)
SUNSTAR q Use "S" in high-temperature season and "W"
PENGUINE in low-temperature season as adhesive for
Polyethylene
SEAL580 417-926-3910 320 ml glass.
container
SUPER "S" (Effective period: four months after date of
or "W" manufacture)
Adhesive
Sika Japan, q Use as adhesive for glass.

Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
256HV manufacture)
For adhered window glass
SUNSTAR q Use as adhesive for glass.

Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
2505
Caulking material
SEKISUI q Use to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translucent
TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL
manufacture)
381
23
Selection of wire ropes used for assembly
Select wire ropes to be used for assembly according to the following table.
Annex 2, Table 1 Using loads of 6 × 24 type rope slings.

Unit: kN {tf}
Number of wire ropes 1 pc. 2 pcs.
Sling angle α α = 0° α Z 90° 90° < α Z 120°

Angle to vertical line β β = 0° β Z 45° 45° < β Z 60°
Mode coefficient M 1 1.4 1
Classification of wire rope
Outer diameter of 24G 24A 24G 24A 24G 24A
wire rope (2)d (mm)
24
8 Max. 4.8 {0.49} Max. 5.2 {0.53} Max. 6.7 {0.68} Max. 7.2 {0.74} Max. 4.8 {0.49} Max. 5.2 {0.53}
9 Max. 6.1 {0.63} Max. 6.6 {0.67} Max. 8.5 {0.88} Max. 9.2 {0.93} Max. 6.1 {0.63} Max. 6.6 {0.67}
10 Max. 7.6 {0.77} Max. 8.2 {0.83} Max. 10 {1.0} Max. 11 {1.1} Max. 7.6 {0.77} Max. 8.2 {0.83}
11.2 Max. 9.5 {0.97} Max. 10 {1.0} Max. 13 {1.3} Max. 14 {1.4} Max. 9.5 {0.97} Max. 10 {1.1}
(12) Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 15 {1.6} Max. 10 {1.1} Max. 11 {1.2}
12.5 Max. 11 {1.2} Max. 12 {1.3} Max. 15 {1.6} Max. 16 {1.8} Max. 11 {1.2} Max. 12 {1.3}
14 Max. 14 {1.5} Max. 16 {1.6} Max. 19 {2.1} Max. 22 {2.2} Max. 14 {1.5} Max. 16 {1.6}
(24) Max. 43 {4.4} — Max. 60 {6.1} — Max. 43 {4.4} —
A. Assembly
Remarks
1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---, but
indicated by (1), (2), (3) --- in the tables and texts.
Example:
(1) Plate
(2) Collar
(3) Washer
(4) Bolt
(5) Bolt
(6) Washer
2. In some places of this manual, the words of front, rear, right hand and left hand
of machine are used. Those words indicate the directions seen from the opera-
tor's seat with the sprocket at the rear as shown below, unless otherwise speci-
fied.
Front
Left hand Right hand
Operator's seat
Sprocket
Rear
25
Assembly process No.
Installation of chassis (1/3)
A-1
1) Lay the 2 sets of track shoe assembly in parallel Fig. 1

on the machine assembly place. (Fig. 1, Fig. 2)
a Distance between track shoe assemblies:

2,500 mm (Fig. 2)
a Set the directions and positions properly.

Weight of each side (Shoe width: 610):
4,300 kg
Number of shoes: 41 pieces/side ＲＦ
Overall length: 11.5 m
Left track Fig. 2

2) Place the 2 stands to set (place) the machine
between the right and left track shoe assem-
blies. (Fig. 3)
For the stands, see "Field assembly jigs and Front
Parallel
Right track
tools list" in this manual.
a One of the stands is for the front of the ma-

Front
chine (967 mm high) and the other is for the end
rear of the machine (952 mm high).
Set the upper stopper of the stand for the
front of the machine forward.
Fig. 3
a Place the front stand at 6,700 mm from the
front end of the track shoe assembly and
place the rear stand further 2,900 mm back-
ward. (L1 and L2 in Fig. 3)
Precautions Necessary tools Necessary equipment

Name Q'ty Name Q'ty
ø20 × 2,000 mm 2 25-ton crane 1
Wire rope sling
Support stand (front) 1
Support stand (rear) 1
Other remarks
26
A-1
3) Sling the machine with 2 cranes having at least 25 ton capacity each to unload from the trailer and
place it on the stands described above. (Fig. 4)
a Match the direction of the machine to that of the track shoe assemblies.
Fig. 4
a Machine weight: 27,000 kg

a Lift points of machine
Front: Install a shackle to the tow hook hole under the radiator guard and sling with 1 wire (ø 36
mm) as shown in (Fig. 4).
Note 1. Put protective pads (rubber seats, wooden boards, cloths, etc.) to the radiator
guard bottom which will be contact with the wire to protect the radiator guard in
(Fig. 4).
2. Remove the radiator mask and install it after the work is completed.
Rear: Install wires (ø 36 mm) to the upper pins for installing the rear work equipment (ripper) (1
each on the right and left sides) and sling as shown in (Fig. 4).
a When slinging the front section, remove the radia- Name Q'ty Name Q'ty
tor mask. After installing the machine install the ø36 × 6,000 mm 4 25-ton crane 2
radiator mask again. Wire rope sling
SA60 shackle 1
Corner pad 1
Other remarks
27
A-1
Install 1 and 2 wire rope slings to the front and rear of the machine respectively as shown in (Fig. 4) and
sling the machine with 2 truck cranes (Install the front sling to 1 truck crane and install the rear slings to
another truck crane). Unload the machine from the trailer and place it on the chassis stand installed on
the ground.
a Install the front wire rope sling to the tow hook installed to the undercover of the machine through a
proper shackle.
If the sling interferes with the machine at this time, put a rubber or felt pad between the sling and
machine to protect the machine.
a Install the rear wire rope slings to the ripper tilt cylinder mounts installed to the machine.
Install each sling to the pin installed to each of the right and left mounts.
a Place the equalizer bar installed to the machine onto the front chassis stand and place the hull frame
(main frame of the machine) onto the rear chassis stand.
At this time, check that the chassis stands are at the lateral center of the machine.
a Before loosening the sling tension, put wooden block (13) between equalizer bar (9) and machine
main frame (10) on each of the right and left sides as shown in (Fig. 5).
<Specifications of wooden block>

Fig. 5
Section : 95 mm square
Length : 180 – 200 mm
a Steel blocks of the same shape may

be used instead of the wooden
blocks.
(9) Equalizer bar

(10) Machine main frame
(11) Front chassis stand
(13) Wooden block
28
Installation of engine air inlet hood
A-2.1
1) Remove the dust/water seal stuck to the air inlet hood mounting opening of the engine hood shown
in the figure. (Fig. 1)
2) Insert air inlet hood (1) in the air inlet mounting opening all the way. It may be installed in any direc-
tion.
3) Tighten the band bolt of air inlet hood (1) to fix.
Fig. 1
No. Part No. Name Q’ty

1 6128-11-5180 Hood 1
29
Installation of engine air pre-cleaner (if equipped)
A-2.2
1) Remove the dust/water seal stuck to the air inlet hood mounting opening of the engine hood shown
in the figure. (Fig. 2)
2) Insert duct (2) in the air inlet mounting opening all the way. It may be installed in any direction.
3) Tighten the duct band with bolt (3), washer (4) and nut (5).
4) Insert pre-cleaner (1) in duct (2) all the way. It may be installed in any direction.
5) Tighten the band bolt of pre-cleaner (1) to fix.
Fig. 2
No. Part No. Name Q’ty

1 195-01-35210 Precleaner 1
2 195-54-68770 Duct 1
3 01016-51045 Bolt 1
4 01643-31232 Washer 1
5 01580-11008 Nut 1
30
Installing direction of exhaust pipe
A-3
1) Remove the temporarily exhaust pipe installed to the machine and then remove rain cap (4).
2) Install rain cap (4) to the exhaust pipe (1) at the angle shown in (Fig. 1) and install exhaust pipe
assembly to the hood with bolts (2) and washers (3).
Fig. 1
4 6162-14-5640 1
3 01643-31232 7
2 195-54-43210 7
1 195-01-41112 1
No. Part No. Q’ty
Install the rain cap in the direction shown in (Fig. 2).
Right of machine Fig. 2
Front of machine
Left of machine
Note) Direct the rain cap toward the inside of the machine so that the exhaust gas will not blow over the
right blade lift cylinder.
31
Installation of undercover
A-4
1) Install the 3 undercovers in the order shown in the (Fig. 1).
Undercovers 1
01010-82470
Part No. of bolt
(8 pieces)
Fig. 1
176-50-11170
Part No. of spacer
(8 pieces)
Length of bolt M24 × 70 mm
Necessary socket 36 mm
See Table 1 “Tightening
Tightening torque
torque”
Undercovers 2
Part No. of bolt 01010-82470 (8 pieces)
Part No. of spacer 176-50-11170 (8 pieces)
Length of bolt 70
Part No. of bolt
01010-82450 (2)
(Hinge area)
Part No. of washer
01643-32460 (2)
(Hinge area)
Length of bolt
M24 × 50 mm
(Hinge area)
Tightening torque
torque”
Undercovers 3
Part No. of bolt 01010-82470 (13 pieces)
Part No. of spacer 176-50-11170 (13 pieces)
Length of bolt M24 × 70
Part No. of bolt
01010-82450 (2)
(Hinge area)
Part No. of washer
01643-32460 (2)
(Hinge area)
Length of bolt
50 mm
(Hinge area)
Tightening torque
torque”
1) Apply adhesive (LT-2) to the bolts before tightening. Name Q'ty Name Q'ty
2) Parts (1), (2) and (3) may be installed before the

machine is delivered.
Other remarks
32
Installation of pivot shaft (1/2)
A-5
1) Slinging pivot shaft

Fig. 1
• To sling the pivot shaft, install the sling as
shown in (Fig. 1).
• A proper length of the sling wire is about 600
mm. Dimension (A) in (Fig. 1)
• Install the sling wire to about 500 mm from the
pivot shaft end. Dimension (B) in (Fig. 1)
2) Setting position of pivot shaft

• Set the pivot shaft to the machine with its
flange directed as shown in (Fig. 2).
3) Bolting to machine
• Use an impact wrench of 450 kg specification
and the socket shown in the following table.
See (Fig. 3)
• While turning the torsion seal cover properly, Fig. 2
tighten the bolts.
Note: After tightening, be sure to check the tight-

ening torque.
01010-83000
Part No. of bolt
(14 pieces each on right and left)
01643-33080
Part No. of washer
Bolt specification M30 × 100 mm
Socket 46 mm
Tightening torque See Table 1 “Tightening torque”
Fig. 3
Tilt hose
4) Installation of cork plug
After tightening the above bolts, drive the cork
plugs into the screw bolt holes in which the bolts of the pivot shaft flange will not be installed.
Part name Part No. Q’ty
2 pieces each on
Plug 07049-03038
right and left
33
Installation of pivot shaft (2/2)
A-5
Remarks 1. Torsion seal (2) is press fitted

to the large diameter end of Fig. 4
pivot shaft (1) in advance. In
addition, torsion seal retainer
(3) is fitted in a free rotation
state to bring the torsion seal
in close contact with the track
frame that will be described
later. (Fig. 4)
2. There are 2 tilt hoses (4) and

(5) for work equipment hydrau-
lic system coming out of the
pivot shaft mounting seat of
the machine. (1) Pivot shaft
Pass both of these tilt hoses (2) Torsion seal
through the center hole of the (3) Torsion seal retainer
pivot shaft so that they will (4) Tilt hose
come out of the shaft end. Set one having identification color mark on
At this time, do not twist the tilt neck up.
hoses spirally inside the pivot (5) Tilt hose
shaft hole and set the one Set one having no identification color mark
having identification color mark on neck down.
up. (Fig. 4)
3. The pivot shaft may have been installed to the machine before delivery.
4. This assembly work shall be performed on the right and left sides of the machine. The
tilt hose piping on both sides are different from each other as shown below.
Installing position in
Machine specification Tilt hose type
machine
Upper 1 hose having identification blue mark
Left
Lower 1 hose having no identification color mark
Dual tiltdozer
Upper 1 hose having identification red mark
Right
Left Without tilt hose
Single tiltdozer Upper 1 hose having identification red mark
Right
34
Installation of undercarriage (1/27)
A-6
1) Installation of track frame assembly to machine
1. 1) Before installing the track frame assembly, remove the following parts from it.
• Rear upper cover parts of track frame assembly --- (1), (2), (3), (4) and (5) in (Fig. 1)
• Equalizer bar side pin and cover parts --- (6), (7), (8), (9), (10), (11), (12), (13), (14), (15), (16),
(17), (18) and (19) in (Fig. 1)
• Pivot shaft end cover parts --- (21), (22), (23) and (24) in (Fig. 1)
• Parts related to torsion seal assembly at pivot shaft end --- (40), (41), (42), (43), (44) and (45) in
(Fig. 1)
• Parts related to hydraulic hose hole cover of tiltdozer --- (31), (32) and (33) in (Fig. 1)
Note 1. This section describes assembly of right and left track frame assemblies of the dual tiltdozer
specification and that of the right track frame assembly of the single tiltdozer specification.
For the left track frame assembly of the single tiltdozer, see 1.2).
2. (Fig. 1) explains the left track frame assembly, and the right track frame assembly is similar
to it.
The O-rings which must not be reused as a rule are not shown in the figure.
3. The removed parts will be installed again during or after assembly of the track frame assem-
bly. Take care not to lose them.
4. The track frame assembly is shipped with the fixing jig installed so that the track roller area
will not sag when the track frame assembly is slung. This fixing jig is unnecessary after
completion of assembly, but do not remove it at this time. For the location of this jig and the
time to remove it, see step 7) of this assembly procedure.
Fig. 1
35
A-6
1.2) The parts to be removed from the left track frame assembly of the single tiltdozer are as follows.
• Rear cover parts of track frame assembly --- (1), (2), (3), (4) and (5) in (Fig. 2)
• Equalizer bar side pin and cover parts --- (6), (7), (8), (9), (10), (11), (12), (13), (15), (16), (17),
(18) and (19) in (Fig. 2)
• Pivot shaft end cover parts --- (64), (65) and (66) in (Fig. 2)
• Parts related to thrust washer of pivot shaft end --- (45), (61), (62) and (63) in (Fig. 2)
• Parts related to hydraulic hose hole cover of tiltdozer --- (32), (33) and (34) in (Fig. 2)
Fig. 2
36
A-6
1.3) Fit the O-ring to the O-ring (51) groove of the

machine side (inside) of the pivot shaft insertion hole Fig. 3
of the track frame assembly. (Fig. 3)
outside
inside
No. Part No. Q'ty Pivot shaft insertion hole
(51) 07000-15300 1 piece each on right and left
Note: Check that the O-ring contact face of the "torsion

seal" press fitted to the pivot shaft installed in
"Assembly procedure A-5" is free from foreign Track frame
matter and harmful material. See (Fig. 9), too
1.4) Sling the track frame assembly with the sling jig,
Fig. 4
wire and crane.
a For the position of the crane and slinging method,

see (Fig. 4) and (Fig. 5).
Note 1. For the sling jig, see "Table of tools for field
assembly".
2. Sling the track frame assembly horizontally.
3. (Fig. 4) and (Fig. 5) show the right track frame

assembly.
Fig. 5
37
A-6
1.5) While aligning the pivot shaft insertion hole of

the track frame assembly with the pivot shaft, Fig. 6
pull the track frame assembly near the
machine gradually.
See (Fig. 6)
1.6) Pull the track frame assembly until the O-ring

in step 1.3) lightly touches the torsion seal Fig. 7
press fitted to the pivot shaft (See (Fig. 9)) and
until the side pin holes of the equalizer bar are
aligned.
See (Fig. 7), (Fig. 8)
Note: Take care extremely that the O-ring (51) in

step will not come off the groove or fall while
the track frame assembly is pulled.
Equalizer bar
Fig. 8
(51) O-ring (See this procedure, 1.3)

Fig. 9
(52) Torsion seal (See assembly procedure A-5)
(53) Torsion seal cover (See assembly proce-
dure A-5)
(73) Pivot shaft (See assembly procedure A-5)
(74) Track frame assembly
(90) Machine body
Remarks The hydraulic hoses of the tiltdozer

are not shown in the figure.
38
A-6
1.7) Insertion of equalizer bar side pins Side pin holes
1.7.1) Align the equalizer bar side pin holes with each
other. See (Fig. 10) Fig. 10
1.7.2) Insert each side pin. See (Fig. 11)

Removed pin (6) in 1.1), 1.2)
195-50-51150
(6) Part No.
(1 each on right and lest sides)
Note: Since each pin head face will be in contact

with the O-ring, take care not to damage it
when inserting the pin.
a Insert from the front side of the machine.
a Insert each pin with the stamp of "UP" on Fig. 11
the pin head up.
a The right and left pin heads seen from the
front of the machine are as follows.
Right side of machine Left side of machine

(Left when seen from (Right when seen from
front) front)
1.7.3) Tighten the side pin fixing bolts temporarily.

Insert bolts (18) and (19) from underside and Fig. 12
install and tighten nuts (16) and (17) from above.
See (Fig. 12)
(16), (17), (18) and (19) removed in 1.1), 1.2) UP
195-50-51510
(18) Part No. of bolt
01643-33080
(19) Part No. of washer
01803-03034
(16) Part No. of nut
01643-33080
(17) Part No. of washer
Bolt s pecification M30 × 305 mm
Socket 46 mm
Note 1. Take care not to damage the O-ring con- Take care of bolt insertion
tact faces of the pin heads. direction (See Note 2)
2. Bolts are inserted from above into the track
frame assembly unit delivered to the field to protect their threads and for the reason of
transportation.
When connecting the track frame assembly to the equalizer bar of the machine, remove
those bolts and then insert them from below.
3. The mudguards (15) in (Fig. 1) and (Fig. 2) removed simultaneously in steps 1.1) and 1.2)
will be install later in step 8). Accordingly, tighten their bolts and nuts temporarily at this
time.
39
A-6
1.7.4) Place grease cover (8) on the equalizer bar side

pin inserted in advance and fix it with mounting
bolts (9) and (10) temporarily. (Fig. 13) Fig. 13
Note 1. Install "O-ring (7)" to the grease cover which

will be in contact with the equalizer bar side
pin head without fail.
2. Install the grease cover to the shape of the

equalizer bar side pin head.
Part No. of grease Left 195-50-52360 (1 piece)

cover (8) Right 195-50-52370 (1 piece)
Part No. of O-ring (7) 07000-12020 (1 piece each on right and left) (7), (8), (9) and (10)
Part No. 01010-81665 (4 pieces each on right and left) removed in (Fig. 1) and
Bolt (9) (Fig. 2)
Specification M16 × 65 mm
Part No. of washer (10) 01643-31645 (4 pieces each on right and left)
1.7.5) Connect the grease tube (A) coming from the equalizer bar to the grease cover.
Note: The tube joint has pipe threads. Take care not to tighten it too much. The reference tightening
torque is shown below.
Tightening torque 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
1.8) Place jacks or wooden blocks under the installed track frame assembly so that the assembly will
not tip over when it is lowered from the crane. (Fig. 14)
Jack
Place the jacks or wooden blocks to at least 2
places so that the track frame assembly will
be kept horizontally in each direction. Fig. 14
1.9) Lower the track frame and start the installation work of the track frame assembly on the opposite
side.
40
A-6
1.10) Install the track frame assembly on the opposite

side according to steps 1.1) – 1.8). Fig. 15
(Fig. 15), (Fig. 16) and (Fig. 17)
Bogie fixing jig
Fig. 16
Fig. 17
Note: As described in 1.1), do not remove the bogie fixing jig for preventing the track rollers from
drooping at this time.
Removal of this jig is described in 11) of this procedure. As a rule, however, remove it after
removing the machine stand installed in "Assembly procedure A-1" and placing the whole
machine, including the track frame assembly, onto the track shoe assembly spread on the
ground.
41
A-6
2) Assembly of pivot shaft end

2.1) Right and left sides of dual tiltdozer and right side of single tiltdozer
Fig. 18
No. Part name Part No. Q’ty Remarks

