Field Assembly Manual: Bulldozer

GEN00012-00
(Replaces SEAW005000)
Field Assembly
Manual
BULLDOZER
-5
SERIAL NUMBERS D475A-5 20001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2004 Komatsu

Printed in U.S.A.
Komatsu America Corp.
December 2004
Preface
You are required to execute full inspection and maintenance before starting the en-
gine and assembling the work equipment. Since the work is often carried out in dan-
gerous places and positions by a team, hold a safety meeting in advance and appoint
a crane director, work leader, etc. so that the all member can work safely.
When the work is carried out in an overseas country, difference in language, customs,
etc. lowers safety. Accordingly, the field liaison man and work supervisor must exam-
ine the above point and take necessary measures.
Instruction system
Work leader
Director
Work supervisor Crane director and
deputy director
Operator for assembly

Liaison man
Mechanics Sharing of work

Interpreter
We hope that the all members will cooperate with each other and assemble the work
equipment quickly in the field, observing the safety, quality, and delivery time.
CONTENTS
SPECIFICATIONS ....................................................................................................................................... 1
PRECAUTIONS FOR FIELD ASSEMBLY ................................................................................................... 3
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE ............................................. 4
LAYOUT OF KIT ......................................................................................................................................... 5
STYLE FOR TRANSPORTATION .............................................................................................................. 6
TOOLS LIST FOR FIELD ASSEMBLY ........................................................................................................ 11
TIGHTENING TORQUE .............................................................................................................................. 18
COATING MATERIALS .............................................................................................................................. 22
A. ASSEMBLY PROCEDURE ..................................................................................................................... 25
A-1 Installation of undercarriage ................................................................................................... 26
A-2 Installation of ripper ................................................................................................................ 33
A-3 Installation of tracks ................................................................................................................. 37
A-4 Adding oil to pivot chamber ................................................................................................... 39
A-5 Installation of ripper shank ..................................................................................................... 40
A-6 Installation of blade lift cylinder ............................................................................................. 41
A-7 Installation of trunnion ............................................................................................................ 43
A-8 Assembly of blade ................................................................................................................... 44
A-9 Adjustment of arm joint (U-blade) ......................................................................................... 50
A-10 Installation of blade ................................................................................................................. 51
A-11 Installation of counterweight .................................................................................................. 53
A-12 Installation of operators cab .................................................................................................. 54
A-13 Installation of ROPS ................................................................................................................. 70
A-14 Adjustment of potentiometer rod ........................................................................................... 71
A-15 Procedure for adjusting blade tilt angle limit ........................................................................ 72
A-16 Method of checking auto-reset system (Superdozer) ........................................................... 81
A-17 Check track tension .................................................................................................................. 82
A-18 Check fuel, coolant and lubricants ......................................................................................... 84
A-19 Greasing of greasing point ..................................................................................................... 86
A-20 Installation of ORBCOMM antenna and wiring harness ....................................................... 89
A-21 Replacement of return filter
(Replacement of standard filter with flushing filter) ............................................................. 90
A-22 Installing direction of exhaust pipe ........................................................................................ 93
A-23 Bleeding air from hydraulic cylinders .................................................................................... 94
A-24 Installing lunchbox band (if equipped) .................................................................................. 95
M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY ..................... 97
M-1 Check and adjustment of operators cab ............................................................................... 98
M-2 Error code ................................................................................................................................. 105
M-3 Flushing of hydraulic circuit .................................................................................................... 114
APPENDIX 1
INSTALLATION OF SPILL GUARDS
APPENDIX 2
PRECAUTIONS FOR INITIALIZATION PROCEDURES
FOR VHMS CONTROLLER
FIELD ASSEMBLY INSPECTION REPORT (U-DOZER SPECIFICATION)
FIELD ASSEMBLY INSPECTION REPORT (SUPERDOZER SPECIFICATION)
SPECIFICATIONS
Semi-U-tiltdozer U-tiltdozer
Item Unit + Giant ripper + Giant ripper Superdozer
Operating weight
(excluding operator's weight) kg 103,900 (*1) 108,000 (*2)
Blade weight
(including cylinders) kg 13,600 14,600
Ripper weight
(including cylinders) kg 9,720
Counterweight kg 6,300
Engine model Komatsu SDA12V140E-1 diesel engine
Rated engine output kW/rpm {HP/rpm} 641/2,000{860/2,000}
Overall length mm 11,560 12,065 10,525
Overall height (with ROPS) mm 4,240 (4,600)
Overall width mm 5,265 6,205 6,465
Travel speed Forward km/h 3.5/6.3/10.9
(1st/2nd/3rd) Reverse km/h 4.7/8.4/14.3
*1: Blade + ripper + ROPS cab + air conditioner
*2: Superdozer + counterweight + ROPS cab + air conditioner
Semi-U-tiltdozer + variable giant ripper
Full U-tiltdozer + variable giant ripper
1
Superdozer + counterweight
2
PRECAUTIONS FOR FIELD ASSEMBLY
1. Selection of workplace
1) When selecting a workplace, consider the following items so that you can load and unload the machine.
Width
Hardness
Flatness
Access road, place for turn
2) Do not work in a place where dust, rainwater, etc. may enter the hydraulic circuit during assem-
bling work.
3) Do not assemble while a strong wind is blowing or it is raining.
2. Preparation and check of slings and tools

1) Check each sling and tool thoroughly. When using wood blocks, etc., check that their inside is
not rotten or broken.
3. Check of actual work

1) Apply the parking brakes of the trailer and crane truck securely and put chocks under their
wheels.
2) Before starting the work lower the temperature and pressure of the engine oil, hydraulic oil,
cooling water, etc.
3) When starting the engine, make an arranged sign such as sounding of the horn and check that
the work equipment control lever and travel lever are in neutral and the fuel control dial (or fuel
control lever) is at the low idling position.
4) When using the crane, balance the load.
5) Allow only the persons concerned into the workplace.
4. Before starting the work, read this manual thoroughly and keep the precautions in your mind.
5. The supervisor shall write down the precautions for each work process and explain them to the workers.
6. Hold a meeting every morning to check today's work plan and safe work.
3
Schedule
No. 1st day 2nd day 3rd day 4th day 5th day
Item
Unloading
Installation of track
1 Installation of stand
Installation of chassis
Unloading of other parts
2 Installation of blade lift cylinder
3 Installation of track frame
4 Installation of ripper (Installation of counterweight)
5 Installation of track
Blade
Welding of spill guard (If equipped)
6
Assembly of blade
Installation of blade
7 Installation of operators cab
8 Installation of ROPS
4
9 Installation of exhaust pipe
10 Adjustment of blade tilt limit rod
11 Adjustment of tilt limit angle
The special work in the field shall be adjusted separately.
12 Check of oil level and addition of oil

13 Greasing
A change of the schedule caused by weather is not considered.
14 Adjustment of track tension

Final assembly inspection
Pm clinic
15 Flushing of hydraulic circuit
Initialization of VHMS
Check of cab pressurization
Workers Assembly 4 4 4 3 2
Welding 2
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE
45ton 2 45ton 1 45ton 1 45ton 1

Crane (Hydraulic type with operator)
1. Arrangement before work 1. Removal of stand

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

Left straight frame
Right track
Left track
Track
Track
Wrecker truck
Approx. 30 m
Chassis
Wrecker truck
Accessories
Ripper parts CAB assembly
ROPS guard
5
STYLE FOR TRANSPORTATION
Since the machine can be divided for transportation, ask us or our service shop before transportation.
Style of each KIT.
Body
A Overall length (mm) 6,600

B Overall height (mm) 3,515
C Overall width (mm) 3,385
Weight (kg) 43,000
Track frame

C Overall width (mm) 972
Weight (kg) 11,200
WORK EQUIPMENT
(1) U-blade

Weight (kg) 14,000
6
(2) Semi U-blade

Weight (kg) 13,000
Super blade

Weight (kg) 14,000
Track shoe
Shoe width 810

A (mm) 4,500
B (mm) 1,400
Weight (kg) 6,600 (1/2)
7
Straight frame
Semi-U, U Super
A Overall length (mm) 4,857 5,020
B Overall height (mm) 674 682
C Overall width (mm) 638 681
Weight (kg) 1,770 1,868
Hydraulic cylinder
(1) Pitch, tilt cylinder
Semi-U, U Super
Weight (kg) 504 508
(2) Blade lift cylinder

B Overall height (mm) 630
Weight (kg) 500
(3) Ripper cylinder
Lift Tilt
Weight (kg) 389 394
8
Giant ripper beam

Weight (kg) 2,400
Giant ripper arm

B Overall height (mm) 580
Weight (kg) 1,800
Giant ripper shank
A Overall length (mm) 115

Weight (kg) 1,000
9
Cab

Weight (kg) 500
ROPS

Weight (kg) 918
Counterweight

C1 1,361
Overall width (mm)
C2 1,290
Weight (kg) 6,300
10
TOOLS LIST FOR FIELD ASSEMBLY
No. Tool name Specification Q'ty Remarks
1 Crane truck Capacity: 441kN {45 tons} 2
2 Service car 2
3 Air compressor 0.74 MPa {7.5 kg/cm2}, 15 m3/min 1
4 Welder 2 For welding blade spill guard (If equipped)
5 Lever block 19.6 kN {2 ton}, 58.8 kN {6 ton} each 1
6 Wire 26 x 6 m 6 For body
36 x 5 m 1 For body
30 x 3 m 2 For body
7 Wire sling 20 x 5 m 2
12 x 2 m 4
8 Nylon sling 25 mm wide x 3 m 2
50 mm wide x 3 m 1
9 Hydraulic wrench 5,884 Nm {600 kgm} 1 For master link bolt
10 Impact wrench 4,413 Nm {450 kgm} 1 For master link bolt
3,138 Nm {320 kgm} 1 KW45FG
2,542 Nm {250 kgm} 1 KW40F
196 Nm {20 kgm} 1 KW20PI
157 Nm {16 kgm} 1 KW14PI
137 Nm {14 kgm} 1 KW12PI
11 Sockets set 50 46 41 36 each 1 M 38.1
36 32 30 27 each 1 M 25.4
12 Extension bar M 38.1 x L300 1
13 Torque wrench 2,059 Nm {210 kgm} 1
1,373 Nm {140 kgm} 1
588 Nm {60 kgm} 1
14 Eyebolt M 12 x P 1.75 4
M 16 x P 2 2 For blade center link
15 Shackle SD22 4
BC36 2
SA60 1 For front hook
16 Sledge hammer 10P 1
17 Bar L = 1000 mm 1
18 Tap M 33 x P 2 1 For master link
M 30 x P 3 1
M 24 x P 3 1
19 Jack 147 kN {15 ton} 2 For assembling track frame
20 Hydraulic jack 785 kN {80 ton} 1 For assembling body
21 Chain block 78 kN {8 ton} x 4 m 2 For assembling blade
22 Spanner wrenches set Width: 19 50 mm each 1
23 Standard tools set 1
24 Hydraulic oil SAE30-CD 50 For pivot
SAE10W-CD 400 For hydraulic tank
25 Grease G2-LI 10
26 Lubricant LM-P (09940-00040) 1 For master link
27 Detergent 20
28 Paint remover 5
29 Paint for repair Natural yellow 5
Black grey 5
30 Glass cleaner 1
11
No. Tool name Specification Q'ty Remarks
31 Cloth Bunch 5
32 Angle meter 1 For dual tilt (If equipped)
33 Grease pump Air type 1
34 Oil pump Manual or air type 1
35 Oil jack 5 1
36 Waste oil receiving pan 1
37 Step Height: 2 m 1
38 Stand Front 1 See attached tool drawing
Rear 1 See attached tool drawing
39 Sling for track frame 1 See attached tool drawing
40 Wood block 350 mm x 750 mm 4
350 mm x 400 mm 4
100 mm x 750 mm 4
41 Vinyl hose (Transparent) 3,000 mm (O.D. 10 mm) 1 For measuring cab pressurization
42 Packaging tape 1
43 Steel plate 1,000 mm x 1,700 mm x 19 t 2 For setting under stand
12
Sketch of tools
Chassis stand (Front side)
13
No. Material Qty Remarks
01 SS400C 4 C150 x 75 x t91432
02 SS400C 2 C150 x 75 x t9925
03 SS400C 2 C150 x 75 x t9925
04 SS400C 2 C150 x 75 x t9425
05 SS400C 2 C150 x 75 x t9459
06 SS400C 2 C150 x 75 x t9378
07 SS400C 2 C150 x 75 x t9250
08 SS400B 4 50-75
09 SS400 4 t25 x 180 x 250
10 SS400 4 t12 x 200 x 739.5
11 SS400 10 t12 x 60 x 128
12 SS400 2 t16 x 124 x 130
13 SS400 2 t25 x 70 x 85
Note) We are not liable for any result of use of tools manufactured according to these drawings.
Chassis stand (Rear side)
14
Material
Total weight
No. Material Qty Remarks

01 SS400C 4 C150 x 75 x t91432
02 SS400C 2 C150 x 75 x t9829
Only
03 SS400C 2 C150 x 75 x t9829
movable
part 04 SS400C 2 C150 x 75 x t9510
05 SS400C 2 C150 x 75 x t9548
Only movable
part 06 SS400C 2 C150 x 75 x t9453
07 SS400C 2 C150 x 75 x t9355
08 SS400B 4 50-500
09 SS400 4 t25 x 180 x 250
10 SS400 4 t12 x 200 x 655
11 SS400 10 t12 x 60 x 128
12 SS400 2 t16 x 124 x 130
13 SS400 2 t25 x 70 x 85
Sling (Track frame)
No. Remarks Qty No. Remarks Qty

01 SS400 1 07 SV063 x 120 link 1
02 SS400 1 08 VG063 1
03 HM080 1 09 M33 x 100 1
04 JIS4, 6 x 24 Z to A 26 x 600 1 10 M33 1
05 TSL6(170 ) 1 11 M30 x 120 2
06 VN063 1
Sling (Track frame) : Detail 01
2-36 drill
Do not
weld
15
Sling (track frame) : Detail 02
393.5
2-36 drill
16
Dimension of shackle (Unit: mm)
Shackle t d B D d1 Diameter L1
(Nominal (Nominal
value) value)
6 6 6 11 17 9 M8 24
8 8 8 14 21 11 M10 32
10 10 10 17 25 13 M12 40
12 12 12 20 32 16 M14 48
14 14 14 24 36 18 M16 56
16 16 16 26 40 20 M18 64
18 18 18 29 45 22 M20 72
20 20 20 31 50 25 M24 80
Shackle for
ripper shank 22 22 22 34 55 27 M24 88
24 24 24 39 62 31 M30 96
26 26 26 41 66 33 M30 104
28 28 28 43 70 35 M33 112
30 30 30 45 75 37 M36 120
32 32 32 48 80 39 M36 128
34 34 34 50 85 41 M39 136
36 36 36 54 90 43 M42 144
38 38 38 57 95 47 M45 152
40 40 40 60 100 49 M48 160

