GEN00241-00

BULLDOZER D475A -8R

SERIAL NUMBERS 55001 and up
FOREWORD

Since this machine is large in size, it is divided into some units to meet the transportation conditions and
regulations applied to the transportation route when shipped from our plant.

This manual describes how to assemble the units into the complete machine in the field. We hope that this
machine will display its quality and you will use it safely according to the operation manual.

Many units are large in size and heavy in weight and may be handled in a dangerous place or posture and
many workers may have to work together to sling them with cranes. Accordingly, before starting the assembly
work, the work supervisor is required to hold a safety meeting to oblige the workers to put on protective gear
and appoint a work leader and a crane work signal man and allot roles to all the workers for safe work.

In particular, the above meeting is more important when workers of different languages and customs work
together.
The following is a reference supervision system diagram.

Instruction system

Work leader
Director
Work supervisor Crane director and
deputy director

Operator for assembly

Liaison man

Mechanics Sharing of work

Interpreter

Note that this manual does not describe the whole specification of the machine but describes only the basic
specification.
 CONTENTS

PRECAUTIONS FOR FIELD ASSEMBLY ........................................................................... 1

DISPOSAL OF REMOVED PARTS ..................................................................................... 2
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENTS, AND SCHEDULE .................. 3
KIT LAYOUT DIAGRAM (WORK SPACE LAYOUT) ........................................................... 4
PACKING STYLE FOR TRANSPORTATION ...................................................................... 5
SPECIFICATIONS................................................................................................................ 19
TOOL LIST FOR FIELD ASSEMBLY .................................................................................. 21
DIAGRAM FOR TOOLS ..................................................................................................... 25
TIGHTEN TORQUE TABLE ................................................................................................ 34
COATING MATERIALS LIST ............................................................................................... 38
SELECTION OF WIRE ROPES USED FOR ASSEMBLY ................................................... 42
SELECTION OF NYLON SLINGS USED FOR ASSEMBLY ............................................... 43

No. Item Page

A ASSEMBLY PROCEDURE 44
A-1 Installation of track shoe assembly 45
A-2 Installation of machine body (chassis) 46
A-3 Installation of operator's cab assembly (When operator cab assembly is not installed) 49
A-4 Installation of pivot shaft (When pivot shaft is not installed) 56
A-5 Installation of final drive assembly 58
A-6 Installation of undercover (When undercover is not installed) 63
A-7 Installation of blade lift hydraulic cylinder 65
A-8 Installation of undercarriage -1 69
A-8 Installation of undercarriage -2 73
A-9 Adding oil to pivot chamber 79
A-10 Inspection of oil level and coolant level 80
A-11 Installation of ripper-1 (Machine with ripper) 83
A-11 Installation of ripper-2 (Machine with ripper) 85
A-11 Installation of ripper-3 (Machine with ripper) 87
A-11 Installation of ripper-4 (Machine with ripper) 89
A-11 Installation of ripper-5 (Machine with ripper) 91
A-11 Installation of ripper-6 (Machine with ripper) 92
A-11 Installation of counterweight (Machine with counterweight) 93
A-12 Installation of trunnion 96
A-13 Installation of track 97
A-14 Adjusting of track tension 100
A-15 Installation of mask 102
A-16 Installation of handrail / step on right side of radiator 103
A-17 Installation of handrail / step on left side of radiator 106
A-18 Installation of cab right side cover (When cab right side cover is not installed) 109
A-19 Installation of cab left side cover (When cab left side cover is not installed) 110
A-20 Assembling of blade unit-1 (Machine with semi-U blade/full-U blade) 111
A-20 Assembling of blade unit-2 (Machine with semi-U blade/full-U blade) 113
A-20 Assembling of blade unit-3 (Machine with semi-U blade/full-U blade) 116
A-20 Assembling of blade unit-4 (Machine with semi-U blade/full-U blade) 120
A-20 Assembling of blade unit-5 (Machine with semi-U blade/full-U blade) 123
A-20 Assembling of blade unit-1 (Machine with superdozer blade) 124
A-20 Assembling of blade unit-2 (Machine with superdozer blade) 126
A-20 Assembling of blade unit-3 (Machine with superdozer blade) 129
A-20 Assembling of blade unit-4 (Machine with superdozer blade) 133
A-20 Assembling of blade unit-5 (Machine with superdozer blade) 136
A-21 Installation of blade assembly (Machine with semi-U blade/full-U blade) 137
A-21 Installation of blade assembly (Machine with superdozer blade) 143
A-22 Installation of KOMTRAX antenna 149
A-23 Installation of ROPS 150
A-24 Installation of engine air intake port hood (When engine air intake port hood is not installed) 151
A-25 Installation of pre-cleaner (optional) (When pre-cleaner is not installed) 152
A-26 Installation of engine exhaust pipe (When engine exhaust pipe is not installed) 154
A-27 Installation of headlamp (When headlamp is not installed) 155
A-28 Installation of giant ripper shank 156
A-29 Adjustment of blade tilt control angle (Machine with semi-U blade/full-U blade) 157
A-30 Adjustment of blade tilt control angle (Machine with superdozer) 161
A-31 ABLADE PITCH CURRENT VALUE CORRECTION (Machine with superdozer) 164
A-32 Installation of platform - 1 166
A-32 Installation of platform - 2 168
A-32 Installation of platform - 3 170
A-32 Installation of platform - 4 171
A-33 Greasing each part 172
A-34 Bleeding air from hydraulic cylinder 175
A-35 Bleeding air from work equipment pump and fan pump 176
A-36 Installation of quick charge piping (optional) 177
A-37 Installation of ladder - 1 (For machine with ladder) 180
A-37 Installation of ladder - 2 (For machine with ladder) 182
A-37 Installation of ladder - 3 (For machine with ladder) 185
A-37 Installation of ladder - 4 (For machine with ladder) 186
A-38 Installation of ladder - 5 (For machine with ladder) 187
A-38 Installation of ladder - 1 (For machine with retrofitting ladder) 188
A-38 Installation of ladder - 2 (For machine with retrofitting ladder) 190
A-38 Installation of ladder - 3 (For machine with retrofitting ladder) 192
A-38 Installation of ladder - 4 (For machine with retrofitting ladder) 194
A-38 Installation of ladder - 5 (For machine with retrofitting ladder) 197
A-38 Installation of ladder - 6 (For machine with retrofitting ladder) 200
A-38 Installation of ladder - 7 (For machine with retrofitting ladder) 203
A-39 Installation of access light and additional work lamp (optional) 205
M CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY 211
M-1 Checking machine monitor - 1 212
M-1 Checking machine monitor - 2 213
M-1 Checking machine monitor - 3 214
M-1 Checking machine monitor - 4 216
M-1 Checking machine monitor - 5 219
M-2 Adjustment menu 244
M-3 Change of return filter (Standard filter → Flushing filter) 245
M-4 Flushing hydraulic circuit and bleeding air from cylinder - 1 247
M-5 Change of return filter (Flushing filter → Standard filter) 248
M-6 Bleeding air from cylinder - 2 250
M-7 How to start operation of KOMTRAX terminal and how to initialize KOMTRAX Plus controller 251
M-8 No-injection cranking of engine 252

Appendix
1 INSTALLATION OF SPILL GUARDS
Appendix
2 FIELD ASSEMBLY INSPECTION REPORT
Appendix
3 Pm-CLINIC
PRECAUTIONS FOR FIELD ASSEMBLY

1. Selection of workplace
1) When selecting a workplace, consider the following.
ꞏ Is the ground flat? (The ground surface must not be uneven or sloping.)
ꞏ Is the road to inlet/outlet of the workplace sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.

2. Work procedure
The work supervisor or the work leader should not do the work while reading this manual but should read and
understand this manual thoroughly and then start the work.

In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the work
place so that all the workers will observe the precautions.

3. Preparation and check of personal protective equipment, slings, and tools

The work supervisor or the work leader must perform the following checks about personal protective equipment,
slings, and tools.

1) All the workers are wearing helmets and other personal protective equipment which they are obliged to wear.
If special personal protective equipment is necessary, check that it is prepared. In addition, check in advance
that it is can be used without problem.

2) All the slings and tools are prepared. Check in advance that they are ready to be used without problem. In
particular, check wooden blocks for internal decay or cracking.

4. Check during actual work

The work supervisor or the work leader must check the following items constantly and make all the workers
observe them.

1) The parking brakes of the trailer and crane truck are applied securely and the wheels of those machines are
chocked during work. The outriggers are used securely, if equipped.

2) The temperature and pressure of the engine, hydraulic oil, coolant, etc. are lowered sufficiently before the
work.

3) When the operator starts the engine, he/she warns around by making an arranged signal such as sounding
of the horn. In addition, all control levers are in neutral. Moreover, the operator checks that the fuel control
dial (or the fuel control lever) is at the low idle position.

4) Workers carefully balance the load lifted by a crane, etc.

5) Only authorized people are allowed to enter the workplace.

5. The work supervisor or the work leader is required to hold a meeting with all the workers at the beginning of
every morning and explain the work plan of the day to them and give them instructions to observe the safe work.

6. Precautions when starting engine

When starting the engine for the first time after assembling it in the field, lubricate its inside with engine oil. For
details, see “M-8 No-injection cranking of engine”.

1
DISPOSAL OF REMOVED PARTS

As described in “Foreword”, when this machine is transported, it is divided into some units of the body, undercarriage, cab,
work equipment, etc. to meet the conditions of transportation or regulations.

Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic devices,
and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and dust, and damage
during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate
loading, unloading, and crane work.

The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after completion of the
machine. Since they are useful when the machine needs to be transported in future, however, we recommend you to keep
them as long as possible.

2
KIT LAYOUT DIAGRAM (WORK SPACE LAYOUT)

ꞏ When selecting the work site, see "Precautions for field assembly" as well.
ꞏ Unload the delivered kits (components) from the trailer and truck, then arrange them as shown in the layout drawing below.
ꞏ The layout drawing below is a reference image for a workplace of approximately 30 m by 30 m. Decide the layout
according to the area and shape of the actual workplace, referring to the packing style for transportation of each kit
(component) described later.

Approx. 30 m

Blade

R.H. Straight frame

L.H. Straight frame
Track

Track
L. H. track

R. H. track
Frame A

Frame A

Approx. 30 m
Mobile crane
Body
Mobile crane

Pivot shaft (*) Pivot shaft (*)

(70 t)

(70 t)

Final drive assembly Finaldrive

Final drive assembly

Ripper parts Cab assembly (*)

Platform ROPS guard
Ladder (*) Undercover (*)
Accessories, etc.

(*): Installation of ladder, CAB assembly, pivot shaft, and undercover may not be necessary
depending on destination.

4
PACKING STYLE FOR TRANSPORTATION

Then machine is divided into kits as a rule when it is transported from the production plant to the field
(assembly site).

Packing style of each kit

ꞏ Machine body

A Overall length 6,810 mm

B Overall height 4,120 mm
C Overall width 3,342 mm
Weight 38,800 kg

ꞏ Remove the track frame assembly.

C A

A Overall length 4,800 mm

B Overall height 1,500 mm
C Overall width 982 mm
Weight 12,200 kg
* This part is delivered in 2 sets; 1 each for right and left.

5
ꞏ Work equipment
(1) Full-U blade assembly (For only full-U blade specification)

A B

A Overall length 6,205 mm

B Overall height 2,610 mm
C Overall width 2,240 mm
Weight 11,750 kg

(2) Semi-U blade assembly (For only semi-U blade specification)

A B

A Overall length 5,390 mm

B Overall height 2,690 mm
C Overall width 1,745 mm
Weight 10,150 kg

6
 (3) Superdozer blade assembly (For only superdozer blade specification)

A B

A Overall length 6,465 mm

B Overall height 2,690 mm
C Overall width 1,950 mm
Weight 13,000 kg

ꞏ Separation and connection of track shoe assembly

Shoe width 710 mm 810 mm 910 mm

A 4,500 mm
B 1,400 mm
Weight 6,770 kg 7,220 kg 7,690 kg

7
ꞏ Blade straight frame assembly (L.H.)

Common to semi-U and full-U Machine with superdozer blade

A Overall length 4,970 mm 5,025 mm

B Overall height 740 mm 705 mm
C Overall width 670 mm 670 mm
Weight 1,805 kg 1,895 kg

ꞏ Blade straight frame assembly (R.H.)

A
Common to semi-U and full-U Machine with superdozer blade

A Overall length 4,970 mm 5,025 mm

B Overall height 770 mm 735 mm
C Overall width 965 mm 965 mm
Weight 2,525 kg 2,590 kg

8
ꞏ Hydraulic cylinder
(1) For blade tilt

C A

Common to semi-U and full-U Machine with superdozer blade

A Overall length 1,930 mm 1,754 mm

C Overall width 350 mm 350 mm
Weight 504 kg 508 kg

(2) For blade lift

A Overall length 2,705 mm

B Overall height 695 mm
C Overall width 500 mm
Weight 523 kg
* This part is delivered in 2 sets; 1 each for right and left.

9
 (3) For ripper

C A

For lift For tilt

A Overall length 1,748 mm 1,698 mm
C Overall width 307 mm 307 mm
Weight 373 kg 383 kg
* This part is delivered in 2 sets for both lift and tilt; 1 each for right and left.

ꞏ Final drive assembly

A C

A Overall length 1,320 mm

B Overall height 1,320 mm
C Overall width 945 mm
Weight 3,600 kg
* This part is delivered in 2 sets; 1 each for right and left.

10
ꞏ Pivot shaft assembly

C A

A Overall length 885 mm

B Overall height 560 mm
C Overall width 580 mm
Weight 400 kg
* This part is delivered with torsion seal fitted.
* This part is delivered in 2 sets for each machine.

ꞏ Undercover
(1) Engine undercover

C
A

A Overall length 1,640 mm

B Overall height 395 mm
C Overall width 805 mm
Weight 300 kg
* This part is delivered with hinge and inspection cover installed.

11
(2) Power train assembly undercover (Front)

C
A
B

A Overall length 1,640 mm

B Overall height 395 mm
C Overall width 890 mm
Weight 340 kg
* This part is delivered with hinge and inspection cover installed.

(3) Power train assembly undercover (Rear)

C
A

A Overall length 1,650 mm

B Overall height 395 mm
C Overall width 980 mm
Weight 420 kg
* This part is delivered with hinge and inspection cover installed.

12
ꞏ Giant ripper beam

C
A

A Overall length 1,230 mm

B Overall height 1,930 mm
C Overall width 1,500 mm
Weight 2,255 kg
* This part is delivered with hydraulic cylinder rod mounting pin installed.

ꞏ Giant ripper arm and multi-shank ripper arm

A C

A Overall length 2,290 mm

B Overall height 580 mm
C Overall width 1,781 mm
Weight 1,750 kg
* This part is delivered with beam connecting pin installed.

13
ꞏ Giant ripper shank assembly

A Thickness 115 mm
B Overall height 2,800 mm
C Overall width 940 mm
Weight 1,000 kg
* This part is delivered with protector and point installed.

ꞏ Multi-shank ripper beam (For only multi-shank ripper specification)

B
C

A Thickness 1,210 mm
B Overall height 1,930 mm
C Overall width 3,065 mm
Weight 3,615 kg

14
ꞏ Multi-shank ripper shank assembly (For only multi-shank ripper specification)

A Thickness 115 mm
B Overall height 2,170 mm
C Overall width 775 mm
Weight 740 kg
Q'ty 3 pcs.
* This part is delivered with protector and point installed.

ꞏ Operator’s cab assembly

B C

A Overall length 2,420 mm

B Overall height 1,840 mm
C Overall width 1,855 mm
Weight 1,400 kg

15
ꞏ ROPS guard

A C

A Overall length 2,100 mm

B Overall height 1,325 mm
C Overall width 500 mm
Weight 745 kg
For ROPS, see “Specifications”.

ꞏ Platform ladder (L.H.)

A Overall length 3,420 mm

B Overall height 1,680 mm
C Overall width 770 mm
Weight 180 kg

16
ꞏ Platform ladder (Rear)

A
A Overall length 965 mm
B Overall height 1,120 mm
C Overall width 2,250 mm
Weight 155 kg

ꞏ Platform ladder (Related parts)

A Overall length -
B Overall height -
C Overall width -
Weight 200 kg

17
ꞏ Ladder (For only machines with ladder)

A Overall length 3,710 mm

B Overall height 1,030 mm
C Overall width 480 mm
Weight 450 kg

ꞏ Counterweight (For only counterweight specification)

B C1 C2

A Overall length 1,950 mm

B Overall height 1,300 mm
C1 1,361 mm
Overall width
C2 1,290 mm
Weight 7,420 kg

18
SPECIFICATIONS
ꞏ Semi-U tilt dozer + variable giant ripper

ꞏ Full-U tilt dozer + variable giant ripper

19
ꞏ Superdozer + counterweight

Semi-U tilt dozer + variable giant Full-U tilt dozer + variable giant
Item Superdozer + counterweight
ripper ripper

Operating weight *1
113,700 kg 114,600 kg 116,900 kg
(excluding operator’s weight)
Blade unit weight (including cylinder) 18,300 kg 19,900 kg 22,300 kg
Ripper unit weight (including cylinder) 7,270 kg -
Counterweight - 7,420 kg
Engine name Komatsu SAA12V140E-7 diesel engine
Engine rated output 777 kw/2,000 rpm {1,040 PS/2,000 rpm}
Overall length 11,300 mm 11,800 mm 10,550 mm
Overall height (*2 with ROPS) 4,710 mm (4,795 mm)
Overall width 5,430 mm 6,205 mm 6,465 mm
Travel speed (1st / 2nd / Forward 3.4 km/h / 6.2 km/h / 7.4 km/h / 11.2 km/h
3rd (Low) / 3rd) Reverse 4.5 km/h / 8.4 km/h / 9.0 km/h / 14.3 km/h
* 1. Operator's cab and air conditioner. With ROPS guard.
* 2. ROPS is an abbreviation for Rollover Protective Structure.

20
TOOL LIST FOR FIELD ASSEMBLY

No. Part name Specification Q'ty Remarks

1 Mobile crane Max. lifting load: 686 kN {70 t} 2
2
Discharged pressure: 7 kg/cm min.
2 Air compressor 3 1
Discharged volume: 3.5 m /min
Use when adding spill guard (optional)
Welding machine (See Decide specifications and quantity according to blade of work equipment.
3
Remarks column) to drawings shown in Remarks column. For drawings, see “Attached material:
Installation procedure for spill guard”.