40-1 Inner washer 195-50-52120 1
40-2 Outer washer 195-50-52130 1 Assembled already
40-3 Torsion seal 195-50-22181 1
41 Bolt 01010-81690 8
42 Washer 01643-51645 8
43 Bolt 01010-81645 3
44 Washer 01643-51645 3
45 Spacer 195-50-22170 1
71 O-ring 07000-15155 1
72 O-ring 07000-15250 1
73 Pivot shaft – –
74 Track frame assembly – –
75 Hydraulic hose – – See Assembly procedure
76 Hydraulic hose – – A-5
42
A-6
2.1.1) Fit the "O-ring" to the O-ring groove at the pivot shaft end. (71) in (Fig. 18)
2.1.2) Fit the spacer to the track frame assembly side of the pivot shaft end. (45) in (Fig. 18)
These parts are the parts remove in step 1.1).
2.1.3) Fit O-rings (5) to torsion seal assemblies (40-1), (40-2) and (40-3) in (Fig. 18) and install the tor-
sion seal assemblies so that they will hold the O-rings in step 2.1.1) and spacers in step 2.1.2)
and then tighten the bolts.
The torsion seal assemblies are the parts removed in step 1.1). See (Fig. 1), (40)
* Bolts to install inner washers of torsion seals. See (41)

and (42) removed in (Fig. 18)
Tool (Socket) 24 mm
* Bolts to install outer washers of torsion seals. See (43)

and (44) removed in (Fig. 18)
Tool (Socket) 24 mm
Note 1. Keep the track frame assemblies horizontally so that no torsion load will be applied to the
torsion seals at the beginning of assembly.
2. Set the 3 bolts to install the outer washer of the torsion seal at irregular intervals as shown
in 2.1.4).
If the bolts are not installed to correct positions, the pivot shaft end cover cannot be installed
in step 4). Take care.
43
A-6
2.1.4) Outer washer mounting bolt positions of torsion seal assembly

Install outer washer mounting bolts (43) and washers (44) of the torsion seal assembly unequally
spaced as shown in (Fig. 19), seeing from the direction of arrow Z in (Fig. 18).
Fig. 19
Note 1. The other equally spaced holes (8 places) to which (43) and (44) are not installed are for
mounting bolts (22) and (23) of pivot shaft end cover (1) removed in (Fig. 1).
2. For the single tiltdozer, perform this work on the right side only. For the left side, see step
2.2).
44
A-6
2.2) Left side of single tiltdozer

Since there are not the torsion seals or hydraulic hoses on the left side of the single tiltdozer,
assemble as shown below.
Fig. 20
No. Part name Part No. Q’ty

45 Spacer 195-50-22170 1
61 Thrust washer 195-50-42160 1
62 Bolt 01010-81665 8
63 Washer 01643-54645 8
71 O-ring 07000-15155 1
73 Pivot shaft – –
77 O-ring 07000-12085 1
2.2.1) Fit O-ring (71) to the O-ring groove at the pivot shaft end.
2.2.2) Fit spacer (45) to the track frame assembly side of the pivot shaft end.
2.2.3) Fit O-ring (77) to the O-ring groove of thrust washer (61) and secure thrust washer (61) to pivot
shaft (73) with the bolts, while holding O-ring (71) and spacer (45).
* Thrust washer mounting bolt (62) and (63) in (Fig. 20)

Tool (Socket) 24 mm
Remark: (45), (61), (62), (63) and (64) are the parts removed in step 1.2).
45
A-6
3) Assembly of torsion seal retainer at pivot shaft base
Fig. 21

51 O-ring 07000-15300 – See the procedure, 1.3.
52 Torsion seal 195-50-22151 – See A-5
53 Torsion seal cover 195-50-22140 – See A-5
54 Bolt 01010-81645 4
55 Washer 01643-31645 4
73 Pivot shaft – – See A-5
As explained in “assembly procedure A-5”, Installation of pivot shaft, torsion seal retainer (53) is
installed to the pivot shaft base in a free rotation state. Install this retainer to track frame assembly
(74) with bolts (54) and washers (55), while holding seal (80) under it.

Tool (Socket) 24 mm
46
A-6
4) Assembly of pivot shaft end cover

4.1) Right and left sides of dual tiltdozer and right side of single tiltdozer
Fig. 22

21 Cover 195-50-22132 1
25 Union 02781-00522 2
Assembled already
26 O-ring 07002-12434 2
27 O-ring 02896-1105 2
22 Bolt 01010-81695 7
23 Bolt 01010-81615 1
24 Washer 01643-31645 8
75 Hydraulic hose (Upper) – 1 With identification color mark
76 Hydraulic hose (Lower) – 1 Without identification color mark
47
A-6
4.1.1) Remove oil plugs (77) and (78) in (Fig. 23) installed to the ends of 2 hydraulic hoses (75) and (76)
in (Fig. 18) coming out of the pivot shaft end.
Fig. 23

77 Plug 07376-70522 2
78 O-ring 02896-11015 2
4.1.2) Connect the above hydraulic hoses to union (25) in (Fig. 22) installed to pivot shaft end cover (21)
in (Fig. 22).
a Take care not to forget to fit O-ring (27) in (Fig. 22).
Connect the hydraulic hoses according to the following table.
Hose discernment Selection of connecting elbow
Blue discernment at hose end Connect to upper elbow.

Left side of
machine No discernment on hose Connect to lower elbow.
Red discernment at hose end Connect to upper elbow. Apply this assembly
Right side of
to right side of single
machine No discernment on hose Connect to lower elbow. tiltdozer, too.
a For the upper and lower unions, see (Fig. 22).
48
A-6
4.1.3) While pushing the hydraulic hoses into the pivot shaft hole, put pivot shaft end cover assembly
connected to the tilt hoses in step 4.1.2) over torsion seal assembly (40) in (Fig. 18) and secure it
to the track frame assembly with the bolts. See (Fig. 22) and (Fig. 24).
M16 × 95 mm (7 pieces each)
Bolt specification
M16 × 115 mm (1 piece each)
Tool (Socket) 24 mm
Fig. 24
4.2) Left side of single tiltdozer

Install pivot shaft end cover having no hydraulic hose connection to the left side of the single tilt-
dozer. See (Fig. 25) and (Fig. 26).
Fig. 25 Fig. 26

64 Cover 195-50-52140 1
65 Bolt 01010-81665 8
66 Washer 01643-31645 8
72 O-ring 07000-15250 1

Tool (Socket) 24 mm
49
A-6
5) Assembly of trunnion
Install trunnions (81) necessary for connection of the blade assembly and machine described in
"Assembly procedure A-15", Installation of blade assembly, to the both right and left track frames
respectively. See (Fig. 27).
Note Before installing the trunnion, remove all the paint from face A of the track frame (mating face
to the trunnion) and face B of the trunniong (mating face to the track frame) with sandpaper
etc.
Fig. 27

81 Trunnion 195-71-511911 1 piece each on right and left
82 Bolt 01010-62475 10 pieces each on right and left
83 Washer 01643-32460 10 pieces each on right and left

Tool (Socket) 36 mm
Note 1. This trunnion may be installed to the track frame before the machine is delivered.
2. This assembly may be performed before "Assembly procedure A-15", Installation of blade
assembly, described later.
50
A-6
6) Assembly of tilt hoses from pivot shaft end cover to trunnion

This assembly is for the right and left sides of the dual tiltdozer and the right side of the single tilt-
dozer.
Fig. 28

86 Elbow 02783-10522 2 135 deg. specification
87 O-ring 07002-12434 2
88 O-ring 02896-11015 2
91 Hydraulic hose 195-71-75631 1 With identification blue mark
92 Hydraulic hose 195-71-75670 2 With no identification color mark
93 Hydraulic hose 195-71-75691 1 With identification red mark
6.1) Fit O-rings (87) to elbows (86) and install them to pivot shaft end cover (21). (Fig. 28)
As a rule, direct the elbows toward the center of the machine. When connecting the hydraulic
hoses described below, however, adjust the elbows so that the hydraulic hoses will not interfere
with or strongly touch other parts.
6.2) Pass hydraulic hoses (91) and (92) on the left side and (92) and (93) on the right side through the
track frame as shown in (Fig. 31) and connect them to the elbows installed in step 6.1).
At this time, take care not to forget to fit O-rings (88) to the elbows.
Connect the hydraulic hoses according to the following table.
Hose discernment Connect to pivot shaft cover

Left side of Blue discernment at hose end Connect to upper
machine No discernment on hose Connect to lower
Right side of Red discernment at hose end Connect to upper
machine No discernment on hose Connect to lower
Note : When passing the hydraulic hoses through the track frame, do not twist them spirally.
51
A-6
6.3) Pull out the opposite ends of the hydraulic

hoses from the center hole of the trunnion as Fig. 29
shown in (Fig. 29).
At this time, set the hydraulic hose having a
identification color mark (A) in (Fig. 29) up.
A: Hydraulic hose with identification color

mark
B: Hydraulic hose without identification
color mark
6.4) Installation of plug at tilt hose end

Install plug (77) and O-ring (78) shown in (Fig. 29) to the end of each of tilt hoses (A) and (B). (Fig.
30)
Fig. 30
Q'ty
No. Part name Part No.
For single tiltdozer For double tiltdozer
77 Plug 07376-70522 2 pieces on only right 2 pieces each on right and left
78 O-ring 02896-11015 2 pieces on only right 2 pieces each on right and left
Note 1. Be sure to install these plugs in this step.

The rear work equipment (ripper) and front work equipment (blade assembly) may be
operated in the installation procedure described later and these plugs stop oil from
spouting out of hydraulic hoses A and B at that time.
2. Plugs (77) removed in step 4.1.1) may be reused.
52
A-6
6.5) Install cover (31) in (Fig. 31) to the track frame to protect the elbows described in step 6.1) and the
hydraulic hoses from the elbows to inside described in step 6.2) from dirt and sand.
Fig. 31

Left side Cover 195-30-69520 1
31
Right side Cover 195-30-69530 1
32 Bolt 01010-81635 3
33 Washer 01643-31645 3
91 Hydraulic hose – –
Left side
See step 6), 6.2)
Right side

Tool (Socket) 24 mm
53
A-6
7) Assembly of front cover of pivot shaft end cover

Perform this assembly for the left track frame of the single tiltdozer specification.
7.1) Install dirt and sand prevention cover (34) with the bolts to the left track frame hole on the front
side of the pivot shaft end cover (the hole for hydraulic hoses for dual tiltdozer specification). (Fig.
32)
Fig. 32

32 Bolt 01010-81635 3
33 Washer 01643-31645 3
34 Cover 195-30-69510 1

Tool (Socket) 24 mm
54
A-6
8) Assembly of parts around equalizer bar side pin

Assemble the parts around the equalizer bar side pin and permanently tighten the equalizer bar side
pin mounting bolts and nuts which were assembled temporarily in step 1.7).
Fig. 33
No. Part name Part No. pcs./machine Remarks

5 O-ring 07000-42020 2
1 Cover 195-50-51360 1
L.H Assembly
2 Connector 07213-50710 1
6
1 Cover 195-50-51370 1
R.H Assembly
2 Connector 07213-50710 1
7 Bolt 01010-81665 8
8 Washer 01643-31645 8
9 Bolt 195-50-51510 4
10 Washer 01643-33080 4
L.H Cover 195-30-68950 1
11
R.H Cover 195-30-68960 1
12 Bolt 01010-61650 6
13 Washer 01643-31645 6
1 Cover (Big) 195-50-52310 1
2 Cover (Small) 198-50-61350 1
L.H Assembly
3 Bolt 01010-81225 2
4 Washer 01643-31232 2
15
1 Cover (Big) 195-50-52320 1
2 Cover (Small) 198-50-61350 1
R.H Assembly
3 Bolt 01010-81225 2
4 Washer 01643-31232 2
16 Nut 01803-03034 4
17 Washer 01643-33080 4
55
A-6
8.1) Remove the nuts (16) and washers (17) installed

temporarily in step 1.7.3) and install the mud cover
(15). (Fig. 33), (Fig. 34)
Note: Take care not drop the bolts.

Fig. 34
8.2) Install and tighten nuts (16) and (17) again to secure
the mudguards. (Fig. 33), (Fig. 34)
Bolt specification M30

Tool (Socket) 46 mm
1,960 – 2,450 Nm
Tightening torque
{200 – 250 kgm}
Note: Do not turn bolt (9) together with related parts
8.3) Tighten the grease cover mounting bolts (7) and

washer (8) tightened temporarily in step 1.7.4). (Fig.
33), (Fig. 35)
Fig. 35
Tool (Socket) 24 mm
8.4) Install front mudguards (11) to grease feed covers

(6) and secure it with bolts (12) and washers (13). Fig. 36
(Fig. 33), (Fig. 36)

Tool (Socket) 24 mm
56
A-6
9) Assembly of mudguards at rear of track frame assembly

Fig. 37
Install mudguards (1) at the rear of track frame assembly
removed in steps 1.1) and 1.2) and secure them with bolts
(2), (3) and washers (4). (Fig. 37)
pcs./
No. Part name Part No. Remarks
machine
1 Cover 195-30-69311 2 Common to right
and left
2 Bolt 01010-62060 2
3 Bolt 01010-62050 8
4 Washer 01643-32060 10
long M20 × 60 mm
Bolt specification
short M20 × 50 mm
Tool (Socket) 30 mm
10) Installation whole machine to track shoe assemblies
10.1) After installing the right and left track frame assemblies to the machine, sling the whole machine
with 2 cranes having at least 25 ton capacity each. For the slinging procedure, see “Assembly
procedure A-1” Installation of machine.
10.2) Remove the support stands and unnecessary stands such as the jacks, wooden blocks, etc.
installed in “Assembly procedure A-1” Installation of machine.
10.3) Place the whole machine on the track shoe assemblies spread on the ground.

Name Q'ty Name Q'ty
ø36 mm × 6 m 4 25-ton crane 2
Wire rope sling
SA60 shakle 2
Corner pad 1
Other remarks
57
A-6
11) Removal of bogie fixing jig
Note: Perform the following work after placing the whole machine on the track shoe assemblies
spread on the ground. If it is performed before placing the machine, the track rollers will sag
more than necessity and the work following will become difficult.
Fig. 38
No. Part name Part No. Q'ty Remarks

1 Plate 195-30-68610 3 each on right and left
2 Collar 198-30-66190 3 each on right and left
Parts to be removed
3 Washer 19M-54-11770 3 each on right and left
4 Bolt 01011-62410 3 each on right and left
5 Bolt 01010-62455 3 each on right and left Parts to removed and installed to
6 Washer 01643-32460 3 each on right and left different places
9 Washer 19M-54-11770 2 each on right and left Parts to be removed
11.1) Remove parts (1) – (11) shown in (Fig. 38). (These parts are installed to 4 places each on the out-
side of the track frame assembly, thus they are installed to 8 places in total on the right and left
track frame assemblies.)
58
A-6
11.2) Tighten the specified bolts and washers into the bolt holes (marked with a) which have been
used to install the bogie fixing jig.
Bolt specification 01010-62455 (5 pieces each on right and left) Use bolts (5) and washers (6) for 6 of
Part No. of washer 01643-32460 (5 pieces each on right and left) total of 10 places.
Tool (Socket) 36 mm
Tightening torque See Table 1 "Tightening torque"
11.3) Drive cork plugs into the tap holes part (A) in (Fig. 39) from which bolts (5) of fixing jig (1) were
removed. (3 places on each side, 6 places in total)
Fig. 39

Part A Plug 07019-02430 3 each on right and left Cork plug
59
A-6
12) Removal of bogie fixing jig of machine with full roller guard (optional)
Fig. 40

* 1 Plate 195-30-69860 3 each on right and left
Parts to be removed
3 Washer 19M-54-11770 3 each on right and left
* 5 Bolt 01010-62460 3 each on right and left Parts to removed and installed
6 Washer 01643-32460 3 each on right and left to different places
9 Washer 19M-54-11770 2 each on right and left Parts to be removed
• Parts marked with * are different from those of track frame assembly of standard specification
([Fig. 38]).
12.1) Remove parts (1) – (11) shown in (Fig. 40). (These parts are installed to 4 places each on the out-
side of the track frame assembly, thus they are installed to 8 places in total on the right and left
track frame assemblies.)
60
A-6
11.2) Tighten the specified bolts and washers into the bolt holes (marked with a: 6 places in total and
marked with u: 4 places in total) which have been used to install the bogie fixing jig.
Part No. of bolt 01010-62460 (3 pieces each on right and left)
Use bolts (5) and washers
Part No. of washer 01643-32460 (3 pieces each on right and left) (6) for 6 of total of 10
places.
Part No. of bolt 01010-62455 (2 pieces each on right and left)
Part No. of washer 01643-32460 (2 pieces each on right and left)
Bolt specification M24 × 60 mm or M24 × 55 mm
Tool (Socket) 36 mm
12.3) Drive cork plugs into the tap holes part (A) in (Fig. 39) from which bolts (5) of fixing jig (1) were
removed. (3 places on each side, 6 places in total)
• When it is standard specification, same as (Fig. 39).

Part A Plug 07019-02430 3 each on right and left Cork plug
The track roller specification undercarriage is installed now.

(For installation of the track shoe, see “Assembly procedure A-13”)
61
Adding oil to recoil chamber and pivot chamber
A-7
1. Adding oil to track frame pivot chamber
1) Remove soil and gravel from around the oil

filler, and then remove the plug and add oil, tak-
ing care that dirt will not enter the case.
Oil : EO30
Quantity : 18 l/each side
Oil filler
2) Pivot case oil level H = 10 – 25 mm
2. Adding oil to track frame recoil chamber
1) After adjusting the track and positioning the

idler, check the oil level and add new oil by the
necessary quantity.
2) Recoil chamber oil level H = 96 – 116 mm
62
Installation of blade lift cylinder (1/2)
A-8
1. Remove the cap and bushing of the yoke.

a When removing the cap, make a match
Bushing
mark on it for reinstallation. (The cap is Cap
a part of the yoke.)
2. Installation of cylinder
Secure the cylinder with ropes for safety as shown in the
photo.
01010-82000
Part No. of bolt
(4 pieces on each side)
06432-32060
Part No. of washer
(4 pieces on each side)
Length of bolt 100 mm
Fix the cylinder at the angle shown in the photo.

• Cap mounting bolts
3. Installation of hoses
Install the hoses as shown in the photo
so that they will not interfere with each other.
Part No. of hose 07125-01216 (2 pieces on each side)

Split flange 07371-31255 (8 pieces on each side)
Part No. of bolt 07375-21035 (16 pieces on each side)
O-ring 07000-13038 (4 pieces on each side)
63
Installation of blade lift cylinder (2/2)
A-8
4. Cylinder sling bracket

Remove cylinder sling bracket than install the cyl-
inder so that sling posture piston.
Sling bracket
5. Installation of right cylinder hose joint cover

1 Cover 195-61-61871 1
2 Cover 195-61-61891 1
3 Sems bolt 01024-81225 4
4 Washer 01643-31232 4
5 Nut 01580-11210 4
6 Sems bolt 01024-81225 4
64
Check fuel, coolant and lubricants (1/2)
A-9
Check the amount of lubricant and coolant in every device.