42 42 42 63 105 53 M48 168
44 44 44 66 110 56 M48 176
46 46 46 68 115 58 M48 184
48 48 48 72 120 60 M56 192
50 50 50 75 125 62 M56 200

Shackle for front hook 55 55 55 83 138 62 M64 220
60 60 60 90 150 72 M72 6 260
70 70 70 105 178 85 M80 6 280

75 75 75 112 192 92 M80 6 300
80 80 80 120 206 98 M90 6 320
85 85 85 128 220 104 M90 6 340
90 90 90 135 232 110 M100 6 360
17
TIGHTENING TORQUE
Remove the plugging parts (flanges, heads, caps, and O-rings) of the work equipment piping and
undercarriage piping, oil stopper plugs of the greasing piping, cylinder fixing jigs, and oil stopper
plugs of the tap holes of the loose-supply items which were used for transportation and keep them
carefully so that they can be used again for the next transportation.
Tighten the bolts to the torque shown in the following table, unless otherwise specified.
1. Tightening torque of bolts

When tightening the bolts with an impact wrench/spanner, apply Table 1.
Tighten the bolts according to Table 1 as a rule. When this rule is applied, the tightening torque
is not shown in the drawing.
Table 1
Unit: Nm {kgm}
Material S43C, SCM435H or equivalent
Nominal size of thread (mm) Range Target
8.8 - 14.7 12
6 {0.9 - 1.5} {1.2}
14.7 - 34 25
8 {1.5 - 3.5} {2.5}
34 - 74 54
10 {3.5 - 7.5} {5.5}
54 - 123 89
12 {5.5 - 12.5} {9}
84 - 196 137
14 {8.5 - 20} {14}
147 - 309 230
16 {15 - 31.5} {23.5}
201 - 427 315
18 {20.5 - 43.5} {32}
319 - 608 460
20 {32.5 - 62} {47}
471 - 829 650
22 {48 - 84.5} {66.5}
588 - 1030 810
24 {60 - 105} {82.5}
883 - 1470 1180
27 {90 - 150} {120}
1130 - 1910 1520
30 {115- 195} {155}
1470 - 2450 1960
33 {150 - 250} {200}
1860 - 3040 2450
36 {190 - 310} {250}
2260 - 3630 2940
39 {230 - 370} {300}
18
When tightening the bolts with a torque wrench, apply Table 2.
Apply Table 2 when the proper tightening torque range is particularly narrow.
Table 2
Unit: Nm {kgm}
Material
S43C, SCM435H or equivalent
Nominal size of thread (mm)
11.8 - 14.7
6 {1.2 - 1.5}
27 - 34
8 {2.8 - 3.5}
59 - 74
10 {6 - 7.5}
98 - 123
12 {10 - 12.5}
157 - 196
14 {16 - 20}
245 - 309
16 {25 - 31.5}
343 - 427
18 {35 - 43.5}
490 - 608
20 {50 - 62}
662 - 829
22 {67.5 - 84.5}
824 - 1030
24 {84 - 105}
1180 - 1470
27 {120 - 150}
1520 - 1910
30 {155- 195}
1960 - 2450
33 {200 - 250}
2450 - 3040
36 {250 - 310}
2890 - 3630
39 {295 - 370}
19
2. Tightening torque of pipe threads
Tighten taper male pipe threads of nominal sizes of R1/8 - R1 and Rc1/8 - Rc1 and parallel female
pipe threads of nominal size of Rp1/8 - Rp1 (coated with adhesive) according to the following
standard.
If tightening torque is specified particularly, however, do not apply the following standard.
2-1. If the material of male threads is SS400, FC, or SGP, apply Table 1.
Table 1
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 material of male threads is S43C, apply Table 2.
Table 2
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}
20
3. Tightening torque of hoses (with taper/face seal)
Unit: Nm {kgm}
Tightening torque
Nominal diameter Width across
of hose flatse. Range Target
02 19 35 - 63 {3.5 - 6.5} 44 {4.5}
22 54 - 93 {5.5 - 9.5} 74 {7.5}

03
24 59 - 98 {6.0 - 10.0} 78 {8.0}
04 27 84 - 132 {8.5 - 13.5} 103 {10.5}
05 32 128 - 186 {13.0 - 19.0} 157 {16.0}
06 36 177 - 245 {18.0 - 25.0} 216 {22.0}
{10} 41 177 - 245 {18.0 - 25.0} 216 {22.0}
{12} 46 197 - 294 {20.0 - 30.0} 245 {25.0}
{14} 55 246 - 343 {25.0 - 35.0} 294 {30.0}
When connecting hoses, take care not to twist them.
21
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Qty Container Main applications, featuresr
Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
Used in places requiring an imme-

diately effective, strong adhesive,
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oethlene and vinyl chloride), rub-
ber, metal and non-metal.
Features: Resistance to heat and

Polyethylene chemicals
LT-2 09940-00030 50 g
container Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: Used as adhesive or sealant for

790-129-9060
1 kg metal, glass and plastic.
(Set of
Hardenin
LT-3 adhesive and Can
g
Adhesives hardening
agent:
agent)
500 g
Polyethylene Used as sealant for machined

LT-4 790-129-9040 250 g
container holes.
Holtz Used as heat-resisting sealant for

790-126-9120 75 g Tube
MH 705 repairing engine.
Quick hardening type adhesive

Three bond Polyethylene Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly for adhesion of met-
als, rubbers, plastics and woods.
Quick hardening type adhesive

Quick cure type (max. strength af-
Aron-alpha Polyethylene
790-129-9130 2g ter 30 minutes)
201 container
Used mainly for adhesion of rub-
bers, plastics and metals.
Resistance to heat, chemicals

Loctite Polyethylene
79A-129-9110 50 cc Used at joint portions subject to
648-50 container
high temperatures.
Used as adhesive or sealent for

LG-1 790-129-9010 200 g Tube gaslets and packing of power
train case, etc.
Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can Used as sealant for tapered plugs,
Gasket elbows, nipples of hydraulic pip-
sealant ing.
Features: Silicon based, resis-

tance to heat, cold
Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
mab Used as sealant for oil pan,
final drive case, etc.
22
Category Komatsu code Part No. Qty Container Main applications, featuresr
Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube Used as sealant for flywheel
Adhesives housing, intake manifold, oil an,
thermostat housing, etc.
Three bond 100 g Tube Used as heat-resisting sealant for

790-129-9090
1211 repairing engine.
60g Can Used as lubricant for sliding por-

LM-G 09940-00051
tion (to prevent from squeaking).
Molybdenum
disulphide Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
Used as lubicant for linkage, bear-
ings, etc.
SYG2-400LI General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA Used for normal temperature,

Grease SYG2-350CA light load bearing at places in
G2-CA SYG2-400CA-A Various Various contact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g Used for places with heavy load

disulphide STG2-400M (10 per Belows type
lubricant case)
23
24
A. ASSEMBLY PROCEDURE
25
Assembly procedure
Installation of undercarriage (1/7)
A-1
1-1 Installation work of tracks

Place the track assemblies in parallel on a finished
place.
Track gauge (W): 2,770 mm
Check the front and rear ends (F R) of the tracks.
1-2 Installation of chassis stand

1. Install the front stand at 4,600 mm (L1) from the
front end of the track.
Height of front stand (H1) : 1,105 mm
Height of rear stand (H2) : 1,020 mm
2. Install the rear stand at 2,450 mm (L2) from the

center of the front stand.
26
Assembly procedure
A-1
1-3 Unloading of chassis

1. Holding the front tow hook and ripper top pin, sling the chassis with 2 45-t wrecker trucks.
2. Use the tow bracket of the undercover to sling

the front section as shown in the photo.
Wire: 36 mm x 5 m (Safety factor: 5)
Shackle: 60 mm x 80 mm wide
Shackle
Use corner pad 16t
3. Use the ripper tilt cylinder pin to sling the rear

section as shown in the photo.
Wire: 30 mm x 3 m x 2 pieces
26t
27
Assembly procedure
A-1
1-4 Installation of track frame

Preparation work
1. Removal of accessories
Remove the following 10 parts (the bolts are not
counted in) from the track frame as shown in the photo.
No. Part No. Part name
1 198-30-62140 Cover
2 198-50-61370 Cover
3 198-50-61150 Shaft
198-30-64170 Cover (L.H.)
4 1 2 3 4 5
198-30-64180 Cover (R.H.)
198-30-61310 Cover (L.H.)
5
198-30-31320 Cover (R.H.)
6 198-50-51390 Cover
198-30-51430 Cover (L.H.)
7
198-30-51440 Cover (R.H.)
198-50-31270 Spacer
8
198-50-51220 Cover Assy
9 195-30-31260 Cover
198-30-62150 Cover (L.H.)
10
198-30-62160 Cover (R.H.) 6 7 8 9 10
2. Maintenance of track frame pivot and application

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

and application of grease
O-ring
28
Assembly procedure
A-1
4. Install the thrust plate to the end of the track frame.

5. Slinging method
In these photos, the track frame is slung without the
Wire (24 mm in diameter, 2 m long, 2 pieces)

Lever block (6 t)
Lever block (3 t)
Wire (24 mm in diameter, 6 m long, 1 piece)
3m
100 mm
Center of gravity is at 100 mm from

Holding part of track frame
holding part of track frame
Rear view Front view
carrier rollers installed. It may be slung

with the carrier rollers directed out so that
the carrier rollers will not interfere with
the fender, etc.
29
Assembly procedure
A-1
6. Installation of track frame

1) Sling the track frame horizontally and insert it,
aligning it to the pivot shaft.
The front worker must not stand between
the chassis and track frame. Standing there
is dangerous.
2) After the wire touches the fender, push in the

track frame with a forklift, etc.
Apply blankets, etc. to the interfering part of
the fender to protect that part.
3) Fix the shaft and track frame with the twisted

seal plate (for fixing).
If you use a long bolt as an installation guide,
you can assemble easily.
30
Assembly procedure
A-1
7. Insertion of equalizer bar pin

1) Adjusting with the crane, align the pin holes
accurately.
The pin must be inserted in the correct directly.
Direct its cut part in.
There is UP mark
2) Connect the grease tube.

Grease tube
Mudguard for pin
3) Install the attached cover.
4) Install the pin fixing bolt.

Insert the pin fixing bolt from below and
install the nut to the upper side.
Part No. of bolt 198-50-61410 (2 pieces on each side)
Part No. of washer 01643-33380 (4 piece on each side)
Part No. of washer 19M-09-12890 (2 pieces on each side)
Length of bolt 320 mm
Necessary socket 50 mm
Tightening torque 2,574 123 Nm {262.5 12.5 kgm}
8. Work around pivot

Tilt hose
Match the band color of each

end of the hose as shown below.
Red: Head (Upper) side
Blue: Bottom (Lower) side
Reference: Perform this step on only the right side of

the single tiltdozer specification and on
both sides of the dual tiltdozer specification
and superdozer specification.
Color band is installed
When connecting the cover and hose, use a for identification.
guide bolt.
Hose torque: 156.9 9.8 Nm {16 1 kgm}

Necessary tools: Spanner, guide bolt
Cover mounting bolt

Upper side:
Head
Part No. of bolt 01010-81695 (9 pieces on each side) Lower side:
01011-81625 (1 piece on each side) Bottom
Part No. of washer 01643-31645 (10 pieces on each side)
Length of bolt 95 mm, 125 mm
Tightening torque 277.0 31.9 Nm {28.25 3.25 kgm}
31
Assembly procedure
A-1
Install the inside twisted seal cover with the

notch down.
When fixing the cover, set the track frame
horizontally.
9. Remove the bogie fixing plate (special jig L) and

keep it for the next modification.
1-5 Unloading of chassis

Sling the front section and pull out the stand.
Sling the rear section, pull out the stand, and place
the chassis on the tracks.
32
A-2 Installation of ripper (1/4)
1. Preparation
Removal of paint and rust prevention oil from
mounting parts
Style
Do not remove the arm pin but pull it out to the

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

Lift cylinder connecting pin lock bolt Block

33
4. Installation of tilt cylinder

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

Direct the hoses as shown in the photo.
Part No. of hose : 07097 01012
(Common to 8 hoses on right and left sides)
Straight openings
L-adapters
6. Sub beam
Assemble the right and left grease hoses and
elbows before installing them to cylinder head pin.
* Connect the pin after installation.
7. Installation of beam assembly

Sling the beam assembly by the 3 points of the
shank pin and cylinder pin.
Beam connecting pin lock bolt
34
Set a block (Height: 670 mm) under the beam so

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

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

35
9. Installation of pin puller hoses

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

and cylinder: 990 mm
2. Between connecting part of
chassis and clamp A: 1,060 mm A
3. Between clamp A and clamp on
side of beam: 1370 mm
Method of installing centralized greasing unit on

mount side
After completing assembly, check the operation
and confirm that the hose is not abnormally
slackened or tensed.
Detail of pin puller hoses installation.
36
Assembly procedure
Installation of tracks (1/2)
A-3
1. Wind the front end of each track up to the idler top.

Set the idler to the shortest position in advance.
2. Put a block to the ripper shank holder to float the

sprocket from the track.
3. Sling the rear end of the track with a crane and lay it
over the sprocket.
4. Wind the track around the sprocket. Slinging the

end of the track with the crane, send it forward.
The operators of the bulldozer and crane must

make clear signs to each other.
5. Connect the master link on the idler.
6. Fit the mating faces of the master link and check

that you can screw in the bolts lightly.
37
Assembly procedure
Installation of tracks (2/2)
A-3
7. Insert the key in the link and place the shoe, then
tighten and seat the 4 bolts evenly first with an
impact wrench of 196 Nm {20 kgm}.
Apply molybdenum disulfide grease to the bolt

holes of the link and thread parts of the bolts.
8. Control of bolt toque
Retightening method
1. Tighten the bolts to torque of 980 98 Nm {100
10 kgm} first and check that the mating faces
of the link are fitted.
2. Make match marks (at the places pointed out
with the arrow).
3. Retighten the bolt by an angle of 180 10.
Tightening order
Tighten the bolts in the order shown at right.
Adjust the track tension when adding grease at

last.
38
Assembly procedure
Adding oil to pivot chamber
A-4
Pivot chamber
Add engine oil through the hole of plug (1).
Quantity of oil: 26 /each side
Oil level (B): 10 30 mm from oil level (2)
39
Assembly procedure
Installation of ripper shank
A-5
Work properly according to the condition of each

field.
Ride over a steel block and pull in the shank from

below.
For dimension of shackle, see TOOLS LIST FOR
FIELD ASSEMBLY.
Align the shank holes and insert the pin.
Steel block
Precautions Necessary tools Necessary equipment

Name Qty Name Qty
Other remarks
40
Assembly procedure
Installation of blade lift cylinder (1/2)
A-6
1. Remove the yoke cap and bushing.
2. Installation of cylinder
Install the cylinder with the right and left tubes
out down.
Install the upper cap and bushing to the cylinder
first. After tightening the bolts temporarily, install
the lower cap and bushing, lifting them up.
Install the upper cap first.
Keep the lower cap removed.
Cap mounting bolts

Tightening torque 1,716 196 Nm {175 20 kgm}
3. Installation of hoses
Install the hoses so that they will not interfere with
each other as shown in the photo.
Installation angle
Hoses must be free from interference.
41
Assembly procedure
Installation of blade lift cylinder (2/2)
A-6
Install the upper and lower hoses correctly.