Chain lever hoist (Chain Using load: 15.7 kN {1.6 t} 2

4 JIS B8819 or equivalent
block) Using load: 31.4 kN {3.2 t} 2
φ12 mm x 2 m (11 kN {1.2 t}) 4
ꞏ ( ): Load when
φ12 mm x 4 m (11 kN {1.2 t}) 1 vertical sling is
used
φ16 mm x 2 m (2.1 kN {2.1 t}) 4
φ20 mm x 5 m (32 kN {3.3 t}) 4 ꞏ JIS B8817 or
equivalent
5 Wire rope sling φ20 mm x 6 m (32 kN {3.3 t}) 4
ꞏ Rope: JIS
φ24 mm x 2 m (47 kN {4.8 t}) 2
G3525 24A or
φ32 mm x 5 m (84 kN {8.56 t}) 4 equivalent
φ52 mm x 3 m (238 kN {24.3 t}) 2 For lifting body
φ65 mm x 5 m (373 kN {38 t}) 1 For lifting body
25 mm wide x 1.5 m (4.9 kN: 0.5 t) 1
25 mm wide x 3 m (4.9 kN: 0.5 t) 2
ꞏ ( ): Load when vertical sling is used
Belt sling (made of synthetic
6 50 mm wide x 3 m (9.8 kN: 1 t) 2 ꞏ JIS B8818, Grade I, Type E or
fibers)
equivalent
50 mm wide x 4 m (9.8 kN: 1 t) 2
100 mm wide x 4 m (19.6 kN: 2 t) 2

12.5 mm in wire diameter x 1.5 m (49

7 Load chain 1
kN: 5 t)

Tightening capacity (torque):

8 Hydraulic wrench 1
6860 Nm {700 kgm} min. For tightening track master link bolt
9 Hydraulic wrench socket Nominal width across flats: 55 mm 1

Tightening capacity (torque):

10 1:16 torque multiplier wrench 1
4400 Nm {450 kgm} min.

Nominal width across flats: 50 mm 1

Socket for 1:16 torque Nominal width across flats: 46 mm 1

11
multiplier wrench Nominal width across flats: 41 mm 1
Nominal width across flats: 36 mm 1

Tightening capacity (torque):

1
2940 Nm {300 kgm} min.

980 Nm {100 kgm} min. 1

12 Pneumatic impact wrench
315 Nm {32 kgm} min. 1
160 Nm {16 kgm} min. 1
140 Nm {14 kgm} min. 1

21
No. Part name Specification Q'ty Remarks
Nominal width across flats: 55 mm 1
Nominal width across flats: 50 mm 1
Nominal width across flats: 46 mm 1
Nominal width across flats: 41 mm 1
Nominal width across flats: 36 mm 1
Socket (For pneumatic
13 Nominal width across flats: 32 mm 1
impact wrench)
Nominal width across flats: 30 mm 1
Nominal width across flats: 27 mm 1
Nominal width across flats: 24 mm 1
Nominal width across flats: 22 mm 1
Nominal width across flats: 19 mm 1
Length: 600 mm 1 Extension bar for pneumatic impact
14 Extension bar
Length: 300 mm 1 wrench

Tightening capacity (torque): ꞏ Prepare torque wrenches so that

1
2060 Nm {210 kgm} min. sockets for pneumatic impact
wrenches are available commonly.
1375 Nm {140 kgm} min. 1 ꞏ If they cannot be prepared,
15 Torque wrench
590 Nm {60 kgm} min. 1 separately prepare sockets for torque
wrenches. (Nominal width across flats
412 Nm {42 kgm} min. 1 is same as sockets for impact
180 Nm {18 kgm} min. 1 wrench.)

Nominal width across flats: 50 mm 2

Nominal width across flats: 46 mm 2
Nominal width across flats: 41 mm 2
Nominal width across flats: 36 mm 2
Nominal width across flats: 32 mm 2
For tightening hydraulic hose sleeve
16 Wrench Nominal width across flats: 30 mm 2
nuts
Nominal width across flats: 27 mm 2
Nominal width across flats: 24 mm 2
Nominal width across flats: 22 mm 2
Nominal width across flats: 19 mm 2
Nominal width across flats: 17 mm 2
ꞏ Match couplers at both ends with air
Inside diameter: 6 - 10 mm, Length:
Pneumatic hose and coupler compressor, pneumatic impact
17 30 m 1
(for pneumatic tools) wrench, grease pump, and oil supply
Using pressure: 0.69 MPa {7 kg/cm2}
pump.

Thread size: M12

4
Using load: 2.16 kN {220 kg}

Thread size: M16 ꞏ JIS B1168 or equivalent

18 Eyebolt 2
Using load: 4.41 kN {450 kg} ꞏ Using load is for vertical lifting

Thread size: M24

1
Using load: 9.32 kN {950 kg}

22
No. Part name Specification Q'ty Remarks
SD16-M, Using load: 9.8 kN {1 t} 4
SD22-M, Using load: 19.6 kN {2 t} 1
SB28-S, Using load: 78.5 kN {8 t} 1
SD34-M, Using load: 49 kN {5 t} 2 ꞏ JIS B2801 or equivalent
ꞏ Specification symbols indicate
19 Lifting shackle SB36-S, Using load: 122.6 kN {12.5 t} 2
shape, nominal No., and grade. (See
SB50-S, Using load: 245.2 kN {25 t} 1 Fig. 8)
BB24-M, Using load: 35.3 kN {3.6 t} 1
BB28-S, Using load: 78.5 kN {8 t} 2
SB50-V, Using load: 392 kN {40 t} 1
O-type, Using load: 80 kN {8.16 t} 1
ꞏ JIS B8817, O-type or equivalent
20 Lifting master link O-type, Using load: 125 kN {12.7 t} 2 ꞏ For using locations, see Fig. 3 and
Fig. 5.
O-type, Using load: 160 kN {16.3 t} 1

Handle diameter x Overall length

Pinch bar 2 ꞏ JCMAS P018 or equivalent
21 φ13 mm x 400 mm or equivalent
(Lever bar) ꞏ For shape, see Fig. 9.
φ25 mm x 900 mm or equivalent 2
φ25 mm x 1 mm 1
S53C (JIS G4051) or equivalent is
22 Lifting bar (Steel bar) φ25 mm x 700 mm 2
recommended as raw material.
φ19 mm x 300 mm 1
23 Sledge hammer Double-face, 4.5 kg (10 lb) 1

Screw jack
24 Jack 2 For assembling undercarriage
Using load: 147.1 kN {15 t}

M24 x Pitch 3 1
Tap
25 M30 x Pitch 3 1
(Tools to repair threads)
M36 x Pitch 4 1 For track master link

ꞏ For adjusting blade tilt limit

26 Angle gauge With level, Min. division: 1 deg. 1
(See Assembly procedure A-29,A-30)

27 Grease pump Pneumatic feed type 1

28 Oil feed pump Manual or pneumatic feed type 1
29 Oil jug Capacity: 5 L 1

Width x Length x Height

Approx. 100 mm x 700 mm x 150 mm
Drain oil receiver 2 pcs.
30
(made of steel sheet) Approx. 400 mm x 700 mm x 150 mm each
Approx. 300 mm x 300 mm x 100 mm

Chassis stand Front stand (See Fig. 1) 1

31
(For installing body) Rear stand (See Fig. 2) 1

Steel plank Thickness x Length x Width

32 4 Weld lifting hooks to corners
(For installing chassis stand) 16 mm x 1000 mm x 500 mm

Thickness x Length x Width 1

33 Steel sheet 25 mm x 300 mm x 300 mm 1
25 mm x 300 mm x 600 mm 4
34 Sling A See Fig. 3 and Fig. 4 1 For lifting track frame assembly

For lifting final drive assembly and

35 Sling B See Fig. 5 and Fig. 6 1
pivot shaft

36 Sling C See Fig. 5 and Fig. 7 1 For lifting final drive assembly

23
No. Part name Specification Q'ty Remarks

Height x Width x Length

4
350 mm x 350 mm x 750 mm

350 mm x 350 mm x 670 mm 2

350 mm x 350 mm x 400 mm 4
37 Wooden block
300 mm x 300 mm x 600 mm 2
100 mm x 100 mm x 750 mm 4
65 mm x 95 mm x 180 - 200 mm 2
350 mm x 350 mm x 800 mm 2
38 Work platform truck 2 m high, with stairs and handrails 1
Number
39 Safety belt Waist belt type of
workers
For welding Necess
40 Safety goggles
ary q'ty
For protection from spatters

Safety rope and “No entry” ꞏ Tiger rope Necess For preventing entry of unauthorized
41
sign ꞏ Standing signboard ary q'ty people to work area

Inside dia. x Thickness x Length

Plastic tube For checking airtightness (internal
42 8 mm x 1 mm x 3 m 1
(Vinyl tube) pressure) of operator’s cab
Soft, transparent

43 Lubricating oil and grease See Assembly procedure "A-11" -

Molybdenum disulfide lubricant (LM-
44 Anti-seize compound 200 g See “Coating materials”
P)
45 Cleaning oil 40 L For removing rust preventive
46 Paint remover 5L For removing phthalic acid paint
47 Paint for touching up 3 each See “Coating materials”
As
For cleaning window glass of
48 Glass cleaner Liquid cleaner necess
ary
operator's cab

49 Cloth 1 kg

Wide x Length x Color

50 Adhesive cloth tapes 1 roll
50 mm x 25 m x Any color

Wire diameter x Length

51 Wire 1 JIS G3532, #10 or equivalent
φ3.2 mm x Approx. 2 m

This table does not contain common hand tools (socket wrench, screwdriver, pliers, etc.) Prepare separately as
necessary.

24
DIAGRAM FOR TOOLS
· If some jigs are not commercially available, make them locally according to their sketches (Fig. 1 to Fig. 7).
★ However, we are not responsible for the jigs made according to Fig. 1 to Fig. 7 as our products.
1. Chassis stand (Front side)

movabl
e part
Only

movable
Only

part

25
2. Chassis stand (Rear side)

movable
Only

part

movable
Only

part

26
3. Sling jig A (Track frame assembly)

Track frame assembly

Crane

· Fig. 3 shows an example of use of sling jig A.

· The bow shackle in Fig. 3 (Figure part No. 06) is used to adjust the level of lifted load (track frame assembly).
· For details of sling jig A (Figure part No. 01), see Fig. 4.

27
 i
44 drill
3. 1 Details of sling jig A

28
2 places
2 places

2-44 drill

2-36

2 places

Weight: Approx. 345 kg

The scale is indefinite.
 4. Sling jig B (Final drive assembly and pivot shaft)
· Fig. 5 shows an example of use for lifting the final drive assembly.

★ For details of sling jigs B and C, see Fig. 6 and Fig. 7.

★ For an example of lifting the pivot shaft, see Assembly procedure A-4 “Installation of pivot shaft”.

29
4. 1 Details of sling jig B

30
4. 2 Details of sling jig C

31
5. Shackle selection table (Excerpt from JIS B2801-1996)

32
6. Pinch bar

33
TIGHTEN TORQUE TABLE

1. Tightening torque of bolts

Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the
specified torque.

Part No. of bolt □□□□□□-□□□□□

Part No. of washer △△△△△△-△△△△△
Bolt specification Thread size (Diameter, pitch, length)
Socket (Tightening tool) Applicable socket size
Tightening torque *** Nm {〇〇〇 kgm}

If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.

The thread diameter is the nominal diameter. For example, 16 mm is expressed as

Remarks 1.
M16 and 20 mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial
direction (Unit: mm).
2. The bolt length is dimension “c” in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm,
etc. correspond to dimension “b” in Fig. 1, an applicable socket can be selected from
Table 1 as well.

4. Tightening torque is expressed as 〇〇〇 – ◎◎◎ or 〇〇〇 ± ▽▽.

If the target tightening torque is set, expression of 〇〇〇 ± ▽▽ is applied.

a: Bolt thread diameter (Nominal diameter)

b: Width across flats of bolt head
c: Bolt length
d: Threads of bolt

34
 Table 1 Tightening torque for bolts not specified in text

Width across flats of

Thread diameter “a” x
bolt head (= Socket Tightening torque
Pitch
size) “b”

M6 x 1 mm 10 mm 11.8 to 14.7 Nm {1.2 to 1.5 kgm}

M8 x 1.25 mm 13 mm 27 to 34 Nm {2.8 to 3.5 kgm}

M10 x 1.5 mm 17 mm 59 to 74 Nm {6 to 7.5 kgm}

M12 x 1.75 mm 19 mm 98 to 123 Nm {10 to 12.5 kgm}

M14 x 2 mm 22 mm 153 to 190 Nm {15.5 to 19.5 kgm}

M16 x 2 mm 24 mm 235 to 285 Nm {23.5 to 29.5 kgm}

M18 x 2.5 mm 27 mm 320 to 400 Nm {33 to 41 kgm}

M20 x 2.5 mm 30 mm 455 to 565 Nm {46.5 to 58 kgm}

M22 x 2.5 mm 32 mm 610 to 765 Nm {62.5 to 78 kgm}

M24 x 3 mm 36 mm 785 to 980 Nm {80 to 100 kgm}

M27 x 3 mm 41 mm 1150 to 1440 Nm {118 to 147 kgm}

M30 x 3 mm 46 mm 1520 to 1910 Nm {155 to 195 kgm}

M33 x 3 mm 50 mm 1960 to 2450 Nm {200 to 250 kgm}

M36 x 3 mm 55 mm 2450 to 3040 Nm {250 to 310 kgm}

M39 x 3 mm 60 mm 2890 to 3630 Nm {295 to 370 kgm}

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

35
 2. Tightening torque for pipe threads
Proper tightening torque for pipe threads depends on combination of the materials of the male
screw and female screw. In this manual, however, select tightening torque from Table 2 and
Table 3 on the basis of the material of the male screw.
If tightening torque is specified in the text, however, apply that tightening torque.

2. 1 When male screw is made of mild steel or cast iron

Table 2
Material of female
screw
Steel Cast iron Light alloy
Thread dia.

1/8 in 3.9 to 6.9 Nm {0.4 to 0.7 kgm} 2.9 to 5.9 Nm {0.3 to 0.6 kgm} 2.0 to 3.9 Nm {0.2 to 0.4 kgm}

1/4 in 5.9 to 11.8 Nm {0.6 to 1.2 kgm} 4.9 to 9.8 Nm {0.5 to 1.0 kgm} 3.9 to 7.8 Nm {0.4 to 0.8 kgm}

3/8 in 16.7 to 26.5 Nm {1.7 to 2.7 kgm} 13.7 to 21.6 Nm {2.7 to 4.4 kgm} 9.8 to 16.7 Nm {1.0 to 1.7 kgm}

1/2 in 32.3 to 52.9 Nm {3.3 to 5.4 kgm} 26.5 to 43.1 Nm {2.7 to 4.4 kgm} 19.6 to 32.3 Nm {2.0 to 3.3 kgm}

3/4 in 51.0 to 85.3 Nm {5.2 to 8.7 kgm} 42.1 to 70.6 Nm {4.3 to 7.2 kgm} 31.4 to 52.9 Nm {3.2 to 5.4 kgm}

1 in 86.2 to 173.5 Nm {8.8 to 17.7 kgm} 72.5 to 146.0 Nm {7.4 to 14.9 kgm} 54.9 to 111.7 Nm {5.6 to 11.4 kgm}

2. 2. When male screw is made of refined steel (heat-treated hard steel)

Table 3
Material of female
screw
Steel Cast iron Light alloy
Thread dia.

1/8 in 16.7 to 29.4 Nm {1.7 to 3.0 kgm} 9.8 to 19.6 Nm {1.0 to 2.0 kgm} 6.9 to 14.7 Nm {0.7 to 1.5 kgm}

1/4 in 19.6 to 44.1 Nm {2.0 to 4.5 kgm} 16.7 to 37.2 Nm {1.7 to 3.8 kgm} 12.7 to 28.4 Nm {1.3 to 2.8 kgm}

3/8 in 44.1 to 93.1 Nm {4.5 to 9.5 kgm} 37.2 to 77.4 Nm {3.8 to 77.4 kgm} 27.4 to 58.8 Nm {2.8 to 6.0 kgm}

1/2 in 98.0 to 188.2 Nm {10.0 to 19.2 kgm} 83.3 to 157.8 Nm {8.5 to 16.1 kgm} 60.8 to 115.6 Nm {6.2 to 11.8 kgm}

3/4 in 170.5 to 316.5 Nm {17.4 to 32.3 kgm} 141.1 to 247.0 Nm {14.4 to 25.2 kgm} 105.8 to 186.2 Nm {10.8 to 19.0 kgm}

1 in 367.5 to 612.5 Nm {37.5 to 62.5 kgm} 309.7 to 514.5 Nm {31.6 to 52.5 kgm} 235.2 to 392.0 Nm {24.0 to 40.0 kgm}

36
3. Tightening torque for hydraulic hose connecting nuts
For the connecting nuts installed to the hydraulic hose fittings in relatively low pressure
systems, apply tightening torque in Table 4.
If tightening torque is specified in the text, however, apply that tightening torque.
Table 4
Width across Tightening torque
Hose out side dia.
flats of nut Range Target

Approx. 6 mm 19 mm 34 to 54 Nm {3.5 to 5.5 kgm} 44 Nm {4.5 kgm}

22 mm 54 to 93 Nm {5.5 to 9.4 kgm} 74 Nm {7.5 kgm}

Approx. 10 mm
24 mm 59 to 98 Nm {6.0 to 10.0 kgm} 78 Nm {8.0 kgm}

Approx. 13 mm 27 mm 84 to 132 Nm {8.5 to 13.5 kgm} 103 Nm {10.5 kgm}

Approx. 16 mm 32 mm 128 to 186 Nm {13.0 to 19.0 kgm} 157 Nm {16.0 kgm}

Approx. 20 mm 36 mm 177 to 245 Nm {18.0 to 25.0 kgm} 216 Nm {22.0 kgm}

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

4. Proper socket sizes for bolts of M39 or larger (Reference)

Table 5 shows the proper sizes of sockets or wrenches (= width across flats) for tightening
hexagon bolts of M39 or larger.
Table 5

Thread dia. Proper size of socket or wrench

M42 65 mm

M45 70 mm

M48 75 mm

M52 80 mm

M56 85 mm

M60 90 mm

M64 95 mm

37
COATING MATERIALS LIST
The coating materials such as adhesives, liquid gaskets, and greases used for disassembly and assembly are listed below.
For coating materials not listed below, use products equivalent to the materials shown in the text of this manual.