When refill is required, perform it reference to [Fig.1] and [Table 1].
Fig. 1 Using temperature range of oil, grease, fuel and coolant
• ASTM : American Society of Testing and Material
65
Check fuel, coolant and lubricants (2/2)
A-9
Table 1 Specified capacity and refill capacity of each part

Hydraulic Cooling
Final drive
Engine oil Damper Power system system
case Fuel tank
pan case train case (With blade, (including
(each)
without ripper) sub-tank)
Specified Liters 87 2.1 275 61 300 120 1,050
capacity US gal 22.99 0.55 72.66 16.12 79.26 31.70 277.41
Refill Liters 86 2.1 150 61 138 – –
capacity US gal 22.72 0.55 39.63 16.12 36.48 – –
Oil and coolant addition condition
• Use Komatsu genuine oil and grease.
• When adding oil, do not mix oils of different types. When changing the type of oil, replace the oil
of the specified capacity (all the oil). (The oil remaining in the piping etc. may be mixed with the
new oil.)
• When the machine is delivered, the oil, fuel and coolant shown in (Table 2) are filled, unless oth-
erwise specified.
Table 2
Item Type
Engine oil pan Engine oil 15W40DH-1 (Komatsu genuine)
Power train case
Final drive case Power train oil TO30 (Komatsu genuine)
Damper case
Hydraulic tank Power train oil TO10 (Komatsu genuine)
Fuel tank JIS No. 1, JIS No. 2, JIS No. 3 in winter (Oct. – Mar.)
Radiator Supercoolant AF-NAC (Concentration: Min. 30%) (Komatsu genuine)
66
No-injection cranking of engine (1/3)
A-10
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.
a Do not continue this operation for more than 5 seconds.
Front panel
(1) Machine monitor

Fig. 1
(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 ser-
vice meter are displayed on this
unit in normal mode (operator
mode).
(4) Starting switch
(5) Buzzer cancel switch
(6) Information switch
67
A-10
2. Procedure
2.1) Turn the starting switch "ON". The

machine monitor is turned ON.
2.2) Turn buzzer cancel switch ((5) in Fig. 2)

to the [U] position (left side) and hold it Fig. 2
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 posi-
tion.
2.3) 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
Fig. 3
USER ADJUST MODE (Fig. 4).
Reference: Each time the information switch is

turned, the 4 modes of OIL, FIL-
TER MAINTENANCE MODE, PM
CLINIC MODE, FAULT CODE
DISPLAY MODE and USER
ADJUST MODE are selected in
either order repeatedly.
2.4) After the display of the multi-information

section changes to USER ADJUST
MODE, turn the buzzer cancel switch to
the [U] position (left side) again to settle Fig. 4
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 mul-
tiinformation section changes to the vari-
ation selection screen in USER ADJUST
MODE.
Note: If the buzzer cancel switch is turned to

the [T] position (right side) by mistake,
the multiinformation section returns to
the state in step (1).
68
A-10
2.5) Turn information switch again to the [<]

position (left side) or [>] position (right Fig. 5
side) several times to change the display
of the multiinformation section to NO
INJECTION (Fig. 5).
2.6) Turn the buzzer cancel switch to the [U]

position (left side) to settle NO INJEC-
TION.
Reference: In step (5), each time the informa-

tion switch is turned, the 7 varia-
tions of LCD BRIGHTNES, DSP
BRIGHTNES, DSP CONTRAST,
FAN 100% SPEED, NO INJEC-
Fig. 6
TION, TILT LIMIT and PRE-LUB
ON are selected in either order
repeatedly.
2.7) 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) Under this condition, turn starting switch

((4) in Fig. 1) to the START position to
rotate the starting motor and perform no-
injection cranking.
Fig. 7
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 5 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-informa-
tion section to indicate that this mode is
not available.
2.9) To reset this mode, turn the buzzer can-

cel switch to the [T] position (right side).
The display of the multi-information sec-
tion returns to the state after step (1)
where the starting switch is turned "ON".
2.10) Turn the starting switch "OFF".
69
Bleeding air from hydraulic cylinders
A-11
a After disassembling for transportation, changing the oil in the hydraulic tank, or removing the hydrau-
lic 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.
a Operate the piston rod to approx. 100 mm form the end of the stroke; do not releive the cir-
cuit under any circumstances.
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 its
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.
a Operate the piston rod to approx. 100 mm form the end of the stroke; do not relieve the cir-
cuit under any circumstances.
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.
k 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.
k Check the oil level, and add oil to the specified level if necessary.

Name Q'ty Name Q'ty
Other remarks
70
Installation of ripper (1/7)
A-12
1. Installation of beam and arm assembly
a The following is the installation proce-

dure for the giant ripper. The installation Fig. 1
procedure for the multi-shank ripper is
basically the same as the following.
a Before starting the following work,

remove the lift cylinders which have
been installed for transportation.
Lift cylinder ass’y (1 piece) : 350 kg
a Remove all the rust-preventive oil from

the ripper mounting pin and then coat the
pin with new grease.
a Clean the pins and pin holes in advance.

Fig. 2
1) Since ripper mounting pins (1) are heavy,
move both of them inward without
removing from the bracket as shown in
the photo, and then install the arm. (Fig.
1)
2) As shown in Fig. 2, sling the beam and

arm assembly and align the pin hole at
the arm end with the hole of the ripper
mounting bracket of the machine.
a Install the rope slings of the arm to 2

chain blocks (2 t) so that inclination to
the right or left can be adjusted.

Name Q'ty Name Q'ty
2-t chain block 2
ø20 mm × 2 m 2
Wire rope sling
ø20 mm × 3 m 1
Wire rope sling
Other remarks
71
A-12
3) Insert either arm pin halfway and then

set the pin hole on the opposite side. Frame Fig. 3
After both pins are inserted halfway,
push them in to the end. (Fig. 3) Arm Beam
assembly assembly
No. Part name Part No. Q'ty
1 Pin 195-78-71190 2
2 Plate 195-78-21171 2
3 Bolt 01010-62040 4
4 Washer 01643-32060 4
5 Fitting 01020-00000 2
a Installed to the machine body.
4) After inserting the pins, place wooden

Fig. 4
blocks under the center of the arm and
under the beam shank holder.
Place the arm horizontally. Slant the
beam a little toward the rear, considering
the length of the cylinder. (Fig. 4)

Name Q'ty Name Q'ty
Wooden block 1
T 300 mm × 800 mm
Wooden block 1
T 300 mm × 600 mm
Other remarks
72
A-12
2. Installation of lift and tilt cylinders

Lift cylinder
1) Installation of lift cylinders
Sling the lift cylinder, which was removed in
Section 1, with the crane and install it to the Fig. 5
Main frame
frame with pin (8), lock plate (2), bolt (3)
and washer (4) (2 places on the right and
left sides). (Fig. 5)
a Take care not to mistake the right and
left cylinders for each other. (The
directions of their pipings are different.)
2 Plate 195-78-21171 2
3 Bolt 01010-62040 4
4 Washer 01643-32060 4
8 Pin 195-78-71170 2
2) Installation of tilt cylinders (on machine side)

a When removing and installing the tilt cylinder Fig. 6
pin, remove the VHMS download box accord-
ing to the following procedure. (Fig. 6)
1) Remove covers (1) and (2).
2) Remove wiring harness connector (3) and
clips (4) and (5). (Fig. 7)
3) Remove the VHMS download box and wir-
ing harness together.
VHMS download box
Fig. 7

Name Q'ty Name Q'ty
Nylon sling for 2 t 2
Sledge hammer (5 lb) 1
Other remarks
73
A-12
Sling the tilt cylinder with the crane and install it to the frame with pin (8), lock plate (2), bolt (3)
and washer (4) (on the right and left sides). (Fig. 8)
a Take care not to mistake the right and left cylinders for each other. (The directions of their
pipings are different.)
Tilt cylinder Right Fig. 8

(Right side)
(Left side)
Piping
Left

2 Plate 195-78-21171 2
3 Bolt 01010-62040 4 Note) Use oil stopping parts
4 Washer 01643-32060 4 of cylinder piping as
parts marked with *.
8 Pin 195-78-71180 2
Fig. 9
3. Installation of hydraulic piping
1) Install hose (6) and O-ring (7) of the tilt cylin-

der. (Fig. 9)

6 Hose 07124-01010 4
7 O-ring 07000-13032 8
Installed angle of hose on inside of tilt cylinder

(Fig. 10) Fig. 10
a After installing the cylinder hoses, perform

"A-11 Bleeding air from cylinder".
Slant only
inside pipings
(on bottom
side) on right
and left sides
by 10 degrees
to inside.
74
A-12
2) Install hose (6) and O-ring (7) of the lift

cylinder. (Fig. 11) Fig. 11
(Forward) Note)
Use oil stopping
parts of cylinder pip-
No. Part name Part No. Q'ty ing as these parts.
Ripper lift cyl-
6 Hose 07124-01010 4 inder (right)
7 O-ring 07000-13032 8
a When mounting cylinder, Do assem-

bling procedure “A-10 No-injection Ripper lift cyl-
cranking of engine” before engine inder (left)
start.
4. Connection of tilt cylinder (on beam side)

1) Run the engine and apply pressure the Fig. 12
tilt cylinder and adjust its length.
2) Set the pin holes and connect the tilt cyl-
inder to the beam by pin (8), lock plate
(2), bolt (3) and washer (4). (2 places on
the right and left sides) (Fig. 12)
a Sling the right or left cylinder first
and position it properly, and then
sling and position the one on the
opposite side.
2 Plate 195-78-21171 2
Condition when
3 Bolt 01010-62040 4 pin is removed
4 Washer 01643-32060 4
8 Pin 195-78-71180 2
5. Connection of lift cylinder (on beam side)

1) Run the engine and apply pressure the Condition when tilt Fig. 13
lift cylinder and adjust its length. cylinder is installed
2) Set the pin holes and connect the lift cyl-
inder to the beam by pin (8), lock plate
(2), bolt (3) and washer (4). (2 places
on the right and left sides) (Fig. 13)
2 Plate 195-78-21171 2
3 Bolt 01010-62040 4
4 Washer 01643-32060 4
8 Pin 195-78-71180 2
a Sling the cylinder and position it

properly.
75
A-12
6. Piping of pin puller cylinder

1) Connect the pin puller cylinder hoses as shown in (Fig. 14), (Fig. 15), (Fig. 16) and (Fig. 17).
a For the hose clamps, see the detailed figures.
a Run the engine, operate the ripper (lifting, tilting, extension and retraction of pin puller) and
check that each hose moves freely.
• Hose: 49 ± 19.6 Nm {5 ± 2 kgm}
Fig. 14 Fig. 15 40° Fig. 16
Part A Part B Part C
40° Fig. 17
C
Bottom
Head
1140
B
A
680
Bottom
Head

1 Hose 07103-50332 2
2 Plate 195-78-72571 1
3 Sems bolt 01024-81225 2
4 Yoke 144-947-2850 1
5 Pin 04205-11028 1
6 Pin 04050-13015 1
7 Cushion 07095-00421 6
8 Clamp 07094-30417 6
9 Sems bolt 01024-81065 3
76
A-12
7. Bleeding air
Bleed air from the hydraulic circuit according to the following procedure.
1) Run the engine at low idle
2) Extend and retract the cylinders to above 100 mm before each stroke end 4 – 5 times. (Do not
relieve the pressure at each stroke end.)
3) Extend and retract the cylinders to each stroke end 3 – 4 times.
4) While the shank point is on the ground, check that the hydraulic oil level is normal. If the hydrau-
lic oil level is lower than the specified level, add hydraulic oil according to the Operation and
Maintenance Manual.
a Lower the blade to the ground, too, at this time.
5) When bleeding air, check that each cylinder hose moves freely and oil does not leak through any
joint.
8. Installation of shank assembly

Fig. 18
1) Install a wire to the hook at the top of the shank
assembly, pass it up through the holder, pull it up
with the crane and set the shank hole to the holder
hole.
2) Insert the pin in the shank by operating the pin

puller cylinder.
a Do not move the holder and shank simultaneously.

1 Shank 195-79-51150 1
2 Pin 195-78-71360 1 Shank
assembly
3 Protector 195-78-71111 1
4 Pin 195-78-71360 2

Name Q'ty Name Q'ty
Wire rope sling 1
ø 12 mm × 2 m
Shackle 1
BC36 (for 8 t)
Other remarks
77
Installation of track (1/2)
A-13
1. Installation of track link

Fig. 1
1-1) Wind the front end of each track up to the top
of the idler. (Fig. 1)
1-2) While rotating the sprockets forward, dis-
charge the grease from the cylinder and
retract the cylinder to the stroke end.
a Keep the grease plug open.
a Clean the master link joint.
T 300 mm × high 600 mm
1-3) Push up the machine with the ripper and dis-

engage the link from the sprocket so that the Fig. 2
machine body will not run on the track. (Fig. Wire 24 ø × 2 m
2)
a Put a steel plate on the block to protect
the block. Inserted
Steel plate 25
mm thick
T 300 mm × high 600 mm

Floated
a Carry out this work on a level place.
1-4) Sling the forward end of the track with a Fig. 3

crane and wind the track link up to the top of
the sprocket as shown in the photo. (Fig. 3)
1-5) Wind the track onto the sprocket. While

slinging the forward end of the track with the
crane, rotate the sprocket to move only the
upper part of the track forward.
a The signal person must stand at a posi-
tion where the bulldozer operator and
crane operator can see him/her easily
and must give signals. Before starting
the work, confirm the signals.
1-6) Connect the master link just above the idler. Fig. 4
1-7) Fit the mating faces of the master link and

check that you can screw in the bolts lightly.
(Fig. 4)
78
Installation of track (2/2)
A-13
2. Tightening of master bolts

Fig. 5
2-1) Installation of shoe to master link
Tighten the master bolts with an impact
wrench of 20 kgm to fit the link mating faces.
(Fig. 5)
a Apply anti-seizure agent LM-P to the

threads of the bolts, threads of the link
and hexagon seats.
a If the bolts are tightened forcibly, their

threads and master link's threads are
damaged. Take care.
2-2) Method of tightening master bolts

Fig. 6
1st tightening
1) Tighten the bolts to initial torque of 686
± 69 Nm (70 ± 7 kgm) with the torque
wrench.
2) Make a match mark at the hexagonal
part of the bolt (at the position to start
tightening the bolt). (Fig. 6)
Tighten until marks
2nd tightening are matched.
3) Retighten with the hydraulic wrench
(See "Field assembly tool list" in this
manual). (Tighten by 180 ± 10 °.)
2-3) Tighten the bolts evenly in the order shown

in the figure at right. (Fig. 7) Fig. 7
a Adjust the track tension when supplying

grease at last.
a Similarly install the track shoe on the opposite side.
79
Assembly of blade (1/16)
A-14
1. Installation of blade
Fig. 1
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 degrees to the ground as
shown in (Fig. 1).
[1] Fix center link (A1) which is at the center

of the blade back with a wire (A2) as
shown in (Fig. 2) by utilizing the bolt Fig. 2
installed to the center link temporarily
and the inverted V-shaped cover so that
the center link will be also stood verti-
cally when the blade is stood vertically
on the ground.
Specifications of wire (A2)

Wire #10 (ø3.2 mm × approx. 2 m long)
(JIS G3532 annealed steel wire or equiv-
alent)
[2] Sling the blade with the crane. While

operating the main and auxiliary hoists,
stand the blade gradually as shown in Fig. 3
Auxiliary
(Fig. 3) and (Fig. 4) until it stands verti-
hoist side
cally on the object position (ground).
Main hoist
a Install the rope slings of the main side
hoist to the blade lift hydraulic cylin-
der 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 Standard Reinforced

U-blade 6.4 t 6.8 t
Weight of full U-blade 6.5 t
Fig. 4
Rope sling ø 24 mm × 5 m (4 pieces)
Shackle SD22, grade M (2 pieces)
Truck crane 25 t (1 unit)
a Use rope slings of JIS B8817 or

equivalent having the lifting capacity
of at least 4.8 ton.
a Use shackles of JI B2801 or equiva-
lent having the lifting capacity of at
least 2 ton.
80
A-14
2. Measures to prevent blade from falling

(Set the blade so that it will stand vertically Fig. 5
and stably even after the slings are loos-
ened.)
[1] Set wooden blocks under the center link

brackets. (Fig. 5)
a Wooden block:
T300 mm × length 400 mm – 2 pieces
[2] Set wooden blocks under the straight

2 parts
frame brackets on both sides. (Fig. 6)
a Wooden block:
T300 mm × length 400 mm – 2 pieces Fig. 6
[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.
[4] After confirming that the blade stands

Plate
stably, loosen and remove the slings.
3. Connection of straight frames to right and left Wooden block

of blades (Insert on both sides)
[1] Check that the joints at the ends of the

straight frames are installed in the cor-
rect directions. (Fig. 7) Fig. 7
a If the joints are installed in wrong Joint
directions, correct their directions.
[2] Remove the connecting pins installed to

the straight frame brackets on the blade.
(Fig. 8)

Good Wrong
1 Bolt 01011-62720 8
2 Washer 01643-32780 8
3 Shim (2 mm) 195-71-61450 2
4 Shim (1 mm) 195-71-61460 4 Fig. 8
5 Shim (0.5 mm) 195-71-61470 4
Bolt specification M20, Length : 45 mm

Tool (Socket) 30 mm
a Do not remove plug (82) from pin

(81).
a The quantity is the number of parts
necessary to 1 machine (1 blade).
81
A-14
[3] Sling the straight frame horizontally with

belt slings. (Fig. 9) Fig. 9
Belt sling
• Lifting load: Approx. 1,400 kg/piece on
each side
• Belt sling: 50 mm wide, 4 m long (2
pieces)
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. Connection
Accordingly, keep the straight frames Wooden block
horizontally.
Reference: A belt sling means a belt made of
[4] While slinging the straight frame, insert synthetic fibers used to sling heavy
the joint at its end in the bracket yoke on things. It is used to prevent damage
the blade and align the connecting pin on the products and protect the
holes. (Fig. 9) paint during sling work.
[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)
[6] Set a wooden block under the rear end

of the straight frame (on the opposite Fig. 10
side to the joint) and adjust the height of Belt sling
the trunnion mounting portion (center) of
the machine above the ground to 940 –
960 mm. (Fig. 10)
a Wooden block:
T300 mm × length 700 mm – 1 piece
[7] Perform steps [1] – [6] on both right and Wooden block
left sides.
[8] Sling the straight frames again and set

the right and left straight frames symmet- Fig. 11
rically about the blade and adjust the dis-
tance between both straight frames
(dimension W) to 3,480 – 3,500 mm.
(Fig. 11)
a Clean each connecting part.
82
A-14
4. Installation of center brace

4.1 Temporary installation Fig. 12
[1] Remove the shims, bolts and washers (90) Center brace
installed temporarily in advance to part F Belt sling
(spherical seat) of the center link and
part G (spherical seat) of the straight
frame. (Fig. 12)
1 Bolt 01011-62720 8
2 Washer 01643-32780 8
3 Shim (2 mm) 195-71-61450 2
4 Shim (1 mm) 195-71-61460 4 Center link Straight frame
5 Shim (0.5 mm) 195-71-61470 2
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 5
mm. Accordingly, the shims removed
from part F should not be mixed with
those removed from part G.
[2] Install the belt sling to the center of cen- Reference: The part name of "Cen-
ter brace (90). While slinging the center ter frame" is described
brace with the crane, put the balls of the as "Arm" in the parts
ball joints respectively to the spherical book.
seat (part F) of the center link and that
(part G) of the straight frame. (Fig. 2)
90 Center brace 195-71-71120 2
a "Q'ty" in above table indicates the

number for each machine.
a Weight of center brace: Approx. 220
kg/piece
[3] Temporarily install the ball caps of center
brace (90) to the spherical seats of the Fig. 13
center link and straight frame (parts F
and G in (Fig. 12)) with bolts (1) and Ball cap
washers (2) removed in step [1], while
inserting shims (3), (4) and (5) removed
in step [1] in parts A. (Fig. 13) and (Fig.
14)
Tool (Socket) 41 mm
a Insert the sets of shims 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.
83
A-14
a Tighten the bolts until the spherical

seat, shims and ball cap are fitted to Fig. 14
each other, although they are being
installed temporarily.
[4] Install the center brace on the opposite

side similarly (according to steps [1] –
[3]).
a When working on the opposite side,

remove the wire installed in step 1-
[1].
[5] Supply a little amount grease through

part M (1 place) and parts N (1 place
each on the right and left sides). (Fig. 14)
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 Fig. 15
straight frame end up and down slowly
with the crane as shown in (Fig. 15).
(Stroke: 300 – 400 mm) Belt sling
While moving up and down, check the
ball joints of the center brace for abnor-
mal sound and ensure that the ball joints
move smoothly (check the balls for inter-
nal interference).
Perform this check on both right and left
straight frames.
a If not 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.
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. 13) perma-
nently.
Tool (Socket) 41 mm
See Table 1 "Tightening
Tightening torque
torque"
a Tighten all the bolts evenly in the

diagonal order.
[2] After tightening permanently, go to step

4.4.
84
A-14
4.3 Shim adjustment (Addition of shims)

[1] If any problem is detected (interference
Fig. 16
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. 16)
a Add shims to both right and left cen-

ter braces so that the shim thickness
will be the same at all 4 places as
long as possible.