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

Hose
Cylinder Upper hose Lower hose
Left lift Bottom side Head side
Right lift Head side Bottom side
42
Assembly procedure
Installation of trunnion
A-7
Sling and install the trunnion.

Before installing the trunnion, remove the paint
from its installing surface.
Trunnion mounting bolts

43
Assembly procedure
Assembly of blade (1/6)
A-8
1. Erect the blade.

Using the crane, erect the blade.
Since the blade is heavy, set the crane as near
the blade as possible.
Set blocks at 4 places to prevent the blade from

falling down.
Joint
Correct Wrong
2 places on right and left side
Pull out the straight frame mounting pins inward.
2 places on right and left side
44
Assembly procedure
A-8
2. Installation of right and left straight frames

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

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

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

parallel with the back of the blade.
3. Installation of arm rod

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

them in, and connect the joints.
Tighten both sides of the arm temporarily.
45
Assembly procedure
A-8
4. Adjustment of clearance in arm ball joint (Adjust

AB

both inside and outside similarly)
Standard: 5 mm
Procedure
(1) Pull the flange with the bolt and seat the joint
end without inserting a shim. (Take care since
the frame slips slightly at this time.)
(2) Insert shims in maximum clearance A and

minimum clearance B, and then calculate the
proper shim thickness by (A + B)/2 + 0.5.
(3) Tighten the bolt with an impact wrench, and then

swing the frame and check the clearance
visually.
Part No. of bolt 01010-83335 (8 pieces on each side) Part No. of shim Thickness (mm)
Part No. of washer 01643-33380 (8 pieces on each side) 198-71-31450 2

Length of bolt 135 mm 198-71-31460 1
198-71-31470 0.5
(4) Adjust the clearance on the opposite side

similarly.

Caution
Install the hoses and cover of the tilt cylinder in
advance.
For superdozer, install the tube, block, hoses and
cover of the tilt cylinder in advance.
Install the tilt cylinder assembly to the straight

frames.
You may insert the pin on the rod side after

starting the engine.
Tilt cylinder connecting pin lock bolt

46
Assembly procedure
A-8
Connection of cylinder hose and installation of cover
Hose
Intermediate cover Step cover
Hose

Step cover

Necessary socket 30 mm Intermediate Length of bolt 25 mm
Tightening torque 549 59 Nm {56 6 kgm} cover Necessary socket 19 mm
Tightening torque 110 12 Nm {11.25 1.25 kgm}
47
Assembly procedure
A-8
6. Move the center link and match the straight frames

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

the chassis trunnion center.
Sling the frame with the crane and adjust its
height.
980
48
Assembly procedure
A-8
Adjustment of length of single tiltdozer brace
1) Raise the blade a little.
2) Tilting to the right and left in the operators seat, rotate the brace.
3) Adjust the length of the brace so that the tilting distances on both sides will be the same.
Rotate with this lever.
Distance between pins
49
Assembly procedure
Adjustment of arm joint (U-blade)
A-9
Check of clearance in arm ball joint
Adjustment of shim
1. Remove shim (1) and tighten bolt (2) until the Shim (1)
play of the ball joint is eliminated.
Bolt (2)
2. Measure clearance A and remove bolt (2).
3. Install shim (1) having thickness of A + (0 to 1)

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

rotates smoothly.
Adjustment of shim
Adjustment of shim
Adjustment of shim
50
Assembly procedure
Installation of blade (1/2)
A-10
Caution
Checking the inside clearance between the track
and straight frame on the right and left sides,
move the chassis forward until it touches the
trunnion.
When connecting the tilt hose, check the marks

(red and blue).
q Red Head side Upper side
w Blue Bottom side Lower side q

w
Pass the bolts through the cap and install wires

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

51
Assembly procedure
Installation of blade (2/2)
A-10
Sling the blade cylinder with the crane and

remove the hanging bracket for shipping.
Nylon sling
Hanging bracket
Connect the cylinders one by one.

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

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

the right and left tilt control rods.
Standard length of rod : 425 mm
Adjustment rod
Potentiometer
Detail of adjusting rod installation

No. Part No. Q'ty
1 01010-81055 2
To blade cylinder yoke 2 01643-31032 2
3 04250-81056 2
4 195-33-11220 2
5 01582-11008 2
6 04248-31037 2
52
Assembly procedure
Installation of counterweight
A-11
(1) Sling the counterweight assembly and set it to the

mounting part.
(2) Insert the mounting pin and lock it.

Tightening torque of bolt:
549 59 Nm {56 6 kgm}

Name Qty Name Qty
Other remarks
53
Assembly procedure
Installation of operators cab (1/16)
A-12
Remove the power supply wiring harness for the

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

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

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

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

Name Qty Name Qty
Other remarks
54
A-12 Installation of operators cab (2/16)
3. Installation of seals to dashboard bracket

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

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

(14) (cab and sealing face) as shown in Photo 3. Photo 3
(14) Apply grease
Remark: Before lowering the cab, apply grease so

that the cab will slip well and the seal
will not be moved or deformed.
55
4. Installation of seals of operators cab mating faces

(1) Sling the operators cab assembly.
Sling the operators cab to stick the seal to its mating faces.
4 Operators cab assembly: 455 kg
(2) Remove dirt, oil, and grease from the seal sticking faces.
(3) Remove the release paper from seals (15), (16), and (17), and then stick the seals, referring
to Fig. 4 on the next page.
No. Part No. Q'ty

14 198-Z11-3540 1
Fig. 3 15 14X-911-5911 5
16 198-Z11-7420 2
17 198-Z11-7430 2

Since the seals are longer than the necessary Name Qty Name Qty
length, cut them properly when sticking.
Other remarks
56
Stick seals so that it will Apply sealant to clearance.

project about 10 mm.
Front
Apply sealant before

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

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

(See Photo 3 on page 5/15)
Spacer plate (t2.3)
Do not place sealing sponge

over spacer plate.
Sealing sponge
Fig. 4 How to stick seals (View from bottom of operators cab)
57
Photo 1 Photo 2
Photo 3

Name Qty Name Qty
Other remarks
58
5. Installation of operators cab

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

that there is not clearance at
Dashboard each corner.
bracket
Fig. 5
No. Part No. Q'ty
18 01010-81275 15
19 124-54-26540 21 Lower cab in direction
of arrow.
20 01010-81245 6
55 198-Z11-3960 1
59
(5) Check that the clearance between the air

Air conditioner duct
conditioner duct on the cab side and monitor is on cab side
even on the right and left sides.
At the same time, check that the air conditioner
duct seal on the cab side is fitted to faces C on
Clearance
the right and left sides of the air conditioner duct Clearance
on the dashboard side and it is not moved to Monitor
the right or left.
(6) If the clearance between the air conditioner duct
on the cab side and monitor is not even, loosen Dashboard
the air conditioner duct mounting screws on the
Fig. 6
cab side and move the air conditioner duct so
that the clearance will be even. on cab side
If the duct on the cab side or air conditioner side
is moved to the right or left, adjust it similarly.
(7) Permanently tighten bolts (18) and (20) which
were tightened temporarily in step (2) above .
(8) Permanently tighten mounting bolts (12) of L-
plates (10) and (11) which were installed Monitor
temporarily in step (2) above. Seal Face C
Face C
Dashboard assembly
on dashboard side
Fig. 7
on cab side
Monitor
Dashboard
Duct mounting screw
Fig. 8
Name Qty Name Qty
Other remarks
60
(9) Install plates (21) with bolts (25) and washers

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

21 198-Z11-2961 2
22 01010-D1230 4
23 01643-71232 4
24 14X-911-5711 1
25 14X-911-5721 1
26 01010-D1230 4
27 01643-71232 4
28 203-43-56450 2

Name Qty Name Qty
Other remarks
61
(12) Referring to Fig. 10, bind the windshield washer hoses, windshield washer connector, and
cab power supply wiring harnesses with strings. Pass them through holes (A) and (B), and
then connect the wiring harnesses on the chassis side from the decorative cover above the
left fender.
Marks at 15 places
Marks at 6 places
Floor frame
assembly
Windshield washer hoses

Red ............. Right door
Blue ............. Left door
Black ............. Rear window
............. Front window
Part under door
Wiring harness
4-pole connector ............................ Windshield washer
From floor From cab Red (Nominal JIS size: 5) ............... Power supply
Yellow (Nominal JIS size: 0.85) ..... Backup power supply (For radio)
Fig. 10
View X (sean from rear)
After connecting the hoses and connectors, fit the grommet on the wiring harness side securely.
62
6. Installation of left parking brake lever knob

(1) Before installing the panel, remove the lever
knob.
(2) After installing the panel, apply adhesive (LT-
2) to the thread part of the knob, and then
install the knob to the lever.
Panel
Knob (Lever)
Fig. 11
63
7. Installation of bellows bracket

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

Name Qty Name Qty
Other remarks
64
8. Installation of interior parts

(1) Install floor covers (29), (30), and (31) with
screws (34) (14 pieces).
(2) Install covers (32), (33), and (34) with button
(37). (16 places)
(3) Install cup holder (40) with screws (41) to plate
(36). Then, install ashtray (38) and cigarette
lighter (39) to plate (36) with screws (41) and
washers (42).
(4) Install grille (44).
(5) Install rubber chutes (45) and (46).
When installing plate (35), connect the ground

wire of the cigarette lighter with the mounting
screw of part (A) (shown on the next page).
When connecting, remove the paint from the Fig. 12
screw fixing part of the cab to secure
grounding. No. Part No. Q'ty
29 198-Z11-6170 1
30 198-Z11-6190 1
31 198-Z11-6150 1
32 198-54-61511 1
33 198-54-61531 1
34 01024-D0820 14
35 198-54-61521 1
36 198-Z11-6160 1
37 23D-950-4450 16
38 20Y-06-21751 1
39 20Y-06-2347 1
40 17A-Z11-3180 1
41 01245-00616 4
42 01643-70623 4
43 01370-40408 2
44 201-979-7820 2
45 198-Z11-6230 1
Fig. 13 46 198-Z11-6240 1
1. Install plate (36) on cover (32) as shown in the Name Qty Name Qty
photo.
2. Install cover (32) first, and then install plate (36).

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

lected, see also A-24.
Other remarks
65
Correct installation
Wrong installation
Plate (36) is installed

under cover (32).

Name Qty Name Qty
Other remarks
66
(6) Install sensor (52) to cover (51), and then install them with screws (53) and washers 54. (4
pieces)
(7) Install plates (47) and (48) with screws (49) and washers (50). (8 pieces)
(8) Install cab door plate (56). (On both sides).
(9) After installing cab door plate (56), apply liquid sealant (55) all around the plate. (On both
sides) Before opening and closing the door, wait until the sealant dries up.
CN-SLS is fixed to dashboard

wiring harness with band.
No. Part No. Q'ty

47 198-Z11-2941 1
48 198-Z11-2951 1
49 01245-00616 8
50 01643-70623 8
51 198-Z11-6280 1
52 20Y-979-6161 1
CN-SLS
53 01245-00616 4
Cut band and connect.
54 01643-70623 4
55 198-Z11-3960 1
56 198-Z11-6410 2
65 01010-D0645 6
66 01643-70623 6
Fig. 14

Name Qty Name Qty
Other remarks
67
(9) Install cushion (57) and install mat (58) on it.

(10) Install mat (59).
(11) Install plate (56). (On both sides)
Fig. 15

Name Qty Name Qty
Other remarks
68
9. Change of antenna mounting angle

When delivered, the antenna is directed down for
packing and transportation of the operators cab
(Fig. 17). After mounting the operators cab, set
the antenna at the correct angle (Fig. 18).
Antenna (198-Z11-4610)
Left window
Directed down when delivered
Rear window
Fig. 17
Loosen the wing bolt at part (b) near the

antenna mounting part and direct the antenna Antenna
up. Then, tighten the wing bolt.
b
Left window Rear window
Fig. 18

Name Qty Name Qty
Other remarks
69
A-13 Installation of ROPS
Sling the ROPS with the crane and install it to the

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

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

1 01011-83310 16
2 01643-33380 16

Name Qty Name Qty
Torque wrench
1
(2,059 Nm {210 kgm})
Socket 50 mm
1
(38.1 )
Other remarks
70
Assembly procedure
Adjustment of potentiometer rod
A-14
Length of rod : 425 mm
Reference: See the A-15 PROCEDURE FOR ADJUSTING

BLADE TILT ANGLE LIMIT.

Name Qty Name Qty
Other remarks
71
Assembly procedure
Procedure for adjusting blade tilt angle limit (1/9)
A-15
1. Dual-tiltdozer
1-1 Set the machine under the standard condition.
Set the potentiometer rod to 425 mm.
Keep the machine horizontally.
1-2 Run the engine at low idling and set the blade
in the following standard position.
1) Set the tilt angle to 0.
2) Set the pitch angle to the maximum pitch
back.
3) Lower the blade to the ground.
4) Set the toggle switch of the blade lever to
the dual tilt position.
Tilt switch
Dual tilt

Name Qty Name Qty
Other remarks
72
Assembly procedure
A-15
1-3 Adjust mounting dimension a of rod (1) and

connect the rod to potentiometer lever (2) and
yoke (3).
Mounting dimension a: 425 mm
1-4 Mode and operation

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

Name Qty Name Qty
Other remarks
73
Assembly procedure
A-15
1-5 Raise the blade tip to about 1 m above the

ground.
1-6 Tilt the blade to the left with the blade control
lever and set the left tilt angle to 12. (User
adjustment mode)
Since the tilt limiting function does not work,
operate slowly so that the tilt angle will not
increase too much.
Adjust the tilt angle accurately with angle
gauge.
1-7 Set the toggle switch of the blade control lever

in the single tilt position, and then set it in the
dual tilt position again to save the left tilt limit Tilt switch
in the system.
When the saving operation is finished, the
buzzer sounds.
Single tilt
Dual tilt

Name Qty Name Qty
Other remarks
74
Assembly procedure
A-15
1-8 Set buzzer cancel switch (3) in the cancel

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

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

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

Name Qty Name Qty
Other remarks
75
Assembly procedure
A-15
1-11 Tilt the blade to the right with the blade control
lever and set the right tilt angle to 12.
increase too much.
gauge.
1-12 Set the toggle switch of the blade control lever in the single tilt position, and then set it in
the dual tilt position again to save the right tilt limit in the system.
When the saving operation is finished, the buzzer sounds.
1-13 The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( )
to leave the adjustment mode, and then lower the work equipment to the ground and stop
the engine.
1-14 Start the engine again and tilt the blade to the right and left and check that the blade does
not interfere with the track shoe, regardless of its height.