Liquid adhesive

Komatsu code Part No. Quantity Container Main features and applications

Used to prevent rubber gaskets, rubber cushions, and

LT-1A 790-129-9030 150 g Tube
cork plugs from coming off.

Used for plastic (except polyethylene, polypropylene,

Polyethylen tetrafluoroethylene and vinyl chloride), rubber, metal, and
LT-1B 790-129-9050 (2 pcs.)
e container non-metal parts which require immediate and strong
adhesion.

ꞏ Features: Resistance to heat and chemicals

Polyethylen
LT-2 790-129-9040 50 g ꞏ Used to prevent bolts and plugs from coming loose and
e container
as sealant.

Adhesive:
790-129-9060
1 kg
LT-3 (Set of adhesive Can ꞏ Used to bond and seal metal, glass, and plastics.
Hardener:
and hardener)
500 g
Polyethylen
LT-4 790-129-9040 250 g ꞏ Used to seal plugs for blank holes.
e container

Holtz MH 705 790-129-9120 75 g Tube ꞏ Heat-resistant seal used to repair engines

ꞏ Instant glue
Polyethylen ꞏ Cure time: Within 5 sec. to 3 min.
ThreeBond1735 790-129-9140 50 g
e container ꞏ Used mainly to bond metals, rubbers, plastics, and
woods.

ꞏ Instant glue
Polyethylen ꞏ Quick cure type (max. strength after 30 minutes)
Aron-alpha 201 790-129-9130 2g
e container ꞏ Used mainly for adhesion of rubbers, plastics and
metals.

Polyethylen ꞏ Features: Resistance to heat and chemicals

Loctite 648-50 79A-129-9110 50 g
e container ꞏ Used for portions fitted at high temperatures.

38
Liquid gasket

Komatsu code Part No. Quantity Container Main features and applications

ꞏ Used to stick or seal gaskets and packings of power

LG-1 790-129-9010 200 g Tube
train case, etc.

ꞏ Used as sealant for various threaded portions, pipe

Polyethylen joints, and flanges.
LG-5 790-129-9080 1 kg
e container ꞏ Used as sealant for tapered plugs, elbows, nipples of
hydraulic piping.

ꞏ Features: ꞏ Silicon-based, heat and cold-resistance

LG-6 790-129-9160 200 g Tube ꞏ Used to seal flywheel housing, intake manifold, oil pan,
thermostat housing, etc.

ꞏ Used as sealant for various threaded portions, pipe

joints, and flanges.
LG-7 790-129-9070 1 kg Tube
ꞏ Used as sealant for tapered plugs, elbows, nipples of
hydraulic piping.

ThreeBond1121 790-129-9090 100 g Tube ꞏ Liquid gasket used to repair engine

ꞏ Features: Silicon-based, heat resistance, vibration

Three Bond 1207B 419-15-18131 100 g Tube resistance, impact resistance
ꞏ Used to seal transfer case, etc.

Molybdenum disulfide lubricant

Komatsu code Part No. Quantity Container Main features and applications

ꞏ Used as lubricant for sliding portion (to prevent

LM-G 09940-00051 60 g Can
squeaking).

ꞏ Used to prevent galling and seizure of press-fitted

LM-P 09940-00040 200 g Tube portions, shrinkage-fitted portions, and threaded portions.
ꞏ Used to lubricate linkages, bearings, etc.

39
Grease
Komatsu code Part No. Quantity Container Main features and applications

SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various ꞏ General purpose type
SYG2-160LI
SYG2-160CNLI

SYG2-400CA
SYG2-350CA
SYG2-400CA-A ꞏ Used for normal temperature, light load bearing at
G2-CA Various Various
SYG2-160CA places in contact with water or steam.
SYG2-
160CNCA

Bellows-
Molybdenum SYG2-400M 400 g x 10
type
disulfide grease SYG2-400M-A 400 g x 20 ꞏ Used for heavy load portions
container
LM-G (G3-M) SYGA-16CNM 16 kg
Can

SYG2-400T-A
Hyper White
SYG2-16CNT Bellows-
Grease ꞏ Seizure resistance and heat resistance higher than
SYG2- 400 g type
G2-T molybdenum disulfide grease
400T-A (*) 16 kg container
G0-T (*) ꞏ Not conspicuous on machine since color is white.
SYG2- Can
*: For cold district
16CNT (*)

SYG2-400B
Biogrease SYG2-16CNB Bellows-
G2-B SYG2- 400 g type ꞏ Since this grease is biodegradable in short period, it has
G2-BT(*) 400BT (*) 16 kg container less impact on microorganisms, animals, and plants.
*: For cold district SYG2- Can
16CNBT (*)

Primer
Komatsu code Part No. Quantity Container Main features and applications

SUNSTAR
Paint Surface Glass ꞏ Used as primer for cab side. (Expiration date: 4
20 mL
Primer 580 container months after production)
SUPER
417-926-3910

SUNSTAR
For adhered window glass

Glass ꞏ Used as primer for glass side

GLASS PRIMER 20 mL
container (Expiration date: 4 months after production)
580 SUPER

SUNSTAR
Glass ꞏ Used as primer for painted surface of cab.
PAINT PRIMER 22M-54-27230 20 mL
container (Expiration date: 4 months after production)
435-95

SUNSTAR ꞏ Used as primer for black ceramic-coated glass

GLASS PRIMER 22M-54-27240 150 mL Pail can surface and for hard polycarbonate-coated surface.
435-41 (Expiration date: 4 months after production)

SUNSTAR
Glass ꞏ Used as primer for sash (Alumite).
SASH PRIMER 22M-54-27250 20 mL
container (Expiration date: 4 months after production)
GP-402

40
Adhesive
Komatsu code Part No. Quantity Container Main features and applications

SUNSTAR ꞏ “S" is used in high-temperature season (Apr. - Oct.)

For adhered window glass

PENGUINE Polyethylen and “W" in low-temperature season (Oct. - Apr.) as
417-926-3910 320 mL
SEAL580 SUPER e container adhesive for glass.
“S" or “W" (Expiration period: 4 months after production)

SIKA JAPAN Polyethylen ꞏ Use as adhesive for glass.

20Y-54-39850 310 mL
Sikaflex 256HV e container (Expiration date: 6 months after production)

SUNSTAR Eco cart

ꞏ Used as adhesive for glass.
PENGUINE 22M-54-27210 320 mL (Special
(Expiration date: 6 months after production)
SUPER 560 container)

Caulking material
Komatsu code Part No. Quantity Container Main features and applications

SUNSTAR
Polyethylen ꞏ Used to seal joints of glass parts.
PENGUINE SEAL 417-926-3920 320 mL

For adhered window glass

e container (Expiration date: 4 months after production)
No. 2505

SEKISUI
Polyethylen ꞏ Used to seal front window.
SILICONE 20Y-54-55130 333 mL
e container (Expiration date: 6 months after production)
SEALANT

GE TOSHIBA ꞏ Used to seal joints of glass parts. Translucent white

CARTRIDG
SILICONES 22M-54-27220 333 mL seal.
E
TOSSEAL 381 (Expiration date: 12 months after production)

Paint
Komatsu code Part No. Quantity Container Main features and applications

SYPA-
Natural yellow - - Spray can
U03SPNY

Black gray SYPA-03SPBG - - Spray can

41
SELECTION OF WIRE ROPES USED FOR ASSEMBLY

Select the wire ropes used for assembly according to the table below.
Unit: kN {tf}
1 pc. 2 pcs.

Number of wire ropes

Sling angle α α = 0° α ≦ 90° 90° ＜ α ≦ 120°

Angle to vertical line β β = 0° β ≦ 45° 45° ＜ β ≦ 60°
Mode coefficient M 1 1.4 1
Classification of wire rope
24G 24A 24G 24A 24G 24A
Wire rope dia. (2) d (mm)
8 4.8 {0.49} max. 5.2 {0.53} max. 6.7 {0.68} max. 7.2 {0.74} max. 4.8 {0.49} max. 5.2 {0.53} max.
9 6.1 {0.63} max. 6.6 {0.67} max. 8.5 {0.88} max. 9.2 {0.93} max. 6.1 {0.63} max. 6.6 {0.67} max.
10 7.6 {0.77} max. 8.2 {0.83} max. 10 {1.0} max. 11 {1.1} max. 7.6 {0.77} max. 8.2 {0.83} max.
11.2 9.5 {0.97} max. 10 {1.0} max. 13 {1.3} max. 14 {1.4} max. 9.5 {0.97} max. 10 {1.1} max.
(12) 10 {1.1} max. 11 {1.2} max. 14 {1.5} max. 15 {1.6} max. 10 {1.1} max. 11 {1.2} max.
12.5 11 {1.2} max. 12 {1.3} max. 15 {1.6} max. 16 {1.8} max. 11 {1.2} max. 12 {1.3} max.
14 14 {1.5} max. 16 {1.6} max. 19 {2.1} max. 22 {2.2} max. 14 {1.5} max. 16 {1.6} max.
16 19 {1.9} max. 21 {2.1} max. 26 {2.6} max. 29 {2.9} max. 19 {1.9} max. 21 {2.1} max.
18 24 {2.5} max. 26 {2.7} max. 33 {3.5} max. 36 {3.7} max. 24 {2.5} max. 26 {2.7} max.
20 30 {3.1} max. 32 {3.3} max. 42 {4.3} max. 44 {4.6} max. 30 {3.1} max. 32 {3.3} max.
22.4 38 {3.9} max. 41 {4.2} max. 53 {5.4} max. 57 {5.8} max. 38 {3.9} max. 41 {4.2} max.
(24) 43 {4.4} max. - 60 {6.1} max. - 43 {4.4} max. -
25 47 {4.8} max. 51 {5.2} max. 65 {6.7} max. 71 {7.2} max. 47 {4.8} max. 51 {5.2} max.
28 59 {6.1} max. 64 {6.5} max. 82 {8.5} max. 89 {9.1} max. 59 {6.1} max. 64 {6.5} max.
30 68 {7.0} max. 73 {7.5} max. 95 {9.8} max. 102 {10.5} max. 68 {7.0} max. 73 {7.5} max.
31.5 75 {7.7} max. 81 {8.3} max. 105 {10.7} max. 113 {11.6} max. 75 {7.7} max. 81 {8.3} max.
33.5 85 {8.7} max. 92 {9.4} max. 119 {12.1} max. 128 {13.1} max. 85 {8.7} max. 92 {9.4} max.
35.5 96 {9.8} max. 103 {10.5} max. 134 {13.7} max. 144 {14.7} max. 96 {9.8} max. 103 {10.5} max.

37.5 107 {10.9} max. 115 {11.7} max. 149 {15.2} max. 161 {16.3} max. 107 {10.9} max. 115 {11.7} max.

40 122 {12.4} max. 131 {13.4} max. 170 {17.3} max. 183 {18.7} max. 122 {12.4} max. 131 {13.4} max.

42.5 137 {14.0} max. 148 {15.1} max. 191 {19.6} max. 207 {21.1} max. 137 {14.0} max. 148 {15.1} max.

42
SELECTION OF NYLON SLINGS USED FOR ASSEMBLY

Select the wire ropes used for assembly according to the table below.
■ Using load table (WW-1D type)

Vertical hitch Choking hitch 1-sling basket hitch 2-sling basket hitch

Sling angle α Sling angle α Sling angle α

Type of hitch

Sling angle α - - α ≦ 45° 45° < α ≦ 90° α ≦ 45° 45° < α ≦ 90°
Mode coefficient M
1 0.8 1.8 1.4 3.6 2.8
Basic using load

25 mm wide 0.8 t 0.8 t 0.64 t 1.44 t 1.12 t 2.88 t 2.24 t

35 mm wide 1.25 t 1.25 t 1.0 t 2.25 t 1.75 t 4.5 t 3.5 t
Type of both end eyes

50 mm wide 1.6 t 1.6 t 1.28 t 2.88 t 2.24 t 5.76 t 4.48 t

75 mm wide 2.5 t 2.5 t 2.0 t 4.5 t 3.5 t 9.0 t 7.0 t
100 mm wide 3.15 t 3.15 t 2.5 t 5.67 t 4.41 t 11.3 t 8.82 t
150 mm wide 5.0 t 5.0 t 4.0 t 9.0 t 7.0 t 18 t 14 t
200 mm wide 6.3 t 6.3 t 5.0 t 11.3 t 8.82 t 22.7 t 17.6 t
300 mm wide 10 t 10 t 8.0 t 18 t 14.0 t 36 t 28 t

43
A. ASSEMBLY PROCEDURE

Example 1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---, but indicated
by (1), (2), (3) --- in the tables or texts.

Fig. 1

6 (1) Plate
5
(2) Collar
(3) Washer
(4) Bolt
(5) Bolt
(6)Washer
1
2
3
4

Example 2. In some places of this manual, the words of front, rear, right hand or left hand of machine are
used. Those words indicate the directions seen from the operator's seat with the sprocket at
the rear as shown below, unless otherwise specified.

Fig. 2

FWD

Left Right

Operator's
seat

Sprocket
Rear

44
A-1 Installation of track shoe assembly

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Crane Commercially available 70 t 1
B Wire rope sling Commercially available φ24 mm × 2 m 2

1. Unload tracks (1) and (2) to the places indicated on the kit layout described before, and spread track
shoe assembly (1) on the left of the body (chassis) and spread track shoe assembly (2) on the right
as shown in the figure below.
REMARKS Place track shoe assemblies (1) and (2) in parallel with each other so that front end (a) is on the
front side (indicated with the arrow) of the body (chassis).

1 Fig. 1
d

2 c b

e a

Symbol Dimension Remarks

b 2,770 mm
c 2,060 mm When shoe width is “d”
d 710 mm
Number of shoes when shoe width is “d”: 40
e 12,700 mm * Only master shoes (1 pc. on each side, 2 pcs./machine) are removed.

1) Each track shoe assembly is folded when unloaded.

Take care not to mistake front (f) and rear (g) when Fig. 2
spreading.

g f

2) When the track shoe assembly is spread on ground

(D) either joint (h) of the master link is directed Fig. 3
down. Set this end as the front end.

h
D

45
A-2 Installation of machine body (chassis)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
F Shackle Commercially available SB50-V 2 JIS SB50 [Grade V] or equivalent
G Protective pad Commercially available 1 Rubber or felt plate
H Wire rope sling Commercially available φ65 mm x 5 m 2
J Crane Commercially available 45 t 1
K Wire rope sling Commercially available φ52 mm x 3 m 2
L Crane Commercially available 70 t
M Chassis stand (Front) - H: 1,105 mm 1
N Chassis stand (Rear) - H: 1,020 mm 1
Cross section: 65 mm x 95 mm,
R Wooden block Commercially available 2
Length: 180 to 200 mm

1. Install the chassis stand.

1) Place L.H. track (1) and R.H. track (2) in parallel on ground (D), and spread steel plate (C) between
them. Install chassis stand (Front) (M) and chassis stand (Rear) (N) on the steel palate.
REMARKS ꞏ For arrangement of chassis stand (Front) (M), chassis stand (Rear) (N), and steel plate (C), see the
figure below.
ꞏ There are 2 types of chassis stands for front and rear sides. Place them on the correct positions.
ꞏ Spread steel plate (C) when the surface of ground (D) is bare soil.

Fig. 1
B A 1
C

B a
e
C C A

D
c b

d d

46
 Symbol Dimension Remarks
b 1,105 mm
c 1,020 mm
d 16 mm min. Recommended steel plate thickness
e 2800 mm From front end (a) of tracks (1) and (2) to front chassis stand (A)
f 3300 mm

REMARKS For the chassis stand, see “List of tools for field assembly” shown before.
2. Install the machine body (chassis).

3. Hull frame (Main frame of machine body) 5. Equalizer bar (Installed to machine body)
4. Ripper tilt cylinder mount pin (attached to the machine
body)

E. Front tow hook (Hole dia.: 70 mm) (Installed to K. Wire rope sling (φ52 mm x 3 m x 2 pieces)
machine body)
F. Shackle: (JIS SB50 [Grade V] or equivalent) x 2 L. 2nd crane (70 t spec.)
piece
G. Protective pad (Rubber or felt plate) M. Chassis stand (Front side)
H. Wire rope sling (φ65 mm x 5 m x 2 piece) N. Chassis stand (Rear side)
J. 1st crane (70 t spec.)
REMARKS For weight of the machine body (chassis), see “Packing style for transportation” shown before.
1) Install 1 wire rope sling to the front side of the machine body (chassis) and 2 to the rear side as
shown in the above figure, and lift the machine body with 2 crane trucks (Install the front 1 sling to
one crane truck, and install the rear 2 slings to the other crane truck). Unload the machine body
from the trailer and lower it to the chassis stands installed on the ground.

REMARKS When lifting the front side, remove the mask in advance since it interferes with the sling.
2) Install the front wire rope sling to the tow hook installed to the undercover of the machine body via
proper shackle.

47
REMARKS When installing, insert a pad made of rubber or felt on the part where the main body and sling interfere to
prevent damage on the main body and the wire.

3) Install the rear wire rope slings to the ripper tilt cylinder mounts installed to the machine body. The
mount is installed with 1 pin each on the right and left. Install 1 sling to each of the pins.
REMARKS When installing, insert a pad made of rubber or felt on the part where the main body and sling interfere to
prevent damage on the main body and the wire.

4) Place the equalizer bar installed to the machine body on front chassis stand (M) and place the hull
frame (main frame of the machine body) on the rear chassis stand.
5) Before lowering the slings, insert wooden blocks (R)
in the clearance between equalizer bar (9) and
machine body main (R) on the right and left as R 10
shown in the figure.