5 Shim (0.5 mm) 195-71-61470 2
a The quantity is the number of shims

necessary to 1 spherical seat.
4.4 Adjustment of distance between tilt cylin-

der mounting pin holes
[1] Sling the straight frame again with the
belt sling as shown in (Fig. 17) and
adjust the distance between the mount- Fig. 17
ing pin holes of the tilt cylinder (or the Belt sling
brace assembly on the left side in step 6
for the single tilt dozer specification)
(dimension K) to about 1,590 mm. Then,
adjust the position of the wooden block
under the straight frame so that the dis-
tance between the holes will be stabi-
lized and then remove the sling.
a Perform this adjustment on the right Wooden block

and left sides.
85
A-14
5. Installation of tilt hydraulic cylinders
5.1 In case of dual tiltdozer specification
[1] Install hydraulic hoses and hose protec-

R. H Fig. 18
tion covers to the right and left hydraulic
cylinders. (Fig. 18), (Fig. 19)

6 Hydraulic cylinder R.H 707-01-0Z420 1
7 Hydraulic cylinder L.H 707-01-0Z410 1
Hydraulic hose
8 195-71-75650 2
(Overall length: 1,640 mm)
Hydraulic hose
9 195-71-75661 2
10 O-ring 07000-13022 4
11 Frange 07371-30500 8
12 Bolt 01010-80830 16
13 Washer 01643-50823 16
14 Cover 195-71-62661 2
15 Bolt 01010-82050 12
L. H Fig. 19
16 Washer 01643-32060 12
Bolt specification Tool (Socket)

M8 13 mm
M20 30 mm
a Flange (11), bolt (12) and washer (13)

are installed to each hydraulic cylinder in
advance.
However, do not reuse the sleeve head
(oil stop cover) installed to the hydraulic
cylinder with (11), (12) and (13) when
installing the hydraulic hoses.
a Replace O-ring (10) with new one, as a

rule.
a The right and left hydraulic cylinders

have different part Nos. (shapes). Take
care. The apparent difference is the
shape of the flange on the rod side as
shown in (Fig. 18) and (Fig. 19). (Left:
Octagonal section, Right: Round section)
86
A-14
[2] Remove the covers and hydraulic cylin-

der mounting pins installed to the
hydraulic cylinder mounting sections of
Fig. 20
the right and left straight frames. (Fig.
20)

M12 19 mm
M20 30 mm
[3] While slinging hydraulic cylinder (6) or

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

inder assembly)
Left side: Approx. 350 kg, Right side:
Approx. 410 kg

Tool (Socket) 30 mm
Tightening torque
torque"
[4] Set a wooden block between hydraulic Fig. 21

cylinder (hydraulic hose protection cover)
and straight frame so that hydraulic cylin-
der (6) or (7) will be positioned as shown
in (Fig. 21), and then loosen and remove
the sling.
a Do not connect the head side of

hydraulic cylinder (6) or (7) part R in
(Fig. 21) at this time.
Connect it after installing the blade
assembly to the machine.
See “assembly procedure A-15”
87
A-14
[5] Connect the free ends of hydraulic hoses

(8) and (9) installed to hydraulic cylinder
Fig. 22
(6) or (7) in step [1] to the elbows of
R. H
flange (22) installed to the straight frame.
(Fig. 22)
Connect according to the letters stamped
on the flange.
Stamp Hose to be connected

Longer hydraulic hose
H
(Head side)
Shorter hydraulic hose
B
(Bottom side)
a Take care not to forget to install O-

rings (23).
L. H
23 O-ring 02896-11015 4
a When connecting the hydraulic hoses,

remove the oil plugs (Part No.: 02789-
00522) installed to the elbows of the
flange in advance.
[6] Reinstall the covers removed in step [2].
Bolt specifi- M12 M20

cation Length : 25 mm Length : 50 mm
Tool
19 mm 30 mm
(Socket)
Tightening
See Table 1 "Tightening torque"
torque
88
A-14
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 pro-

tection cover to the hydraulic cylinder.
Fig. 23
(Fig. 23)

31 Hydraulic cylinder 707-01-0Z390 1
Hydraulic hose
32 195-71-75730 1
Hydraulic hose
33 195-71-75740 1
34 O-ring 07000-13022 2
35 Frange 07371-30500 4
36 Bolt 01010-80830 8
37 Washer 01643-50823 8
38 Cover 195-71-62130 1
39 Bolt 01010-82050 6
40 Washer 01643-32060 6

M8 13 mm
M20 30 mm
a Flange (35), bolt (36) and washer

(37) are installed to hydraulic cylin-
der (31) in advance.
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.
89
A-14
[2] Remove the covers and hydraulic cylin-

der mounting pin (41) installed to the tilt Fig. 24
hydraulic cylinder mounting section of
the right straight frame. (Fig. 24)

M12 19 mm
M20 30 mm
[3] While slinging tilt hydraulic cylinder (31)

with belt sling (21), with the hydraulic
hose cover side down, align the mount- Fig. 25
ing pin hole on the bottom side (clevis
side) with that of the straight frame.
(Fig. 25)
• Sling weight (Weight of hydraulic cyl-

inder assembly)
Approx. 345 kg

Tool (Socket) 30 mm
Tightening torque
torque"
[4] Set a wooden block between hydraulic

cylinder (hydraulic hose protection cover)
and straight frame so that the hydraulic
cylinder will be positioned as shown in
(Fig. 25), and then loosen and remove
the sling.
a Do not connect the head side of the

hydraulic cylinder part Q in (Fig. 25)
at this time.
Connect it after installing the blade
assembly to the machine.
See “assembly procedure A-15”
90
A-14
[5] Connect the free ends of hydraulic hoses

(32) and (33) installed to the hydraulic Fig. 26
cylinder in step [1] to the elbows of
flange (46) installed to the straight frame.
(Fig. 26)
Connect according to the letters stamped
on the flange.
Stamp Hose to be connected

Longer hydraulic hose
H
(Head side)
Shorter hydraulic hose
B
(Bottom side)
a Take care not to forget to fit O-rings

(47).

47 O-ring 02896-11015 4
a When connecting the hydraulic hoses,

remove the oil plugs (Part No.:
02789-00522) installed to the elbows
of the flange in advance.
[6] Reinstall the covers removed in step [2].
Bolt specifi- M12 M20

cation Length : 25 mm Length : 50 mm
Tool
19 mm 30 mm
(Socket)
Tightening
See Table 1 "Tightening torque"
torque
91
A-14
6. Installation of brace assembly

Fig. 27
a The brace assembly is the portion shown
in (Fig. 27) which is applied to the single
tiltdozer specification.
[1] Remove covers (51 – 54) and brace

assembly mounting pins (55 – 58) Fig. 28
installed to the brace assembly mounting
section of the left straight frame in
advance. (Fig. 28)
Bolt specification : 53, 57 M20

Tool (Socket) 30 mm
[2] Remove brace assembly mounting pins

(59 – 62) installed to the brace assembly Fig. 29
mounting section of the blade in
advance. (Fig. 29)
Bolt specification : 61 M20

Tool (Socket) 30 mm
92
A-14
[3] The brace assembly consists of the fol-

lowing parts. (Fig. 30)
Fig. 30
63 Brace 195-71-61561 1
64 Fitting 07020-00000 2
65 Seal 177-50-11170 2
66 Screw 195-71-61540 1
67 Screw 195-71-51152 1
68 Bushing 195-71-51263 1
69 Ring 04071-11160 1
70 Handle 195-71-62151 1
71 Bolt 01010-61660 2
72 Washer 01643-31645 2
[4] Supply grease (See step [9]) through fit-

ting (64) installed to brace (63) and Fig. 31
rotate brace (63) with attached lever (73)
to adjust dimension L between the holes
at both ends of brace assembly to
approximately 1,590 mm. (Fig. 31)
Reference
If brace (63) is rotated with lever (73)
while screws (66) and (67) at both ends
are fixed, dimension L increases or
decrease 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.
93
A-14
[5] While slinging brace assembly with the

belt sling, with the handle (70) up, align Fig. 32
the mounting pin hole of the brace
assembly with that of the straight frame.
(Fig. 32)
• Sling weight (Weight of brace assem-

bly)
Approx. 190 kg

Tool (Socket) 30 mm
Tightening torque
torque"
[6] While still slinging the brace assembly

with the belt sling (21), align the mount-
ing pin hole on the opposite side of step
[5] with the mounting pin hole of the If brace (63) is rotated with lever (73)
blade. to adjust dimension L, the direction of
handle (70) changes. According, do
a At this time, if the mounting pin holes not apply this method.
cannot be aligned because of dimen-
sion L adjusted in step [4], rotate
screw (67) one half by one to adjust
dimension L finely while locking
brace (63).

in step [2] and fix it to the blade with lock
(60), bolt (61) and washer (62). (Fig. 32)

Tool (Socket) 30 mm
Tightening torque
torque"
[7] Loosen and remove the sling.
94
A-14
[8] Reinstall covers (51) – (54) removed in

step [1].

Tool (Socket) 30 mm
Tightening torque
torque"
[9] Greasing
After finishing installation, supply grease Fig. 33
to the 5 places indicated with the arrows
in (Fig. 33) until it comes out.
a G2-LI in "Coating material list" in this

manual is recommended as grease
for the above purpose.
95
Installation of blade (1/8)
A-15
Condition1) Before starting the following work, complete "Assembly procedure A-14".
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
Fig. 1 Fig. 2
Adjust the posture of the blade assembly before installation with wooden blocks (E) and (F) as
shown in (Fig. 1) and (Fig. 2).
Undercarriage specification Dimension a Dimension b (Disconnect between sphere centers)
7-track roller About 945 mm
About 3,480 mm
8-track roller About 995 mm
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 grous-
ers 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-14" as it is.
2) Connection of blade assembly and machine

Fig. 3
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 Seat

of the trunnion.
G2-LI : See [Coating materials]
2.2) Set the machine within dimension "b" of the

blade assembly and move it forward so that
the right and left 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)
96
A-15
a If the trunnion and trunnion holder are different in height, trunnion 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) Set the trunnion parts (Fig. 4) and tighten the bolts.
Fig. 4
Q'ty for each of

right and left
1 Blade assembly ----- ---- See “assembly procedure A-14”
2 Bushing 195-71-74250 2
3 Plate 195-71-74260 4
4 Cap 195-71-74231 1
5 Nut 195-71-11512 4
6 Bolt 207-46-12141 4
7 Washer 01643-32780 4

Tool (Socket) 41 mm
2.5) Remove wooden block (E) set under the straight frame in step 1).
97
A-15
3) Connection of tiltdozer hydraulic hoses

Fig. 5
3.1) Remove the plugs from the ends of the
hydraulic hoses coming out of the center hole
of the trunnion (See “assembly procedure A-
6.1”, 6.4 and “assembly procedure 6.2”, 6.4).
a Take care not to lose the "O-rings".
3.2) Remove the upper and lower locknuts 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 assembly O-ring (02896-11015) removed in step 3.1).
a Connect the hydraulic hoses according to the following table.
Hose discernment Selection of connecting nipple

Left side is blue and
Blue discernment at hose end Connect to upper nipple. right side is red.
No discernment on hose 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.
Dual tiltdozer Single tiltdozer

Part name/Part No.
Q'ty Q'ty
Nut 07221-20522 2 pieces each on right and left 2 pieces on only right
Plug 07376-50522 2 pieces each on right and left 2 pieces on only right
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.
98
A-15
4) Installation of tiltdozer hydraulic hose protection cover
Install tiltdozer hydraulic hose protection cover (8) (Fig. 6) connected in step 3).
Fig. 6

1 Blade assembly ------- -------
4 Trunnion cap ------- ------- See 2.4) of this procedure
8 Cover 195-71-74240 1 each on right and left
10 Washer 01643-32060 6 each on right and left

Tool (Socket) 30 mm
a Before installing the protection cover, check the operation of the tilt cylinder in the blade adjust-
ment work described later and confirm that there is not oil leakage or another problem in the tilt
hose connection.
99
A-15
5) Connection of blade assembly and blade lift cylinders

Fig. 7
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 Fig. 8
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) 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)
198-71-61240
Connecting pin part No.
(1 piece each on right and left)
198-72-62170
Part No. of lock
(1 piece each on right and left)
01010-81635
Part No. of bolt
01643-31645
Part No. of washer
Socket 24 mm
Fig. 10
5.6) Install blade cylinder holdfast (11) on the
inside of the cylinder to fix the cylinder.
100
A-15
6) Connection of blade assembly and blade tilt hydrau-

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

the right side. For the left side, see “assembly
procedure A-15” Installation of brace assembly.

1 peace
12 Pin 195-71-61590
each side
1 peace
13 Lock 195-71-51450
each side
2 peaces
14 Bolt 01010-62050
each side
2 peaces
15 Washer 01643-32060
each side

Tool (Socket) 30 mm
6.2) The bottom side (clevis side) of the hydraulic

cylinder has been connected to the straight Fig. 12
frame already. See “assembly procedure A-14"
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 pine hole (Q) of the
blade. (Fig. 12)
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.
101
A-15
6.4) After aligning the pin holes, stop the engine and
insert pin (12) removed in step 6.1) and fix it to Fig. 13
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 "Tight-

ening 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-9” Check on the amount of lubri-
cants 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).
102
A-15
7.3) Confirmation of operation of single tiltdozer

[1] Confirm that the blade is "raised" and "low- Fig. 14
ered" according to the operation of the
blade control lever. (Fig. 14) Raise
[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
Lower
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 con-
sequently as a result of the check, Fig. 15
return to “assembly procedure A-14”
Assembly of blade, 6. Installation of
brace assembly, and readjust those Right tilt
items.
The above items can be adjusted with
the adjustment handle attached to the
brace, the direction of the handrail may
change. Accordingly, do not apply this
method. Left tilt
If brace (63) is rotated with lever (73) to
adjust dimension L, the direction of
handle (70) changes. According, do
not apply this method.
7.4) Confirmation of operation of dual tiltdozer

[1] In addition to [1] and [2] of the single tilt-
dozer specification, ensure that the blade Fig. 16
is "pitched back" and "pitched forward" Reverse pitch
according to the operation of the blade
control lever. (Fig. 16)
[2] Furthermore, confirm that the blade is "left- Forward pitch
dual-tilted" and "right-dual-tilted" accord-
ing to the operation of the blade control
lever.
[3] Inspect according to the "Field assembly
inspection check sheet" attached to the
end of this manual.
7.5) 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 abnor-
mal sound and add the thinnest shim (0.5 mm) according to “assembly procedure A-14” Assem-
bly of blade, step 4, and tilt the blade again to check.
103
Installation of operator’s cab (1/17)
A-16
1) Installation of open lock striker

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

Install indoor L-plate (9) and outdoor L-plate (10)
temporarily with bolts (11) and washers (12) as
shown in (Fig. 2). (3 pieces on each side)
Before installing the cab, loosen bolts (11).
Fig. 2
Q'ty for each of

right and left
1 Bracket (L.H) 198-Z11-3341 1 Left
2 Bracket (R.H) 198-Z11-3351 1 Right
3 Sems bolt 01024-D1230 10
4 Striker 14X-911-1921 2
5 Nut 01580-11008 8
6 Washer 01643-31032 8
7 Stopper 09453-00002 2
8 Nut 01580-01210 2
9 Bracket 198-Z11-3571 1
10 Bracket 198-Z11-3581 1
11 Bolt 01010-D1230 12
12 Washer 01643-71232 12
104
A-16
3) Installation of rubber seals (13) to dashboard bracket

3.1) Apply paste seal (55) to the mating faces of the Fig. 3
dashboard bracket and floor as shown in (Fig. 3).
3.2) Fit rubber seal (13) to the guide plate of the dash- Fig. 4
board bracket and apply paste seal (55) as shown
in (Fig. 4).
3.3) Apply grease (G2-LI) to the outside of rubber seal Fig. 5

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

seal (13) will slip well against each other
and rubber seal (13) 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

13 Rubber seal 198-Z11-3540 1 Sponge rubber
55 Paste seal 198-Z11-3960 1
105
A-16
4) Installation of rubber seals to mating face of operator cab bottom
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 (14), (15) and (16) 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 stick-
ing.
Fig. 6

14 Rubber seal 14X-911-5911 3
15 Rubber seal 198-Z11-7420 2
16-1 Rubber seal 198-Z11-7410 1
16-2 Rubber seal 198-Z11-7430 1
106
A-16
Fig. 7 How to stick seals (View from bottom of operator’s cab)
Remark : For the base seal shown in the figure, see the next page.
107
A-16
Fig. 8 Fig. 9
Apply paste seal (55)

to clearance
Fig. 10
Fig. 11
Apply paste seal (55)

to clearance

55 Paste seal 198-Z11-3960 1
108
A-16
5) Installation of operator cab (hereinafter referred to as Fig. 12

cab)
After installing cab,
5.1) Lower the operator's cab assembly slowly onto the check that there is not
floor frame. clearance at each cor-
ner.
a Since the clearance between the air conditioner
duct on the cab side and the machine monitor
(instrument panel) is narrow, lower the cab care-
fully, 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.
Lower cab in direction
a Take care that the rubber seal will not be moved or of arrow.
damaged.
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.
Fig. 13
Remark: For the machine monitor, see "assembly pro-
cedure M-2".
5.2) Tighten bolts (17) and (19) and washers (18) tem-
porarily. See (Fig. 15)
a The bolts at the cab door inlet have different After installing cab,
length. Take care. check that there is not
clearance at each cor-
ner.
Lower cab in direction

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

Fig. 14
part (a) of the rubber seal and floor frame. (Fig. 14)
Flange
a If there is a clearance as a result of the confirma- Cab body
tion, 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).
Dashboard
bracket
109
A-16
Operator cab assembly Fig. 15
15 parts
6 parts
Floor frame assembly
Lower part of door

17 Bolt 01010-81275 15
18 Washer 124-54-26540 21
19 Bolt 01010-81245 6
55 Paste seal 198-Z11-3960 1
110
A-16
5.4) Check that the clearance between the air condi-

tioner 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 (17) and (19) which

were tightened temporarily in step 5.2) above .
5.7) Permanently tighten mounting bolts (11) of

Lplates (9) and (10) which were installed tempo-
rarily in step 2 above.
111
A-16
5.8) Install plates (20) with bolts (21) and washers (22). (2 pieces on each side)
5.9) Install right and left foot rests (23) and (24) with bolts (25) and washers (26).
5.10) Install pedal caps (27) to the foot rests.
Fig. 19

20 Plate 198-Z11-2961 2
21 Bolt 01010-D1230 4
22 Washer 01643-71232 4
23 Foot rest (left) 14X-911-5711 1
24 Foot rest (right) 14X-911-5721 1
25 Bolt 01010-D1230 4
26 Washer 01643-71232 4
27 Pedal cap 203-43-56450 2
112
A-16
5.11) The bundle of window washer tubes and the

power supply wiring harness for cab (A) in Fig. 20
(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).
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 X-> in (Fig.
20). (Fig. 22), (Fig. 23)
a The window washer tubes and power sup-

ply 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.
Fig. 21
113
A-16
Identification color marks Fig. 22
Red - - - - For right door

Blue- - - - For left door
Black - - - For rear window
— - - - - - For front window
Window washer tubes
Connectors No.
Wiring harness connectors
Connector No. indicating ring
Fig. 23
Cab power supply

Windshield washer
wiring harness

28 Clip 198-Z11-2961 1
29 Clip 01010-D1230 1
30 Sems bolt 01643-71232 1
114
A-16
6) Installing the internal decorative parts and accessories
Fig. 24

35 Cover (left) 198-Z11-2872 1
36 Cover (right) 198-Z11-2882 1
37 Cover 198-Z11-2892 1
38 Handle 198-Z11-2850 6
39 Bracket 198-Z11-3990 1
40 Bolt 01435-30825 2
41 Screw 01245-00820 13
42 Washer 01643-70823 13
43 Box 198-Z11-7490 1
44 Tray 20G-54-13420 1 Ashtray
45 Lighter 20Y-06-23472 1 Cigarette lighter
46 Screw 01245-00820 2
47 Washer 01643-70823 2
115
A-16
6.1) Install handles (38) to covers (35), (36) and (37) around the floor frame (at the right, left and
rear). (6 places)
6.2) Install the bracket (39) to the floor frame using bolts (40). (1 place)
6.3) Install the floor edge covers to each of which the handle was installed according to the above
Paragraph (41) to their positions using the screws and washers (41) and (42). (Use a total of 13
units each.) (13 places)
6.4) Install box (43) having ashtray (44) and cigarette lighter (46) with screws (47) and washers (48).
a When installing, connect the cigarette lighter connector coming out of the operator cab to
that on box (43) side.
a When the machine is delivered, ashtray (44) and cigarette lighter (46) are installed to box
(43).
7) Installation of cover to rear side of front duct
Fig. 25 Fig. 26

49 Cover 198-54-68282 1
50 Screw 01245-00616 4
51 Washer 01643-70623 4
52 Btracket (left) 198-Z11-3850 1
53 Btracket (right) 198-Z11-3860 1
Installed already
54 Screw 01245-00616 2
55 Washer 01643-70623 2
7.1) Install cover (49) to the rear side of the box of the front duct containing the machine monitor
(instrument panel) with screws (50) and washers (51).
a Install the cover to the brackets (52) and (53) which are already installed to the bottom of the
duct with screws (54) and washers (55). (Fig. 26)
116
A-16
8) Installation of rear view mirror (optional)
Fig. 27

1 Mirror 14X-911-6140 1
2 Bracket 198-Z11-3670 1
3 Bolt 01010-D0845 2
4 Washer 01643-70823 2
8.1) Install rear view mirror (1) to bracket (2)
8.2) Install bracket (2) to the front duct top of the operator cab.
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.
117
A-16
9) Installation of floor mats
9.1) Install the floor mats (57), (58).
Fig. 28 a Floor mat (56) is installed

together with the operator seat
to the floor frame when deliv-
ered.