Name Qty Name Qty
Other remarks
76
Assembly procedure
A-15
2. Superdozer
2-1 Set the machine under the standard condition.
Set the potentiometer rod to 425 mm.
Keep the machine horizontally.
2-2 Run the engine at low idling and set the blade
in the following standard position.
1) Set the tilt angle to 0.
2) Set the pitch angle to the maximum pitch
back.
3) Lower the blade to the ground.
2-3 Adjust mounting dimension a of rod (1) and

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

Name Qty Name Qty
Other remarks
77
Assembly procedure
A-15
2-4 Mode and operation

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

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

Name Qty Name Qty
Other remarks
78
Assembly procedure
A-15
2-6 Set the buzzer cancel switch in the select

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

changing the blade pitch angle adjusted in step 2-5
and tilt it 7 to the left. Under this condition, press
the pitch-dump button (upper button), and the
buzzer sounds and the left limit position is saved.
increase too much.
gauge.
1000mm
2-8 Tilt the work equipment 7 to the right. Under
this condition, press the pitch-dump button
(upper button), and the buzzer sounds and the
right limit position is saved.
increase too much.
gauge.

Name Qty Name Qty
Other remarks
79
Assembly procedure
A-15
2-9 The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( )
to leave the adjustment mode, and then lower the work equipment to the ground and stop
the engine.
2-10 Start the engine again and tilt the blade to the right and left and check that the blade stops
tilting to the right and left in the following range automatically, regardless of its height.
Automatic tilt stopping angle: 7 1

Name Qty Name Qty
Other remarks
80
Assembly procedure
Method of checking auto-reset system
A-16 (Superdozer)
System to return the blade to the digging position

automatically
Pitch dump
1. Pitch the blade forward.
Pitch back
2. Set the gear speed in R1 or R2.
3. Press the pitch-back button.
4. The blade is fully pitched back.
5. The blade returns to the digging position.
The auto-reset system is used to set the blade in the digging position automatically (to lower the
blade to the ground and set its angle to 52). To reset this system, press the pitch button.
Tilt forward Digging posture
Controller
Valve
Pitch back solenoid

Name Qty Name Qty
Other remarks
81
Assembly procedure
Check track tension (1/2)
A-17
WHEN INCREASING TENSION

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

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

NOTICE Name Qty Name Qty
Grease inside the adjusting mechanism is under high
pressure.
Grease coming from plug (4) under pressure can penetrate
the body causing injury or death. For this reason, do not
loosen plug (4) more than one turn. Do not loosen any part
other than plug (4). Furthermore, do not bring your face in
front of the grease fitting.
If the track tension is not relieved by this procedure, please
contact your Komatsu distributor.
When removing cover (2), be careful not to let any dirt get
inside.
There is a safety label stuck to the back of cover (2). Be Other remarks
careful not to damage the safety label.
82
Assembly procedure
Check track tension (2/2)
A-17
INSPECTION
Stop the machine on level ground (stop with 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 is 20 to 30 mm, the tension
is standard.
If the track tension is not at the standard value, adjust it
in the following manner.
Set the track tension to 30 mm for the first 100

operating hours to fit the bushings and pins.

Name Qty Name Qty
Other remarks
83
Assembly procedure
Checking oil/coolant levels (1/2)
A-18
Fuel and oil

Choose fuel and oil as shown in the following table, depending on the atmospheric temperature.
The rated capacity is the total quantity of oil in each device and its piping. The refill capacity is
the quantity of oil replaced for inspection or maintenance.
When starting the engine at a temperature below 0C, be sure to use SAE10W, SAE10W-30, or
SAE15W-40, even if the temperature rises to about 10C during the daytime.
Even if single-grade oil is mixed in multi-grade oil (SAE10W-30, SAE15W-40), no problem occurs.
Add the single-grade oil matched to the atmospheric temperature shown in the following table,
however.
Use city water as coolant.
Coolant
The coolant is a mixture of Komatsu genuine Super Coolant (AF-NAC) and water, so it does not
need to be changed as long as the atmospheric temperature does not lower below 10C.
If the atmospheric temperature lowers below 10C, adjust the ratio of Super Coolant to water.
84
Assembly procedure
Checking oil/coolant levels (2/2)
A-18
Check the lowest atmospheric temperature in the past and decide the ratio of antifreeze to water
according to the following mixing ratio table. Actually, set the mixing ratio for a temperature about
10C below the recorded lowest atmospheric temperature.
Min. atmospheric
temperature (C)
10 15 20 25 30
Quantity ()
Antifreeze 73.5 88 100.5 113 122.5
Water 171.5 157 144.5 132 122.5
WARNING
Since antifreeze is flammable, take care of fire.
Use city water as the coolant.
Control the mixing ratio with an antifreeze densitometer.
WARNING
When removing the drain plug, take care that the
coolant will not splash over you.

If the oil/coolant is insufficient, add new oil/coolant. Name Qty Name Qty
Other remarks
85
Assembly procedure
Greasing of greasing point (1/3)
A-19
1. Blade Center ball joint
Center link pin
Left ball joint
Right ball joint
2. Blade lift cylinder support yoke
Cap upper side Cap lower side
86
Assembly procedure
A-19
3. Blade lift cylinder support shaft
Support shaft
LH and RH
4. Ripper
Cylinder foot LH and RH
LH & RH LH & RH
LH & RH
Arm foot LH and RH
87
Assembly procedure
A-19
5. Equalizer bar side pin
Equalizer bar side pin

LH and RH
6. Equalizer bar both end.
Pivot shaft lubrication plug

LH and RH
Track adjustment plug

LH and RH
88
Assembly procedure
Installation of ORBCOMM antenna and wiring harness
A-20
1. Remove left cover (6) (above the left fender).
2. Install the wiring harness and antenna (3) as shown

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

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

Name Qty Name Qty
Other remarks
89
Replacement of return filter
A-21 (Replacement of standard filter with flushing filter)
(1/3)
Replace the hydraulic oil return filter element with

flushing element (1) and plate (2).
When replacing the element, lift it up slowly so

that the dirt sticking to it will not drop in the tank.
Remove the dirt remaining in the case with your
hand.
Replace the relief valve with this plate

only when flushing the piping. Replacement Valve
Strainer
Flushing element
Absolute filtration rating 6
Hydraulic tank
(Note 1) When the atmospheric temperature is below 15C,
install the valve and strainer (without installing oil
stopper plate (2)) and flush the piping with the engine
speed at low idling.
(Note 2) For the flushing procedure, see Testing and No. Part No. Q'ty
maintenance procedure after completing assembly 1 208-60-71170 1
M-3. 2 21T-60-13730 1

Keep removed standard element (208-60-71120)-1, Name Qty Name Qty
strainer (07069-25400)-1, and valve (208-60-71160)-1
carefully, since they will be used again after flushing
is finished.
Other remarks
90
(2/3)
Return removed hydraulic oil return filter element (1),

strainer (2), and valve (3).
When replacing the element, lift it up slowly so

that the dirt sticking to it will not drop in the tank.
Remove the dirt remaining in the case with your
hand.
Valve
Replacement
Strainer
Standard element
Hydraulic tank

Before performing the work in this section, perform Name Qty Name Qty
A-23: Bleeding air from hydraulic cylinder and M-3:
Flushing in order.
Other remarks
91
(3/3)
Installing condition of element
Element
Fig. 1 Good condition Fig. 2 Bad condition
Do not install the element with its bottom on the elevated part of the case bottom as shown in
Fig. 2. In particular, if the filter case is filled with oil, it is difficult to see if the element is installed
normally. In this case, turn the element with your hand. If you can turn it smoothly, it is installed
normally.

After finishing flushing, discard the removed flushing Name Qty Name Qty
element.
Keep the removed plate, however, since it will be used
again.
Other remarks
92
Assembly procedure
Installing direction of exhaust pipe
A-22
After installing the exhaust pipe, connect komaclone tube (4), using gasket (1), bolt (2), and
washer (3).
Right of chassis
Left of chassis
Front of chassis
No. Part No. Q'ty

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

Name Qty Name Qty
Other remarks
93
Assembly procedure
Bleeding air from hydraulic cylinders
A-23
After disassembling for transpotation, changing the oil in the hydraulic tank, or removing the
hydraulic cylinders or work equipment piping, bleed the air from the hydraulic circuit as follows.
1. Blade lift cylinder (with piston valve)
1) Start the engine and run at low idling for approx. 5 minutes.
2) With the engine at low idling, extend and retract the cylinder four or five times without operating
it to the end of its stroke.
Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the
circuit under any circumstance.
3) Keeping the engine at low idling, extend the cylinder to a point approx. 100 mm before the end
of the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of
stroke. Hold it in this position for 3 minutes.
4) With the engine at high idling, extend the cylinder to a point approx. 100 mm before the end of
the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of its
stroke. Hold it in this position for 1 minute.
2. Blade tilt cylinder (without piston valve)
1) Start the engine and run at low idling for approx. 5 minutes.
2) With the engine at low idling, raise and lower the blade four or five times without operating
the cylinder to the end of its stroke.
Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the
circuit under any circumstance.
3) Repeat this operation with the engine at full throttle, then run the engine at low idling and
operate the piston rod to the end of its stroke to relieve the circuit.
If from the beginning the engine is run at full throttle; or the cylinders are operated to the end of
their stroke, the piston packing may be damaged, so never operate in this way.
Check the oil level, and add oil to the specified level if necessary.

Name Qty Name Qty
Other remarks
94
Assembly procedure
Installing lunchbox band (if equipped) (1/2)
A-24
Note) When performing the following procedure, refer to A-12 Installing operator's cab (12/15), too.
1. After installing plate (1) to the operator's cab, pass the band through the rear U-hook as shown
below.
2. Install cover (3).

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

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

Name Qty Name Qty
Other remarks
95
Assembly procedure
Installing lunchbox band (if equipped) (2/2)
A-24
3. Referring to A-12 Installing operator's cab (12/15), install the lining and rubber plate.
4. Install the band as shown below.
After installing cover (3), pass

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

Name Qty Name Qty
Other remarks
96
M. CHECK AND MAINTENANCE PROCEDURES
AFTER COMPLETION OF ASSEMBLY
97
M-1 Check and adjustment of operators cab (1/7)
1. Measuring pressure in cab

(1) Measure the pressure in the cab.
Criterion: Measured value 98.1 Pa {10 mmH2O}
Testing condition : Run the engine at full throttle and set the engine fan to 100%.
: Set the blower to the high (Hi).
Operate the blower according to the following procedure.
1) Depress air outlet selector switch (2) on the air Front-Rear-Foot area
conditioner control panel to select the front-rear- (including defroster)
foot area mode (shown at right).
<Indication on LCD and air flow>
2) Select the fresh air mode with the RECIRC/FRESH
air selector switch (3). Indication on LCD Air flow
Low
3) Depress fan switch (1) to set the blower to the
high (Hi). Medium 1
Medium 2
Medium 3
Medium 4
Blower
High
at high (Hi)
If the standard pressure is not obtained, check the
seals around the dashboard and the seals of the
fitting faces of the cab and floor for an opening.
(Run water over outside to see if it enters the cab.)
If there is an opening, fill it with liquid seal.
98
(2) Outlined below is a simplified method for the internal

pressure measurement of the operators cab: Lock lever
mount hole
(a) Prepare a transparent vinyl hose (of an outer

diameter of 10 mm and 3,000 mm long).
(b) Pour water into the hose bore for about a half of
the hose length.
(c) Remove the sliding windshield lock lever located
on the side panel of the operators cab to insert
one end of the vinyl hose before fastening an
adjacent part of the hose to the top end of the
back seat using packing tape.
(d) Seal the gap occurring between the lock-lever
hose and the outer periphery-of the hose.
10 mm or more
(e) Match the water levels of the beginning part and
the ending part of the water cloumn inside the
transparent vinyl hose at the outside of the
operators cab.
(f) Start the engine and run it at full speed to read
the difference between the two water levels.
Inside the Outside

operators cab (Atmospheric pressure)
Remove lock lever and insert vinyl hose.
Fix vinyl hose to top end of back seat
Vinyl hose
99
2. Shower test for water-tightness
(1) Close all the opening sections of the operators cab.

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

Name Qty Name Qty
Other remarks
100
3. Checking the door lock

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

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

Mounting screw (01023-20616)
Packing tape strip

Door
Shim (14X-911-1761)
(2) Check the correlation between the door latch and the striker (on both, L.H and R.H side).
Moving the door toward the closing direction, observe the engaging state between the
latch and the striker.
Latch
Striker
Latch
Make the observation to Center of the striker
check the engagement from Center of the latch
this side.
Striker
Check if the center of the striker and the

center of the latch are not deviated.
101
3.2 Adjustments
(1) Adjusting the elevation of the damper rubber
When adjusting the elevation of the damper rubber, supplement or reduce the shims
being inserted below the damper rubber to adjust the elevation of the damper rubber
properly.
Damper rubber
Shims
Door structure t1.2

The shape of the shim
(14X-911-1761)
(2) Adjusting the correlation between the latch and the striker
(a) Loosening the striker mounting bolts to a temporarily tightened state, open and
close the door 2 to 3 times to aligh the centers of the latch and the striker.
(b) Check the engaging state between the latch and the striker.
(c) Tighten the striker mounting bolts back to their original tightened state.
(d) Try to open and close the door to see if the door lock can be released smoothly.
When the door lock cannot be released smoothly (when the turning effort to move
the knob feels too heavy), repeat the adjustment all over again. (Appropriate knob
turning effort: 68.6 19.6 N {7 2 kg}
(3) Apply grease (G2-LI) over the latch surface.
When the grease adhering over the latch surface dries Name Qty Name Qty
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
102
4. Checking the open-locked state of the door

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

(1) Check the correlation between the open -lock latch and the striker.
(Check them on both L.H and R.H sides.)
Move the door toward the opening direction to observe the engaging state between the
latch and the striker.
Check if the claw of the latch is
not riding over the bent section
of the striker.
Releasing lever
The status is normal if the latch
is not riding over the bent
Shake the door section of the striker.
back and forth.
Latch (20Y-54-36380)
Bolt (01435-30820)
Make the
Striker (14X-911-1921)
observation
through this Nut (01580-11008)
direction Washer (01643-31032)
Bracket
(198-Z11-3341)
(198-Z11-3351)
Check and make sure that

the body of the latch and the
striker are not interfering.
The correlation is normal
if they are not interfering.
(2) Check the mounted elevation of the stopper rubber. (At 2 places each on one side. Check
them on both L.H and R.H sides.)
(a) Shaking the door back and forth in open-locked state, check for rattling.
(b) Check if the turning effort for the releasing lever is too heavy.