REMARKS ꞏ Steel blocks of the same shape may be used 9 R

instead of wooden blocks (R).
ꞏ Insert and place each wooden block on its 95 mm
side (b). b

48
 Installation of operator's cab assembly
A-3
(When operator cab assembly is not installed)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Crane - 45 t 1
B Wire rope sling Commercially available 4
C Shackle Commercially available 4
D Chain block Commercially available 1.6 t 2
Width across
E Socket Commercially available 1
flats 24 mm

Width across
F Socket Commercially available 1
flats 19 mm

Width across
G Socket Commercially available 1
flats 17 mm

Width across
H Socket Commercially available 1
flats 13 mm

I Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more

J Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
K Torque wrench Commercially available 1 Torque 412 Nm (42 kgm) or more

Part list
Part No. Part name Q'ty Part state
1 - Oprerater's cab Ass'y (1) 1
2 01010-D1685 BOLT 4
3 01010-D1685 BOLT 4
4 195-54-72910 BOLT 3
5 195-54-72910 BOLT 3
21T-06-33160 CLAMP 1
4
01024-81220 BOLT, SEMS 1
20Y-62-15960 CLAMP 1
8
01024-81220 BOLT, SEMS 1
11 08037-12536 CLAMP 1
12 08037-12536 CLAMP 1
198-06-8546A BRACKET 1
195-06-77930 CLAMP 1
13 195-01-43660 COLLAR 2
01024-81260 BOLT, SEMS 1
01024-81230 BOLT, SEMS 2
198-06-8547A BRACKET 1
04434-52712 CLAMP 2
14
01095-20413 CUSHION 2
01024-81230 BOLT, SEMS 3
21 01024-80825 BOLT, SEMS 4
22 195-54-56291 COVER 1

49
Part list
Part No. Part name Q'ty Part state
198-911-4480 CLAMP 1
23
01011-81210 BOLT 1
24 01024-81230 BOLT, SEMS 1
198-Y1-3290 BRACKET 1
27
01024-81030 BOLT, SEMS 2
28 01024-80625 BOLT, SEMS 1
30 01435-00625 BOLT 1
04434-51512 CLAMP 1
32
01024-81230 BOLT, SEMS 1
04434-51512 CLAMP 1
33 07095-20314 CUSHION 1
01024-81230 BOLT, SEMS 1
04434-52112 CLAMP 1
35 07095-20314 CUSHION 1
01024-81230 BOLT, SEMS 1
36a 09479-12400 CLIP 2
04434-52711 CLAMP 1
38a 07095-20419 CUSHION 1
01024-81025 BOLT, SEMS 1
04434-53211 CLAMP 1
38b 07095-20522 CUSHION 1
01024-81025 BOLT, SEMS 1
04434-53211 CLAMP 2
38c
07095-20523 CUSHION 2
04434-52512 CLAMP 1
39
01024-81230 BOLT, SEMS 1

REMARK This operation may not be necessary depending on destination.

Precautions for disconnecting air conditioner piping
CAUTION When replacing the air conditioner unit, air conditioner compressor, condenser or receiver
drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit
before disconnecting the air conditioner hoses.

REMARK ꞏ Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner
gas:R134a).
ꞏ Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
Warning Put on the protective eyeglasses, gloves and working clothes with long sleeves while you
are collecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your
eyes, you may lose your sight, and when it touches your skin, you may suffer from frostbite.

REMARK When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
CAUTION ꞏ When installing the air conditioner piping, be careful so that dirt, dusts and water do not
enter the hose.
ꞏ Check that the O-rings are fitted to the joints when connecting the air conditioner piping.

50
 ꞏ Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
ꞏ When removing the O-rings, use a soft tool so that the piping is not damaged.
ꞏ Check that the O-ring is not damaged or deteriorated.
ꞏ Apply compressor oil for refrigerant (R134a) to O-ring.
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one
wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench
for tightening).

The figure shows an example of fitting of O-ring.

An O-ring is fitted to every joint of the air conditioner O-ring
piping.

O-ring

1. Lift and install operator's cab (1) by using sling (A).

1
REMARK Put the chain blocks on 2 places of the rear, and
install them so that the operator's cab is level in
right/left and back/forth directions.

CAUTION When installing, do not pinch the wiring or

piping.
Weight of operator's cab assembly (1): 1600kg

2. Install L.H. bolts (2) (4 pieces) and R.H. bolts (3) (4

pieces) to the rear of operator's cab.
Tightening torque of bolts (2), (3): 235 to 285 Nm
{23.5 to 29.5 kgm} 3 2

51
 3. Install L.H. bolts (4) (4 pieces) and R.H. bolts (5) (4
pieces) to the front of operator's cab.
Tightening torque of bolts (4), (5): 235 to 285 Nm 4
{23.5 to 29.5 kgm}

4. Connect connector FDR (6), and install clamps (7)

and (8). 6
7

5. Connect connectors PL1 (9) and FDL (10).

REMARKS ꞏ Check that the seal is installed to the plug correctly.

ꞏ Check that the key is matched to the groove on the

receptacle side.
ꞏ Match the connector on the plug side straight with
the receptacle (since the seal is projected), and fit
the connector lightly while checking that the seal
does not roll up.

ꞏ Tighten the hexagonal head bolt at the center of the connector by 2 to 3 turns.
ꞏ Fit the connector on the plug side fully and adjust it so that the clearance between it and receptacle
will be even when viewed from each direction.
Hexagonal socket head bolt: 2.8 ± 0.3 Nm {0.28 ± 0.03 kgm}
6. Install clamps (11), (12), (13), and (14).
Bolt of clamps (13), (14): Width across flats: 19 mm,
M12
Tightening torque of bolt of clamps (13), (14): 98 to
123 Nm {10 to 12.5 kgm}
7. Connect connectors ES1 (15), CJC9 (16), ES3 (17),
MVC2 (18), F105 (19), and F60 (20).

52
 8. Install cover (duct) (22) and hose as a unit with bolts
(21) (4 pieces).
Bolt (21): Width across flats 13mm, M8
Tightening torque of bolt (21): 27 to 34 Nm {2.8 to
3.5 kgm}
9. Install clamp (23).
Bolt of clamp (23): Width across flats: 19 mm, M12
Tightening torque of bolt of clamp (23): 98 to 123
Nm {10 to 12.5 kgm}
10. Connect cab ground cable (24).
Bolt of ground cable (24): Width across flats: 19 mm, 24
M12
Tightening torque of ground cable (24) bolt: 98 to 25 27
123 Nm {10 to 12.5 kgm}
11. Install the bracket (28), and connect the air 26
conditioner tubes (25) and (26).

CAUTION ꞏ Take care that dirt, dust, water, etc. do not enter
the air conditioner piping.
ꞏ Check that an O-ring is fitted to each of the air conditioner piping connections.
ꞏ Check that O-rings are not damaged or deteriorated.
ꞏ When connecting the air conditioner piping, apply compressor oil for new refrigerant (air
conditioner gas: R134a) to the O-rings and thread portions.
Coating material for air conditioner tube: Compressor oil (DENSO-made ND-OIL8)
REMARK When connecting the air conditioner piping, use 2 wrenches.
Thread size (M22 x 1.5) (Width across flats: 24 mm), Tightening torque: 235 to 285 Nm {23.5 to
29.5 kgm}
Thread size (M24 x 1.5) (Width across flats: 27 mm), Tightening torque: 320 to 400 Nm {33 to 41
kgm}
Bolt of bracket (27): Width across flats 17 mm, M10
Tightening torque of bolt of bracket (27): 59 to 74 Nm {6 to 7.5 kgm}
12. Connect the air conditioner hose (29) with the bolt
(28). 29
Bolt of clamp (28): Width across flats 10 mm, M6
Tightening torque of bolt(28): 11.8 to 14.7Nm｛1.2 to 1.5kgm｝ 30
13. Connect the air conditioner hose (31) with the bolt 28
31
(30).
Bolt of clamp (30): Width across flats 10 mm, M6
Tightening torque of bolt(28): 11.8 to 14.7Nm｛1.2 to 1.5kgm｝

53
 14. Install clamp (32) and (33).
REMARK Clamp the clamp (33) at the taped position with 34
white tape on the air conditioner hose. 32

Bolt of clamp (32) and (33): Width across flats 19

33
mm, M12
Tightening torque of bolt of clamp (32) and (33): 98
to 123 Nm {10 to 12.5 kgm}
15. Connect the connector CN-AC05 (34).
16. Install clamp (35).
REMARK Install the clamp (35) at the angle (a) in the figure. a
35
Angle (a): 20°
Bolt of clamp (35): Width across flats 19 mm, M12
Tightening torque of bolt of clamp (35): 98 to 123
Nm {10 to 12.5 kgm}

17. Connect the heater hoses (36) and (37) with the
clips (36a) (2 pieces). 38a
18. Install the clamp (38a), (38b), and (38c) (2 pieces). 36 38b
REMARK Clamp them at the taped position with white tape on
the heater hoses (36) and (37).
Bolt of clamp (38a) and (38b): Width across flats 17 36a 38c
mm, M10
37
Tightening torque of bolt of clamp (38a) and (38b):
59 to 74 Nm {6 to 7.5 kgm}
19. Install clamp (39).
b
REMARK Install the clamp (39) at the angle (b) in the figure.
Angle (b): 15° 39
Bolt of clamp (39): Width across flats 19 mm, M12
Tightening torque of bolt of clamp (39): 98 to 123
Nm {10 to 12.5 kgm}

20. Install clamp (40) and (41).

REMARK ꞏ Clamp them disregarding the taped position with
white tape on the washer hose.
ꞏ Install the clamp (39) at the angle (c) in the figure.
Angle (c): 45°
Bolt of clamp (40) and (41): Width across flats 19
mm, M12
Tightening torque of bolt of clamp (40) and (41): 98
to 123 Nm {10 to 12.5 kgm}
21. Connect the connector CN-WSH1 (42).

54
 22. Connect the hoses (43) (4 pieces).
REMARK When connecting them, align the identification
tapes attached to the hose (red, black, blue,
colorless) on the machine body side and cab side.

23. Fill refrigerant from the air conditioner circuit.

REMARK Use R134a air conditioner gas.
Refrigerant refill amount: 1050 ± 50g

55
A-4 Installation of pivot shaft (When pivot shaft is not installed)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Crane - 45 t 1
B Sling jig B - - 1 See sketches of jigs
C Chain block Commercially available 1.6t 2
Width 25 mm
D Belt sling Commercially available 1
×3 m

E Pinch bar Commercially available φ25 mm 1

F Air impact Commercially available 1 Torque 2940 Nm (300 kgm) or more

Width acress
G Socket Commercially available 1
flats 46 mm

Length 600
H Extension bar Commercially available 1
mm

I Torque wrench Commercially available 1 Torque 2060 Nm (210 kgm) or more

J Eyebolt (M20) Commercially available 1

Coating materials
Komatsu code Part No.
A LM-P 09940-00040
B LT-2 790-129-9040

Part list
Part No. Part name Q'ty Part state
5 198-30-34170 BOLT 34
6 207-46-52130 WASHER 34

REMARKS This operation may not be necessary depending on destination.

1. Install pivot shaft assembly (1) by using sling jig (B)
and crane (A). Fig. 1
A
ꞏ Faucet joint
ꞏ Torsion seal and holding cover (3)
REMARKS ꞏ Since mounting face (b) of pivot shaft assembly (1)
is deeper than outermost part (a), install by using B
sling jig B, while avoiding interference.
a
ꞏ When slinging pivot shaft assembly (1), direct cut
portion (e) of its flange toward the rear of machine. b

d
ꞏ Install sling jig B to slinging point dimension (c) in
C c
axial direction.

Dimension (c): Approx. 600 mm 1

ꞏ Install pivot shaft assembly (1) and sling jig B to 2 3
dimension (d) in the vertical direction.
Dimension (d): 600 to 700 mm

56
 ꞏ Install chain block (C) (2 pieces) and eyebolt (M20)
(J) to the pivot shaft assembly (1) to lifting. Fig. 2

C
C
J

CAUTION ꞏ When using a lever block as the sling, wrap

cloths, etc. around pivot shaft assembly (1) for
protection. It is not necessary, however, when
using a belt (cloth) sling.
ꞏ Take care than no load is applied to the torsion
seal and holding cover (3) during work.

e
2. Apply LM-P to faucet joint (2) of pivot shaft before
inserting before inserting in the shaft hole in the
machine body.

3. Finely align the shaft hole in the machine body and

bolt holes of faucet joint (2), and adjust pivot shaft
(1) to the machine body.

REMARKS ꞏ When blade tilt cylinder hose (4) are installed, pass
them through the center hole of pivot shaft (1), and
pull them out of the shaft end.

ꞏ When the bolts are tightened, faucet joint (2) of

pivot shaft (1) is fitted to the shaft hole in the
machine body.

CAUTION Lightly tighten the mounting bolts alternately

until they are seated on the mounting surface
and so that the clearance between the pivot
shaft and mounting surface is constant.

4. Apply adhesive LT-2 to mounting bolts (5) and

washers (6), and finger-tighten them, then tighten 5
6
them in order with the impact wrench.
Bolt (5): Width across flats 46 mm, M30, L115 mm
Tightening torque of bolt (5):
1520 to 1910 Nm {155 to 195 kgm}
5. Visually check that the pivot shaft flange is securely
seated on the machine body, then check the
tightening torque of all mounting bolts with the 4
torque wrench.

REMARKS Check that the tightening torque is within the

specified range.

6. Remove the sling.

57
A-5 Installation of final drive assembly

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A - Sling jig C 1
B - Sling jig B 1
C Crane Commercially available 45 t 1
D Air impact Commercially available 1 Torque 2940 Nm (300 kgm) or more
E Shackle Commercially available SD34-M 1
F Pinch bar Commercially available 1 φ25 mm × 900 mm
Width across
G Socket Commercially available 1
flats 50 mm

Part list
Part No. Part name Q'ty Part state
1 01010-83090 BOLT 2
3 01643-33080 WASHER 2
5 198-27-33181 COVER 1
6 198-22-24112 SHAFT 2
7 295-22-12570 BUTTON 2
8 195-22-12580 BUTTON 2
9 07000-A5250 O-RING 2
10 01011-63310 BOLT 22
11 01643-33380 WASHER 22
13 198-27-31471 BUTTON 1
14 07000-A2135 O-RING 1
15 01010-81640 BOLT 3
16 01643-31645 WASHER 3

The figure shows the L.H. final drive.

A 1 2, 3 A Fig. 1
Front

58
 1. Install sling jig C.
1) Remove bolts (1) (2 pieces) from the final drive assembly.
Bolt (1): Width across flats 46 mm, M30
2) Install sling jig C (A) with bolts (2) and washers (3).
REMARKS After installing the final drive assembly to the machine body, remove sling jig C (A) and bolts (2),
and install bolts (1) and washers (3) again.

3) Connect sling jig C (A) and sling jig B (B) installed

to the final drive assembly with 2 shackles. Lift sling Fig. 2
B (B) with crane (C) and hold final drive assembly C
(4) erected perpendicular to ground (D).

Weight of final drive assembly (4): 3,600 kg

Weight of sling jig B (B): 175 kg
Weight of sling jig C (A): 14.5 kg
B

D
4
REMARKS ꞏ There are 2 holes in sling jig C (A) for use on right
or left side. Whether the jig is used on right or left
side, install shackle (E) to the rear hole. B Fig. 3
E
ꞏ The figure shows the L.H. final drive assembly (4).
A
4) Stably erect final drive assembly (4) perpendicular
to the ground, and lower the sling. 4
REMARKS When final drive assembly (4) is installed to the
machine body, it needs to be lifted again.
Accordingly, keep sling jig C (A), shackle (E), and
final drive assembly (4) installed.

5) Remove shaft end cover (5) (mounted with 3 bolts)

of 1st gear (pinion) torque shaft of final drive
assembly.

Cover (5) mounting bolt: Width across flats 24 mm,

M16

REMARKS When removing this cover, do not damage the O-

5
ring installed to it.

59
 6) Insert torque shaft assembly (6) along the spline of
1st gear of final drive assembly (4), and push it until Fig. 5
it touches the sprocket. 8
Weight of torque shaft assembly (6): 31 kg 6
REMARKS ꞏ Buttons (7) and (8) are press fitted respectively to
the shaft ends.
7
ꞏ Insert the 2-tapped hole end of torque shaft (6) in
outward direction (a) through the mounting face of
final drive assembly (4) on the machine body. a
ꞏ Torque shaft assembly (6) is a part of the torque
power train assembly. It transmits the power of 6
power train assembly to final drive assembly (4).

ꞏ The end of torque shaft assembly (6) is projected to

the sprocket side.

7) Install O-ring (9) to the inner linkage end (faucet

joint) of the 1st gear. 9

8) Clean the mounting face of machine body.

REMARKS ꞏ Remove harmful material such as oil, paint, dirt, etc.
sticking to the mounting face, if any.

ꞏ Remove harmful material from the faucet joint (b)

(O-ring contact surface) to which the inner cage of
1st gear will be fitted, and clean with cloth.

9) Sling final drive assembly (4), and bring it near the

mounting location on the machine body.

REMARKS ꞏ For slinging method, see 2). 6

ꞏ Sling and move torque shaft assembly (6), while
keeping it level.

60
 10) Push in the final drive assembly, while aligning
inner cage faucet joint (c) of the 1st gear with the
c
end face of faucet joint (b) on the machine body b
side. Take care that O-ring (9) is positioned
correctly.

11) After the faucet joint is fitted, adjust the deviation of

the outside mounting bolt holes of final drive
F
assembly (4) with pinch bar (F), and finger-tighten
the outside bolts.

REMARKS For details of pinch bar (F), see “List of tools for
field assembly”.
4

B Fig. 12 Fig. 13
A
10 11

d
11 12
10
12) Install outside bolts (10) (22 pieces).
REMARKS ꞏ Among the outside bolts, 22 pieces are accessed from the sprocket side and 10 pieces are
accessed from inside of machine body frame (center of machine body). At this time, install on the 22
pieces to be accessed from the sprocket side.
ꞏ Install the 10 bolts to be accessed from inside of the machine body frame (center of machine) when
removing the rear chassis stand from the machine body in “A-8 Installation of undercarriage-2”
described later.
13) Tighten bolts (10) and washers (11) with the impact wrench until the mating faces of the final drive
assembly and machine body are fitted together, while keeping the clearance between the mating
faces even.
REMARKS When some bolts cannot be tightened because of sling jig C, tighten them after removing sling jig C.