56 Mat 195-54-78550 1 Installed already
57 Mat 17A-54-12411 1
58 Mat 195-54-68640 1
a If the floor mats may be stained during the following work, floor mats (57) and (58) should be
installed just before completion of the assembly of the machine.
118
A-16
9.2) Hold the right and left ends of floor mat (57) with plates (59) and (60) installed to the bottom of
the operator cab doorway. See (Fig. 29)
Fig. 29
Detail of section A-A

59 Plate (left) 198-Z116410 1
60 Plate (right) 198-Z116410 1
119
A-16
10) Change of installed angle of radio antenna
Fig. 30
10.1) Loosen the wing bolt at the center of rotation of the radio antenna, rotate the antenna from posi-
tion (T) indicate with the broken line to position (P) indicated with the solid line, and stand it verti-
cally.
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.
120
Installation of ROPS (1/2)
A-17
1. Installation of roof to ROPS

Roof: 80 kg
ROPS: 600 kg
Mounting bolt (1)
Tightening torque: See Table 1 "Tightening torque"
Front of
machine 2
Set stamp F on
front side.

1 Bolt 01010-81640 20
2 Washer 01643-31645 20

Name Q'ty Name Q'ty
Torque wrench (60 kgm) 1 25-ton crane 1
M24 socket 1
ø12 mm × 2 m 2
Wire rope sling
Other remarks
121
Installation of ROPS (2/2)
A-17
2. Sling the ROPS with the crane and set it to

the installing position.
ROPS assembly: 700 kg
Tightening torque: 1,520 – 1,910 Nm

{155 – 195 kgm}
4 3

3 Bolt 01010-83010 12
4 Washer 01643-33080 12

Enter the tightening torque (measured) of the mounting Name Q'ty Name Q'ty
bolts in the Record column on page 8/8 of "Field Torque wrench 1
assembly check sheet" at the end of this manual. (210 kgm)
46-mm socket 1
ø12 mm × 2 m 2
Wire rope sling
Other remarks
122
Installation of VHMS, ORBCOMM antenna
A-18
Fig. 1
Antenna wire
ROPS guard
from the machine

(ORBCOMM terminal)

1 Antenna 8A13-10-2100 1
2 Bracket 195-54-73450 1
3 Bolt 01024-81016 2
4 Clamp 04434-51408 4
5 Bolt 01024-80816 4
1) Install antenna installation bracket (2) to the hood of the ROPS guard.
2) Install the antenna cable from the ORBCOMM terminal installed to the machine to the ROPS guard
with clamps (4) and then install its end to the antenna installation bracket (2).
a When installing the antenna cable end to the antenna installation bracket, apply adhesive (LT-2)
to the female threads of the nut and male threads of the cable end, and then tighten the nut. Do
not stick the adhesive to the core or internal material of the antenna cable.
a Adjust the route of the antenna cable so that the antenna cable will not interfere with the hood
(particularly part A) or legs of the ROPS by changing the directions of the clamps (4) properly.
3) Install antenna (1) to the antenna cable end.
VHMS: Abbreviation for Vehicle Health Monitoring System
123
Check track tension (1/2)
A-19
Adjusting
• When increasing tension Fig. 1
1. First remove the bolts (1) and then re-
move the cover (2). (Fig. 1)
2. Pump in grease through the grease fit-
ting (3) with a grease pump. (Fig. 2)
3. To check that the correct tension has
been achieved, move the machine back-
wards 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 cov- Fig. 2
er (2). (Fig. 1)
2. Loosen plug (4) gradually to release the
grease. (Fig. 2)
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 back-
wards and forwards.
7. Check the track tension again, and if the
tension is not correct, adjust it again.

• There is danger of plug (4) flying out under the high Name Q'ty Name Q'ty
internal pressure of the grease. Never loosen plug (4)
more than 1 turn.
Never loosen any part other than plug (4). Never put
your face in the mounting direction of plug (4).
If the track tension cannot be loosened with the proce-
dure given here, please contact your Komatsu distrib-
utor.
• 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). Other remarks
Be careful not to damage the safety label.
124
Check track tension (2/2)
A-19
Inspection
Stop the machine on level ground (stop with Fig. 3
the transmission in FORWARD without
applying the brake). 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 between the bar
and the grouser at the midpoint. If the clear-
ance is 20 to 30 mm (0.79 to 1.18 in), the
tension is standard. If the track tension is not
at the standard value, adjust it in the follow-
ing manner. (Fig. 3)

Name Q'ty Name Q'ty
Other remarks
125
Lubricating (1/4)
A-20
1. Blade lift cylinder support yoke (4 places)

Fig. 1
(Fig. 1)
2. Blade lift cylinder support shaft (2 places)
(Fig. 1)
3. Blade arm ball joint (3 places) (Fig. 2) Fig. 2

4. Brace screw (2 places) (Fig. 2)
5. Ripper tilt cylinder bottom pin (2 places) Fig. 3

(Fig. 3)
6. Ripper lilt cylinder bottom pin (2 places)
(Fig. 3)
7. Ripper tilt cylinder rod end pin (2 places)
(Fig. 3)
8. Ripper lilt cylinder rod end pin (2 places)
(Fig. 3)
9. Ripper arm pin (front) (2 places) (Fig. 3)
10. Ripper arm pin (rear) (2 places) (Fig. 3)

About the kind of used fluids refer to “Assembly Name Q'ty Name Q'ty
procedure A-9” Check on the amount of lubricants and
coolant.
For other related matters, confirm them by Operation
Manual.
Other remarks
126
Lubricating (2/4)
A-20
11. Equalizer bar side shaft (1 place) (Fig. 4)

Fig. 4
12. Suspension (Equalizer bar center shaft) Fig. 5

(1 place) (Fig. 5)
13. Decelerator pedal shaft (1 place) (Fig. 6) Fig. 6

Name Q'ty Name Q'ty
Other remarks
127
Lubricating (3/4)
A-20
14. Brake pedal (1 place) (Fig. 7)

Fig. 7
15. Brake rod lever (1 place) (Fig. 7)
16. Steering, directional, gearshift lever rotating Fig. 8

link (4 places) (Fig. 8), (Fig. 9)
Fig. 9

Name Q'ty Name Q'ty
Other remarks
128
Lubricating (4/4)
A-20
17. Universal joint (2 places) (Fig. 10)

Fig. 10
a Do not use molybdenum disulfide
grease.
Remove inspection cover (3) of the under-
cover on the rear bottom of the chassis as
follows.
1) Remove 2 bolts (1) at the front of the
machine. (Fig. 11)
Fig. 11
2) Support the cover with your elbow
while gradually removing 2 bolts (2)
at the rear of the machine. (Fig. 11),
(Fig. 12)
3) Lower the cover gradually to open it.
18. Steering/directional/gear shift lever rotation Fig. 12

link (4 places)

The undercover is heavy (Approx. 50 kg). Never try to Name Q'ty Name Q'ty
open or close the cover when directly beneath it. When
removing bolts (2), carry out the work from the rear of
the cover so that you can easily get out of the way.
Other remarks
129
Installation of fuel quick charge piping (if equipped)
A-21
(1) Remove the blind plug from the left top of the fuel tank and connect the hose. (Fig. 1)
(2) Remove the left ripper pin lock plate and install the brackets and tubes. (Fig. 1)
(3) Connect the hoses to the tubes. (Fig. 1)
(4) Fix the hoses to the fuel tank with the clamps. (Fig. 1)
(5) Tighten the U-bolts permanently so that the tubes will be set in the specified directions. (Fig. 2)
Fig. 1
To be reused.
To be replaced with
ripper pin lock plate.
Take care of angle.
Apply LG-5 to
threaded part.
Tightening torque
196.1 Nm {20 kgm}
Fig. 2
To be reused.

1 Flange 07371-32076 4
2 Sems bolt 07375-21240 8
3 Clip 07283-36163 2
4 Seat 07283-56170 2
5 Washer 01643-31032 4
6 Nut 01597-01009 4
Fix coupler chain. 7 Plate 195-04-42680 1
8 Tube 195-04-42670 1
9 Receiver 198-04-66170 1
10 Hose 195-04-42660 1
Actual angle: 30°C 11 O-ring 07000-12060 2
12 Clamp 42C-16-11510 2
13 Cusion 07095-02062 1
14 Bolt 01011-81210 2
15 Washer 01643-31232 2
16 Bolt 01010-62040 2
17 Washer 01643-32060 2
18 Screw 01023-10610 1
130
M. Check and maintenance procedures
after completion of assembly
131
Check and adjustment of operator's cab (1/7)
M-1
1. Measuring pressure in cab
(1) Measure the pressure in the cab.
• Criterion : Measured value X 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).
a 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.
a Operate the blower according to the following procedure.
Fig. 1
1) Depress air outlet selector switch (2) Fig. 2

on the air conditioner control panel to
select the front-rear-foot area mode Front-Rear-Foot area
(shown at right). (Fig. 2) (including defroster)
2) Select the fresh air mode with the

RECIRC/FRESH air selector switch <Indication on LCD and air flow> Fig. 3
(3).
Indication on LCD Air flow
3) Depress fan switch (1) to set the Low
blower to the high (Hi). (Fig. 3)
Medium 1
a If the standard pressure is not obtained, Medium 2
check the seals around the dashboard
Medium 3
and the seals of the fitting faces of the cab
and floor for an opening.(Run water over Medium 4
outside to see if it enters the cab.) If there Blower
High
is an opening, fill it with liquid seal. at high (Hi)
132
M-1
(2) Outlined below is a simplified method for

the internal pressure measurement of Fig. 4
the operator’s cab:
a) Prepare a transparent vinyl hose (of
an outer diameter of 10 mm and Lock lever
3,000 mm long). mount hole
b) Pour water into the hose bore for
about a half of the hose length.
c) Remove the sliding windshield lock
lever located on the side panel of the
operator’s cab to insert one end of
the vinyl hose before fastening an
adjacent part of the hose to the top
end of the back seat using packing Fig. 5
10 mm or more
tape. (Fig. 7)
d) Seal the gap occurring between the
lock-lever hose and the outer periph-
ery-of the hose.
e) Match the water levels of the begin-
Inside the
ning part and the ending part of the operator's cab Outside
water cloumn inside the transparent (Atmospheric pressure)
vinyl hose at the outside of the oper-
ator’s cab.
f) Start the engine and run it at full
speed to read the difference between
the two water levels. (Fig. 5)
Remove lock lever and insert vinyl hose. Fig. 7
a Before measuring the internal pressure,
ensure that the grommets shown in Fig.
6 are fitted securely.
Fig. 6
Fix vinyl hose to top end of back seat Fig. 8
• Fig. 6 is the same as Fig. 21 in "Assembly

procedure A-16".
Vinyl hose
133
M-1
2. Check of sealing performance

(1) Close all the opening sections of the operator's cab.
(2) Prepare to pour water of a flow of about 5 gal. (about 19 l)/min. through a water hose.
(3) Pour water to the area around the hatched section in Fig. 18 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". (Fig. 9)
(5) Carefully check the area around the dashboard, in particular.
a When any water leakage is found, apply due caulking before re-checking the section if the water
leakage still occurs.
Fig. 9

Name Q'ty Name Q'ty
Other remarks
134
M-1
3. Checking the door lock

Check the correlation between the operator's cab structure and the door when the door is opened
and closed. When anything is found abnormal, make due adjustment to correct it.
3-1 Checking the current statuses
(1) Check the mounted elevation of the damper rubber. (Located at 4 places per a side and check
them on both L.H and R.H sides.)
Applying a packing tape strip over the contact surfaces of the damper rubber, open and close the
door for 2 to 3 times. After finishing this opening and closing cycles of the door, check the contact
surface of the packing tape with the operator's cab structure. (Fig. 10)
Normal: The back surface of the packing tape comes in light contact the operator's cab struc-
ture when the door is being closed.
Abnormal: The back surface of the packing tape does not come in contact with the operator's
cab structure when the door is being closed, or if the two sections come in a harsh
contact such as peeling off the applied packing tape.
Fig. 10
(2) Check the correlation between the door latch and the striker (on both L.H and R.H side). (Fig. 11)
Moving the door toward the closing direction, observe the engaging state between the latch and
the striker.
Fig. 11

Name Q'ty Name Q'ty
Other remarks
135
M-1
3-2 Adjustments
(1) Adjusting the elevation of the damper rubber (Fig. 12)
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.
Fig. 12
(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 align 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.
a Appropriate knob turning effort: 68.6 ± 19.6 N {7 ± 2 kgf}
(3) Apply grease (G2-LI) over the latch surface.

When the grease adhering over the latch surface dries Name Q'ty Name Q'ty
out, the turning effort for the knob will become heavier.
Therefore, apply grease sufficiently in order not to allow
it to become dried up.
Other remarks
136
M-1
4. Checking the open-locked state of the door (Fig. 13)

Check the correlation between the operator's cab structure and the door when the door is in open-
locked state. When anything is found abnormal, make due adjustment to correct it.
4-1 Checking the current statuses
(1) Check the correlation between the open-lock latch and the striker. (Check them on both L.H and
R.H sides.)
Move the door toward the opening direction to observe the engaging state between the latch and
the striker. (Fig. 13)
Fig. 13
(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.

Name Q'ty Name Q'ty
Other remarks
137
M-1
4-2 Adjustments
(1) Adjusting the correlation between the latch and the striker (Fig. 14)
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 form the latch side.
Fig. 14
(2) Adjusting the elevation of the stopper rubber

(a) Loosen the stopper rubber fastening nut.
(b) When rattling 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 rattling of the door does not
occur.
(c) Tighten the fasting nut back to the original state.

Name Q'ty Name Q'ty
Other remarks
138
Inspection of machine monitor (1/14)
M-2
Machine monitor
There are the following 2 designs in the machine monitor, the functions of which are the same.
Serial No. 50001 – 50090
Serial No. 50091 and up
139
M-2
Check that the "machine monitor" on the front panel can be set in the "service mode" with its special
function and the "failure codes" can be displayed normally in that mode.
Fig. 1 Front panel
(1) Machine monitor
(2) Upper display unit
(3) Lower display unit (Multi-information unit)
(4) Starting switch
(7) Lower cover
(8) Service switch
Note: The "Service mode" is used in "Initialization of VHMS controller" of the VHMS specification de-
scribed later in "Attached material 2". Accordingly, understand the operating procedure thor-
oughly.
140
M-2
1) Setting in "Service mode"
1.1) Remove cover (7) under the front panel so that you can operate service switch (8).
1.2) Turn starting switch (4) "ON".
1.3) While pressing service switch (8), turn and hold buzzer cancel switch (5) toward the [U] mark for
3 seconds, and P, N, F2, R2, etc. displayed on upper display unit (2) of machine monitor (1)
changes to 1C, 55, etc. (See Fig. 2)
a If 1C, 55, etc. is displayed, the machine monitor is set in the "service mode". 1C and 55 are ser-
vice mode codes among the 8 of 1C, EE, bE, Cb, Ld, 5R, dR and 55. For details of the service
mode codes, see "Testing and adjusting volume" of the shop manual.
Upper display unit (2)
Lower display unit (3)
2) Display check of "Failure code"

In the service mode, a trouble that occurred in the machine can be displayed by a classification code
named the "Failure code" on lower display unit (3) of machine monitor (1). With this function, the
operator can grasp the cause of the trouble precisely and repair the machine quickly.
The "Failure codes" are classified into the electrical system failure codes and mechanical system
failure codes, which are displayed on lower display unit (3) by setting the service mode code of
upper display unit (2) to "EE (Electrical system failure code display mode)" or "bE (Mechanical sys-
tem failure code display mode)".
141
M-2
2.1) Check of "Electrical system failure code

display mode"
Fig. 3
-1) Set upper display unit (2) in the service
mode and turn information switch (6)
toward the > mark or < mark to display
service mode code "EE". See (Fig. 3)
Remark:Operation of information switch

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

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

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

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

display mode"
Fig. 4
-1) Turn buzzer cancel switch (5) to the t
mark to cancel the "EE" mode.
-2) Turn information switch (6) toward the >

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

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

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

play unit (3), see step 2.3).
142
M-2
2.3) Contents of display on lower display unit
The "failure codes" of both "EE (Electrical system failure code display mode)" and "bE (Electrical
system failure code display mode" are displayed in the same format on lower display unit (3) as
shown below.
-1) When the assembly work is completed, no past

trouble is recorded and no trouble is detected cur- Fig. 5
rently, thus the display is as shown in (Fig. 5) in
both modes.
-2) If a trouble occurs after this machine is put in

operation or if there is the record of a past trouble, Fig. 6
the display of (EE) becomes as shown in (Fig. 6).
(1): Record No. (up to 20 Nos.)