Name Qty Name Qty
Other remarks
103
4.2 Adjustment
(1) Adjusting the correlation between the latch and the striker
Loosen the striker mounting nut and adjust the position of the striker so that it does not
interfere with the latch nor the overriding over the bent section occurs before tightening
the nut back to its original state.
When the interference cannot be corrected by the adjustment on the striker side, loosen
the latch side mounting bolts to make the adjustment from the latch side.
Latch
Clearence
Striker
Door structure
Striker
Stopper rubber
Latch
Depress the door and if it moves

until the clearance disappears,
bring out the stopper rubber
toward the depressed side.
(2) Adjusting the elevation of the stopper rubber

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

Name Qty Name Qty
Other remarks
104
Assembly procedure
Error code (1/9)
M-2
1. Turn starting switch (2) ON.
2. Operate service switch (3) and buzzer cancel switch

(4) to select the service mode.
While holding the service switch in the ON position,

hold the buzzer cancel switch in the [ ] position
for 2.5 seconds.
When the system is set in the service mode, [1C] is

displayed in gear speed display unit (1).
3. Display of electrical and mechanical failure codes
1) Select EE (electrical system failure code display

mode) with information switch (5) and execute
with buzzer cancel switch (4).
2) Select bE (mechanical system failure code display

mode) with information switch (5) and execute
with buzzer cancel switch (4).
[ ]: Increase the mode No.

[ ]: Decrease the mode No.
[ ]: Execute the mode.
105
Assembly procedure
Error code (2/9)
M-2
Electrical system failure coad display mode
Mechanical system failure coad display mode
106
Assembly procedure
Error code (3/9)
M-2
Display when any code is not recorded

If there is not any past or current failure code
recorded, the panel displays as shown at right.
Display when any code is recorded

If there is any past or current failure code recorded,
the panel displays as shown at right.
(1): Record No. (Max. 20 Nos.)
(2): Failure code (Current failure code flashes)
(3): Number of occurrences up to now
(4): Elapsed time indicated by service meter after
first occurrence
(5): Elapsed time indicated by service meter after
last occurrence
107
Assembly procedure
Error code (4/9)
M-2
Caution Caution
Failure code Failure Trouble Controller Action code lamp buzzer
1500L0 Double failure of transmission * See separate list (LO) TM CALL E03
15SAL1 Forward clutch oil pressure * See separate list (L1) TM CALL E03
15SALH Forward clutch oil pressure * See separate list (LH) TM CALL E03
15SBL1 Reverse clutch oil pressure * See separate list (L1) TM CALL E03
15SBLH Reverse clutch oil pressure * See separate list (LH) TM CALL E03
15SEL1 1st clutch oil pressure * See separate list (L1) TM CALL E03
15SELH 1st clutch oil pressure * See separate list (LH) TM CALL E03
15SFL1 2nd clutch oil pressure * See separate list (L1) TM CALL E03
15SFLH 2nd clutch oil pressure * See separate list (LH) TM CALL E03
15SGL1 3rd clutch oil pressure * See separate list (L1) TM CALL E03
15SGLH 3rd clutch oil pressure * See separate list (LH) TM CALL E03
1800MW Power train clutch slip Slip (MV) TM E02
2201L1 Right clutch oil pressure * See separate list (L1) ST CALL E04
2201LH Right clutch oil pressure * See separate list (LH) ST CALL E04
2202L1 Left clutch oil pressure * See separate list (L1) ST CALL E04
2202LH Left clutch oil pressure * See separate list (LH) ST CALL E04
2300NR Brake thermal load Abnormal heating (NR) ST E00
2301L1 Right brake oil pressure * See separate list (L1) ST CALL E04
2301LH Right brake oil pressure * See separate list (LH) ST CALL E04
2301NR Right steering brake thermal load Abnormal heating (NR) ST E00
2302L1 Left brake oil pressure * See separate list (L1) ST CALL E04
2302LH Left brake oil pressure * See separate list (LH) ST CALL E04
2302NR Left steering brake thermal load Abnormal heating (NR) ST E00
A000N1 Engine speed sensor abnormality Over run (N1) VHMS E00
A70XLK Governor servo system right abnormality * See separate list (LK) ENG CALL E04
A70YLK Governor servo system left abnormality * See separate list (LK) ENG CALL E04
AA1ANX Air cleaner clogging Clogging (NX) Machine E00
AB00MA Battery charge abnormality Malfunction (MA) Machine E00
B@BAZG Engine oil pressure lowering Lowering of oil pressure (ZC) Machine E00
B@BAZK Engine oil level lowering Lowering of level (ZK) Machine E00
B@BCNS Coolant overheating Overheating (NS) Machine E00
B@BCZK Coolant water level lowering Lowering of level (ZK) Machine E00
B@CENS Power train overheating Overheating (NS) Machine E00
B@HANS Hydraulic oil overheating Overheating (NS) Machine E00
B@HAZK Hydraulic oil level lowering Lowering of level (ZK) Machine E00
D110KA BR relay holding Disconnection (KA) ST E00
D110KB BR relay holding Short circuit (KB) ST E00
D130KA N safety relay Disconnection (KA) TM E02
D130KB N safety relay Short circuit (KB) TM E02
D161KA Backup alarm relay Disconnection (KA) TM E01
D161KB Backup alarm relay Short circuit (KB) TM E01
D182KZ Preheating relay Lowering of level (ZK) ST E01
D1D0KA Governor cut relay right disconnection Disconnection (KA) ENG E01
D1D0KB Governor cut relay right short circuit Short circuit (KB) ENG E01
D1D1KA Governor cut relay left disconnection Disconnection (KA) ENG E01
108
Assembly procedure
Error code (5/9)
M-2
Controller Action code Caution Caution

Failure code Failure Trouble lamp buzzer
D1D1KB Governor cut relay left short circuit Short circuit (KB) ENG E01
D5ZFKA N-signal 1 Disconnection (KA) TM E01
D5ZFKB N-signal 1 Short circuit (KB) TM E01
D5ZFL4 N-signal abnormality * See separate list (L4) ENG E01
D5ZGKA N-signal 2 Disconnection (KA) TM E01
D5ZGKB N-signal 2 Short circuit (KB) TM E01
D5ZKKX Chassis throttle signal abnormality Out of input signal range (KX) ENG CALL E03
D5ZRKA Snap shot signal disconnection Disconnection (KA) ST E00
D5ZRKB Snap shot signal short circuit Short circuit (KB) ST E00
Defective communication (Objec- MON CALL E03
DAFRKR RTCDB abnormality tive component abnormality) (KR)
Lowering of source voltage (input) TM CALL E04
DAQ0KK Source voltage abnormality (KK)
DAQ0KT Saved value abnormality Internal defect of controller (KT) TM E01
Lowering of source voltage (input) TM CALL E03
DAQ5KK Potentiometer power supply abnormality (KK)
Lowering of source voltage (input) TM E01
DAQ6KK Sensor power supply abnormality (KK)
Disagreement of model selection TM CALL E04
DAQ9KQ Model selection 1, 2, 3 signals (KQ)
Defective communication (Objec- TM CALL E03
DAQRKR RTCDB abnormality tive component abnormality) (KR)
Defective communication (Objec- TM E01
DAQSKR Network abnormality tive component abnormality) (KR)
Lowering of source voltage (input) ST CALL E04
DB30KK Source voltage abnormality (KK)
DB30KT Saved value abnormality Internal defect of controller (KT) ST E01
DB35KK Potentiometer power supply abnormality (KK)
DB36KK Sensor power supply abnormality KK)
Disagreement of model selection ST CALL E04
DB39KQ Model selection 1, 2, 3 signals (KQ)
Defective communication (Objec- ST CALL E03
DB3RKR RTCDB abnormality tive component abnormality) (KR)
Defective communication (Objec- ST E01
DB3SKR Network abnormality tive component abnormality) (KR)
Lowering of source voltage (input) ENG CALL E04
DB40KK Source voltage abnormality (KK)
DB41KK Switch power supply abnormality (KK)
DB42KK Solenoid power supply 1 abnormality (KK)

DB43KK Backup power supply abnormality (KK)
DB44KK Solenoid power supply 2 abnormality (KK)
DB45KP Rack sensor power supply abnormality Lowering of output voltage (KP) ENG CALL E03
DB49KM Connector wrong connection Mistake in operation or setting (KM) ENG CALL E04
Disagreement of model selection ENG E02
DB49KQ Model selection abnormality signals (KQ)
109
Assembly procedure
Error code (6/9)
M-2

DBB0KK VHMS supply constant voltage abnor- Lowering of power source voltage VHMS E00
mality (KK)
Disagreement of model selection VHMS E00
DBB0KQ VHMS contoroller abnormality signals (KQ)
VHMS contoroller battery direct power Lowering of battery direct source VHMS E00
DBB3KK source voltage (KK)
DBB5KP 5V power source for sensor abnormality Lowering of output voltage (KP) VHMS E00
DBBQKR VHMS KOM-NET network abnormality Defective communication (KR) VHMS E00
DD12KA Shift-up SW Disconnection (KA) TM E02
DD12KB Shift-up SW Short circuit (KB) TM E02
DD13KA Shift-down SW Disconnection (KA) TM E02
DD13KB Shift-down SW Short circuit (KB) TM E02
DD14KA Travel lock SW Disconnection (KA) TM CALL E03
DD14KB Travel lock SW Short circuit (KB) TM CALL E03
DDB9KA Reverse SW Disconnection (KA) TM CALL E03
DDB9KB Reverse SW Short circuit (KB) TM CALL E03
DDK3KA Forward SW Disconnection (KA) TM CALL E03
DDK3KB Forward SW Short circuit (KB) TM CALL E03
DDK5KA Shift SW Disconnection (KA) TM E02
DDK5KB Shift SW Short circuit (KB) TM E02
DDN2LD PPC tilt right oil pressure SW * See separate list (LD) TM E02
DDN3LD PPC tilt left oil pressure SW * See separate list (LD) TM E02
DDN7KA Pitch SW Disconnection (KA) TM E02
DDN7KB Pitch SW Short circuit (KB) TM E02
DDN9KA Dual tilt SW Disconnection (KA) TM E01
DDN9KB Dual tilt SW Short circuit (KB) TM E01
DDNALD PPC lift raise full oil pressure SW * See separate list (LD) TM E00
DDNBLD PPC ripper raise oil pressure SW * See separate list (LD) TM E00
DDNCLD PPC ripper lower oil pressure SW * See separate list (LD) TM E00
DDNDLD PPC ripper tilt oil pressure SW * See separate list (LD) TM E00
DDNELD PPC ripper tilt back oil pressure SW * See separate list (LD) TM E00
DDNFLD PPC lift lower full oil pressure SW * See separate list (LD) TM E00
DDQ2KA Travel lock SW Disconnection (KA) ST CALL E03
DDQ2KB Travel lock SW Short circuit (KB) ST CALL E03
DDQ2L4 Travel lock inconsistency 1, 2 * See separate list (L4) ST CALL E03
DDT5KA Neutral SW Disconnection (KA) TM CALL E04
DDT5KB Neutral SW Short circuit (KB) TM CALL E04
Disagreement of model selection TM CALL E04
DDT5KQ Lever specification selection error signals (KQ)
DGE1KB Engine oil temperature sensor Short circuit (KB) VHMS E00
DGE1KY Engine oil temperature sensor Disconnection (KY) VHMS E00
DGE2KX Water temperature sensor abnormality Out of input signal range (KX) ENG E02
Water temperature sensor abnormality Disconnection (KA) ST E01
DGE3KA (Low temperature side)
DGE5KB Atmospheric temperature sensor Short circuit (KB) VHMS E00
110
Assembly procedure
Error code (7/9)
M-2

DGS1KX Hydraulic oil temperature sensor Out of input signal range (KX) TM E00
DGT5KA Left bank exhaust temperature sensor Disconnection (KA) VHMS E00
DGT5KB Left bank exhaust temperature sensor Short circuit (KB) VHMS E00
DGT6KA Right bank exhaust temperature sensor Disconnection (KA) VHMS E00
DGT6KB Right bank exhaust temperature sensor Short circuit (KB) VHMS E00
DH22KA Hydraulic oil pressure 1 (F) sensor Disconnection (KA) TM E00
DH22KB Hydraulic oil pressure 1 (F) sensor Short circuit (KB) TM E00
DH23KA Hydraulic oil pressure 2 (R) sensor Disconnection (KA) TM E00
DH23KB Hydraulic oil pressure 2 (R) sensor Short circuit (KB) TM E00
DHE4KA Engine oil pressure sensor Disconnection (KA) ST E02
DHE4KB Engine oil pressure sensor Short circuit (KB) ST E02
DHE5KB Blow-by pressure sensor Disconnection (KB) VHMS E00
Short circuit with power supply line VHMS E00
DHE5KY Blow-by pressure sensor (KY)
DHT3KX Transmission oil pressure sensor Out of input signal range (KX) VHMS E00
DK01KA Left yoke angle sensor Disconnection (KA) TM E02
DK01KB Left yoke angle sensor Short circuit (KB) TM E02
DK03KA Right yoke angle sensor Disconnection (KA) TM E02
DK03KB Right yoke angle sensor Short circuit (KB) TM E02
DK10KX Fuel control dial abnormality Out of input signal range (KX) ENG CALL E03
DK12KX Deceleration potentiometer abnormality Out of input signal range (KX) ENG CALL E03
DK30KA Swing potentiometer 1 disconnection Disconnection (KA) ST CALL E03
DK30KB Swing potentiometer 1 short circuit Short circuit (KB) ST CALL E03
DK30KX Swing system 2 system Out of input signal range (KX) ST CALL E04
DK30KZ Steering potentiometer abnormality Disconnection or short circuit (KZ) ST CALL E04
DK30L8 Swing potentiometer shifting * See separate list (L8) ST CALL E03
DK31KA Swing potentiometer 2 disconnection Disconnection (KA) ST CALL E03
DK31KB Swing potentiometer 2 short circuit Short circuit (KB) ST CALL E03
DK40KA Brake potentiometer Disconnection (KA) ST CALL E03
DK40KB Brake potentiometer Short circuit (KB) ST CALL E03
DK55KX Forward-Reverse system 2 system Out of input signal range (KX) TM CALL E04
Forward-Reverse potentiometer abnor-
DK55KZ mality Disconnection or short circuit (KZ) TM CALL E04
Forward-Reverse potentiometer shifting

DK55L8 and OK& potentiometer shifting when * See separate list (L8) TM CALL E03
key is turned ON
Forward-Reverse potentiometer 1 dis-
DK56KA connection Disconnection (KA) TM CALL E03
Forward-Reverse potentiometer 1 short

DK56KB circuit Short circuit (KB) TM CALL E03
Forward-Reverse potentiometer 2 dis-

DK57KA connection Disconnection (KA) TM CALL E03
Forward-Reverse potentiometer 2 short

DK57KB circuit Short circuit (KB) TM CALL E03
DK60KA Acceleration sensor Disconnection (KA) ST E01