14) Lower and remove sling C.

15) Tighten bolts (10) which could not be tightened because of sling jig C.
Bolt (10): Width across flats 50 mm, M33
Tightening torque of bolt (10): 1960 to 2450 Nm {200 to 250 kgm}

61
 16) Check the tightening torque of all bolts (10) with a torque wrench.
REMARKS Check that the tightening torque is within the specified range.
Tightening torque of bolt (10): 1960 to 2450 Nm {200 to 250 kgm}
17) Install original bolts (1) and washers (3) to the holes
from which sling jig C was removed. 1, 3 Fig. 14
Bolt (1): Width across flats 46mm, M30
Tightening torque of bolt (1): 1520 to 1910 Nm {155
to 195 kgm}

18) Push the torque shaft projected from the shaft hole
of 1st gear (pinion) toward the machine body to a
depth of approximately 70 mm from the hole side
end.

REMARKS If the torque shaft assembly stops at the bottom,

slightly turn the sprocket with a jack, etc. and
engage the spline, then push in the torque shaft
assembly again.

19) Install shaft end cover (5).

REMARKS ꞏ Install shaft end cover (5) so that flat portion (e) of
its outside is directed toward sprocket center (f).
5, 13, 14 15, 16 Fig. 17

ꞏ Button (13) is press fitted to the end center of shaft

end cover (5). When installing shaft end cover (5), e
check that button (13) is installed.
f
ꞏ Check that O-ring (14) is installed, and install shaft
end cover (5) with care not to damage O-ring (14).

Bolt (15): Width across flats 24 mm, M16, L 40 mm

Tightening torque of bolt (15): 235 to 285 Nm {23.5
to 29.5 kgm}
15, 16 Fig. 18

14

13
2. The final drive assembly on one side is installed by 5
the above work. Similarly install the final drive
assembly on the opposite side. A-A 6

62
A-6 Installation of undercover (When undercover is not installed)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 24 mm 1
B Socket Commercially available 46 mm 1
C Air impact Commercially available 1 Torque 2940 Nm (300 kgm) or more
D Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more
E Torque wrench Commercially available 1 Torque 2060 Nm (210 kgm) or more
F Torque wrench Commercially available 1 Torque 412 Nm (42 kgm) or more

Part list
Part No. Part name Q'ty Part state
1 198-54-88921 COVER 1 Unit shipment
2 198-54-88931 COVER 1 Unit shipment
198-54-88941 COVER 1 #50001 to #500XX
3
198-54-88942 COVER 1 After #500XX
4 01010-83065 MOUNTING BOLT 28
5 01643-33080 WASHER 28
6 01010-81645 MOUNTING BOLT 3
418-18-31160 WASHER 3 #50001 to #500XX
7
06143-31645 WASHER 3 After #500XX

REMARKS This operation may not be necessary depending on destination.

1. Install the undercovers (3 pieces) to the machine body main frame by using the lifter.
REMARKS Install the parts in the order of their Nos.

3 2 1

63
 1) By using the lifter, align the engine undercover (1)
with the installation position. 1

2) Install the engine undercover (1) with the bolts (4)

(10 pieces).
REMARKS The part No. is a representative No. the assembly.
In the packing style for transportation, the hinge
parts, inspection parts, and cover parts are
assembled. 4, 5
Weight of engine undercover (1): 300 kg
Bolt (4): Width across flats 46 mm, M30
Tightening torque of bolt (4): 1520 to 1910 Nm {155 to 195 kgm}
3) By using the lifter, align the power train assembly
undercover (front) (2) with the installation position. 2

4) Install the power train assembly under cover (front)

(2) with the bolts (4) (10 pieces).
REMARKS The part No. is a representative No. the assembly.
In the packing style for transportation, the hinge 4, 5
parts, inspection parts, and cover parts are
assembled.

Bolt (4): Width across flats 46mm, M30

Tightening torque of bolt (4): 1520 to 1910 Nm {155 to 195 kgm}
5) By using the lifter, align the power train assembly
undercover (rear) (3) with the installation position. 3

6) Install the power train assembly undercover (rear)

(3) with the bolts (4) (8 pieces) and bolts (6) (3 4, 5
pieces).

REMARKS The part No. is a representative No. the assembly. 6, 7

In the packing style for transportation, the hinge
parts, inspection parts, and cover parts are
assembled.

Bolt (4): Width across flats 46mm, M30

Bolt (6): Width across flats 24 mm, M16
Tightening torque of bolt (4): 1520 to 1910 Nm {155 to 195 kgm}
Tightening torque of bolt (6): 235 to 285 Nm {23.5 to 29.5 kgm}

64
A-7 Installation of blade lift hydraulic cylinder

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 46 mm 1
B Socket Commercially available 19 mm 1
C Wrench Commercially available 17 mm 1
D Wrench Commercially available 16 mm 1
E Wrench Commercially available 14 mm 1
F Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
G Air impact Commercially available 1 Torque 2940 Nm (300 kgm) or more
H Crane Commercially available 45t 1
Width 25
I Belt sling Commercially available 2
mm × 3 m
J Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more

Part list
Part No. Part name Q'ty Part state
4 01011-83040 BOLT 8
5 01643-33080 WASHER 8
7 07089-01216 HOSE 4
8 07371-51260 SPLIT FLANGE 16 Reuse for installation
9 01024-81245 BOLT 32 Reuse for installation
10 07000-F3038 O-RING 8
11 21K-62-18170 HOSE 2
12 203-62-22160 HOSE 4
13 203-62-21740 NIPPLE 6
14 202-62-21430 ELBOW 4
15 201-62-41910 ELBOW 2
16 198-904-4280 CLAMP 2
17 01024-81225 BOLT 2

1. Install the blade lift hydraulic cylinder.

1) Remove the bolts (4) (4 pieces), and remove the
caps (1) (2 pieces), the bushings (2) (2 pieces), and 1
the pins (3) (2 pieces) from the yoke. 3
5
REMARKS To prevent installation mistakes, put the
matchmarks on the bushings (2) before removing it. 4
Bolt (4): M30, L 140 mm 1
3
2) Shrink the hydraulic cylinder as short as possible so 2
that it does not stretch, and then fix the rod with a
wire, etc.

65
 3) Sling the blade lift hydraulic cylinder horizontally
with the belt slings (H) (2 pieces), and align the
H
hydraulic cylinder with the installation position.

CAUTION Be careful that the yoke falls off when the yoke
reaches the angle (a) in the figure.

Angle (a): 28 ± 5°

4) Install the cap (1) to the hydraulic cylinder, and fix it

with the pin (3). 1
3

3
1

5) Install cap (1).

6) Install the bushings (2) with the bolts (4) so that the 2
matchmarks that were put on step 1) align.
Bolt (4): Width across flats 46 mm, M30, L 140 mm
Tightening torque of bolt (4): 1520 to 1910 Nm {155
to 195 kgm}

4, 5 4, 5
1

7) Install hydraulic hoses (7).

CAUTION ꞏ When connecting the hose, collect waste oil by 7 8, 9, 10
a waste oil container in order not to release oil
on the ground.

ꞏ Do not put the hydraulic hose and feet on the

upper surface of the engine hood (mesh part).
Doing so may dent the engine hood.

ꞏ The hook on the blade cylinder and engine food

is provided for a safety belt. Do not use the
hook for slinging.

66
REMARKS ꞏ When installing, prevent interference between
hydraulic hoses (7) with the cylinder. 8, 9, 10
ꞏ Install L.H. cylinder (11) and R.H. cylinder (12) in 7
lateral symmetry. 11
Bolt (9): Width across flats 19 mm, M12, 45 mm
long
Tightening torque of bolt (9): 98 to123 Nm {10 to
12.5 kgm}
Target tightening torque of bolt (9): 111 Nm {11.5
kgm}

Left side view 40°

L.H. cylinder

Right side view 40°

R.H. cylinder

8) Install the belt sling (J).

9) Remove the belt slings (H) (2 pieces) that are slung
horizontally.
J
10) Fully expand the cylinder.
11) Adjust the hydraulic cylinder to the blade grounding
angle.
12) Remove the sling bracket for delivery (K) and
change its orientation, and install it to the fixing
position.

REMARKS For the bolts and washers on the main body, use
the ones that are installed to the main body. K
13) Remove the belt sling (J).
14) Steps 1) to 13) mainly describe installation of the
L.H. hydraulic cylinder. Install the R.H. cylinder
similarly.

67
 2. Install the grease piping of yoke.
1) Install the nipples (13) to the left and right yokes
and the block on the machine side. L. H
Nipple (13): Width across flats 14 mm
16, 17 13 14
Tightening torque of nipple (13): 3.9 to 6.9 Nm {0.4 11
to 0.7 kgm}
2) Install the elbows (14) to the left and right yokes.
REMARKS Install the elbows (14) on the front side of the
machine so that the hoses (11) and the blade lift
cylinder are at an angle (a).
Angle (a): 20°
Elbow (14):Width across flats 16 mm
Tightening torque of elbow (14): 3.9 to 6.9 Nm {0.4
to 0.7 kgm} 14 15 12 13
3) Install the elbows (15) to the left and right yokes. R. H 14 13 16, 17 11
REMARKS Install the elbows (15) so that the hoses (12) and
the tubes are at an angle (b).
Angle (b): 30°
Elbow (15):Width across flats 17 mm
Tightening torque of elbow (15): 3.9 to 6.9 Nm {0.4
to 0.7 kgm}
4) Connect the hoses (11), (12) to the nipples (13) and
elbows (14), (15).
Tightening torque of hose (11), (12): 14.7 ± 3.3 Nm 13 12 15 14
{1.50 ± 0.34 kgm}
5) Fix the hoses (11) with the clamps (16).
REMARKS Install so that the clamp (16) and yoke are at an angle (c).
Angle (c): 45°
Bolt (17): Width across flats 19 mm, M12
Tightening torque of bolt (17): 98 to 123 Nm {10 to 12.5 kgm}

L. H < Same for the right side >

a 15 12 c Yoke
11
16
17

14
11
b

Blade lift cylinder Tube

68
A-8 Installation of undercarriage -1

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Sling jig - 1
B Chain block Commercially available 3.2 t 2
C Crane - 4.5 t 1
D Socket Commercially available 50 mm 1
E Socket Commercially available 30 mm 1
F Socket Commercially available 24 mm 1
G Jack Commercially available 15 t 1
H Wooden block - 1
I Wire rope sling Commercially available 2
J Socket Commercially available 41 mm 1
K Bogie fixing jig -

Coating materials
Komatsu code Part No.
1 Natural yellow SYPA-U03SPNY
2 G2-LI SYG2-400LI, SYG2-350LI, SYG2-400LI-A, SYG2-160LI

Part list
Part No. Part name Q'ty Part state
1 198-30-69830 COVER 2
2 198-50-61360 COVER (L.H.) 1
3 198-50-61370 COVER (R.H.) 1
4 198-50-61150 SHAFT (SIDE PIN) 2
5 198-30-69460 COVER (L.H.) 1
6 198-30-69470 COVER (R.H.) 1
7 198-50-62311 COVER (L.H.) 1
8 198-50-62321 COVER (R.H.) 1
9 198-50-51390 COVER 2
10 198-30-51430 COVER (L.H.) 1
11 198-30-51440 COVER (R.H.) 1
12 198-50-31270 SPACER 2
13 198-50-52171 COVER ASSEMBLY 2
14 195-30-31260 COVER 2
15 198-30-69851 COVER (L.H.) 1
16 198-30-69861 COVER (R.H.) 1
17 07000-15355 O-RING 2
31 198-50-61410 BOLT 4 2 each on right and left
32 01643-33380 WASHER 8 4 each on right and left
33 19M-09-12890 WASHER 4 2 each on right and left

69
Part list
Part No. Part name Q'ty Part state
35 198-50-31270 SPACER 2
36 07000-05190 O-RING 2
37 07000-15315 O-RING 2

TORSION SEAL ASSEMBLY

38 198-50-31160 2
(INNER WASHER)

TORSION SEAL ASSEMBLY

39 198-50-31241 2
(TORSION SEAL)

TORSION SEAL ASSEMBLY

40 198-50-52171 2
(OUTER WASHER)

41 01010-81655 BOLT 6
42 01643-31645 WASHER 6
43 01011-82005 BOLT 20
44 01643-32060 WASHER 20
47 01010-81640 BOLT 12 6 each on right and left
48 01643-31645 WASHER 12 6 each on right and left
49 198-50-51390 COVER 2 Common to right and left
50 02781-00628 UNION 2 Per cover
51 07040-12412 PLUG 2 Per cover
52 02782-1062A ELBOW 2 Per cover
53 07002-22434 O-RING 6 Per cover
54 198-71-62172 HOSE 1 With red band (Quantity per cover assembly)
55 198-71-62271 HOSE 1 With blue band (Quantity per cover assembly)
56 02896-21018 O-RING 2 Quantity per cover assembly
57 07376-70628 PLUG 4
58 02896-61018 O-RING 4
59 02896-21018 O-RING 2
62 01010-81695 BOLT 9 Quantity per cover assembly
63 01011-81625 BOLT 1 Quantity per cover assembly
64 01643-31645 WASHER 10 Quantity per cover assembly
68 07376-70628 PLUG 4
69 02896-61018 O-RING 4
70 198-30-51440 COVER (R.H.) 1
71 198-30-51430 COVER (L.H.) 1
72 01010-81635 BOLT 3 Quantity per cover
73 01643-31645 WASHER 3 Quantity per cover
74 198-50-51220 COVER 1
75 01010-81695 BOLT 10
76 01643-31645 WASHER 10
77 198-30-51330 PLATE 1
78 01010-81635 BOLT 3
79 01643-31645 WASHER 3
80 01011-63310 BOLT 10
81 01643-33380 WASHER 10

70
Part list
Part No. Part name Q'ty Part state
83 198-30-69280 PLATE 6
84 198-30-66190 COLLAR 6
85 19M-54-11770 WASHER 6
86 01011-62710 BOLT 6
87 01010-62765 BOLT 6
88 01643-32780 WASHER 6
89 198-30-68950 PLATE 2
90 198-30-68960 COLLAR 2
91 19M-54-11770 WASHER 4
92 01011-62710 BOLT 4
93 01010-62765 BOLT 6
94 01643-32780 WASHER 6
95 01010-62765 BOLT 4
96 01643-32780 WASHER 4
97 07049-02734 PLUG 6

1. Preparatory work
1) Remove the accessories from the track frame 4
assembly.

5, 6
14
9 2, 3 7, 8

10, 11 12, 13

15, 16

71
 2) Clean the track frame pivot and apply grease to it.

ꞏ Apply grease (G2-LI) to the groove and stick O-ring

(17) to it.

17

ꞏ Check torsion seal (18) attached to the pivot shaft

for distortion or damage and clean the shaft. Apply
18
grease (G2-LI) to pivot shaft surfaces (a) and (b).

a b

Fig. 1

19
A
B
C C
A
A

B
19
20
21

19

20

2. Lift the track frame assembly.

1) Sling track frame assembly (19) with crane (C) while keeping it horizontal by using sling jig (A) and
chain lever hoist (hereinafter referred to as chain block) (B) as shown in Fig. 1, and bring it near the
machine body (chassis).

REMARKS ꞏ For sling jig (A) and chain block (B), see “List of tools for field assembly”.
ꞏ Use 2 sets of chain block (B) with a rated load of 31.4 kN (3.2 t).
ꞏ U-hooks (20) are welded to the lift points of track frame assembly (19) in advance.
ꞏ The center hook (for sling jig (A)) is located a little (approximately 100 mm) rearward from the center
of gravity of track frame assembly. (19). Adjust the horizontal posture of track frame assembly (19)
with chain block (B).

ꞏ Lifting load of track frame assembly (19) + Sling jig (A) + Chain block (B) (2 pieces): Approx. 124
kN {12.65 t}

72
A-8 Installation of undercarriage -2

3. Install track frame assembly (19). (Bring close to

machine body) Fig. 2
1) While slinging track frame assembly (19)
horizontally, bring it close to the machine body and
insert the pivot shaft installed to the machine body
into pivot shaft hole (21) of track frame assembly
(19).

REMARKS At this time, the workers must not stand between

the machine body and track frame assembly (19).

2) While slinging track frame assembly (19)

horizontally, further bring it close to the machine
body as shown in Fig. 2.

3) Bring the track frame assembly until pin holes (c) of

equalizer bar side pins are aligned as shown in Fig. Fig. 3
3.

22

4) After track frame assembly (19) is brought close,

27 24 23 Fig. 4
check that torsion seal (24) fitted to pivot shaft (23)
in advance is in contact with O-ring (26) mounting
face of track frame (25) described in step 1-2) as
shown in Fig. 4.

26
28 25
4. Assemble the equalizer bar side pin section.
1) While adjusting with the crane as shown in Fig. 5, 29 Fig. 5
align the pin hole of equalizer bar side pin and the
pin hole on track frame side, and insert side pin
(29).
d
REMARKS Insert the side pin with its head toward the front of
machine body and UP mark (d) on the head up as
shown in Fig. 5.

73
 2) Connect grease tube (30).
3) Install the side pin mounting bolt. Fig. 6
REMARKS Insert the pin mounting bolt from below and install
the nut from above shown in Fig. 6.
30
4) Install the accessory cover with bolts (31).
Bolt (31): Width across flats 50 mm, M33, length
320 mm 34
Tightening torque of bolt (31): 2450 to 2700 Nm
31
{250 to 275 kgm}

5. Assemble pivot shaft end portion.

Fig. 7
1) Set spacer (35) removed in “1 Preparatory work” to
the pivot shaft end inserted into the track frame
assembly (See Fig. 7). Install smaller O-ring (36) to 37
the pivot shaft end, and insert larger O-ring (37) to 38, 39, 40
torsion seal assembly (38, 39, 40). Install torsion 44
43
seal assembly (38, 39, 40) and hold the spacer and 35
O-rings with them. Install the inner washer with bolts 36
(41) and washers (42) to the pivot shaft. Install the 42
outer washer with bolts (43) and washers (44) to the 41
track frame.
REMARKS Torsion seal assembly (38, 39, 40) is included in the parts (12, 13) removed in “1. Preparatory
work”, Step 1.