(2): Failure code (Code of trouble occurring at
present blinks)
(3): Number of occurrence up to now
(4): Elapsed time by service meter after first oc-
currence
(5): Elapsed time by service meter after last occur-
rence
-3) If a trouble occurs after this machine is put in Fig. 7

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

(2): Failure code (Code being output currently is
flashing)
(3): Number of past occurrences
(4): Time tested by service meter after first occur-
rence
(5): Time tested by service meter after last occur-
rence
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.
143
M-2
Error codes list (Related to machine controller)
Applicable
Failure code Trouble Action code
equipment
1380MW Lockup clutch slip TM —
1500L0 Transmission clutch dual engagement TM CALL E03
15E0MW Transmission clutch slip TM —
When forward clutch oil pressure command current
15SAL1 TM CALL E03
is OFF, fill signal is ON
When forward clutch oil pressure command current
15SALH TM CALL E03
is ON, fill signal is OFF
When reverse clutch oil pressure command current
15SBL1 TM CALL E03
is OFF, fill signal is ON
When reverse clutch oil pressure command current
15SBLH TM CALL E03
is ON, fill signal is OFF
When 1st clutch oil pressure command current is
15SEL1 TM CALL E03
OFF, fill signal is ON
When 1st clutch oil pressure command current is
15SELH TM CALL E03
ON, fill signal is OFF
When 2nd clutch oil pressure command current is
15SFL1 TM CALL E03
When 2nd clutch oil pressure command current is
15SFLH TM CALL E03
When 3rd clutch oil pressure command current is
15SGL1 TM CALL E03
15SGLH TM CALL E03
1800MW Power train clutch slip TM E02
When right steering clutch oil pressure command
2201L1 ST CALL E04
current is OFF, fill signal is ON
When right steering clutch oil pressure command
2201LH ST CALL E04
current is ON, fill signal is OFF
When left steering clutch oil pressure command
2202L1 ST CALL E04
When left steering clutch oil pressure command
2202LH ST CALL E04
2300NR Brake thermal load abnormality ST —
When right steering brake oil pressure command
2301L1 ST CALL E04
When right steering brake oil pressure command
2301LH ST CALL E04
2301NR Right steering brake thermal load abnormality ST —
When left steering brake oil pressure command
2302L1 ST CALL E04
When left steering brake oil pressure command
2302LH ST CALL E04
144
M-2
Applicable
equipment
2302NR Left steering brake thermal load abnormality ST —
6001ZK Failure code for design — —
A000NS Engine overheat — —
AA10NX Air cleaner clogging ST —
AB00MA Alternator malfunction ST —
B@BAZK Engine oil level reduction ST —
B@BCZK Engine coolant level reduction ST —
B@BFZK Fuel level reduction ST —
B@CENS Power train oil overheat ST —
B@CHZG HSS charge oil pressure reduction ST —
B@CHZK Power train oil level reduction — —
B@GAZK Battery electrolyte level reduction — —
B@HANS Hydraulic oil overheat ST —
B@HAZK Hydraulic oil level reduction ST —
D110KA Battery relay hold line disconnection ST —
D110KB Battery relay hold line short circuit ST —
D130KA Neutral safety relay disconnection TM E02
D130KB Neutral safety relay short circuit TM E02
D161KA Backup alarm relay disconnection TM E01
D161KB Backup alarm relay short circuit TM E01
D182KZ Preheater relay disconnection or short circuit ST E01
D190KA Engine controller ACC signal cut relay disconnection ST —
D190KB Engine controller ACC signal cut relay short circuit ST —
D5ZRKA Snap shot switch disconnection ST —
D5ZRKB Snap shot switch short circuit ST —
DAFRKR Machine monitor CAN communication error MON CALL E03
daFRKR Machine monitor CAN communication error ST CALL E03
dAFRKR Machine monitor CAN communication error TM CALL E03
DAQ0KT Transmission controller internal abnormality — E01
Transmission controller main power supply voltage
DAQ1KK TM CALL E04
reduction
Transmission controller load power supply voltage
DAQ2KK TM CALL E04
reduction
Transmission controller sensor 5V power supply (1)
DAQ5KK TM CALL E03
voltage reduction
Transmission controller sensor 24V power supply
DAQ6KK TM E01
voltage reduction
145
M-2
Applicable
equipment
Transmission controller sensor 5V power supply (2)
DAQ7KK TM CALL E03
voltage reduction
Transmission controller model selection signal
DAQ9KQ TM CALL E04
disagreement
DAQRKR Transmission controller CAN communication error ST CALL E03
DAQSKR Transmission controller S-NET communication error TM E01
DB2RKR Engine controller CAN communication error ST CALL E03
dB2RKR Engine controller CAN communication error TM CALL E03
DB30KT Steering controller internal abnormality ST E01
Steering controller main power supply voltage
DB31KK ST CALL E04
reduction
Steering controller load power supply voltage
DB32KK ST CALL E04
reduction
Steering controller sensor 5V power supply (1)
DB35KK ST CALL E03
voltage reduction
Steering controller sensor 24V power supply voltage
DB36KK ST CALL E03
reduction
Steering controller sensor 5V power supply (2)
DB37KK ST CALL E03
voltage reduction
Steering controller model selection signal
DB39KQ ST CALL E04
disagreement
dB3RKR Steering controller CAN communication error TM CALL E03
DB3SKR Steering controller S-NET communication error ST E01
(or VHMS LED display “n901”) VHMS supply voltage
DBB0KK VHMS —
abnormality
(or VHMS LED display “nF11”) VHMS connector
DBB0KQ VHMS —
connection abnormality
(or VHMS LED display “n905”) VHMS controller
DBB3KK VHMS —
battery direct power supply voltage reduction
(or VHMS LED display “n904”) Sensor power supply
DBB5KP VHMS —
(5V) system abnormality
DBB6KP VHMS —
(24V) system disconnection or short circuit
DBB7KP VHMS —
(12V) system disconnection or short circuit
(or VHMS LED display “n802”) CAN communication
DBBQKR VHMS —
error (VHMS controller)
dbBRKR VHMS controller CAN communication error ST —
DD12KA Shift-up switch disconnection TM E02
DD12KB Shift-up switch short circuit TM E02
DD13KA Shift-down switch disconnection TM E02
DD13KB Shift-down switch short circuit TM E02
146
M-2
Applicable
equipment
DD14KA Parking brake lever switch disconnection TM CALL E03
DD14KB Parking brake lever switch short circuit TM CALL E03
DDB9L4 Reverse switch disagreement TM CALL E03
DDK3L4 Forward switch signal disagreement TM CALL E03
DDK5KA Shift switch disconnection TM E02
DDK5KB Shift switch short circuit TM E02
Blade tilt right oil pressure switch is held down for
DDN2LD TM E02
long time
Blade tilt left oil pressure switch is held down for long
DDN3LD TM E02
time
DDN7KA Blade pitch switch disconnection TM E02
DDN7KB Blade pitch switch short circuit TM E02
DDN9KA Blade tilt switch disconnection TM E01
DDN9KB Blade tilt switch short circuit TM E01
Blade lift raise oil pressure switch is held down for
DDNALD TM —
long time
DDNBLD TM —
long time
DDNCLD TM —
long time
Ripper tilt in oil pressure switch is held down for long
DDNDLD TM —
time
Ripper tilt back oil pressure switch is held down for
DDNELD TM —
long time
Blade lift lower oil pressure switch is held down for
DDNFLD TM —
long time
DDQ2KA Parking brake lever switch disconnection ST CALL E03
DDQ2KB Parking brake lever switch short circuit ST CALL E03
Parking brake lever switch ON/OFF signal
DDQ2L4 ST CALL E03
disagreement
Parking brake lever switch ON/OFF signal
dDQ2L4 TM CALL E03
disagreement
DDT5KA Neutral switch disconnection TM CALL E04
DDT5KB Neutral switch short circuit TM CALL E04
DDT5KQ Lever specification selection signal disagreement TM CALL E04
(or VHMS LED display “n401”) Ambient temperature
DGE5KX VHMS —
sensor system disconnection or short circuit
DGS1KX Hydraulic oil temperature sensor signal out of range TM —
DGT1KA Power train oil temperature sensor disconnection TM E01
Power train oil temperature sensor input signal out of
DGT1KX TM E01
range
147
M-2
Applicable
equipment
(or VHMS LED display “n322”) Front exhaust
DGT5KA VHMS —
temperature sensor system short circuit
DGT5KB VHMS —
temperature sensor system disconnection
DGT6KA VHMS —
temperature sensor system short circuit
DGT6KB VHMS —
temperature sensor system disconnection
Work equipment pump oil pressure sensor 1
DH22KA TM —
disconnection
Work equipment pump oil pressure sensor 1 short
DH22KB TM —
circuit
Work equipment pump oil pressure sensor 2
DH23KA TM —
disconnection
Work equipment pump oil pressure sensor 2 short
DH23KB TM —
circuit
(or VHMS LED display “n332”) Engine blow-by
DHE5KB VHMS —
pressure sensor system disconnection
DHE5KY VHMS —
pressure sensor system short circuit
(or VHMS LED display “n614”) Transmission oil
DHT3KX VHMS —
pressure sensor input signal out of range
DK10KA Fuel control dial disconnection ST CALL E03
DK10KB Fuel control dial short circuit ST CALL E03
DK30KA Steering potentiometer 1 disconnection ST CALL E03
DK30KB Steering potentiometer 1 short circuit ST CALL E03
DK30KX Steering potentiometer 1 input signal out of range ST CALL E04
Steering potentiometer 1 disconnection or short
DK30KZ ST CALL E04
circuit
DK30L8 Steering potentiometer 1 analog signal disagreement ST CALL E03
DK31KA Steering potentiometer 2 disconnection ST CALL E03
DK31KB Steering potentiometer 2 short circuit ST CALL E03
DK40KA Brake potentiometer disconnection ST CALL E03
DK40KB Brake potentiometer short circuit ST CALL E03
DK55KX Direction potentiometer input signal out of range TM CALL E04
DK55KZ Direction potentiometer disconnection or short circuit TM CALL E04
DK55L8 Direction potentiometer analog signal disagreement TM CALL E03
DK56KA Direction potentiometer 1 disconnection TM CALL E03
DK56KB Direction potentiometer 1 short circuit TM CALL E03
DK57KA Direction potentiometer 2 disconnection TM CALL E03
DK57KB Direction potentiometer 2 short circuit TM CALL E03
148
M-2
Applicable
equipment
DK60KA Acceleration sensor disconnection ST E01
DK60KB Acceleration sensor short circuit ST E01
DKH1KA Pitch angle sensor disconnection ST CALL E03
DKH1KB Pitch angle sensor short circuit ST CALL E03
DKH1KX Pitch angle sensor input signal out of range TM CALL E01
DLF1KA Torque converter output speed sensor disconnection TM —
DLT3KA Transmission output speed sensor disconnection 1 ST E01
dLT3KA Transmission output speed sensor disconnection 2 TM E01
DLT3KB Transmission output speed sensor short circuit TM E01
DV00KB Alarm buzzer short circuit MON —
DW59KA Blade dual selector solenoid disconnection TM E01
DW59KB Blade dual selector solenoid short circuit TM E01
DW59KY Blade dual selector solenoid hot short TM E01
DW5AKA Blade pitch selector solenoid disconnection TM E02
DW5AKB Blade pitch selector solenoid short circuit TM E02
DW5AKY Blade pitch selector solenoid hot short TM E02
DW7BKA Fan reverse solenoid disconnection ST E01
DW7BKB Fan reverse solenoid short circuit ST E01
DW7BKY Fan reverse solenoid hot short ST E02
DWN3KA Sudden stop prevention solenoid disconnection ST CALL E04
DWN3KB Sudden stop prevention solenoid short circuit ST CALL E04
DWN3KY Sudden stop prevention solenoid hot short ST CALL E04
DWN5KA Fan pulley solenoid 1 disconnection TM E01
DWN5KB Fan pulley solenoid 1 short circuit TM E01
DWN5KY Fan pulley solenoid 1 hot short TM E02
DWNCKA Fan pulley solenoid 2 disconnection TM E01
DWNCKB Fan pulley solenoid 2 short circuit TM E01
DWNCKY Fan pulley solenoid 2 hot short TM E02
DXH1KA Lockup solenoid disconnection TM E01
DXH1KB Lockup solenoid short circuit TM E01
DXH1KY Lockup solenoid hot short TM CALL E03
DXH4KA 1st clutch ECMV disconnection TM CALL E03
DXH4KB 1st clutch ECMV short circuit TM CALL E03
DXH4KY 1st clutch ECMV hot short TM CALL E03
DXH5KA 2nd clutch ECMV disconnection TM CALL E03
DXH5KB 2nd clutch ECMV short circuit TM CALL E03
149
M-2
Applicable
equipment
DXH5KY 2nd clutch ECMV hot short TM CALL E03
DXH6KA 3rd clutch ECMV disconnection TM CALL E03
DXH6KB 3rd clutch ECMV short circuit TM CALL E03
DXH6KY 3rd clutch ECMV hot short TM CALL E03
DXH7KA Reverse clutch ECMV disconnection TM CALL E03
DXH7KB Reverse clutch ECMV short circuit TM CALL E03
DXH7KY Reverse clutch ECMV hot short TM CALL E03
DXH8KA Forward clutch ECMV hot short TM CALL E03
DXH8KB Forward clutch ECMV short circuit TM CALL E03
DXH8KY Forward clutch ECMV hot short TM CALL E03
DXH9KA Right steering clutch ECMV disconnection ST CALL E03
DXH9KB Right steering clutch ECMV short circuit ST CALL E03
DXH9KY Right steering clutch ECMV hot short ST CALL E04
DXHAKA Left steering clutch ECMV disconnection ST CALL E03
DXHAKB Left steering clutch ECMV short circuit ST CALL E03
DXHAKY Left steering clutch ECMV hot short ST CALL E04
DXHBKA Right brake ECMV disconnection ST CALL E04
DXHBKB Right brake ECMV short circuit ST CALL E04
DXHBKY Right brake ECMV hot short ST CALL E04
DXHCKA Left brake ECMV disconnection ST CALL E04
DXHCKB Left brake ECMV short circuit ST CALL E04
DXHCKY Left brake ECMV hot short ST CALL E04
F@BBZL VHMS —
pressure abnormally high level
F@BYNR VHMS —
temperature abnormally high level (2)
F@BYNS VHMS —
(or VHMS LED display “n372”) Rear exhaust
F@BZNR VHMS —
(or VHMS LED display “n371”) Rear exhaust
F@BZNS VHMS —
150
M-2
Error codes list (Related to engine controller)
Applicable
equipment
B@BAZG Engine oil pressure reduction ENG —
B@BCNS Transmission clutch dual engagement ENG —
B@BEBF Water in engine fuel ENG —
CA111 Engine controller internal abnormality ENG CALL E04
CA115 Engine Ne/Bkup speed sensor abnormality ENG CALL E04
CA122 Charge pressure sensor abnormally high leve ENG CALL E03
CA123 Charge pressure sensor abnormally low level ENG CALL E03
CA131 Throttle sensor abnormally high level ENG CALL E03
CA132 Throttle sensor abnormally low level ENG CALL E03
CA135 Engine oil pressure sensor abnormally high level ENG E02
CA141 Engine oil pressure sensor abnormally low level ENG E02
CA144 ENG E02
CA145 Coolant temperature sensor abnormally low level ENG E02
CA153 Charge temperature sensor abnormally high level ENG E01
CA154 Charge temperature sensor abnormally low level ENG E01
CA187 Sensor power supply 2 abnormally low level ENG CALL E03
CA212 Engine oil temperature sensor abnormally high level ENG E01
CA213 Engine oil temperature sensor abnormally low level ENG E01
CA221 Ambient pressure sensor abnormally high level ENG CALL E03
CA222 Ambient pressure sensor abnormally low level ENG CALL E03
CA227 Sensor power supply 2 abnormally high level ENG CALL E03
CA234 Engine overspeed ENG E00
CA238 Ne speed sensor power supply abnormality ENG CALL E03
CA263 Fuel temperature sensor abnormally high level ENG E01
CA265 Fuel temperature sensor abnormally low level ENG E01
CA271 PCV1 short circuit ENG CALL E03
CA272 PCV1 disconnection ENG CALL E03
CA273 PCV2 short circuit ENG CALL E03
CA274 PCV2 disconnection ENG CALL E03
CA322 Injector #1 system disconnection or short circuit ENG CALL E03
151
M-2
Applicable
equipment
CA342 Engine controller data mismatch ENG CALL E04
CA351 Injector drive circuit abnormality ENG CALL E03
CA352 Sensor power supply 1 abnormally low level ENG CALL E03
CA386 Sensor power supply 1 abnormally high level ENG CALL E03
CA441 Power supply voltage abnormally low level ENG CALL E04
CA442 Power supply voltage abnormally high level ENG CALL E04
CA449 Common rail pressure abnormally high pressure 2 ENG CALL E03
CA451 Common rail pressure sensor abnormally high level ENG CALL E03
CA452 Common rail pressure sensor abnormally low level ENG CALL E03
CA553 Common rail pressure abnormally high pressure 1 ENG E02
CA554 Common rail pressure sensor in-range abnormality ENG CALL E03
CA559 Supply pump low pressure 1 ENG E02
CA689 Engine Ne speed sensor abnormality ENG CALL E03
CA731 Engine Bkup speed sensor phase abnormality ENG CALL E03
CA757 Engine controller all data loss ENG CALL E04
CA778 Engine Bkup speed sensor abnormality ENG CALL E03
CA1633 CAN communication error (Engine controller) ENG CALL E03
CA2185 Throttle sensor power supply abnormally high level ENG CALL E03
CA2186 Throttle sensor power supply abnormally low level ENG CALL E03
CA2249 Supply pump low pressure 2 ENG CALL E03
a The items in this table are arranged in the order of the failure codes.
a A component in charge is a controller or the machine monitor in charge of the system check.
MON: Monitor panel
ENG: Engine controller
TM: Transmission controller
ST: Steering controller
VHMS: VHMS controller
152
Checking operation of dual tilt mechanism (If equipped)
M-3
<Dual tilt operation> (Fig. 1)

Fig. 1
(C)+(B): Left dual tilt (While selector switch (C) is
in the DUAL position, move the knob in direction
(B).) (Fig. 2)
(C)+(A): Right dual tilt (While selector switch (C)

is in the DUAL position, move the knob in direc-
tion (A).) (Fig. 2)
If the blade is tilted while knob switch (C) is in the

DUAL position, it is tilted more than by the nor-
mal tilting operation. (Fig. 2)
The dual tilt operation is applicable while the

blade is raised, hold, or lowered, regardless of Fig. 2
its position.
<Pitch operation> (Fig. 3)

Fig. 3
(D)+(B) Reverse pitch: Reduce the cutting edge
angle (Pressing button (D) and move the knob in
direction (B).) (Fig. 4)
(D)+(A) Reverse pitch: Increase the cutting edge

angle (Pressing button (D) and move the knob in
direction (A).) (Fig. 4)
The pitch circuit is given priority. If the pitch but-

ton is pressed while the blade is being tilted, the
blade is pitched.
Fig. 4
153
Setting procedure for USER ADJUST MODE (1/3)
M-4
To set the cooling fan speed which is a measuring condition to about 100% of the maximum speed forc-
ibly for measurement of the pressure inside the cab in [M-1: Testing and adjusting operator cab], operate
the machine monitor and display USER ADJUST MODE in the multi-information section. Display this
USER ADJUST MODE according to the following procedure.
1. Set the machine monitor to the USER ADJUST MODE with multi-information (3), starting switch (4),
buzzer cancel switch (5) and information switch (6).
Front panel section
(1) Machine monitor

Fig. 1
(2) Upper display section
• Displays gear speed in normal
mode (operator mode).
(3) Lower display section

(Multi-information section)
• Displays transmission shift mode
and service meter in normal mode
(operator mode).
(4) Starting switch
154
M-4
2. Procedure
2.1 Turn the starting switch to the "ON" posi-

tion.
The machine monitor is turned on.
2.2 Turn buzzer cancel switch (5) in (Fig. 2) Fig. 2

to the [U] (left) position and hold for
about 2 - 3 seconds.
The display of multi-information (3) in
(Fig. 1) changes to OIL, FILTER MAIN-
TENANCE MODE. (Fig. 3)
After the display changes, release the
switch. The switch returns to the neutral
position.
2.3 Turn information switch (6) in (Fig. 2) to

the [<] or [>] (right) position several times
to change the display of the multi-infor-
Fig. 3
mation to USER ADJUST MODE. (Fig.
4)
Reference: Each time the information switch is

turned, 1 of the following 4 modes
is selected in order; OIL, FILTER
MAINTENANCE MODE, PM
CLINIC MODE, FAULT CODE
DISPLAY MODE and USER
ADJUST MODE.
2.4 When the display of the multi-information

changes to USER ADJUST MODE, turn
the buzzer cancel switch to the [U] (left) Fig. 4
position again to settle the USER
ADJUST MODE. Once the USER
ADJUST MODE is settled, it does not
change to another mode described in
step 2.3 even if the information switch is
turned but the display of the multi-infor-
mation changes to the variation selection
screen in the USER ADJUST MODE.
Note: If the buzzer cancel switch is turned to

the [T] (right) position by mistake in
step 2.4, the display returns to the
state in step 2.1.
155
M-4
2.5 Turn the information switch again to the

[<] (left) position or [>] (right) position Fig. 5
several times to change the display of
the multi-information to FAN 100%
SPEED. (Fig. 5)
2.6 Turn the buzzer cancel switch to the [U]

(left) position to settle the FAN 100%
SPEED.
Reference: In step 2.5, each time the infor-

mation switch is turned, 1 of the
following 7 variations is selected
in order; LCD BRIGHTNESS,
DSP BRIGHTNESS, DSP CON-
TRAST, FAN 100% SPEED, NO
INJECTION, TILT LIMIT and
PRE-LUB ON.
2.7 If the engine is started under this condi-

tion, the cooling fan speed is constantly
controlled to about 100% of the maxi-
mum speed.
a The setting of 2.7 is effective only in this

mode. It becomes ineffective if the
machine monitor is set out of this mode.
2.8 To reset this mode, turn the buzzer can-

cel switch to the [T] (right) position.
The display of the multi-information
returns to the state after the starting
switch is turned to the "ON" position in
step 2.1.
156
APPENDIX 1.
Installation procedure for spill guard

(Installation by welding)
1. Spill guard fabrication drawings...................................................................... 158

1-1. For semi U-blade ........................................................................................ 158
1-2 For U-dozer ................................................................................................ 161
2. Installation (Welding) of spill guard................................................................. 164
3. Spill guard installation (welding) procedure................................................... 165
3-1. For semi U-dozer........................................................................................ 165
3-2. For U-dozer ................................................................................................ 166
a Weld the spill guard to the blade according to the following procedure.
157
(1) Spill guard (middle): 195-71-72211 fabrication drawing 1.
1-1. For semi U-blade
Spill guard fabrication drawings
158
1. This dwg shown co2-gas arc welding groove
Dimensions and leg length. for manual welding per
kes 04.351
2. Welding quality to conform to kes 04.343
3. Flatness of surface (A) in drawing to be within 2
04 Plate SS400F 10 1.75 65 × t12