DK60KB Acceleration sensor Short circuit (KB) ST E01
111
Assembly procedure
Error code (8/9)
M-2
Caution Caution
DKF0KX Fuel injection pump rack sensor Out of input signal range (KX) VHMS E00
DKF1KX Rack sensor right abnormality Out of input signal range (KX) ENG CALL E03
DKF2KX Rack sensor left abnormality Out of input signal range (KX) ENG CALL E03
DKH1KA Pitch angle sensor Disconnection (KA) ST CALL E03
DKH1KB Pitch angle sensor Short circuit (KB) ST CALL E03
DLE1KA Engine speed sensor Disconnection (KA) ST E01
DLE4LC Engine speed sensor A abnormality * See separate list (LC) ENG CALL E03
DLE5LC Engine speed sensor B abnormality * See separate list (LC) ENG CALL E03
DLF1KA Transmission speed sensor Disconnection (KA) TM E01
DLT3KA Transmission output shaft speed sensor Disconnection (KA) TM E01
DV00KB Caution buzzer Short circuit (KB) MON E01
DW55KA Pitch back solenoid Disconnection (KA) TM CALL E03
DW55KB Pitch back solenoid Short circuit (KB) TM CALL E03
DW56KA Pitch dump solenoid Disconnection (KA) TM CALL E03
DW56KB Pitch dump solenoid Short circuit (KB) TM CALL E03
DW57KA Left tilt limit solenoid Disconnection (KA) TM E02
DW57KB Left tilt limit solenoid Short circuit (KB) TM E02
DW58KA Right tilt limit solenoid Disconnection (KA) TM E02
DW58KB Right tilt limit solenoid Short circuit (KB) TM E02
DW59KA Dual tilt selection solenoid Disconnection (KA) TM E01
DW59KB Dual tilt selection solenoid Short circuit (KB) TM E01
DW5AKA Pitch selection solenoid Disconnection (KA) TM E02
DW5AKB Pitch selection solenoid Short circuit (KB) TM E02
DW5DKA Pitch selection solenoid Disconnection (KA) TM CALL E03
DW5DKB Pitch selection solenoid Short circuit (KB) TM CALL E03
DW7BKA Fan reverse solenoid Disconnection (KA) TM E01
DW7BKB Fan reverse solenoid Short circuit (KB) TM E01
DWJ0KA Pump merge-divider solenoid Disconnection (KA) ST CALL E03
DWJ0KB Pump merge-divider solenoid Short circuit (KB) ST CALL E03
DWN3KA Sudden stop prevention solenoid Disconnection (KA) ST CALL E04
DWN3KB Sudden stop prevention solenoid Short circuit (KB) ST CALL E04
DWN5KA Fan control solenoid 1 Disconnection (KA) TM E01
DWN5KB Fan control solenoid 1 Short circuit (KB) TM E01
DWNCKA Fan control solenoid 2 Disconnection (KA) TM E01
DWNCKB Fan control solenoid 2 Short circuit (KB) TM E01
DXE0KA LS set selector solenoid (LSV) Disconnection (KA) TM E02
DXE0KB LS set selector solenoid (LSV) Short circuit (KB) TM E02
DXH1KA Lockup solenoid Disconnection (KA) TM E01
DXH1KB Lockup solenoid Short circuit (KB) TM E01
DXH4KA 1st clutch ECMV Disconnection (KA) TM CALL E03
DXH4KB 1st clutch ECMV Short circuit (KB) TM CALL E03
DXH5KA 2nd clutch ECMV Disconnection (KA) TM CALL E03
DXH5KB 2nd clutch ECMV Short circuit (KB) TM CALL E03
DXH6KA 3rd clutch ECMV Disconnection (KA) TM CALL E03
DXH6KB 3rd clutch ECMV Short circuit (KB) TM CALL E03
112
Assembly procedure
Error code (9/9)
M-2
Caution Caution
DXH7KA Reverse clutch ECMV Disconnection (KA) TM CALL E03
DXH7KB Reverse clutch ECMV Short circuit (KB) TM CALL E03
DXH8KA Forward clutch ECMV Disconnection (KA) TM CALL E03
DXH8KB Forward clutch ECMV Short circuit (KB) TM CALL E03
DXH9KA Right clutch ECMV Disconnection (KA) ST CALL E03
DXH9KB Right clutch ECMV Short circuit (KB) ST CALL E03
DXHAKA Left clutch ECMV Disconnection (KA) ST CALL E03
DXHAKB Left clutch ECMV Short circuit (KB) ST CALL E03
DXHBKA Right brake ECMV Disconnection (KA) ST CALL E04
DXHBKB Right brake ECMV Short circuit (KB) ST CALL E04
DXHCKA Left brake ECMV Disconnection (KA) ST CALL E04
DXHCKB Left brake ECMV Short circuit (KB) ST CALL E04
DXHDKA Governor solenoid right disconnection Disconnection (KA) ENG CALL E04
DXHDKB Governor solenoid right short circuit Short circuit (KB) ENG CALL E04
DXHEKA Governor solenoid left disconnection Disconnection (KA) ENG CALL E04
DXHEKB Governor solenoid left short circuit Short circuit (KB) ENG CALL E04
DXHFKA Pre-stroke solenoid left disconnection Disconnection (KA) ENG CALL E03
DXHFKB Pre-stroke solenoid left short circuit Short circuit (KB) ENG CALL E03
DXHGKA Pre-stroke solenoid left disconnection Disconnection (KA) ENG CALL E03
DXHGKB Pre-stroke solenoid left short circuit Short circuit (KB) ENG CALL E03
F@BBZL Blow-by pressure sensor abnormality Over pressure (ZL) VHMS E00
Left bank exhaust temperature sensor
F@BYNR (2) abnormality Abnormal heating (NR) VHMS E00
Left bank exhaust temperature sensor

F@BYNS (1) abnormality Overheating (NS) VHMS E00
Right bank exhaust temperature sensor

F@BZNR (2) abnormality Abnormal heating (NR) VHMS E00
Right bank exhaust temperature sensor

F@BZNS (1) abnormality Overheating (NS) VHMS E00
113
Assembly procedure
Flushing of hydraulic circuit
M-3
After finishing assembly, flush the hydraulic circuit.
(1) Run the engine at low idling with the lever in neutral for 30 minutes.
(2) Run the engine at medium speed with the lever in neutral for 30 minutes.
(3) Run the engine at about 1,700 rpm and operate the levers (Hold the lever for 1 minute - 1minute
30 seconds in each operation). Repeat the following operation pattern 4 times.
Raise blade Lower blade Tilt blade to left Tilt blade to right
Raise ripper Lower ripper Tilt ripper in Tilt ripper back

Note Name Qty Name Qty
When the atmospheric temperature is below 15C,
install the valve and strainer (without installing oil
stopper plate and flush the piping with the engine
speed at low idling.
Flushing is performed to separate dirt from the

hydraulic oil. Install the flushing element (See A-21
(1/3)) and perform the work in this section to separate
the dirt.
Other remarks
114
APPENDIX 1.
INSTALLATION OF SPILL GUARDS
DESCRIPTION
1. Introduction
When installing the spill guards in field, refer to the installation procedure described in this installation
procedure.
2. Additional parts
Blade Part No. Part Name Qty Weight (kg) Remarks

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

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

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

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

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

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

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

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

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

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

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

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

13
per KES 04.351
to be within 2.
(4) Spill guard (for superdozer, right) 198-72-63830 fabrication drawing
01 PLATE SS400F 1 1.65 t 19 65
02 PLATE SS400P 1 2.05 t 19
03 PLATE SS400F 1 1.75 t 19 65
04 PLATE SS400P 1 3.05 t 19
05 PLATE SS400F 1 2.05 t 19 65
06 PLATE SS400P 1 3.20 t 19
07 PLATE SS400F 1 2.35 t 19 65
08 PLATE SS400F 1 9.35 t 19 65
09 PLATE SS400F 1 6.50 t 19 65

4. Installation procedure
4-1 For disassembly and assembly procedures which are not described in this manual, see the
Shop Manual.
4-2 Weld the spill guard to the blade according to the drawing.
4-3 Precautions for welding
4-3-1 Remove all dirt, rust, and paint from the parts to be removed with a grinder.
4-3-2 If the parts to be welded are wet, dry them with a gas burner.
4-3-3 Do not use anti-spatter agents.
4-3-4 Use coated welding rods specified by JIS 4316 (Low-hydrogen welding rod for mild steel)
or welding wires specified by JIS YGW11.
4-3-5 Before using coated welding rods, dry them at 300 - 350C for 30 - 60 minutes.
4-3-6 Preheat the area about 50 mm from the beat to be laid at 150 - 200C. When the ambient
temperature is below 10C, post-heat the same area, too, at 150 - 200C.
4-3-7 Set the welding current to the lower limit of the current range specified for the diameter
of the welding rod or wire.
4.3.8 When performing multi-layer welding, weave the welding rod.
4.3.9 Do not weld by letting the melted metal flow, but weld from below to above with sufficient
penetration. Keep the arc length as short as possible, and take care not to make an
overlap, undercut, etc.
4.3.10 Before welding the spill guard, remove all the paint (or rust) from the parts to be welded
with a grinder. Then, perform tack welding, permanent welding and finishing in order.
4.3.11 Connect the ground cable to a part of the blade where paint is removed or a part where
the ground cable can be connected securely electrically.
(Remark) If a painted part is welded, hydrogen in the paint will be mixed in the welded
part, and that can cause cold cracking.
14
APPENDIX 2.
PRECAUTIONS FOR INITIALIZATION PROCEDURES

FOR VHMS CONTROLLER
1
PRECAUTIONS FOR INITIALIZATION OF VHMS CONTROLLER
AND ORBCOMM TERMINAL (OPTIONAL)
When a machine equipped with VHMS controller is delivered to a customer,
Delivery of machine equipped with VHMS controller
Step 1) Notify the machine information for registration in WebCARE.
Application for registration in WebCARE
If you have not registered an ID for reading WebCARE,
Application for registration of WebCARE user
Step 2) When installing an ORBCOMM communication terminal optionally, notify the

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

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

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

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

fit the cap to the connector.
Never set the communication

system before making contract
with ORBCOMM.
Step 2) After receiving notification of date of opening the terminal (After that date), set ORB-
COMM.
Connection of antenna
ORBCOMM terminal
Case 2:Procedure for operating the machine after opening the terminal
Initialize of both VHMS controller and ORBCOMM simultaneously.
VHMS controller ORBCOMM terminal
5
3. Preparation of tools and items to be executed after initialization (IMPORTANT)
a A cable to connect a personal computer and the VHMS controller is necessary for setting VHMS/ORB-
COMM. Purchase and prepare it.
a A setting program to be installed to the personal computer is also necessary. (This program is contained in
the VHMS analysis tool software.) Purchase the VHMS analysis tool software.
Service kit 799-608-3101
Components
Analysis tool CD & FD 799-608-3211
Cable 799-608-3220
1) The initialization procedures of VHMS controller are entered in the Shop Manual for each model.
2) Initialize the VHMS controller according the Shop Manual or the field assembly manual.
3) Fax the check sheet filled when the VHMS controller is initialized.
4) When performing step 3) above, send the first setting downloaded data to VHMS/WebCARE Global
Support Center by E-mail.
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan

FAX: 81-3-5561-4766 (from outside of Japan)
webcare@komatsu.co.jp
6
PLACE TO STORE DOWNLOADED DATA
1. Open the "VHMS_DATA" icon in drive C (or the drive specified when the software was installed).
2. Open the icon of the applicable model. Next, open the icon of the serial No., and then open the icon of the
date and time of downloading.
Example: D475 Example: Example:

Serial No.20002 Sept. 4, 2003
Caution:
All of the files downloaded
today are stored in the icons.
The icon of the largest number
has the latest file.
3. After finishing initialization and downloading the data, send all the files in this icon by E-mail.
7
METHOD OF INSTALLING VHMS SETTING TOOL
1. Insert the CD-ROM in the CD drive, and installation of the analysis tool is started automatically. Perform the
shown procedures, and the analysis tool icon is made on the desktop.
Now, installation of the analysis (including download and FTP) tool is completed.
2. Insert the CD-ROM again, and installation of the analysis tool is started automatically again. When the fol-
lowing screen is displayed, click "Cancel" and interrupt the operation by clicking "Exit Setup".
8
3. Select the drive of the CD-ROM by "My computer" (or "Explorer") and click "Open".
a Do not double-click.
4. Select and open the "Setting Tool" icon.
5. Click "Set up.EXE".
6. Installation of the setting tool is started automatically and the icon is made on the desktop. Now, installation
of the setting tool is completed.
9
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER
a Initialization tools for VHMS controller a The VHMS controller and ORBCOMM termi-
nal are in the VHMS controller box under the
Symbol Part No. Part name
left side cover of the floor.
799-608-3101 Service kit
1 799-608-3211 Diskette
W 799-608-3220 Wiring harness

Notebook type personal com-
Commercially
2 puter (OS: Windows98/2000/
available
NT/Me/XP)
a Before starting operation after completion of lo-

cal assembly or before resuming operation after
storage for a long period, initialize the VHMS
controller according to the following procedure.
a Machine data collected with the VHMS controller
are stored and managed in WebCARE data-
base. To process the data smoothly on the We-
2. Connection of personal computer
bCARE, it is necessary to s et the VHMS
1) Make sure the starting switch is turned to
controller consistently. If it is not set correctly,
the OFF position.
k Be sure to connect and disconnect the
data will not be taken into the WebCARE and
data in the VHMS controller may not be utilized.
personal computer while the starting
Be sure to perform the initialization.
switch is turned to the OFF position.
a For method of installation for the VHMS Initializa-
2) Connect the personal computer W2 and the
tion Program to a personal computer, refer to the
download connectors DL1 and VDW with
Operation and Maintenance Manual contained in
wiring harness [1] of service kit W1.
the W1 service kit package.
a The download connectors are installed
a The initialization procedures cover both "ORB-
to the following places.
COMM Specification" and "ORBCOMMLESS
VDW: Inside of cab (Left rear lower
Specification". In case of "ORBCOMMLESS"
part)
Specification", omit the procedures necessary
DL1: Rear side of chassis (Hull
for "ORBCOMM Specification" only.
frame)
a During the initialization work, make necessary
a Connect the personal computer to the
confirmations for each work according to the
RS232C terminal.
"VHMS Initialization Work Checklist".
1. Check of machine information, engine infor-

mation, and controller information
a This step applied to works on the whole ma-
chine.
Check and record the machine information,
engine information, VHMS controller informa-
tion, and ORBCOMM terminal information.
Information to be checked
No. Information Remarks
1 Machine model
2 Machine serial No. 5 digits
3 Engine serial No. 6 digits
4 Transmission serial No. 6 digits
5 VHMS controller serial No. 5 digits
ORBCOMM terminal serial No.
6 11 digits
[For only ORBCOMM specification]
10
4. Startup of VHMS initialization tool
1) Switch on the personal computer and start
the OS.
2) Click the icon of [VHMS Initialization Tool]
on the personal computer screen to start the
VHMS initialization tool.
3) Input the 10-digit service ID in [Service ID].

a Service ID: 7826113000
4) Select [Data clear and Set up] in the [Select
Function] column.
5) Press the [OK] button to shift to the setup
screen.
3. Performance check of VHMS controller