2) Install the bolts.

REMARKS Check that the track frame is in parallel with the machine body.
Bolt (41) specification: Width across flats 30 mm, M20, length 105 mm
Bolt (43) specification: Width across flats 24 mm, M16, length 65 mm
Tightening torque of bolt (41): 455 to 565 Nm {46.5 to 58 kgm}
Tightening torque of bolt (43): 235 to 285 Nm {23.5 to 29.5 kgm}
6. Fix the torsion seal on the large diameter side of
pivot shaft.

1) Fix torsion seal (45) on the large diameter side of

pivot shaft (inside of track frame assembly) to the
track frame with seal cover (46) on the large
diameter side (inside).

2) Install the seal cover with bolts (47) and washers 47, 48
(48) to the track frame, with its cut-out portion down
(toward the ground).

Bolt (47): Width across flats 24 mm, M16, length 40 mm

46 47, 48
Tightening torque of bolt (47): 235 to 285 Nm {23.5 45
to 29.5 kgm}

26 25
28 23

74
 7. Paint the pivot shaft.
Fig. 8
1) Paint the large diameter side of pivot shaft (For
painting area (e), see Fig. 8).

8. Remove the oil plugs(98) (2 pieces) installed to the

ends of tilt hoses coming out of the pivot shaft end.
Fig. 9

98

9. Install the hoses (60) and (61) to connect the work

equipment piping to the union of the cover assembly UP
(49).
59 h
REMARKS ꞏ Be sure to install O-ring (59).
ꞏ Install hose (60) with red band (h) to the upper 60
union of the cover assembly to be installed, and
install hose (61) with blue band (i) to the lower
union. 49 59
i 61
Hose: Width across flats 36 mm

10. Tighten cover assembly (49) together with the large

washer of torsion seal assembly installed in Step 6. Fig. 10
62, 63, 64

49 54
j: hydraulic hose with color identification marking
k: hydraulic hose without color identification marking j

55

11.Install the hoses (54) and (55) to connect the work

equipment piping to the elbow of the cover UP 56
assembly (49) that was mentioned on step 10. 54
REMARKS ꞏ Be sure to install O-ring (56).
f
ꞏ Install the hose with red band (f) to the upper elbow
of the cover assembly to be installed, and install the g
hose with blue band (g) to the lower elbow.
ꞏ Leave the opposite end of the hose unfixed. 56 55
Hose: Width across flats 36 mm
Tightening torque of hose fitting: 177 to 245 Nm {18 to 25 kgm}

75
 12. Install the oil plugs(98) (2 pieces) to the ends of tilt
hoses. Fig. 9

98

13. Lower the sling.

1) After completing up to Step 12, lower the sling. Fig. 13
REMARKS ꞏ When installing the other track frame assembly after
G
installing the first track frame assembly, install jacks
(G) or wooden blocks (H) under the installed track
frame assembly as shown in Fig. 13 in order to
prevent the frame from falling down when the sling
is lowered.

ꞏ Install the jacks or wooden blocks on at least 2

places so that the track frame assembly is kept
level in the front-rear direction as well.

14. Lower the machine body. (Remove the chassis

stand)
Fig. 14
1) Sling only the rear of machine body according to
Assembly procedure “A-2 Installation of machine
body (chassis)” as shown in Fig. 14, and pull out the
rear chassis stand from under the machine body.
Lifting load: Approx. 353 kN {36 t}
2) Sling only the front of machine body according to
Assembly procedure “A-2 Installation of machine
body (chassis)” as shown in Fig. 15, and pull out the
front chassis stand from under the machine body.
Lifting load: Approx. 343 kN {35 t}

3) Slowly lower the rear of machine body, and place

the all track rollers on the track links as shown in
Fig. 14 and Fig. 15. Fig. 15

4) Gradually lower the front of machine body, and

place the idlers of track frame assembly on the
tracks.

5) Remove the front sling.

6) Some of the peripheral bolts could not be installed in
Assembly procedure “A-5 Installation of final drive
assembly” due to the rear chassis stand. Install
those bolts as shown in Fig. 16.

REMARKS Perform this work on both R.H. and L.H. final drives.

76
 7) Check the tightening torque of all bolts tightened in
6) by using the torque wrench. Fig. 16
REMARKS If the tightening torque is out of the specified range,
tighten again.

Bolt (80) specification: Width across flats 50 mm,

M33, length 110 mm

Tightening torque of bolt (80): 1960 to 2450 Nm

{200 to 250 kgm}
80
8) Remove the rear sling. 81

15. Remove the bogie fixing jigs.

1) Remove bogie fixing jigs (K) from the track frame Fig. 17
assembly as shown in Fig. 17.

REMARKS The fixing jigs are installed to 4 places on each

K
outside of R.H. and L.H. track frame assemblies as
shown in Fig. 18. (Only 1 of the 4 jigs is different in
size from the others.)

ꞏ Remove the jigs only after the machine is lowered

to the tracks. If the machine body on the chassis
stands is lowered as it is, the track rollers sag and
the remaining work becomes difficult.

ꞏ These fixing jigs are for transportation. They prevent the track rollers from sagging when the track
frame assembly is loaded onto a trailer or unloaded or lifted with a crane.

ꞏ Keep the removed jigs according to the customer’s request or dispose of them according to the
decision of the service section.

Fig. 18 88 90
87 89
91
92

84
83
85 86 91 92

77
 2) Install bolts and washers (93), (94), (95), and (96) to
the triangular covers of the portions from which the 93, 94 Fig. 19
fixing jigs were removed as shown in Fig. 19. 95, 96
95, 96
REMARKS Reuse bolts (93) and washers (94) removed from
the fixing jigs in order to install the triangular covers (3
places) which compose the track roller bogie.
(See Fig. 18)

Bolt (93), (95): Width across flats 41 mm, M27

Tightening torque of bolts (93), (95): 1150 to 1440 Nm
{118 to 147 kgm}
97 Fig. 20
3) Drive cork plugs (97) in the threaded holes (3
places) from which the fixing jigs were removed in
order to protect the threads of the holes as shown in
Fig. 20. 97

78
A-9 Adding oil to pivot chamber

Pivot chamber
A
1. Add engine oil through plug (1) hole. 1
Plug (1): Insertion angle 19 mm
REMARKS For the oil type, see Assembly procedure “A-10
Inspection of oil level and coolant level”.
Oil quantity: 26 L on each side A
Oil level (a): 10 - 30 mm from oil level (b)

A-A

79
A-10 Inspection of oil level and coolant level

1. Check that each oil chamber and radiator (including the reservoir tank) are filled with oil or coolant
up to the specified level.
REMARKS Table 1 shows the oil types (and coolant types), Table 2 shows the specified capacity, and Table 3
shows the mixing proportion of the coolant and water.
Table 1
Ambient temperature (°C)
Recommended genuine
Lubrication point Type of oil °C [°F]
oil (typical part No.)
Min. Max.
EOS0W30 (KES) -30 {-22} 30 {86}
Engine oil (Note 1)
EOS5W40 (KES) -25 {-13} 40 {104}

Engine oil pan EO10W30-DH (KES) -20 {-4} 40 {104}

Engine oil EO15W40-DH (KES) -15 {5} 50 {122}

EO30-DH (KES) 0 {32} 40 {104}

Power train case (including TO 10 (KES) -30 {-22} 10 {50}

transmission, torque
Power train oil (Note 2)
converter, bevel gear case,
damper case, pivot) TO 30 (KES) 0 {32} 50 {122}

Final drive case (both sides) Power train oil TO 30 (KES) -30 {-22} 50 {122}
Power train oil TO 10 (KES) -20 {-4} 50 {122}
Hydraulic system
Hydraulic oil HO46-HM (KES) -20 {-4} 50 {122}

Hyper white grease

G2-TE (KES) -20 {-4} 50 {122}
Grease fitting (Note 3)

Lithium EP grease G2-LI (KES) -10 {14} 50 {122}

Non-Amine Coolant
Cooling system AF-NAC (KES) -30 {-22} 50 {122}
(Note 4)

ASTM D975 No. 1-D S15 -30 {-22} 20 {68}

Fuel tank Diesel fuel
ASTM D975 No. 2-D S15 0 {32} 50 {122}
KES: Komatsu Engineering Standards ASTM: ASTM International
Note 1: Since cold district specification engine oil for KDPF deteriorates more easily than the one
for normal area (Oil replacement interval: 500 hours), replace it and filter cartridge every 250 hours.
When changing the maintenance period of machine monitor, ask your Komatsu distributor.

Notes 2, 3, 4: For details, see "Operation and Maintenance Manual".

80
 Table 2

Power train case (including

Damper Final drive Hydrauli Cooling
Engine oil pan transmission, torque Fuel tank
converter, bevel gear case)
case case c system system

75 L on each
Specified capacity 128 L 325 L 2.2 L 465 L 1920 L 250 L
right and left

75 L on each
Refill capacity 120 L 210 L 2.2 L 190 L - -
right and left
Decide the mixing proportion of coolant and water so that the freezing point of the mixture will be
approximately 10°C lower than the past minimum ambient temperature.
Table 3
Min. ambient °C -10 min. -15 -20 -25 -30 -35 -40 -45 -50
temp. °F 14 min. 5 -4 -13 -22 -31 -40 -49 -58
Density % 30 36 41 46 50 54 58 61 64

Warning ꞏ The coolant is flammable. Keep it away from open flame.

ꞏ When removing the drain plug, take care not to get coolant on you.
ꞏ When adding oil to the power train case or hydraulic system (tank), loosen the pump air
bleeding plug described in “A-34 Bleeding air from work equipment pump and fan pump”.
ꞏ After adding oil or coolant to each portion, lubricate the engine according to “M-8 No-
injection cranking of engine”. Then, bleed air from the pump again according to “A-34
Bleeding air from work equipment pump and fan pump”, and check the oil or coolant level
again.

REMARKS ꞏ Use tap water to dilute.

ꞏ Control the mixing proportion with an antifreeze concentration meter.

Precautions for disconnecting air conditioner piping

CAUTION When replacing the air conditioner unit, air conditioner compressor, condenser or receiver
drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit
before disconnecting the air conditioner hoses.

REMARKS ꞏ Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner
gas:R134a).
ꞏ Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
Warning Put on the protective eyeglasses, gloves and working clothes with long sleeves while you
are collecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your
eyes, you may lose your sight, and when it touches your skin, you may suffer from frostbite.

REMARKS When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use
one wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
CAUTION ꞏ When installing the air conditioner piping, be careful so that dirt, dusts and water do not
enter the hose.
ꞏ Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
ꞏ Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
ꞏ When removing the O-rings, use a soft tool so that the piping is not damaged.
ꞏ Check that the O-ring is not damaged or deteriorated.
ꞏ Apply compressor oil for refrigerant (R134a) to O-ring.

81
REMARKS Do not apply oil to the threaded portion of a bolt, nut or union.
Manufatuer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG（PAG46 or equivalent）
SANDEN SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one
wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench
for tightening).

Refrigerant (air conditioner gas)

Part name Filling amount

R134a 1050±50 g

82
A-11 Installation of ripper-1 (Machine with ripper)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Wooden block - 1 300 mm ×300 mm ×600 mm
B Socket Commercially available 30 mm 1
C Air impact Commercially available 1 Torque 980 Nm (100 kgm) or more
D Crane Commercially available 45 t 1
E Wire rope sling Commercially available φ16 × 3m 3
F Chain block Commercially available 1.6 t 1
G Shackle Commercially available SD16-M 2
H Shackle Commercially available SD22-M 1
Width 25
I Belt sling Commercially available 1
mm × 3 m

Part list
Part No. Part name Q'ty Part state
2 - ARM ASSEMBLY 1
3 01010-82045 ARM PIN LOCK BOLT 4
4 01643-32060 WASHER 4

1. Remove paint and rust prevention oil from mounting

portions.

2. Remove arm pin lock bolt (3), and move arm pin (1)
aside.
REMARKS ꞏ Do not remove arm pin (1).
ꞏ Keep the machine so that the engine can be
started, since the engine needs to be started in
order to connect the cylinder in Assembly of "A-11
Installation of ripper-3".
1
Arm pin lock bolt (3):
Width across flats: 30 mm, M20, L45 mm

83
 3. Lift arm assembly (2) at 3 points.
REMARKS Securely level arm assembly (2) in lateral direction. 3, 4
4. Install arm assembly (2) with arm pin (1).
1
REMARKS Apply grease and lubricate.
Weight of arm assembly (2): 1750 kg
Arm pin lock bolt (3):
Width across flats: 30 mm, M20, L45 mm
Tightening torque of arm pin lock bolt (3): 2
A
455 to 565 Nm {46.5 to 58 kgm}
5. After installing the arm assembly (2), install the
wooden block (A) to hold the arm assembly (2).

84
A-11 Installation of ripper-2 (Machine with ripper)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 30 mm 1
B Socket Commercially available 19 mm 1
Torque 980 Nm (100 kgm) or
C Air impact Commercially available 1
more
D Crane Commercially available 45 t 1
Width 25
E Belt sling Commercially available 1
mm × 3 m
F Wooden block - 1 200 mm ×150 mm ×400 mm

Part list
Part No. Part name Q'ty Part state
4 - LIFT CYLINDER ASSEMBLY 2
6 - TILT CYLINDER ASSEMBLY 2
7 - SERVICE CENTER BOX 2
7a 01024-81230 BOLT 10
10 - BEAM ASSEMBLY 1
CYLINDER CONNECTING
11 01010-82045 4
PIN LOCK BOLT
12 01643-32060 WASHER 4

Left side Right side

1.
Remove the service center box (7) on the rear of the right and left fender with the bolts (7a) (10
pieces, 5 pieces each for the right and left).
REMARKS ꞏ When installing tilt cylinder connecting pin (5), remove service center boxes (7) in order to avoid
interference.
ꞏ The figure shows the right side. Remove the one on the left side by following the indication for the
right side symmetrically.
Bolt (7a): Width across flats 19 mm, M12

85
 2.
Remove cylinder connecting pin lock bolt (11), and
move lift cylinder connecting pin (3) and tilt cylinder 3
connecting pin (5) aside.
Cylinder connecting pin lock bolt (11): Width across
flats 30 mm, M20, L45 mm
3. Install lift cylinder assembly (4) with lift cylinder
connecting pin (3). 11
REMARKS ꞏ Apply grease and lubricate. 12
Weight of lift cylinder assembly (4): 373 kg 4

4.
Install tilt cylinder assembly (6) with tilt cylinder
connecting pin (5). 7 6 5
REMARKS ꞏ Apply grease and lubricate.
7
ꞏ Install the wooden block (F) between the lift cylinder
and tilt cylinder.

Weight of tilt cylinder assembly (6): 383 kg

Cylinder connecting pin lock bolt (11): Width across F
11
flats 30 mm, M20, L45 mm 6 F 12
Tightening torque of cylinder connecting pin lock
bolt (11): 455 to 565 Nm {46.5 to 58 kgm}

5. Install the R.H. and L.H. lift and tilt hoses.

CAUTION When connecting the hose, collect waste oil by
a waste oil container in order not to release oil
on the ground.
b
REMARKS When installing each hose, pay attention to the a
directions of straight fitting (a) and L-fitting (b).

Flange mounting P bolt: Width across flats 14 mm,

M10

6. Install the service center box (7) on the rear of the

right and left fender with the bolts (7a) (10 pieces, 5
pieces each for the right and left).
7. Install grease hoses (8) and elbow (9).
9
REMARKS Install these before installing the cylinder head pin.
8. Connect hoses (8) to the pins.
Hose (8): Width across flats 14 mm

8 10

86
A-11 Installation of ripper-3 (Machine with ripper)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 30 mm 1
B Wooden block - 2 350 mm×350 mm×670 mm
C Air impact Commercially available 1 Torque 980 Nm (100 kgm) or more
D Crane Commercially available 45 t 1
E Wire rope sling Commercially available φ16 × 3m 3
F Chain block Commercially available 1.6 t 1

Part list
Part No. Part name Q'ty Part state
14 01010-82045 CYLINDER CONNECTING PIN LOCK BOLT 4
15 01643-32060 WASHER 4
16 01010-82045 ROD SIDE CONNECTING PIN LOCK BOLT 4
17 01643-32060 WASHER 4

CAUTION Before starting the engine for the first time, lubricate the engine inside according to “M-8 No-
injection cranking of engine”.
1. Install beam assembly (10) with beam connecting
pin (11).
REMARKS Sling the beam assembly at 3 points of the shank
pin and cylinder pin.
Weight of beam assembly: 2255 kg 14
Beam connecting pin lock bolt (14): 15
Width across flats: 30 mm, M20, L45 mm
Tightening torque of beam connecting pin lock
10 11
bolt (14): 455 to 565 Nm {46.5 to 58 kgm}

2. Place block (B) under beam assembly (10) so that

arm (2) is level.
Wooden block (B) height: 670 mm 10
3. Connect the cylinder.
1) Start and run the engine at low idle, and check
extension and retraction of lift cylinder (4) and tilt
cylinder (6).

REMARKS ꞏ If the rod does not move smoothly, check the B 2

hydraulic oil level and add oil as necessary. ꞏ
Bleed air according to “A-33 Bleed air from
hydraulic cylinders".

87
2) While adjusting extension and retraction of the
cylinder rod, connect lift cylinder (4) with lift cylinder 13 6
rod side connecting pin (12).

3) While adjusting extension and retraction of the 16

cylinder rod, connect tilt cylinder (6) with tilt cylinder 17

rod side connecting pin (13).