03 Plate SS400P 9 3.65 t12
02 Plate SS400F 1 14.00 65 × t12
01 Plate SS400F 1 6.85 32 × t12
(2) Spill guard (L.H.): 195-71-74820 fabrication drawing
159
Dimensions and leg length. for manual welding per
kes 04.351
3. Flatness of surface A, B, C, D, E in drawing to be
within 2
4. Flatness of surface (E) in drawing to be within 2
10 Plate SS400F 1 9.80 65 × t12
09 Plate SS400F 1 1.10 65 × t12
08 Plate SS400F 1 1.35 65 × t12
07 Plate SS400F 1 1.65 65 × t12
06 Plate SS400P 1 1.65 100 × t12
05 Plate SS400P 1 1.75 t12
04 Plate SS400P 1 2.30 t12
03 Plate SS400P 1 2.90 t12
02 Plate SS400F 1 6.45 65 × t12
01 Plate SS400F 1 2.90 100 × t12
(3) Spill guard (R.H.): 195-71-74830 fabrication drawing
160
Dimensions and leg length. for manual welding
per kes 04.351
3. Flatness of surface A, B, C, D, E in drawing to
be within 2
4. Flatness of surface (E) in drawing to be within 2
10 Plate SS400F 1 0.80 65 × t12
09 Plate SS400F 1 1.10 65 × t12
08 Plate SS400F 1 1.35 65 × t12
07 Plate SS400F 1 1.65 65 × t12
06 Plate SS400F 1 1.65 t12
05 Plate SS400P 1 1.75 t12
04 Plate SS400P 1 2.30 t12
03 Plate SS400P 1 2.90 t12
02 Plate SS400F 1 6.45 65 × t12
01 Plate SS400F 1 2.90 32 × t12
(1) Spill guard (middle): 195-72-74610 fabrication drawing
1-2 For U-dozer
161
dimensions and leg length. for manual welding per
kes 04.351
3. Flatness of surface a in drawing to be within 2
06 Plate SS400P 2 3.70 t12

05 Plate SS400P 9 3.65 t12
04 Plate SS400F 1 2.85 32 × t9
03 Plate SS400F 1 7.15 32 × t12
02 Plate SS400F 10 1.70 65 × t12
01 Plate SS400F 1 14.65 65 × t12
(2) Spill guard (L.H.): 195-72-74620 fabrication drawing
162
Dimensions and leg length. for manual welding per kes 04.351
3. Flatness of surface A, B, C, D, E in drawing to be within 2
12 Plate SS400F 2 0.23 32 × t9
11 Plate SS400F 1 1.15 65 × t12
10 Plate SS400F 1 1.20 65 × t12
09 Plate SS400F 1 1.25 65 × t12
08 Plate SS400F 1 1.35 65 × t12
07 Plate SS400F 1 1.45 65 × t12
06 Plate SS400P 1 2.10 t12
05 Plate SS400P 1 2.10 t12
04 Plate SS400P 1 2.35 t12
03 Plate SS400P 1 2.80 t12
02 Plate SS400F 1 7.15 65 × t12
01 Plate SS400F 1 7.50 65 × t12
(3) Spill guard (R.H.): 195-72-74630 fabrication drawing
163
Dimensions and leg length. for manual welding per kes
04.351
3. Flatness of surface A, B, C, D, E in drawing to be within 2
12 Plate SS400F 2 0.23 32 × t9
11 Plate SS400F 1 1.15 65 × t12
10 Plate SS400F 1 1.20 65 × t12
09 Plate SS400F 1 1.25 65 × t12
08 Plate SS400F 1 1.35 65 × t12
07 Plate SS400F 1 1.45 65 × t12
06 Plate SS400P 1 2.10 t12
05 Plate SS400P 1 2.10 t12
04 Plate SS400P 1 2.35 t12
03 Plate SS400P 1 2.80 t12
02 Plate SS400F 1 7.15 65 × t12
01 Plate SS400F 1 7.50 65 × t12
2. Installation (Welding) of spill guard
(1) After making the spill guard, weld it to the blade according to "3. Installation drawing for spill guard" shown
below.
(2) Precautions for welding

(a) Remove all matter harmful to welding such as dirt, rust, and paint from the parts to be welded.
(b) If the parts to be welded are wet, dry them with a gas burner.
(c) Do not use anti-spatter agents.
(d) Use coated welding rods specified by JIS 4316 (Low-hydrogen welding rod for mild steel) or welding
wires specified by JIS YGW11.
(e) Before using coated welding rods, dry them at 300 – 350 °C for 30 – 60 minutes.
(f) Preheat the area about 50 mm from the bead to be laid at 150 - 200 °C. When the ambient tempera-
ture is below 10 °C, post-heat the same area at 150 – 200 °C, too.
(g) Set the welding current to the lower limit of the current range specified for the diameter of the welding
rod or wire.
(h) When performing multi-layer welding, weave the welding rod.
(i) Do not weld by letting the melted metal flow, but weld from below to above with sufficient penetration.
Keep the arc as short as possible and take care not to make an overlap, undercut, etc.
(j) Before welding the spill guards, remove all the paint from the parts to be welded with a grinder (See
note marked with a below). Then, perform tack welding, permanent welding and finishing in order.
a If the painted surface is welded, the base metal cracks easily.
(k) Connect the ground cable to a part from which the paint has been removed or a part at which the cable
can be grounded securely (blade unit).
(I) When welding the spill guard with the blade assembly installed to the machine (body), cover the rods of
the blade lift cylinder and blade tilt cylinder to protect them from welding spatters.
164
3. Spill guard installation (welding) procedure
3-1. For semi U-dozer
As shown in Fig., weld spill guards (1), (2) and (3) to the semi U-blade.
165
3-2. For U-dozer
As shown in Fig., weld spill guards (1), (2) and (3) to the U-blade.
166
APPENDIX 2.
PRECAUTIONS FOR INITIALIZATION PROCEDURES

FOR VHMS CONTROLLER
167
Initialization procedures for VHMS 1. Check of machine information, engine
controller 1 information and controller information
a This step is a work performed on the
a Initialization tools for VHMS controller whole machine.
Symbol Part No. Part name Check and record the machine information,
engine information, VHMS controller informa-
1 799-608-3211 Diskette tion and ORBCOMM terminal information.
2 799-608-3220 Wiring harness
No. Information to be checked
Z Notebook type personal com-
1 Machine model
Commercially puter (OS: Windows98/2000/
3
available NT/Me/XP Terminal 2 Machine serial No.
"RS232C" is with it)
3 Current service meter reading
a Before starting full operation after completion 4 Engine serial No.

of local assembly or before resuming operation 5 Transmission serial No.
after storage for a long period, initialize the 6 VHMS controller serial No.
VHMS controller according to the following
procedure. ORBCOMM terminal serial No.
7
[For ORBCOMM specification only]
a Machine data collected with the VHMS control-
ler are stored and managed in WebCARE
database. To process the data smoothly on the a VHMS controller (1) is in the control box
WebCARE, it is necessary to set the VHMS on the left side of the floor and ORB-
controller consistently. If it is not set correctly, COMM terminal (2) is in the control box on
data will not be taken into the WebCARE and the right side of the floor.
data in the VHMS controller may not be uti-
lized. Accordingly, be sure to carry out the ini-
tialization.
a For the method of installing the VHMS Initial-
ization Program to the personal computer,
refer to the Operation and Maintenance Man-
ual contained in the package of diskette Z1.
a Since the service menu of the monitor panel
will be used in the following procedure, read
"Special functions of monitor panel" and under-
stand the operating procedure in advance.
a The initialization procedures cover both "ORB-
COMM Specification" and "ORBCOMMLESS
Specification". In case of "ORBCOMMLESS”
Specification", omit the procedures necessary
for "ORBCOMM Specification" only.
a During the initialization work, confirm each
work according to the "VHMS Initialization
Work Checklist".
168
2. 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 start-
ing switch is in the OFF position.
2) Connect personal computer Z3 and down-
load connectors (VDW) and (DL1) by wir-
ing harness Z2.
a The download connectors are installed
to the following places.
q (VDW): Inside of cab (Left rear
lower part)
q (DL1): Right rear side of machine
(Side of backup lamp) 3. Check of operation and satellite capturing
a Connect the personal computer to the condition of VHMS controller
RS232C terminal. a This step is a work performed in the oper-
ator's cab.
a Check of satellite capturing condition is
necessary o only [ORBCOMM specifica-
tion].
1) Set the starting switch in the ON position.
2) Select "Service mode" and "Real-time
monitoring mode" in order on the monitor
panel.
3) Input ID = 20301.
4) If the central part of the lower line of the
multi-information display unit counts up,
the VHMS controller is normal.
a Execute initialization of VHMS from

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

controller by the state of the dot at the
right bottom of the LED digit of the VHMS
controller.
169
6) The dot at the right bottom of the LED digit 8) Check the controller for normal operation
of the VHMS controller can be checked in referencing 7-segment LED of VHMS con-
the multi-information display unit of the troller.
monitor by the following method. a VHMS controller is fed with switch
1] Set the starting switch in the ON posi- power supply. Thus, its operation is
tion. judged normal if its 7-segment LED
2] For monitor panel specification: starts flashing while rotating as the
Referring to 10. "Real-time monitoring starting switch is turned on and then if
mode" or 11. "Dual display monitoring the controller starts counting in the
mode", input ID = 20301. ascending order.
7) At least 3 minutes after starting the VHMS,

9) Watch the decimal point LED on the right
check the decimal point at the right bottom
of the right-hand 7 segments of the VHMS
of the LED of the VHMS controller or the
controller to check that the ORBCOMM
decimal point at the right bottom of the
central part of the lower line of the multi- controller is capturing the satellite [ORB-
information display unit. COMM specification].
a Check the communication satellite
capturing condition of the ORBCOMM
controller on the VHMS controller
side.
a If the ORBCOMM controller is nor-
mal, the decimal point LED of the
right-hand 7 segments flashes.
Right decimal
Display
point
• Power is not supplied to ORB-
COMM controller.
OFF
• Communication line to VHMS
controller is abnormal.
• Satellite is not captured.
• Power is supplied to ORB-
ON COMM controller.
• Communication line to VHMS
controller is normal.
• Power is supplied to ORB-
COMM controller.
Blinking • Communication line to VHMS
controller is normal.
• Satellite is captured.
170
4. Startup of VHMS initialization tool 5. Initialization of VHMS controller (Tool
a This step is a work performed in the oper- before Ver. 3.5.2.1)
ator's cab (on the personal computer). a This step is a work performed in the oper-
1) Turn on the personal computer and start ator's cab (on the personal computer).
the OS. a When initializing, do not change the data
2) Click the icon of [VHMS Initialization Tool] of service meter [SMR].
on the personal computer screen to start [Machine information]
the VHMS initialization tool. 1) Open the [Machine information] tab.
a The [Machine information] tab is dis-
Important played first in the [Data clear and Set
a The setting screen varies with the up] menu.
version No. of the VHMS setting tool. 2) Check all the data.
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 SMP-
623)
3) Input the 10-digit service ID in [Service
ID].
a Service ID: 7826147000
4) Select [Data clear and Set up] in the
[Select Function] column.
5) Press the [OK] button to go to the setup
screen. 3) If information in the [Date/Time] box is not
correct, change it according to the follow-
ing procedures:
1] Press [Edit] button (1) on the right
lower part of the [Date/Time] box to
display the correction screen.
2] Correct the information and press the
[OK] button.
171
4) If information in the [Machine information] [Communication Setting] [For ORBCOMM spec-
box is not correct, change it according to ification only]
the following procedures: a Execute this setting after requesting for open-
1] Press the [Edit] button (2) on the right ing of the ORBCOM terminal and finishing the
lower part of the [Machine informa- opening procedure.
tion] box to display the correction 6) Open the [Communication Setting] tab.
screen. 7) Check all the data.
2] Correct the information and press the
[OK] button.
5) After checking/changing all the data in

[Machine information], press [Apply] but-
ton (3) to settle the setting.
a Press the [Apply] button (3), and the
screen for checking the setting will 8) To change the setting in [SHORT FAULT
appear. Check the setting again and HISTRY], follow the procedure below:
press the [OK] button if the setting is 1] Select [SHORT FAULT HISTRY] on
correct. the screen and press [Edit] button (5)
a In case of the ORBCOMM Specifica- on the left lower part of the [File
tion, execute [Communication Set- Transfer Setting] block to display the
ting] first and then settle the setting. setting screen.
2] Change the setting and then press
the [OK] button.
a At initialization, select [Occur-
rence] at [Timing] and set the
function to [ON].
172
9) To change setting in [SHORT TREND 11) After checking/changing all the data in
ANALYSIS], follow the procedures below: [Communication Setting], press [Apply]
1] Select [SHORT TREND ANALYSIS] button to settle the setting.
on the screen and press [Edit] button a If the [Apply] button is pressed, the
on the left lower part of the [File s c r ee n f o r c he c k i ng th e s et ti n g
Transfer Setting] block to display the appears. Check the setting again and
setting screen. press the [OK] button if the setting is
2] Change the setting and then press correct.
the [OK] button.
a At initialization, input [20h] to
[SMR] and set the function to
[ON].
10) To change the setting of [Satellite Setting], 12) After checking/changing the data of
follow the procedure below. [Machine Information] and [Communica-
1] Press the [Edit] button in the [Satellite tion Setting], press the [Exit] button at the
Setting] block to display the setting right lower part of the screen to finish
screen. [VHMS Initialization Tool].
2] Set the GCC Code to the applicable
area and then press the [OK] button.
GCC codes and applicable areas

Applicable Applicable
Code Code
Area Area
1 U.S.A. 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
173
6. Initialization of VHMS controller (Ver. 3.5.2.1 3) Check the machine information. If it does
or after) not need to be corrected, press the "Next"
a This step is a work performed in the oper- button.
ator's cab (on the personal computer).
a When initializing, do not change the data
of service meter [SMR].
1) Select [VHMS Setting] and press the
"Next" button.
a If the VHMS was installed addition-

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

"Next" button.
174
4) Select the time zone. 8) The contents of the setting are displayed
5) Input the local time. finally. If there is not a problem, press the
6) If the DST (Daylight Saving Time) is used "Apply" button.
now, select it and press the "Next" button.
a If the DST is selected, the clock is
advanced 1 hour automatically, thus
the time must be corrected again.
9) The system asks you if you save the data

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

and then press the "Next" button.
GCC codes and applicable areas

Applicable Applicable
Code Code
Area Area
1 U.S.A. 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
10) After finishing the work of changing the

contents of initialization, press the "OK"
button to finish the program.
175
7. Procedures for executing Quick Pm 2] Set the buzzer cancel switch in the
a The Quick Pm means the Pm Clinic exe- [U] position.
cuted with the manual snap shot function 3] "READY" is displayed and the system
of the monitor panel. is ready to start.
a Data in 7 minutes 30 seconds are saved in a On the lower line, 15 pieces of "-"
the VHMS controller. are displayed.
k Stop the machine on a flat place.
1) Start the engine.

2) Set the monitor panel to display the ser-
vice menu.
a For the operating method, see "Spe-
cial functions of monitor panel".
3) Selection and execution of mode.
1] Select "Snap shot mode" on the
mode selection screen.
a If the mode is selected, code (55)
is displayed in gear speed dis-
play unit (1) and the title is dis-
played in multi-information unit
(2). 4] Set the buzzer cancel switch in the
Serial No.: 50001 – 50090 [U] position, and the snap shot oper-
ation starts.
a After the snap shot operation
starts, the elapsed time is dis-
played on the upper line.
a On the lower line, 1 " " is added
every 30 seconds. While multiple
" " are displayed, the one at the
right end blinks.
a To interrupt the snap shot opera-
tion, set the buzzer cancel switch
in the [t] position.
Serial No.: 50091 and up
176
5] After starting the snap shot operation,
operate the machine according to
Table 1.
a Check that the engine coolant
temperature and torque con-
verter oil temperature are in the
operating range.
a After 10 " " are displayed (After 5
minutes), "#" is added up to 5.
q " ": The data sampling interval is
10 seconds.
q "#": The data sampling interval is
1 second.
177
Table 1 Operations of machine to be executed while snap shot is operated
Operation of machine
Time (sec)
Finish
Start
Fuel
No.
State of machine Steer- Decelera- Brake Parking

Transmission Work equipment control
ing tor pedal pedal brake
dial
1 0:00 1:00 60 N LH N LOW HI Released Released
Low idle
2 1:00 2:00 60 N RH N LOW HI Released Released
3 2:00 3:00 60 High idle N N N HI HI Released Released
4 3:00 4:00 60 Deceleration slow N N N HI LOW Released Released
5 4:00 4:30 30 Relief & high idle N N HI HI Released Released
Ripper lift
6 4:30 5:00 30 Relief & low idle N N LOW HI Released Released
NoF1oF2oF
Torque converter
7 5:00 5:30 30 3oNoR1oR2 N N LOW HI ON Released
stall & low idle
oR3oN
NoF3 (Shift to
Torque converter LOWo
F3, then run
8 5:30 6:00 30 stall (F3) & high N N HI Shift to F3, ON Released
engine at full
idle (Note 1) then HI
throttle)
9 6:00 6:30 30 High idle N N N HI HI Released Released
NoF3 (Shift to
LOWo
Torque converter F3, then run
10 6:30 7:00 30 N Ripper lift HI Shift to F3, ON Released
stall + Relief engine at high
then HI
idle)
High idleo HIo
11 7:00 7:30 30 N N N HI Released ON
Low idle (Note 2) LOW
(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.
(Note 2): Keep running the engine at low idle until the oil temperature is lowered to the normal level.
a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine
speed to high idle.
a After stalling the torque converter, watch the power train oil temperature gauge and take care not to
overheat the power train oil.
(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature
gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the
engine at high idle to lower the oil temperature.)
178
6] The screen shown below appears 7 q Blowby Press
minutes 30 seconds after the snap q Exhaust Temp FB (Exhaust tem-
shot is started, and then the initial perature of front bank: 1, 2, 3)
screen appears 5 seconds after. (End q Exhaust Temp RB (Exhaust tem-
of snap shot) perature of rear bank: 1, 2, 3,)
q Boost press
q Engine Oil Press
q Engine Oil Temp
q Eng Coolant Temp
q Ambient Temp
q Demand Eng Speed
(Engine speed demanded by
controller)
q T/C Oil Temp
(Torque converter oil tempera-
ture)
q T/M Main Press
(Transmission main relief pres-
sure)
Important q T/M Output Speed
The data of the Quick Pm is recorded only (Transmission output speed)
once. If the Quick Pm is executed again, q Shift Position
the current data are overwritten. Accord- ( Tr a n s m i s s i o n , t r a v e l , g e a r
ingly, be sure to save the data in the per- speed)
sonal computer after executing the Quick q S/T Clutch Pos.
Pm, referring to "8. Downloading of set (Steering clutch position)
data". q S/T Brake Pos. (Steering brake
7] Using the analysis tool, read the data position)
of the Quick Pm. q Hydr Oil Temp
a For the usage of the analysis tool, (Hydraulic oil temperature)
see the operation manual. q Pump 1 Press
8] Open the data of the Quick Pm and (Work equipment pump 1 oil
translate them into a graph. pressure)
a Set the time to the X-axis and set the q Pump 2 Press
following items to the Y-axis. (Work equipment pump 2 oil
q Engine Speed pressure)
q Fuel Inject q Body Pitch Angle (Pitch angle)
179
9] Check "Click position graphic value
display".
180
10] Click a point in the graph, and the
value of each test item at that point on
the X-axis is displayed under the
graph.
(Example of displayed graph: This is
different from the actual graph.)
181
11] Enter the above value in the Pm Clinic Inspection Sheet.
a The relationship between the data necessary for the Pm Clinic and the test conditions is as fol-
lows.
Test items
Transmission main relief pressure
Steering right clutch fill switch
Steering right brake fill switch