1) Set the starting switch to the ON position.
2) Select "Service mode" and "Real-time moni-
toring mode" in order on the monitor panel.
3) Input ID = 20300.
4) If the central part of the lower line of the
multi-information display unit counts up, the
VHMS controller is normal.
11
5. Performance check of ORBCOMM terminal
Decimal point
[For only ORBCOMM specification] Indication
at right bottom
1) Judge the operation of the ORBCOMM con-
troller by the state of the dot at the right bot- Power is not applied to ORBCOMM
OFF
controller.
tom of the LED digit of the VHMS controller.
2) The dot at the right bottom of the LED digit ON Satellite is not captured.
of the VHMS controller can be checked in ORBCOMM controller does not
the multi-information display unit of the mon- Quick flashing have transmission data.Satellite is
itor by the following method. captured.
i) Set the starting switch to the ON posi-
ORBCOMM controller has transmis-
tion. Slow flashing
sion data.Satellite is captured.
ii) For monitor panel specification: Refer-
ring to 10 "Real-time monitoring mode"
6. Initialization of VHMS controller
or 11 "Dual display monitoring mode"
[Machine information]
above, input ID = 20300.
1) Open the [Machine information] tab.
a The [Machine information] tab is dis-
played first in the [Data clear and Set up]
menu.
2) Check all the data.
3) At least 3 minutes after starting the VHMS,

check the decimal point at the right bottom
of the LED of the VHMS controller or the
decimal point at the right bottom of the cen-
tral part of the lower line of the multi-infor-
mation display unit.
3) When information in the [Date/Time] box is

not correct, change it according to the fol-
lowing procedures:
i) Click on [Edit] (1) located in the right
lower part of the [Date/Time] box to dis-
play the correction screen.
ii) Correct the information, then click [OK].
12
4) When information in the [Machine informa- [For ORBCOMM specification only]
tion] box is not correct, change it according a Set the ORBCOMM terminal after the date of
to the following procedures: opening the terminal.
i) Click on [Edit] (2) located in the right 1) Open the VHMS Setting Tool according to
lower part of the [Machine information] the procedure for "Start of VHMS initializa-
box to display the correction screen. tion tool".
ii) Correct the information, then click [OK]. 2) Open the [Communication Setting] tab.
5) After checking and changing all the data in

[Machine information], click on the [Apply]
(3) to apply the settings.
a Click [Apply] (3), the screen for checking
the settings will appear. Recheck the
settings and click [OK] when all the set- 3) To change setting in [SHORT FAULT
tings are correct. HISTRY], follow the procedure below:
a In case of the ORBCOMM Specification, i) Select [SHORT FAULT HISTRY] on the
execute [Communication Setting] and screen and click [Edit] (5) located in the
settle it. left lower part of the [File Transfer Set-
ting] block to display the setting screen.
ii) Change the settings, then click [OK].
a At initialization, select [Occurrence] at
[Timing] screen, and set the function to
[ON].
6) After checking/changing the data of

4) To change setting in [SHORT TREND
[Machine Information], click [Exit] (4) to fin-
ANALYSIS], follow the procedures below:
ish [VHMS Initialization Tool].
i) Select [SHORT TREND ANALYSIS] on
the screen and click [Edit] (5) located in
the left lower part of the [File Transfer
Setting] block to display the setting
screen.
ii) Change the settings, then click [OK].
13
a At initialization, select [20h] at [SMR]
screen, and set the function to [ON].
5) To change the setting of [Satellite Setting],

follow the procedure below: (Important)
[Exit]
i) Click [Edit] (6) in the [Satellite Setting]
7) After checking/changing the data of [Com-
block to display the setting screen.
munication Setting], click [Exit] (8) to finish
ii) Bring GCC Code to the applicable area,
[VHMS Initialization Tool].
then click [OK].
GCC Code and Application Area

Code Applicable Area
1 U.S.A.
120 Italy
121 Malaysia
122 Korea
123 Brazil
130 Japan
6) After checking and changing all data in the

[Communication Setting], click [Apply] (7) to
apply the settings.
a Click [Apply] (3), the screen for checking
the settings will appear. Recheck the
settings and click [OK] when all the set-
tings are correct.
14
PROCEDURES FOR EXECUTING QUICK PM
a The Quick Pm means the Pm Clinic executed
with the snap shot function of the monitor panel.
k Stop the machine on a flat place.
1. Start the engine.
2. Set the monitor panel to display the service

menu.
a For the operating method, see "Special func-
tions of monitor panel".
3. Mode selection and excution

1) Select "Snap shot mode" on the mode
selection screen.
a If the mode is selected, code (55) is dis-
played in gear speed display unit (1) and the
title is displayed in multi-information unit (2).
2) Set the buzzer cancel switch in the [U]
position.
3) "READY" is displayed as shown in the figure

and the system is ready to start.
4) If the buzzer cancel switch is set in the [U]

position, the snap shot function starts.
a After the snap shot function is started, the
elapsed time is displayed.
a On the lower line, 1 " " is added every 30
seconds. While multiple " " are displayed,
the one at the right end flashes.
a To interrupt the snap shot function, set the
buzzer cancel switch in the [t] position.
15
5) After starting the snap shot function, operate
the machine according to Table 1.
a Check that the engine coolant and torque
converter oil temperatures are in operating
range.
a After 10 " " are displayed (After 5 minutes),
"#" is added up to 5.
" ": The data sampling interval is 10
seconds.
"#": The data sampling interval is 1 sec-
ond.
Operation of machine
Time (sec)
Finish
Start
Fuel
No.
State of machine Steer- Decelera- Brake Parking

Transmission Work equipment control
ing tor pedal pedal brake
dial
1 0:00 0:30 30 N LH N LOW HI Released Released
Low idling
2 0:30 1:00 30 N RH N LOW HI Released Released
3 1:00 2:00 60 High idling N N N HI HI Released Released
4 2:00 3:00 60 Deceleration slow N N N HI LOW Released Released
High-pressure Right tilt (or
5 3:00 3:30 30 N N HI HI Released Released
relief & high idling pitch back in
High-pressure case of dual tilt
6 3:30 4:00 30 N N model) LOW HI Released Released
relief & low idling
Port relief &
7 4:00 4:30 30 N N Left tilt (or pitch HI HI Released Released
high idling
dump in case of
Port relief & dual tilt model)
8 4:30 5:00 30 N N LOW HI Released Released
low idling
NoF1oF2oF3o
Torque converter
9 5:00 5:30 30 NoR1oR2oR3 N N LOW HI ON Released
stall & low idling
oN
Torque converter NoF3 (Shift to F3, LOWo
10 5:30 6:00 30 stall (F3) & high then run engine at N N HI Shift to F3, ON Released
idling (Note 1) full throttle) then HI
11 6:00 6:30 30 High idling N N N HI HI Released Released
Torque converter NoF3 (Shift to F3, Left tilt (or pitch LOWo
12 6:30 7:00 30 stall + High-pres- then run engine at N dump in case of HI Shift to F3, ON Released
sure relief high idling) dual tilt model) then HI
High idlingo HIo
13 7:00 7:30 30 N N N HI Released ON
Low idling (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 idling 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 idling.
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 idling to lower the oil temperature.)
16
6) The screen shown below appears 7 minutes 8) Open the data of the Quick Pm and trans-
30 seconds after the snap shot is started, late them into a graph.
and then the initial screen appears 5 sec- a Set the time to the X-axis and set the follow-
onds after. (End of snap shot) ing items to the Y-axis.
Engine Speed
Fuel Inject
Blowby Press
Exhaust Temp RB (Exhaust tempera-
ture of right bank: 1, 2, 3, 4, 5, 6)
Exhaust Temp LB (Exhaust temperature
of left bank: 1, 2, 3, 4, 5, 6)
Engine Oil Press
Engine Oil Temp
Eng Coolant Temp
Ambient Temp
Demand Eng Speed
(Engine speed demanded by controller)
T/C Oil Temp
Important (Torque converter oil temperature)
The data of the Quick Pm is recorded on once. T/M Main Press
If the Quick Pm is executed again, the current (Transmission main relief pressure)
data are overwritten. Accordingly, be sure to T/M Output Speed
save the data in the personal computer after (Transmission output speed)
executing the Quick Pm. Shift Position
(Transmission, travel, gear speed)
7) Using the analysis tool, read the data of the S/T Clutch Pos.
Quick Pm. (Steering clutch position)
a For the usage of the analysis tool, see the S/T Brake Pos. (Steering brake position)
operation manual. Hydr Oil Temp
(Hydraulic oil temperature)
Pump 1 Press
(Work equipment pump 1 oil pressure)
Pump 2 Press
(Work equipment pump 2 oil pressure)
Body Pitch Angle (Pitch angle)
17
9) Check "Click position graphic value display".
18
10) Click a point in the graph, and the value of
each measurement item at that point on the
X-axis is displayed under the graph.
(Example of displayed graph: This is differ-
ent from the actual graph.)
19
11) Enter the above value in the Pm Clinic Inspection Sheet.
a The relationship between the data necessary for the Pm Clinic and the measurement conditions is as
follows.
Measurement items
Transmission main relief pressure
Steering right clutch fill switch
Steering right brake fill switch

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

Front clutch fill switch
Rear clutch fill switch

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

Engine oil pressure
1st clutch fill switch

Blow-by pressure
Engine at low idling Engine speed
Q Q Q Q Q Q Q
Engine at high idling Q Q Q
Deceleration slow Q
High-pressure relief & engine at full throttle Q Q
High-pressure relief & engine at slow Q
Port relief & engine at full throttle Q Q
Port relief & engine at slow Q
Torque converter stall & engine at slow Q Q Q Q Q Q Q Q
Torque converter stall (F3) & engine at full throttle Q Q Q
Engine at full throttle
Torque converter stall & high-pressure relief Q
Engine at high idling o Engine at low idling Q Q
20
4. Downloading of Set Data 5. Check of Downloaded Data
1) Turn the starting switch to the ON position. a This step applies to works in the cab (on the
2) Click the icon of [VHMS Technical Analysis personal computer).
Tool] on the personal computer to start the 1) Check the set data with [View] function.
VHMS analysis tool. a For the operation procedures, refer to
the Operation and Maintenance Manual
for VHMS Technological Analysis Tool.
a Make sure that the [MFA0] code at the
time of snapshot is displayed in [Fault
History].
a Make sure that the SNAPSHOT data
has been recorded.
a Input [User Name] and [Password].

a For the operation procedures, refer to
the Operation and Maintenance Manual
2) After having checked the set data, terminate

[VHMS Technical Analysis Tool].
6. Disconnection of Personal Computer

1) Make sure the starting switch is turned to
the OFF position.
k Be sure to turn off the starting switch be-
fore connecting or disconnecting the
personal computer.
3) Use the [Download] function to download 2) Terminate the OS of the personal computer
the data recorded in the VHMS controller to and switch off the personal computer.
the personal computer. 3) Disconnect the wiring harness [1] of the
a For the operation procedures, refer to service kit W1 from the download connec-
the Operation and Maintenance Manual tors VDW and DL1.
a Make sure that the downloading has
completed before proceeding to the next
step.
21
7. Communication to Komatsu
After having completed Steps 1 to 15 success-
fully, please send the check sheet and the
VHMS data to VHMS/WebCARE Support Cen-
ter of Komatsu, Tokyo.
a Since Komatsu has to arrange the setting for
satellite communication on the receiving
side, please be sure to inform Komatsu of
the completion of the setting.
a Fax the check sheet to Komatsu.
a Send the VHMS data by Notes (LAN) or E-
mail (WAN).
Contact VHMS/WebCARE Support

Center by
Telephone: 81-3-5561-2765
FAX: 81-3-5561-4766
E-mail: webcare@komatsu.co.jp
22
23
24
25
26
27
U-dozer specification 1/5
Report No.
FIELD ASSEMBLY INSPECTION REPORT

(For Full U-dozer or Semi U-dozer)
After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.
Model-Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
D475A-5 SDA12V140
Service Meter Reading Date of Inspection Specification
Blade U Semi U (Dual Single)

Location of Machine at Inspection Ripper or
VGR. VMR. CW ( )
counterweight
Shoe width 910 mm 810 mm 710 mm

Distributors Name
Others
Customers name Address Signature : Delivery

Report No.
attached
Date :
Inspectors Comments
Inspectors Name KOMATSU USE ONLY :

C. Sheet Receiving Date :
Title
By :
Signature : Remark :
Check sheets filling instruction :
1. Use following indexes for entry of judgement

.......... Normal .......... Correction made on abnormal point
.......... Abnormal ........... Not applied
2. Enter actually measured values in parenthese, [ ].
Note :
(1) Criteria are based on the standards when the machine is shipped out of the factory
q Distributor copy Printed in Japan

Category Inspection Item Inspection Criteria

Main radiator coolant level Main radiator Sub-radiator
Above the bottom surface
Strainer
Sub radiator coolant level Full Strainer
Reserve tank coolant level (H+L)/2 to (H+10)
Engine oil level (H+L)/2 to (H+15) Engine : Stopped
Power train oil level L to (H+20) Engine : Low idling

(After 3 to 5 minutes)
Damper case oil level (H+L)/2 to (H+10) Engine : Stopped
COOLANT AND OIL LEVEL
Hydraulic tank oil level Refer to Operation Center to upper level Pitch back on the ground.
Between H - L & Maintenance of sight gauge Ripper point on the ground.
Manual Engine : stopped
Final draive oil level LH H to (H20) See operation manual.
RH Engine : stopped
Pivot shaft oil level Oil level (H+10) to (H+30) See operation manual.
LH
from shaft end
RH
Recoil spring oil level a=100 10 See operation manual.

LH
RH
Battery electrolyte level Between L and H
Check battery UPPER LEVEL Must be no adhesion of grease, loosened

LOWER LEVEL terminal, or crack
Window washer tank water level Full
LH
Fuel tank Full (1670 )

Horn Must be of no beat sound or sound deterioration.
Backup alarm Backup alarm must sound when the
(Starting engine) transmission lever is at the back position.
Monitor display Monitor must be turned on with buzzer sound, then go off
after 3 seconds. After that all gauge lamps must come on.
Operation of service meter No error code indicated in the service meter.
(Engine: Low idling) Before engine start, meter must not operate
when the key switch turned on.
Charge lamp (Engine: Low ilding) Must not light up when all lamps are turned on.
INSPECTION
Lamp ON (Head lamp, tail lamp and work lamp) Must light up when turned on.
Preheating switch (Auto preheating when at ON position) Preheating lamp (green) must light up
(Manual preheating when turned to left)
Main corrosion resistor cock Must be fully open.
Sub corrosion resistor cock Must be fully open.
Heater hose cock Must be fully open.
Controller error code indication (make sure that error does not recur) Clear error code after confirming it.
Air bleeding of the hydraulic cylinder Perform air bleeding of the hydraulic cylinder
Measurement of cab pressurization Max. 0.10 kPa {10 mm Aq.}
(If pressure is below standard value, adjust it,
referring to M-1, pages 4/7 - 7/7.)
Confirmation of VHMS controller initialization Must be done.
q Distributor copy

Parking lever The transmission lever must not be moved to the
F/R position when the parking lever is locked.
The engine must not be started when the

parking lever is free.
Operability of the travel lever

Gear change Must be of no pinching or abnormal sound.
Notch must not be released.
Forward-reverse Must be of no pinching or abnormal sound.
Must return to the N position smoothly.
Steering (right/left)
Play of the lever at N position Max. 10 mm
Check of the gear speed indication on the monitor panel. N, F1, F2, F3, R1, R2 and R3 are indicated.
Must be able to be shifted to any position with the engine at low Must be no indication error.
idling and the brake turned on.
FUNCTION / OPERATION
Check of front/rear adjustment of the travel lever box

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

Set the fuel dial to high idle position. Play of pedal A required at high idle position.
Check the deceleration RPM 900 50 rpm
Check of the fuel dial operation Must move smoothly.