Rod side connecting pin lock bolt (16):
Width across flats: 30 mm, M20, L45 mm 12
4
Tightening torque of rod side connecting pin lock
bolt (16): 455 to 565 Nm {46.5 to 58 kgm}

88
A-11 Installation of ripper-4 (Machine with ripper)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
C Wrench Commercially available 24 mm 2

Part list
Part No. Part name Q'ty Part state
1 07094-30315 CLAMP 2
2 07095-00314 CUSHION 2
3 01024-81270 BOLT 1
4 01580-11008 NUT 1
5 198-78-61261 BRACKET 1
6 01024-81230 BOLT 2
7 04205-11028 PIN 1
8 01640-21016 WASHER 1
9 04050-13015 COTTER PIN 1
10 07094-30315 CLAMP 2
11 198-68-21551 BRACKET 1
12 07095-00314 CUSHION 2
13 01024-81270 BOLT 1
14 198-78-61251 BRACKET 1
15 01024-81240 BOLT 2
16 07094-30315 CLAMP 2
17 07095-00314 CUSHION 2
18 01024-81270 BOLT 1
19 07094-30315 CLAMP 2
20 07095-00314 CUSHION 2
21 01024-81270 BOLT 1
22 198-79-52231 HOSE 1
23 02896-21009 O-RING 1
24 198-79-52241 HOSE 1
25 02896-21009 O-RING 1

89
 1. Install the pin puller hose according to the following d
procedure.
e
CAUTION When connecting the hose, collect waste oil by
a waste oil container in order not to release oil
on the ground.
f
c

1) Connect hoses (22) and (24) to portion (c).

Hose (22): Yellow band Portion c

Hose (24): Blue band

Hose (22), (24): Width across flats 22 mm 24, 25 22, 23
REMARKS Install O-rings (23) and (25) to the hoses.

2) Install clamps (16) and (19) and cushions (17) and

(20) to portion (d) with bolts (15) and (18). Portion d 16, 17, 18

REMARKS Install clamps (16) and (19) to the tape positions.

14, 15
Bolt (15), (18): Width across flats 19 mm, M12

19, 20, 21

3) Install brackets (5) and (11), pin (7), clamp (10), and
cushion (12) to portion (e) with bolts (6) and (13), Portion e
washer (8), and cotter pin (7). 7, 8, 9
5, 6
REMARKS Install clamp (10) to the tape position.
Bolt (6), (13): Width across flats 19 mm, M12

10, 11, 12, 13

4) Install clamp (1) and cushion (2) to portion (f) with

bolt (3) and nut (4). Portion f

REMARKS Install clamp (1) to the tape position.

Bolt (3): Width across flats 19 mm, M12
Nut (4): Width across flats 19 mm
1, 2, 3, 4

90
A-11 Installation of ripper-5 (Machine with ripper)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
C Wrench Commercially available 14 mm 2

Part list
Part No. Part name Q'ty Part state
1 04434-51712 CLAMP 1
2 07095-20211 CUSHION 1
3 01024-81230 BOLT 1
4 198-68-11350 ELBOW 4
5 198-68-11341 ELBOW 2

1. Install the grease hose to the machine side.

4 1, 2, 3 4

a a

5 5

1) Install elbows (4) and (5), and connect the grease hose.
REMARKS ꞏ Install R.H. elbow (4) level.
ꞏ Install elbow (5) at angle (a) shown in the figure.
Angle (a): 90°
2) Install clamp (1) and cushion (2) with bolt (3).

91
A-11 Installation of ripper-6 (Machine with ripper)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
C Wrench Commercially available 14 mm 2

Part list
Part No. Part name Q'ty Part state
1 07020-00000 NIPPLE 2
2 198-68-1141 ELBOW 2
3 07020-00000 NIPPLE 2
4 203-62-21740 NIPPLE 2
5 195-68-11940 HOSE 2
6 04434-51712 CLAMP 6
7 07095-20211 CUSHION 6
8 01024-81230 BOLT 6

1. Install grease hose (5) on the ripper beam side.

2. Install clamp (6) and cushion (7) with bolt (8).
6, 7, 8

5 3

1) Remove nipple (1), and install elbow (2).

1, 2
REMARKS Install elbow (2) at angle (a) shown in the figure.
Angle (a): 45°
a
2) Install nipples (3) and (4).
3) Install clamp (6).
REMARKS ꞏ Install clamp (6) to portion (b) level. b
ꞏ Install clamp (6) to portion (c) at angle (d) shown in
the figure.
Angle (d): 45°

1, 2
c
c
a
d d
d
c d
b
c

92
A-11 Installation of counterweight (Machine with counterweight)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 30 mm 1
B Socket Commercially available 19 mm 1
C Air impact Commercially available 1 Torque 980 Nm (100 kgm) or more
D Crane Commercially available 45 t 1
E Wire rope sling Commercially available 4
F Chain block Commercially available 1
G Shackle Commercially available 4

Part list
Part No. Part name Q'ty Part state
3 01010-82045 ARM PIN LOCK BOLT 4
4 01643-32060 WASHER 4
7 - SERVICE CENTER BOX 2
7a 01024-81230 BOLT 10
CYLINDER CONNECTING
11 01010-82045 4
PIN LOCK BOLT
12 01643-32060 WASHER 4

1.
Remove arm pin lock bolt (3), and move arm pin (1) 3, 4
aside.
REMARKS ꞏ Do not remove arm pin (1).
Arm pin lock bolt (3): 1
Width across flats: 30 mm, M20, L45 mm

93
 Left side Right side

2.
Remove the service center box (7) on the rear of the right and left fender with the bolts (7a) (10
pieces, 5 pieces each for the right and left).
REMARKS ꞏ When installing lift cylinder connecting pin (5), remove service center boxes (7) in order to avoid
interference.
Bolt (7a): Width across flats 19 mm, M12
3. Remove cylinder connecting pin lock bolt (11), and
move lift cylinder connecting pin (5) aside.

4. Sling and set the counterweight assembly.

Weight of counterweight assembly: 7420 kg

94
 5. Install counterweight assembly with arm pin (1).
REMARKS Apply grease and lubricate.
Arm pin lock bolt (3):
Width across flats: 30 mm, M20, L45 mm 3, 4

Tightening torque of arm pin lock bolt (3):

455 to 565 Nm {46.5 to 58 kgm} 1

6. Install counterweight assembly with lift cylinder

connecting pin (5)
REMARKS Apply grease and lubricate.
Cylinder connecting pin lock bolt (11):
Width across flats 30 mm, M20, L45 mm
Tightening torque of cylinder connecting pin lock 5 11, 12
bolt (11):
455 to 565 Nm {46.5 to 58 kgm}

7. Install service center box (7) in the reverse order of

step 2.

95
A-12 Installation of trunnion

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Crane - 45 t 1
B Belt sling Commercially available 1
C Pinch bar Commercially available 1 φ25 mm × 900 ｍｍ
D Socket Commercially available 46 mm 1
E Air impact Commercially available 1 Torque 2940 Nm (300 kgm) or more

Part list
Part No. Part name Q'ty Part state
1 198-72-85151 BOLT 24 (12 on each right and left)
2 01643-33080 WASHER 24 (12 on each right and left)
3 - TRUNNION 2
4 - TRACK FRAME 2

1. Sling and install the trunnion.

1) Remove paints from trunnion mounting faces (a) on a
both sides.
Weight of trunnion: 1.57 kN {160 kg}

2) Install trunnion (3) to track frame (4) with bolts (1)

and washers (2). 4
2
Bolt (1): Width accross flats 46 mm, M30, length
110 mm
1
Bolt (1): Tightening torque: 1520 to 1910 Nm {155
to 195 kgm}
3

2) If tilt hose (5) is installed, pull it out through the

center of trunnion (3) as shown in the figure. 3

96
A-13 Installation of track

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Crane - 1
□ 300 mm x
B Wooden block - 3
600 mm

Round steel bar

C Lifting bar - φ25 mm x 1m
1

D Wire rope sling - φ24 mm x 2 m 2 Specification load: 47 kN {4.8 t}

t25 mm x □
E Steel sheet - 1
300 mm

Round steel bar

F Lifting bar - φ25 mm x 700 2
mm

12.5 mm in wire
G Load chain - diameter x 1.5 1 Specification load: 49 kN {5 t}
m

Width 75
H Belt sling - 1 Specification load: 19.6 kN {2 t}
mm x 5 m
I Socket Commercially available 55 mm 1
J Air impact Commercially available 1 Torque 980 Nm (100 kgm) or more
K Torque wrench Commercially available 1 Torque 1375 Nm (1140 kgm) or more
L Hydraulic wrench Commercially available 1
Socket for hydraulic
M Commercially available 55 mm 1
wrench

Part list
Part No. Part name Q'ty Part state
198-32-31484 MASTER SHOE(910 mm wide) 2 1 on each right and left
1 198-32-31475 MASTER SHOE (810 mm wide) 2 1 on each right and left
198-32-16143 MASTER SHOE (710 mm wide) 2 1 on each right and left
2 198-32-31342 Master bolt 8 4 on each right and left
3 19M-32-11450 KEY 4 2 on each right and left

CAUTION ꞏ The crane operator, machine operator, and signalman must work in cooperation when
installing the tracks.

ꞏ Accordingly, those 3 people must hold meeting and confirm the signs before starting the
work.

ꞏ The signer must stand and signal at a place where the machine operator and crane operator
can see him/her clearly.

97
 1. Lift the front end of track with crane (A), and wind it
onto the idler. Place wooden block (B) under the D Fig. 1
C
track grouser in order to prevent the track from
rewinding as shown in Fig. 1, then remove the sling. B

REMARKS To perform fine adjustment of the wooden block (B)

height, insert a steel plate between the wooden
block (B) and the groucer as necessary.

2. Push down the ripper beam and raise the rear of the
D Fig. 2
machine until the sprocket separates from the track.
E
(Fig. 2)

a: Float b

b: Insert

B a

3. Sling one side of the rear end of track (sprocket

side) and bring it close to the sprocket as shown in Fig. 3
the figure. c

c: Crane main hook

G
d: Outside
F
e: Inside d e

4. Connect belt sling (H) and track (4) by using crane

auxiliary hook (g), and place the belt sling on carrier
Fig. 4
roller (6) as shown in Fig. 4, then pull the belt sling
until track (4) moves over sprocket (5). H
f F g

f: Crane main hook 5

g: Crane auxiliary hook
4
6

5. Move the track forward until the 5th link pin is

meshed with the sprocket, then remove the track Fig. 5
from the crane auxiliary hook.

6. Remove all harmful dirt, metal chips, etc. from the

mating faces of the master link.

REMARKS Clean the master link on the idler described in step 1.

98
 7. Start the engine and slowly turn the sprocket and
gradually move the track forward. Connect the h Fig. 6
master link at the leading end to the master link on
the idler as shown in portion (h) in Fig. 6.
B

CAUTION During this work, the crane operator, machine

operator, and signalman must work in close
cooperation.

8. When the master links are connected together, stop slinging the track.
9. Install the master shoe (1) to the connected master
links by tightening the master bolts (2) (4 pieces) Fig. 7
lightly. After that, make the master links contact 1
firmly by using the key (3). 2

REMARKS If master bolts (2) are tightened forcibly before the

master links are fitted together, their threads and
3
the threads of master links may be damaged.
Before installing the master bolts, check that the
master links are fitted together.

Master bolt (2): Width across flats 55 mm, M36

10. Confirm that the mating faces are fully fitted together, then loosen master bolts (2) and remove
master shoe (1).

11. Apply seizure prevention compound (LM-P) to the threads of master bolts (2) in advance.
REMARKS For seizure prevention compound (LM-P), see “Coating materials list”.
12. Tighten master bolts (2).
Fig. 8
1) Install master shoe (1) and key (3) again to the
master links, and install master bolts (2).

2) First, tighten to the following torque and check

again that the mating faces of the master links are
fitted together.
Tightening torque of master bolt (2): 1176 ± 118 Nm
{120 ± 12 kgm}
3) Make a matchmark on each bolt head and shoe in white paint (indicated with arrow in Fig. 8) in
order to indicate the initial position of the bolt head in the turning direction.

4) After making the matchmark, retighten the bolt with

an impact wrench until the matchmark on the bolt Fig. 9
head moves 120 ± 0 to -20 degrees.
I III
REMARKS ꞏ Tighten the bolts in the order shown in Fig. 9.
ꞏ For the track tension adjustment procedure, see
IV II
Assembly procedure “A-14 Adjusting of track
tension”.

13. Remove wooden blocks (B) placed in steps 1 and 2.

99
A-14 Adjusting of track tension

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 24 mm 1
B Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
C Socket Commercially available 27 mm 1
D Extension bar Commercially available 300 mm 1
E Ratchet wrench Commercially available 1

CAUTION ꞏ Grease inside the adjusting mechanism is under high pressure and may spout out when
plug (4) is loosened. For this reason, do not loosen plug (4) more than 1 turn. Do not loosen
any peripheral parts other than plug (4). Do not face in the mounting direction of grease
fitting.
ꞏ If the track cannot be loosened with the procedure given here, ask your Komatsu distributor
for repair.
ꞏ When removing cover (2), be careful not to let any dirt get in.
ꞏ The safety label is stuck on the back of cover (2). Be careful not to damage the safety label
during work.
Check method
1. Stop the machine on a level surface (stop from
forward travel without applying the brake). Then,
place a straight bar on the track between the carrier a
roller and the idler as shown in the right figure, and
measure the clearance between the bar and the
grouser at the midpoint. If the clearance is (a), the
tension is standard. If the track tension is out of
standard, adjust it according to the following
procedure.

REMARKS Adjust the track tension to 30 mm for the first 100 operating hours to fit the bushings and pins.
Dimension (a): 20 to 30 mm

100
 Adjustment procedure
2. When increasing tension
1) Remove both bolts (1), and remove cover (2).
2) Add grease through grease fitting (3) with a grease 1
pump.
3) Move the machine forward and backward, and
check that the tension is correct. 2

4) Check the track tension again. If the tension is not

correct, adjust it again.
3. When decreasing tension
1) Remove both bolts (1), and remove cover (2).
2) Loosen plug (4) gradually and release the grease. 4
REMARKS ꞏ Do not loosen plug (4) more than 1 turn.
ꞏ If the grease does not come out smoothly, move the
machine forward and backward a short distance.
Plug (4): Width across flats 27 mm
3
4) Tighten plug (4).
5) Move the machine forward and backward, and
check that the tension is correct.
6) Check the track tension again. If the tension is not correct, adjust it again.

101
A-15 Installation of mask

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Crane Commercially available 45 t 1
B Belt sling Commercially available 1
C Socket Commercially available 24 mm 1
D Air impact Commercially available 1 Torque 980 Nm (100 kgm) or more
E Trque Wrench Commercially available 1 Torque 412 Nm (42 kgm) or more

Part list
Part No. Part name Q'ty Remark
1 198-54-85151 MASK R.H. 1 Unit shipment
2 198-54-85141 MASK L.H. 1 Unit shipment
3 01010-81655 BOLT 4 Unit shipment
4 01643-31645 WASHER 4 Unit shipment
5 01011-81630 BOLT 4 Unit shipment
6 01643-31645 WASHER 4 Unit shipment

1. Install the masks (1) and (2).

Tightening torque of bolts (3), (5): 235 to 285 Nm {23.5 to 29.5 kgm}

102
A-16 Installation of handrail / step on right side of radiator

Tools and equipment

Symbol Part name Part No. Specifications Q'ty Remarks
A Socket Commercially available 17 mm 1
B Socket Commercially available 19 mm 1
D Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
E Hexagonal wrench Commercially available 5 mm 1
F Crane - 45 t 1
G Wire rope sling Commercially available 1
H Chain block Commercially available 1

Parts list
Part No. Part name Q'ty State of parts
1 198-54-87831NK STEP 1
2 198-54-79441NK PLATE 1
3 01245-00820 BOLT 7
4 01643-70823 WASHER 7
5 01024-81230 BOLT, SEMS 4
6 198-54-85671NK STEP 1
7 01024-81230 BOLT, SEMS 4
8 198-54-86861RJ HANDRAIL R.H. 1
9 01024-81260 BOLT, SEMS 2
10 21U-60-61350 COLLOR 2
11 01024-81270 BOLT, SEMS 2
12 195-54-81351RJ HANDRAIL R.H. 1
13 01024-81260 BOLT, SEMS 2
14 21U-60-61350 COLLOR 2
15 01024-81235 BOLT, SEMS 1
16 198-54-79381RJ PLATE 1
17 07283-53444 U-BOLT 2
18 22P-70-12160 NUT 4
19 01643-31032 WASHER 4
20 198-54-71360RJ PLATE 1
21 07283-33450 U-BOLT 2
22 22P-70-12160 NUT 4
23 01643-31032 WASHER 4

103
 8, 9, 10, 11
20, 21, 22, 23

16, 17, 18, 19

12, 13, 14, 15

6, 7 1, 2, 3, 4, 5

REMARK Installation of step on the right side of radiator may not be necessary depending on destination.
1. Install the step on the right side of the radiator.
1) Install the plate (2) with the bolts (3) (7 pieces).
Bolt (3): width across flats 5 mm, M8

2) Install the step (1) with the bolts (5) (4 pieces).

Bolt (5): width across flats 19 mm, M12

3) Install the step (6) with the bolts (7) (4 pieces).

Bolt (7): width across flats 19 mm, M12

104
2. Install the handrail on the right side of radiator.
8, 9, 10, 11
1) Install the handrails (8), (12) with the bolts (9), (11),
(13), and (14).
Bolt (7): width across flats 19 mm, M12

12, 13, 14, 15

2) Install the plates (16) and (20) with the U-bolts (17)
16, 17, 18, 19
and (21).
Nut (18), (22): width across flats 17 mm
Nut (18), (22) tightening torque: 59 to 74 Nm
{6 to 7.5 kgm}

20, 21, 22, 23

105
A-17 Installation of shandrail / step on left side of radiator

Tools and equipment

Symbol Part name Part No. Specifications Q'ty Remarks
A Socket Commercially available 17 mm 1
B Socket Commercially available 19 mm 1
D Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
E Hexagonal wrench Commercially available 5 mm 1
F Crane - 45 t 1
G Wire rope sling Commercially available 1
H Chain block Commercially available 1

Parts list
Part No. Part name Q'ty State of parts
1 198-54-87821NK STEP 1
2 198-54-79441NK PLATE 1
3 01245-00820 BOLT 7
4 01643-70823 WASHER 7
5 01024-81230 BOLT, SEMS 4
6 198-54-85671NK STEP 1
7 01024-81230 BOLT, SEMS 4
8 198-54-86851RJ HANDRAIL L.H. 1
9 01024-81260 BOLT, SEMS 2
10 21U-60-61350 COLLOR 2
11 01024-81270 BOLT, SEMS 2
12 195-54-81351RJ HANDRAIL L.H. 1
13 01024-81260 BOLT, SEMS 2
14 21U-60-61350 COLLOR 2
15 01024-81235 BOLT, SEMS 1
16 198-54-79371RJ PLATE 1
17 07283-53444 U-BOLT 2
18 22P-70-12160 NUT 4
19 01643-31032 WASHER 4
20 198-54-71370RJ PLATE 1
21 07283-33450 U-BOLT 2
22 22P-70-12160 NUT 4
23 01643-31032 WASHER 4

106
 8, 9, 10, 11
20, 21, 22, 23

16, 17, 18, 19

12, 13, 14, 15

6, 7
1, 2, 3, 4, 5

REMARK Installation of step on the left side of radiator may not be necessary depending on destination.
1. Install the step on the left side of the radiator.
1) Install the plate (2) with the bolts (3) (7 pieces).
Bolt (3): width across flats 5 mm, M8

2) Install the step (1) with the bolts (5) (4 pieces).