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

Front clutch fill switch
Rear clutch fill switch

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

Engine oil pressure
1st clutch fill switch

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

Engine at high idle Q Q Q
Deceleration slow Q
Relief & engine at full throttle Q Q
Relief & engine at slow Q
Torque converter stall & engine at slow Q Q Q Q Q Q Q Q
Torque converter stall (F3) & engine at full
Q Q Q
throttle
Engine at full throttle
Torque converter stall & relief Q
Engine at high idle o Engine at low idle Q Q
182
8. Downloading of set data 2) When using download connector (VDW)
1) Connect personal computer Z3 and down- in the cab, set the starting switch in the
load connectors (VDW) in the cab or ON position.
ground download connector (DL1) by wir- 3) When using ground download connector
ing harness Z2. (DL1), turn switch (3) ON.
a The green LED lights up.
4) Operate the icon of [VHMS Technical
Analysis Tool] on the personal computer to
start the VHMS technical analysis tool.
a Download connector (VDW) in the a Input [User Name] and [Password].

cab is installed to the left rear lower a For the operation procedures, see the
part of the operator's seat. Operation and Maintenance Manual
for VHMS Technical Analysis Tool.
5) Use the [Download] function to download

the data recorded in the VHMS controller
a The ground download connector (DL1) to the personal computer.
is installed to the side of the right a For the operation procedures, see the
backup lamp on the rear frame of the Operation and Maintenance Manual
machine. for VHMS Technical Analysis Tool.
a Make sure that downloading has
completed before proceeding to the
next step.
183
9. Check of downloaded data 3) If the data was downloaded in the cab,
a This step is a work performed in the oper- disconnect wiring harness Z2 from down-
ator's cab (on the personal computer). load connector (VDW).
1) Check the set data with the [View] func-
tion.
a For the operation procedures, refer to
the Operation and Maintenance Man-
ual for VHMS Technical Analysis Tool.
a Make sure that the [MFA0] code at
the time when the snapshot was
operated is displayed in [Fault His-
tory].
a Make sure that the snap shot data is
recorded.
4) If the data was downloaded on the

ground, turn switch (3) OFF and discon-
nect wiring harness Z2 from download
connector (DL1).
2) After checking the set data, terminate

[VHMS Technical Analysis Tool].
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 dis-
connecting the personal computer.
2) Finish the OS of the personal computer
and then turn the personal computer OFF.
11. Communication to Komatsu
After completing steps 1 to 9 successfully,
send the "VHMS/WebCARE setting notification
form" to VHMS/WebCARE Support Center of
Komatsu, Tokyo.
a Since Komatsu has to set the receiving
side of the satellite communication, be
sure to inform Komatsu of the completion
of the setting.
a Send the VHMS data by Notes (LAN) or
E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: [email protected]
184
(Objective model: D375A-5E0 Bulldozer)
185
(Objective model: D375A-5E0 Bulldozer)
186
187
1/8
Report No.
Field assembly inspection report

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model-Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
D375A-5E0 SAA6D170E-5
Service Meter Reading Date of Inspection

Specification
Blade U Semi U (Dual Single)

Location of Machine at Inspection
Ripper or
VGR. VMR. CW ( )
counterweight
Distributor's Name Shoe width 610 mm 710 mm 810 mm
Others
Customer's Name Address: Signature: Delivery

Report
No. attached
Date:
Inspector's Comments:
Inspector's Name: KOMATSU USE ONLY :
C. Sheet Receiving Date :

Title
By :
Signature:
Remark:
Check sheets filling instructions:
1. Use following indexes for entry of judgement
T..... Normal T ..... Correction made on abnormal point

T..... Abnormal T..... Not applied
2. Enter actually measured values in parenthese, [ ].
Notes:
(1) Criteria are based on the standards when the machine is shipped out of the factory.
SUBMITTANCE OF THIS REPORT (AND CHECK SHEETS) TO KOMATSU IS ONE OF THE CONDITIONS OF WARRANTY VALIDATION, COPY
FOR KOMATSU SHALL BE FORWARDED TO THE KOMATSU REGIONAL OFFICE TOGETHER WITH THE COPY OF DELIVERY SERVICE RE-
PORT.
Printed in Japan
2/8
Cate- Inspec-
Inspection item Criteria
gory tion
Bat- Check of electrolyte level Must be between L and H.
tery Check of battery unit Must be free from grease, looseness of terminals, and
cracking.
Radiator water level Above the bottom of
strainer net Radiator
Reserve tank water level Low to Full
Antifreeze% 65 58 50 41 30
Must be contained.
°C -50 -40 -30 -20 -10
Engine oil level (H + L) / 2 to H + 10 Engine: Stopped
Engine: Stopped
Power train oil level (H + L) / 2 to H + 10
(After 3 – 5 min)
Damper case oil level (H + L) / 2 to H + 10 Engine: Stopped
Refer to Operation &
Maintenance Manual Pitch back on the
Hydraulic tank H to L sight gauge ground. Ripper point
oil level on the ground. (Shank
Water and oil level
• Between H - L must be vertical.) Stop

the engine.
Final drive oil level LH H to H + 20 See operation manual.
RH Stop the engine.
Pivot shaft
LH See operation manual.
oil level H + 10 to H + 30
from shaft end
RH
Recoil spring
oil level LH H = 96 to 116 See operation manual.
RH
Use the diagram below for reference, and check if the The electrolyte level is up to the
Correct level bottom of the sleeve, so the sur-
electrolyte reaches the bottom of the sleeve.
face tension causes the surface
to rise and the plate appears to
be warped.
Tool low
The electrolyte level is not up to
the bottom of the sleeve, so the
plate appears normal.
Window washer tank water level LH Full

Fuel tank Full
Horn Must be of no beat sound or sound deterioration.
Backup alarm Backup alarm must sound when the T/M lever is at
(Starting engine) the back position.
Monitor display When starting switch is turned ON, caution lamp,
warning lamp and alarm buzzer are turned ON simul-
taneously for 2 seconds.
No error code indicated in the service meter.
Operation of service meter
Before engine start, meter must not operate when the
(Engine: Low idling)
key switch turned on.
Inspection
Charge lamp (Engine: Low idling) Must not light up when all electrical equipment are
turned on.
Lamp ON (Heated lamp, tail lamp and work lamp) Must light up when turned on.
Heater hose cock. Must be fully open.
Controller error code indication (make sure that error does not Clear error code after confirming it.
recur)
Air bleeding of the hydraulic cylinder Perform air bleeding of the hydraulic cylinder.
1. Start and run the engine for 5 minutes at low idling.
2. With the engine at low idling, extract and retract the cylinder
4 to 5 times without bringing it to the stroke end.
3. With the engine at high idling, stop the cylinder at 100 mm
before the stroke end. Then slowly bring it to the stroke end.
Hold it at the position for 1 minute.
3/8
Cate- Inspec-
gory tion
Check of auto shift-down function (When stalled) Auto shift-down function must not work when stalled.
Effect of parking brake lever When parking brake lever is in FREE position, engine
Free Lock must not start.
Travel and gear shifting must be prohibited when
locked.
Free
Lock
Operability of travel lever Must be free from hitch and abnormal sound.
• Gear shifting operation Must not come off notch.
• Travel direction change operation Must be free from hitch and abnormal sound.
• Steering operation Must return smoothly.
(To each direction) Max. 10 mm
Play when lever is
in “N” position.
Check of the gear speed indication on the monitor panel. N, F1, F2, F3, R1, R2 and R3 are all indicated.
• Must be able to be shifted to any position with the engine at Must be of no indication error.
low idling and the brake turned on.
Check of longitudinal adjustment Must be adjustable.
of steering lever box Free Must not move after locking.
• Adjustment of steps Case
Function/ operation
Lock
• Check of lock lever of box
(Upper and lower)
Case
Case Knob
Check of the L/U operation Lockup must be turned ON and OFF. (When lockup is
With the T/M lever at the “N” position, engine idling must turned ON, symbol lamp must light up.)
change from low to high, then to low again. High idling : L/U indicator ON
Low idling : L/U indicator OFF
Check of the deceleration pedal operation Must work smoothly.
• Set the fuel dial to high idle position. Must be contained play at high idle.
• Check the deceleration RPM 850 – 950 rpm
Check of the fuel dial operation Must move smoothly.
Check of tilting directions Blade must move to left.
Blade must move to right.
Right tilt
Left tilt
Check of dual tilt and pitch direction

Check of tilt direction
Pitch back Blade must move backward. (D) + (B)
Pitch dump Blade must move forward. (D) + (A)
LH dual tilt Blade must move to left (both cylinders move) (E) + (B)
Dual
RH dual tilt Blade must move to right (both cylinders move) (E) + (A)
LH tilt Blade must move to left (right cylinder moves) (B) + (F)
RH tilt Blade must move to right (left cylinder moves) (A) + (F)
4/8
Cate- Inspec-
gory tion
Clearance between straight frame and track Difference between right and left must be 30 mm or
Left mm
less (when measured on flat ground).
Move the blade up and down and stop it at 100 mm
Right mm above ground, then measure.
Check of the safety lever lock function No actuator must work when the safety lock lever is at
ON position (Lever can move but work equipment
Free
must not move)
Lock
Check of the blade lever floating Must be of no hydraulic drift (Engine: Low idling)
Check of the blade lever floating notch release Engine stops at floating, then notch must be released.
Check of the quick drop valve operation At the engine full, set the blade lever at down position.
Work equipment
• Quick dropping of the blade from top 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 idling) 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 OL Must be none.
• Leakage from U-packing, damaged rod, quick drop LH
valve, tube, flange or dust seal
RH
Tilt cylinder/pitch cylinder OL Must be none.
• Leakage from U-packing, damaged rod, quick drop LH
valve, tube, flange or dust seal
RH
End bit, cutting edge mounting bolt Must be tightened.
Blade and bit stopper contact Must be contacted
1. End bit (partial contact is acceptable)
2. Stopper
Track tension adjustment Tense a string or a bar between the first

• With the gear at F1 and the engine at low idling, travel LH 20 – 30 mm carrier roller and the idler to measure dis-
on flat place for about 10 m, and when the grouser tance between the string (bar) and the
RH 20 – 30 mm
comes over the first carrier roller, stop the machine by grouser. Max. 20 mm
Ground peripherals
depressing the brake pedal.

Carrier roller alignment Flanges must be free from contact with links at all
• Travel on flat place with the gear at F1 and R1 for LH times.
about 10 m, repeatedly about 3 or 4 times, then gradu-
RH
ally apply brake to stop.
Undercarriage OL Must be none.

• Leakage from idler, carrier roller, bogie, pivot shaft, LH
adjustment cylinder, and lubricated track (plug, seal)
RH
Beat noise inside the cabin, beat noise of the outer cover Must be none.
Space between S/T lever and the cabin at forward travel + left Must be 40 mm or more.
steering with the S/T lever at the front position.
Opening/closing and locking effect of the cabin doors. Must work smoothly to securely lock the doors by
door-locking or key-locking.
Cabin 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 Must work smoothly to securely lock.
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.
Cabin
Wiper: Must operate smoothly (without beat noise)

Operation of the radio and cassette system Must operate correctly
(Volume, tuning, AM/FM switching, cassette)
Operation of the cigar lighter Must be red-heated.
Ash tray installation Must be installed.
Power supply of 12 V (Accessory socket, etc.) Power of 12 V must be supplied.
• Check by connecting the ratio unit
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 (Hi, Mid or Lo)
Air flow amount must be able to be adjusted (Hi, Mid or Lo)
• Louver must be smoothly switched (Left/right of monitor panel) Air comes out from each blowout port.
5/8
Cate- Inspec-
gory tion
Portions to be lubricated Q’ty Example: When U-blade is used
• Equalizer bar side pin shaft
2
• Equalizer bar center pin shaft
• Blade lift cylinder support shaft and yoke
Lubrication
1
• Brace center pin
• Blade oblique arm ball joint 6
• Brace screw 1
3
2
Check of ripper direction
(a) Raise
(c) Lower
(A) Tilt in Raise
(B) Tilt out
TILT
IN TILT
Lower OUT
Ripper lift cylinder OL Must be none

• U-packing, damaged rod, tube, flange, dust seal
LH
loosing
RH
Ripper tilt cylinder OL Must be of no contact.
• U-packing, damaged rod, tube, flange, dust seal loos-
LH
ing
RH
Contact with the hose at ripper operation Must be of no contact.
(Entire operation area must be checked)
Creak of the ripper link pin Must be of no creak.

Check of the pin puller switch direction Must be the same as the pin puller cylinder operation
(a): Pin out direction.
(b): Pin in
Ripper
Machine front
Check of the pin puller cylinder hose cramp position Must be of no contact Must be of no excess hose ten-
(Entire operation area must be checked) sion.
Pin puller cylinder OL Must be none

• Leakage from U-packing, damaged rod, tube of flange
Check of ripper lubricated hose installation LH Must be of no contact or no excess bend.

RH
Portions to be lubricated Q’ty Must be lubricated (right and left)
• Ripper lift cylinder head (8)
• Ripper lift cylinder bottom (6) 2
• Ripper tilt cylinder head (7) 2
• Ripper tilt cylinder bottom (5)
• Ripper arm pin (front) (9) 2
• Ripper arm pin (rear) (10) 2
2
2
6/8
Refer to the “Testing and adjusting” on Shop manual for the measurement
<Precautions for measurement>

Measure each performance value after each oil temperature has increased.
(Reference) Engine coolant temperature: Within operating range
Power train oil temperature: 75 – 85 °C
Hydraulic oil temperature: 45 – 55 °C
Engine speed
Cate-
Item Condition Unit Standard Result
gory
Engine speed Run engine at low idling (low speed). rpm 700 – 800
* Measure stall
speed 1 segment Run engine at high idling (at full throttle). rpm 1850 – 1900
before red range of
torque converter oil Set decelarator at low speed. rpm 850 – 950
Engine
temperature gauge
Stall torque converter. (Service mode: 0530) rpm 1490 – 1580
Stall torque converter and work equipment relief. rpm 1250 – 1370
(Service mode: 0530)
Large pump relief (ripper lift relief) rpm 1800 – 1900
Hydraulic pressure
Cate- Stan-
Item Condition Unit Result Category
gory dard
Clutch pressure Run engine at full throttle and Release pedal. Mpa 0
(L.H and R.H) set transmission in N. {kg/cm²} {0}
Run engine at full throttle and Press pedal to Mpa 2.55 – 2.84
set transmission in N. stroke end. {kg/cm²} {26 – 29}
Transmission
Brake pressure Run engine at full throtlle and Release pedal. Mpa 2.5 – 2.79
(L.H and R.H) set transmission in N. {kg/cm²} {25.5 – 28.5}
Run engine at full throttle and Press pedal to Mpa 0

set transmission in N. stroke end. {kg/cm²} {0}
Main oil pressure Run engine at full throttle and set transmission in N. Mpa 0 Measure by monitor
{kg/cm²} {0} panel
Mpa 0 0
Run engine at low speed and set transmission in N.
{kg/cm²} {0}
7/8
Hydraulic pressure
Cate-
gory
Run engine at low speed Mpa 19.6 – 21.3 Measure by monitor
Single tilt Single tilt and set transmission in N. {kg/cm²} {200 – 217} panel
specification relief Run engine at full throttle Mpa 20.6 – 21.6 Measure by monitor
Work equipment
and set transmission in N. {kg/cm²} {210 – 220} panel
pump (large
pump) Dual tilt
Ripper lift specification Run engine at low speed Mpa 19.6 – 21.3 Measure by monitor
(Measure by (Only ripper- and set transmission in N. {kg/cm²} {200 – 217} panel
Ripper tilt
monitor panel) installed specifi-
relief
cation or ripper- Run engine at full throttle Mpa 20.6 – 21.6 Measure by monitor
Oil pressure
installable spec- and set transmission in N. {kg/cm²} {210 – 220} panel

ification)
Run engine at low speed Mpa 19.6 – 21.3 Measure by monitor
Work equipment Single tilt Single tilt and set tronsmission in N. {kg/cm²} {200 – 217} panel
pump (small specification relief Run engine at full throttle Mpa 20.6 – 21.6 Measure by monitor
pump) and set transmission in N. {kg/cm²} {210 – 220} panel
Ripper lift
Dual tilt
(Measure by Run engine at low speed Mpa 19.6 – 21.3 Measure by monitor
specification
monitor panel) and set tronsmission in N. {kg/cm²} {200 – 217} panel
(Only ripper-
(Only machine Ripper tilt
installed specifi-
equipped with relief
cation or ripper- Run engine at full throttle Mpa 20.6 – 21.6 Measure by monitor
ripper)
installable spec- and set transmission in N. {kg/cm²} {210 – 220} panel
ification)
Work equipment speed

Cate-
gory
Blade lift RAISE Run engine at full throttle. sec 4.0 – 5.1
Semi U
Blade lift RAISE Run engine at full throttle. sec 4.0 – 5.1
Full U
Single tilt LEFT tilt Run engine at full throttle. sec 4.0 – 5.0
Semi U • Full U
RIGHT tilt Run engine at full throttle. sec 3.0 – 4.0
Single tilt (Dual tilt specification) LEFT tilt Run engine at full throttle. sec 2.5 – 3.5
Full U • Semi U
Dual tilt LEFT tilt Run engine at full throttle. sec 4.0 – 5.0
Dual tilt Pitch DUMP Run engine at full throttle. sec 4.0 – 5.0
Pitch BACK Run engine at full throttle. sec 3.0 – 4.0
Ripper lift RAISE Run engine at full throttle. sec 2.5 – 3.5
(Use lowest pin hole)
LOWER Run engine at full throttle. sec 2.0 – 3.0
Ripper tilt Tilt IN Run engine at full throttle. sec 4.5 – 5.5
Tilt BACK Run engine at full throttle. sec 3.0 – 4.0
Hydraulic drift of work equipment

Cate-
gory
Blade lift Cutting edge height: 500 – 800 mm. mm/min Max. 200/5
Ripper lift Ripper point height: 300 – 600 mm. mm/min Max. 80/5
8/8
Tightening torque record/check sheet for ROPS mounting bolts
ROPS
Mounting bolt
Sketch
(Front)
Nameplate side is rear.
a, b, c
Front right Mounting bolt (Rear)
Rear right
g, h, i
d, e, f
Front left
Rear left
Bolt position symbols j, k, l
Mounting bolt specification : M30 × 110 mm ---- 12 pieces

Specified tightening torque : 1,520 – 1,910 Nm {155 – 195 kgm}
Record of measured values : Symbolize the bolt positions as [a, b, c], [d, e, f], [g, h, i]
and [j, k, l] from the right to the left.
Record
Bolt position
(Unit: )
a
Recording column
Rear right b
c
d
Rear left e
f
g
Front right h
i
j
Front left k
l

D375 A-3

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GEN00054-04

Field Assembly Instruction

BULLDOZER D375A -5E0

Operator for assembly

Mechanics Sharing of work

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

• Semi U-tiltdozer + variable multi ripper

• Fell U-tiltdozer + variable giant ripper

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

4. k Check during actual work

6. Precautions for starting engine

Assembling blade sub-assembly

Adding and checking oil

Installing ripper sub-assembly

man-hours 32H 32H 24H 24H

Grand total 112H

Ripper parts CAB assembly

t Style of each KIT.

A Overall length (mm) 5,848

Shoe wide 610 710

A Overall length (mm) 5,140

A Overall length (mm) 4,695

• Work equipment Straight frame

A Overall length (mm) 4,300

A Overall length (mm) 2,500

A Overall length (mm) 770

a This part may be delivered installed to the machine.

A Overall length (mm) 1,450

a This part may be delivered installed to the machine.

A Overall length (mm) 1,450

A Overall length (mm) 1,450

A Overall length (mm) 1,787

A Overall length (mm) 2,055

* ROPS is an abbreviation for Rollover Protective Structure.

A Overall length (mm) 2,880

A Overall length (mm) 1,397

Stand (Front side)

Sling (Track frame assembly)

Idler SYM. Part name Q'ty/set Remarks

Part No. of bolt TTTTT-TTTTT

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

a : Bolt thread diameter (Nominal diameter)

Nominal size of thread Width across flats Tightening torque

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

Table 4.1 Hydraulic hose of face seal type

Type that uses

Approx. 6 19 34 – 54 {3.5 – 5.5} 44 {4.5}

Approx. 10 22 54 – 93 {5.5 – 9.5} 74 {7.5}

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}

Table 4.2 Hydraulic hose of taper seal type

Type that does

Approx. 6 19 34 – 63 {3.5 – 6.5} 44 {4.5}

Approx. 10 24 59 – 98 {6.0 – 10.0} 78 {8.0}

Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}

Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}

Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}

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