Check of tilt direction
RH tilt
RH tilt Blade must move to left

LH tilt
Blade must move to right
LH tilt
Check of dual tilt and pitch 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) a + B
RH dual tilt Blade must move to right (both cylinders move) a + A
DUAL
LH tilt Blade must move to left (right cylinder moves) B + b

RH tilt Blade must move to right (left cylinder moves) A + b
Check of tilting restriction adjustment Note: See manual of tilting restriction.

Measure tilting angle at the top of the cutting LH tilt 12 1
edge when the tilting limit switch is turned on.
RH tilt 12 1
q Distributor copy

Check of the clearance between frame and track Difference of LH and RH is max. 30 mm
LH
(Measure on flat ground)
Move Blade up and down and stop 100 mm
RH
above ground, and 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 must not move)
Check of the blade lever floating Must be of no hydraulic drift (Engine: Low idling)
WORK EQUIPMENT
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
Quick dropping of the blade from top position. 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 ilding) Must be bridged with the blade and the ripper (Chassis)
Check of the accumulator function (blade, ripper) Must function immediately after the engine
stops then drop from the top to the ground.
Blade cylinder oil leakage Must be none.

Leakage from U-packing, damaged rod, quick drop valve, LH
tube, flange or dust seal RH
Tilt cylinder/pitch cylinder oil leakage Must be none.
Leakage from U-packing, damaged rod, LH
Track tension adjustment Tense a string or a bar between the
first carrier roller and the idler to
With the gear at F1 and the engine at low idling, travel on flat LH 20 30 mm measure distance between the
place for about 10 m, and when the grouser comes over the RH 20 30 mm string (bar) and the grouser.
first carrier roller, stop the machine by depressing the brake (Difference between
UNDERCARRIAGE
pedal. LH and RH : Max. 20 mm)

Target is 30 mm when new.
Carrier roller alignment Flanges must be free from contact
Travel on flat place with the gear at F1 and R1 for about 10 m, LH with links at all times.
repeatedly about 3 or 4 times, then gradually apply brake to RH
stop.
Undercarriage oil leakage 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.
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 Must work smoothly to securely lock
Opening/closing and locking effect of the left/right side slide glass Must work smoothly to securely lock.
Lighting of the room lamp Must come on/go off by turning the switch on/off.
Operation of the window wiper and the window washer Must be on/off by turning the switch on/off.
Wiper: Must operate smoothly (without beat noise)
Operation of the radio and cassette system Must operate correctly
CABIN
(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 Power of 12 V must be supplied.
Check by connecting the radio 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
Air flow amount must be able to be adjusted (Hi, Mid or Lo) Air comes out from each blowout port.
Louver must be smoothly switched
q Distributor copy

LUBRICATION Portions to be lubricated Qty Example: U blade
Equalizer bar side pin shaft 2
Equalizer bar center pin shaft 1
Blade lift cylinder support shaft and yoke 6
Blade center pin 1
Blade oblique arm ball joint 3
Brace screw 2
Check of ripper direction
a Raise
c Lower
A Tilt in
B Tilt out
Ripper lift cylinder oil leakage Must be none

U-packing, damaged rod, tube, flange, dust seal loosing LH
RH
Ripper tilt cylinder oil leakage Must be of no contact.
RH
Contact with the hose at ripper operation Must be of no contact.
Entire operation area must be chedked
Creak of the ripper link pin Must be of no creak.
RIPPER
Check of the pin puller switch direction Must be the same as the pin puller cylinder
A: Pin out operation direction
B: Pin in
Check of the pin puller cylinder hose clamp position Must be of no contact
(Entire operation area must be checked) Must be of no excess hose tension.
Pin puller cylinder oil leakage Must be none
Leakage from U-packing, damaged rod, tube or flange
Check of ripper lubricated hose installation LH Must be no contact or no excess bend.
RH
Portions to be lubricated Qty Must be lubricated (right and left)
Ripper lift cylinder head i 2
Ripper lift cylinder bottom y 2
Ripper tilt cylinder head u 2
Ripper tilt cylinder bottom t 2
Ripper arm pin (front) o 2
Ripper arm pin (rear) !0 2
q Distributor copy
Superdozer specification 1/5
Report No.
FIELD ASSEMBLY INSPECTION REPORT

After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.
Model-Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
D475A-5 SDA12V140
Service Meter Reading Date of Inspection Specification
Blade Super.
Location of Machine at Inspection Ripper or
VGR. VMR. CW ( )
counterweight
Shoe width 910 mm 810 mm

Distributors Name
Others
Customers name Address Signature : Delivery

Report No.
attached
Date :
Inspectors Comments
Inspectors Name KOMATSU USE ONLY :

C. Sheet Receiving Date :
Title
By :
Signature : Remark :
Check sheets filling instruction :
1. Use following indexes for entry of judgement

.......... Normal .......... Correction made on abnormal point
.......... Abnormal ........... Not applied
2. Enter actually measured values in parenthese, [ ].
Note :
(1) Criteria are based on the standards when the machine is shipped out of the factory
q Distributor copy Printed in Japan


Main radiator coolant level Main radiator Sub-radiator
Above the bottom surface
Strainer
Sub radiator coolant level Full Strainer
Reserve tank coolant level (H+L)/2 to (H+10)
Engine oil level (H+L)/2 to (H+15) Engine : Stopped
Power train oil level L to (H+20) Engine : Low idling

(After 3 to 5 minutes)
Damper case oil level (H+L)/2 to (H+10) Engine : Stopped
Hydraulic tank oil level Refer to Operation Center to upper level Pitch back on the ground.
of sight gauge
COOLANT AND OIL LEVEL
Between H - L & Maintenance Ripper point on the ground.

Manual Engine : stopped
Final draive oil level LH H to (H20) See operation manual.
RH Engine : stopped
Pivot shaft oil level Oil level (H+10) to (H+30) See operation manual.
LH
from shaft end
RH
Recoil spring oil level a=100 10 See operation manual.

LH
RH
Battery electrolyte level Between L and H
Check battery UPPER LEVEL Must be no adhesion of grease, loosened

LOWER LEVEL terminal, or crack
Window washer tank water level Full
LH
Fuel tank Full (1670 )

Horn Must be of no beat sound or sound deterioration.
Backup alarm Backup alarm must sound when the
(Starting engine) transmission lever is at the back position.
Monitor display Monitor must be turned on with buzzer sound, then go off
after 3 seconds. After that all gauge lamps must come on.
Operation of service meter No error code indicated in the service meter.
(Engine: Low idling) Before engine start, meter must not operate
when the key switch turned on.
Charge lamp (Engine: Low ilding) Must not light up when all lamps are turned on.
INSPECTION
Lamp ON (Head lamp, tail lamp and work lamp) Must light up when turned on.
Preheating switch (Auto preheating when at ON position) Preheating lamp (green) must light up
(Manual preheating when turned to left)
Main corrosion resistor cock Must be fully open.
Sub corrosion resistor cock Must be fully open.
Heater hose cock Must be fully open.
Controller error code indication (make sure that error does not recur) Clear error code after confirming it.
Air bleeding of the hydraulic cylinder Perform air bleeding of the hydraulic cylinder
Measurement of cab pressurization Max. 0.10 kPa {10 mm Aq.}
(If pressure is below standard value, adjust it,
referring to M-1, pages 4/7 - 7/7.)
Confirmation of VHMS controller initialization Must be done.
q Distributor copy

Parking lever The transmission lever must not be moved to the
F/R position when the parking lever is locked.
The engine must not be started when the

parking lever is free.
Operability of the travel lever

Gear change Must be of no pinching or abnormal sound.
Notch must not be released.
Forward-reverse Must be of no pinching or abnormal sound.
Must return to the N position smoothly.
Steering (right/left)
Play of the lever at N position Max. 10 mm
Check of the gear speed indication on the monitor panel. N, F1, F2, F3, R1, R2 and R3 are indicated.
Must be able to be shifted to any position with the engine at low Must be no indication error.
idling and the brake turned on.
Check of front/rear adjustment of the travel lever box

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

Set the fuel dial to high idle position. Play of pedal A required at high idle position.
Check the deceleration RPM 900 50 rpm
Check of the fuel dial operation Must move smoothly.

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

RH tilt
LH tilt RH tilt Blade must move to left

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

Measure tilting angle at the top of the cutting LH tilt 7 1
edge when the tilting limit switch is turned on.
RH tilt 7 1
Check of auto pitch back operation 52 3
After pitch dumping, move backward with the speed gear at R1, Blade should be horizontal after pitch back
then turn the pitch back switch on. to the stroke end, and pitch dumping is
performed to return to the digging posture.
q Distributor copy

Check of the clearance between frame and track Difference of LH and RH is max. 30 mm
LH
(Measure on flat ground)
Move Blade up and down and stop 100 mm
RH
above ground, and 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 must not move)
Check of the blade lever floating Must be of no hydraulic drift (Engine: Low idling)
WORK EQUIPMENT
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
Quick dropping of the blade from top position. 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 ilding) Must be bridged with the blade and the ripper (Chassis)
Check of the accumulator function (blade, ripper) Must function immediately after the engine
stops then drop from the top to the ground.
Blade cylinder oil leakage Must be none.

Leakage from U-packing, damaged rod, quick drop valve, LH
Tilt cylinder/pitch cylinder oil leakage Must be none.
Leakage from U-packing, damaged rod, LH
Track tension adjustment Tense a string or a bar between
the first carrier roller and the idler
With the gear at F1 and the engine at low idling, travel on flat LH 20 30 mm to measure distance between the
place for about 10 m, and when the grouser comes over the RH 20 30 mm string (bar) and the grouser.
first carrier roller, stop the machine by depressing the brake (Difference between
UNDERCARRIAGE
pedal. LH and RH : Max. 20 mm)

Target is 30 mm when new.
Carrier roller alignment Flanges must be free from contact
Travel on flat place with the gear at F1 and R1 for about 10 m, LH with links at all times.
repeatedly about 3 or 4 times, then gradually apply brake to RH
stop.
Undercarriage oil leakage 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.
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 Must work smoothly to securely lock
Opening/closing and locking effect of the left/right side slide glass Must work smoothly to securely lock.
Lighting of the room lamp Must come on/go off by turning the switch on/off.
Operation of the window wiper and the window washer Must be on/off by turning the switch on/off.
Wiper: Must operate smoothly (without beat noise)
Operation of the radio and cassette system Must operate correctly
CABIN
(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 Power of 12 V must be supplied.
Check by connecting the radio 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
Air flow amount must be able to be adjusted (Hi, Mid or Lo) Air comes out from each blowout port.
Louver must be smoothly switched
q Distributor copy

LUBRICATION Portions to be lubricated Qty Example: U blade
Equalizer bar side pin shaft 2
Equalizer bar center pin shaft 1
Blade lift cylinder support shaft and yoke 6
Blade center pin 1
Blade oblique arm ball joint 3
Brace screw 2
Check of ripper direction
a Raise
c Lower
A Tilt in
B Tilt out
Ripper lift cylinder oil leakage Must be none

RH
Ripper tilt cylinder oil leakage Must be of no contact.
RH
Contact with the hose at ripper operation Must be of no contact.
Entire operation area must be chedked
Creak of the ripper link pin Must be of no creak.
RIPPER
Check of the pin puller switch direction Must be the same as the pin puller cylinder
A: Pin out operation direction
B: Pin in
Check of the pin puller cylinder hose clamp position Must be of no contact
(Entire operation area must be checked) Must be of no excess hose tension.
Pin puller cylinder oil leakage Must be none
Leakage from U-packing, damaged rod, tube or flange
Check of ripper lubricated hose installation LH Must be no contact or no excess bend.
RH
Portions to be lubricated Qty Must be lubricated (right and left)
Ripper lift cylinder head i 2
Ripper lift cylinder bottom y 2
Ripper tilt cylinder head u 2
Ripper tilt cylinder bottom t 2
Ripper arm pin (front) o 2
Ripper arm pin (rear) !0 2
q Distributor copy

Field Assembly Manual: Bulldozer

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Field Assembly Manual: Bulldozer

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GEN00012-00

Copyright 2004 Komatsu

Operator for assembly

Mechanics Sharing of work

Semi-U-tiltdozer + variable giant ripper

Full U-tiltdozer + variable giant ripper

2. Preparation and check of slings and tools

3. Check of actual work

12 Check of oil level and addition of oil

14 Adjustment of track tension

45ton 2 45ton 1 45ton 1 45ton 1

1. Arrangement before work 1. Removal of stand

Right straight frame

A Overall length (mm) 6,600

A Overall length (mm) 4,604

A Overall length (mm) 6,205

A Overall length (mm) 5,263

A Overall length (mm) 6,465

Shoe width 810

(2) Blade lift cylinder

A Overall length (mm) 2,900

(3) Ripper cylinder

A Overall length (mm) 1,545

Giant ripper arm

A Overall length (mm) 2,300

Giant ripper shank

A Overall length (mm) 115

A Overall length (mm) 1,875

A Overall length (mm) 2,100

A Overall length (mm) 1,950

Chassis stand (Front side)

No. Material Qty Remarks

No. Remarks Qty No. Remarks Qty

Sling (Track frame) : Detail 01

40 40 40 60 100 49 M48 160

50 50 50 75 125 62 M56 200

70 70 70 105 178 85 M80 6 280

1. Tightening torque of bolts

2-2. If the material of male threads is S43C, apply Table 2.

02 19 35 - 63 {3.5 - 6.5} 44 {4.5}

22 54 - 93 {5.5 - 9.5} 74 {7.5}

04 27 84 - 132 {8.5 - 13.5} 103 {10.5}

05 32 128 - 186 {13.0 - 19.0} 157 {16.0}

06 36 177 - 245 {18.0 - 25.0} 216 {22.0}

{10} 41 177 - 245 {18.0 - 25.0} 216 {22.0}

{12} 46 197 - 294 {20.0 - 30.0} 245 {25.0}

{14} 55 246 - 343 {25.0 - 35.0} 294 {30.0}

When connecting hoses, take care not to twist them.

Used to prevent rubber gaskets,

Used in places requiring an imme-

Features: Resistance to heat and

Adhesive: Used as adhesive or sealant for

Polyethylene Used as sealant for machined

Holtz Used as heat-resisting sealant for

Quick hardening type adhesive

Quick hardening type adhesive

Resistance to heat, chemicals

Used as adhesive or sealent for

Used as sealant for various

Features: Silicon based, resis-

Ftures: Silicon based, quick hard-

Three bond 100 g Tube Used as heat-resisting sealant for

60g Can Used as lubricant for sliding por-