Bolt (5): width across flats 19 mm, M12

3) Install the step (6) with the bolts (7) (4 pieces).

Bolt (7): width across flats 19 mm, M12

107
2. Install the handrail on the left side of radiator.
8, 9, 10, 11
1) Install the handrails (8), (12) with the bolts (9), (11),
(13), and (14).
Bolt (7): width across flats 19 mm, M12

12, 13, 14, 15

2) Install the plates (16) and (20) with the U-bolts (17)
and (21). 16, 17, 18, 19

Nut (18), (22): width across flats 17 mm

Nut (18), (22) tightening torque: 59 to 74 Nm
{6 to 7.5 kgm}

20, 21, 22, 23

108
 Instalation of cab right side cover
A-18
(When cab right side cover is not installed)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Air impact Commercially available 1 Torque 980 Nm (100 kgm) or more
C Trque Wrench Commercially available 1 Torque 412 Nm (42 kgm) or more

Part list
Part No. Part name Q'ty Remark
1 198-54-86391 COVER R.H. 1 Unit shipment
2 01034-81230 BOLT 5 Unit shipment

REMARK This operation may not be necessary depending on destination.

1
2
1. Install the COVER R.H. (1).
REMARK Install it so that the clearance on the cover R.H. (1)
is as shown as the dimension (a) in the figure. a
a
Dimension (a): 5 mm (Reference dimensions)
Tightening torque of bolt (2): 98 to 123 Nm {10 to
12.5 kgm}

109
 Instalation of cab left side cover
A-19
(When cab left side cover is not installed)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Air impact Commercially available 1 Torque 980 Nm (100 kgm) or more
C Trque Wrench Commercially available 1 Torque 412 Nm (42 kgm) or more

Part list
Part No. Part name Q'ty Remark
1 198-54-86391 COVER L.H. 1 Unit shipment
2 01034-81230 BOLT 9 Unit shipment
3 21N-53-31870 CAP 3 Unit shipment

REMARK This operation may not be necessary depending on destination.

1. Install the COVER L.H. (1).

REMARK Install it so that the clearances on the cover L.H. (1)
are as shown as the dimension (a) and (b) in the a a
figure.

Dimension (a): 10mm

Dimension (b): 7mm
Tightening torque of bolt (2): 98 to 123 Nm {10 to
12.5 kgm}
b

2. Install the cap (3).

110
 Assembling of blade unit-1
A-20
(Machine with semi-U blade/full-U blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
C Wrench Commercially available 14 mm 1
D Wrench Commercially available 17 mm 1
E Wrench Commercially available 10 mm 1

Part list
Part No. Part name Q'ty Part state
70 203-62-21740 NIPPLE 1
71 198-68-11640 NIPPLE 1
72 198-68-21180 GREASING HOSE 1
73 07020-00000 FITTING 1
74 04434-51712 CLAMP 11
75 07095-20211 CUSHION 11
76 01024-81225 BOLT 11
77 198-68-21141 COVER 2
78 198-68-21150 COVER 1
79 198-68-21131 COVER 1
80 198-68-21121 COVER 1
81 01024-81225 BOLT 11

1. Install the greasing hose. 70 72

1) Install nipples (70), (71) and connect the greasing
hose (72).
Nipple (70), (71): Width across flats 14 mm
Greasing hose (72): Width across flats 17 mm
Tightening torque of nipple (70), (71): 3.9 to 6.9 Nm
{0.4 to 0.7 kgm}
Tightening torque of greasing hose (72): 13.2 to
16.2 Nm {1.3 to 1.7 kgm}
71

2) Install the fitting (73).

Fitting (73): Width across flats 10 mm
Tightening torque of fitting (73): 3.9 to 6.9 Nm {0.4
to 0.7 kgm}

73

111
 3) Install the clamps (74).
74, 75, 76
REMARKS Install the clamps (74) in part (a) at the angle (b)
shown in the figure.
Angle (b): 45 °
Bolts (76): Width across flats 19 mm, M12
Tightening torque of bolts (76): 98 to 123 Nm {10 to
12.5 kgm}

4) Install the covers (77), (78), (79), (80). 81 78 79

Bolts(81): Width across flats 19 mm, M12
Tightening torque of bolts (81): 98 to 123 Nm {10 to
12.5 kgm}

77 80

112
 Assembling of blade unit-2
A-20
(Machine with semi-U blade/full-U blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Wire rope sling Commercially available φ32 mm× 5 m 4
B Shackle Commercially available BB28-S 2
C Wooden block - 4 350 mm × 350 mm × 400 mm
D Plate Commercially available 1
E Belt sling Commercially available 1 Width 50 mm × 4 m
F Crane - 45 t 1
G Socket Commercially available 36 mm 1
H Air impact Commercially available 1 Torque 980 Nm (100 kgm) or more
I Wooden block - 2 350 mm × 350 mm × 750 mm

Part list
Part No. Part name Q'ty Part state
81 198-72-51810 PIN 2
82 09257-11219 LOCK 2
83 01010-82455 BOLT 8
84 01643-32460 WASHER 8

1. Stand delivered blade (1) vertically on the assembly

place according to the following procedure.
1
REMARKS Stand the blade with its back (a) at 90 degrees to a
the ground.

90°

1) Sling blade (1) with the crane. Raise blade (1) A

gradually until it is vertical to the ground by b
simultaneously operating main hook (b) and c
auxiliary hook (c). 2
B
REMARKS ꞏ Install the wire rope sling (A) of main hook (a) to the d
blade lift cylinder mounting pin (2).
1
ꞏ Install the rope sling (A) of auxiliary hook (b) to
lifting holes (d) at both ends of the blade top
through shackles (B).

113
 ꞏ Use wire rope slings JIS B8817 or equivalent, the
using load of which is 84 kN {8.56 t} or higher. A b
ꞏ Use shackles JIS B2801 or equivalent, the using c
load of which is 49 kN {5 t} or higher. B
A
Weight of semi-U blade: 11 t 1
Weight of full-U blade: 12 t
Wire rope sling: φ32 mm x 5 m (4 pcs.)
Shackle: BB28-S (2 pcs.)
CAUTION When adding the spill guard to the blade, add it before standing the blade vertically.
For installation (welding) procedure, see “Attached material: Installation of spill guard”.
2. Take measures so that the blade does not fall down
even if wire rope slings (A) are loosened. A

1) Place the wooden blocks (C) (2 pieces) under the

center link bracket.

Wooden block (C): Width 350 mm × length 400 mm

C C

2) Place the wooden block (C) under the straight frame

bracket.

Wooden block (C): Width 350 mm × length 400 mm

D
3) If it is difficult to stand the blade vertically only with
the wooden blocks (C) on step 1) and 2) , perform
fine adjustment by adding the plate (D).

4) Check that the blade is stable, then loosen and C

remove slings (A).

3. Weld the straight frame.

1) Check that the joint is installed in correct direction
(e).

REMARKS If the joint is not installed in the correct direction (f),

reinstall it in correct direction (e).

e f

2) Remove bolt (83) and lock (82), and remove

connecting pin (81).

REMARKS Remove all rust preventive oil, and add grease.

Bolt (83): Width across flats 36 mm, M24

83, 84
81 82

114
 3) Sling the straight frame horizontally with belt sling
(E).
E
REMARKS ꞏ If the straight frame is not slung horizontally, the
joint does not easily go into the bracket yoke. Be
sure to sling it horizontally.

ꞏ Belt sling (E) is made of synthetic fibers. It can

prevent damage to the product and protect paint.

Weight of straight frame (R.H.): 2525 kg

Weight of straight frame (L.H.): 1805 kg
Belt sling (E): 50 mm wide, 4 m long (2 pieces)
4) Sling the straight frame, insert its joint end into the blade bracket yoke, and align the connecting pin
holes.

5) Install connecting pin (81) with bolt (83) and lock

(82).
81
Bolt (83): Width across flats 36 mm, M24, L 55 mm
Tightening torque of bolt (83): 785 to 980 Nm {80 to
100 kgm}

82 83, 84

6) Sling by using the belt sling (E), and place the

wooden block (I) on the rear end of the straight
frame. E

REMARKS Adjust the trunnion mounting portion of machine to

height (g).

Height (g): Approx. 1085 mm (height to the center of g

the trunnion)
I
Wooden block (I): Width 350 mm × length 750 mm
(2 pieces for right and left)

7) Connect the straight frame on the opposite side according to steps 1) to 2).
8) Sling the right and left straight frames again and
adjust them so that they are symmetrical to the
blade to make the center width of the trunnion
spherical surface (h) approximately 4,000 mm.

h
REMARKS Clean each connection.

115
 Assembling of blade unit-3
A-20
(Machine with semi-U blade/full-U blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Belt sling Commercially available 2 Width 25 mm × 3 m
B Wooden block - 2 350 mm × 350 mm × 750 mm
C Socket Commercially available 46 mm 1
D Socket Commercially available 50 mm 1
E Air impact Commercially available 1 Torque 2940 Nm (300 kgm) or more
F Belt sling Commercially available 1 Width 100 mm × 4 m
G Crane - 45 t 1

Part list
Part No. Part name Q'ty Part state
1 198-71-85751 BOLT 12
2 01643-33380 WASHER 12
3 198-71-85450 SHIM (2 mm) 2
4 198-71-85460 SHIM (1 mm) 4
5 198-71-85470 SHIM (0.5 mm) 4
6 198-71-85130 PIN 1
7 198-71-85120 LOCK 1
8 01010-83065 BOLT 4
9 01643-33080 WASHER 4
10 07049-02025 PLUG 1
90 198-72-85351 CENTER BRACE 1

4. Install the center brace.

Tightening lightly
1) Sling the center brace with the belt sling (A). A
2) Remove bolts (1), washers (2), and shims (3), (4),
and (5) which are lightly installed to spherical seat
(a) of the center bracket.

Bolt (1): Width across flats 50 mm, M33, L 175 mm

Detail of part A

90
2 1
4 3
5

116
 3) Remove pin (6), bolt (8), washer (9), and lock (7)
which are lightly installed to connection (b) of the 8, 9
straight frame. 10

Bolt (8): Width across flats 46 mm, M30, L 65 mm 7

90 6 b

4) Remove and clean paint from the ball joint.

REMARKS Check that the ball joint moves smoothly. 90
2 1
5) Sling and adjust center brace (90) to the installation 3
location. 5 4

Weight of center brace (90): 650 kg/piece

REMARKS Adjust the thickness by combining (c) and (d) of the
same thickness.

d
c

View Z

6) Install center brace (90) to connection (b) of the

straight frame with pin (6), bolt (8), washer (9), and 8, 9
lock (7).
10
Bolt (8): Width across flats 46 mm, M30, L 65 mm
7
Tightening torque of bolt (8): 1520 to 1910 Nm {155
to 195 kgm}

90 6 b

7) Lightly install center brace (90) with bolts (1),

washers (2), and shims (3), (4), and (5).
3, 4, 5 Ball cap
Bolt (1): Width across flats 50 mm, M33, 175 mm 1, 2
long

REMARKS ꞏ Adjust and insert the shims so that their total

thickness is +0.5 mm when bolts (1) (4 pieces) are
tightened evenly lightly. Tighten bolts (1) to the
specified torque, and check that the blade moves 90
smoothly. e

ꞏ Insert each shim set 4.5 mm thick in total into the upper and lower 2 places. (2 mm shim: 1 piece, 1
mm shim: 2 pieces, 0.5 mm shim: 1 piece)

Standard shim thickness: 4.5 mm

ꞏ Lightly tighten bolts (1) until the spherical seat, shims, and ball cap are fitted.

117
 8) Add a little amount of grease through grease fitting
(f).

REMARKS Use GS-LI. See “Coating materials list”.

f
90

Checking shim thickness

9) Sling the R.H. straight frame with belt sling (F), and
slowly move it up and down.
F
Width of stroke (g): 300 to 400 mm g
REMARKS ꞏ While moving straight frame up and down, check
that the ball joint of center brace moves smoothly
without making unusual noise.

ꞏ Check that there is no interference inside the ball

joint.

10) If there is any problem in the ball joint, adjust the shims again according to “Shim adjustment
(Addition of shims)”.

Tighten to specified torque

11) Tighten bolts (1) to the specified torque.
REMARKS Evenly tighten bolts (1) in the normal order. Ball cap
Tightening torque of bolt (1): 1960 to 2450 Nm {200 1, 2
to 250 kgm}

Shim adjustment (Addition of shims)

12) If there is any problem (interference of the ball joint)
in step 7), remove bolts (1) and washers (2), and 3, 4, 5 Ball cap
add a 0.5 mm shim. 1, 2
13) Lightly install center brace (90) with bolts (1),
washers (2), and shims (3), (4), and (5).

REMARKS Adjust the thickness by combining (c) and (d) of the

same thickness. 90

Bolt (1): Width across flats 50 mm, M33, L 175 mm e

d
c

View Z

118
 Adjustment of distance between tilt cylinder mounting pin holes
14) Sling the straight frame with the belt sling(F), and
adjust distance (h) between tilt cylinder mounting
pin holes to 1,845 mm. F
h

15) To make the adjusted distance between the holes

(h) constant, adjust the wooden block (B) position,
and release slinging of the straight frame.

16) Adjust on both right and left sides.

B

119
 Assembling of blade unit-4
A-20
(Machine with semi-U blade/full-U blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Belt sling Commercially available 1 Width 25 mm × 3 m
B Wooden block - 1 350 mm × 350 mm × 400 mm
C Socket Commercially available 17 mm 1
D Socket Commercially available 19 mm 1
E Socket Commercially available 30 mm 1
F Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
G Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more
H Socket Commercially available 45 t 1
I Wrench Commercially available 36 mm 2

Part list
Part No. Part name Q'ty Part state
15 707-H1-05040 TILT CYLINDER 2
16 197-71-21561 PIN 2
17 198-71-21620 LOCK 2
18 01010-82050 BOLT 4
19 01643-32060 WASHER 4
20 198-71-62131 HOSES 2
21 198-71-62121 HOSES 2
22 07000-23025 O-RING 4
23 07371-30640 FLANGE 8
24 07375-21035 BOLT 16
26 198-71-85911 COVER 2
27 01010-82045 BOLT 12
28 01643-32060 WASHER 12
29 01024-81230 BOLT 4
30 01010-82045 BOLT 8
31 01643-32060 WASHER 8

120
 5. Install the tilt cylinder.
1) Remove the covers and tilt cylinder mounting pin
installed to the tilt cylinder mounting portion of the 30, 31
straight frame. 16

Bolt (18): Width across flats 30 mm, M20, L50 mm

Bolt (30): Width across flats 30 mm, M20, L45 mm

18, 19 17
COVER

2) Sling tilt cylinder (15) with cover (26) (hydraulic

hose side) down, and align it with the mounting pin 22
22
23
hole in the straight frame. 23
24
Weight of tilt cylinder (15): 481 kg 24
3) Connect tilt cylinder (15) by using pin (16), lock
(17), bolts (18), and washers (19) remove in step
1).
Bolt (18): Width across flats 30 mm, M20, L50 mm
Tightening torque of bolt (18): 455 to 565 Nm 28
{46.5 to 58 kgm} 21 20 26 27
4) Install hoses (20) and (21), and install cover (26).
REMARKS ・Flange (23) and bolts (24) are installed to each
hydraulic cylinder in advance.
・When installing the hydraulic hoses, do not reuse the sleep head (oil stop cover) install to
the hydraulic cylinder.
・Replace O-rings (22), (25) with brand-new ones, as a rule.
Bolt (24): Width across flats 17 mm, M10, L35 mm
Bolt (27): Width across flats 30 mm, M20, L45 mm
Tightening torque of bolt (24): 59 to 74 Nm {6.0 to 7.5 kgm}
Tightening torque of bolt (27): 455 to 565 Nm {46.5 to 58 kgm}

5) Place the wooden block (B) between the tilt

hydraulic cylinder (15) (cover (26)) and the straight A a
frame, and loosen the belt sling (A) to remove it.
15
CAUTION When connecting the hose, collect waste oil by
a waste oil container in order not to release oil
on the ground.

REMARKS At this time, do not connect head side (a) of tilt

B
cylinder (15). Head side (a) will be connected in
“A-21 Installation of blade unit (Machine with semi-
U blade/full-U blade)”.

121
 6) Connect hoses (20) and (21) to the elbows on the
flange.
R. H
REMARKS ꞏ Connect hoses (20) and (21) according to the
25
letters stamped on the flange.
H: Longer hydraulic hose (20) (Head side) 21
B: Shorter hydraulic hose (21) (Bottom side)

ꞏ Be sure to install O-ring (25). 25

ꞏ When connecting the hoses, remove the oil plugs 20
(Part No.: 02789-00628) installed to the elbows on
the flange in advance.
L. H
Hose (20), (21): Width across flats 36 mm 25
Tightening torque of hoses (20), (21): 785 to 980 21
Nm {80 to 100 kgm}

25

20

7) Install the covers removed in step 1).

Bolt (30): Width across flats 30 mm, M20, L45 mm 30, 31
Tightening torque of mounting bolt (30): 455 to 565
Nm {46.5 to 58 kgm}

COVER

122
 Assembling of blade unit-5
A-20
(Machine with semi-U blade/full-U blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 24 mm 1
B Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more

Part list
Part No. Part name Q'ty Part state
29 198-71-85491 HANDRAIL 2
31 01010-81665 BOLT 16
32 01643-31645 WASHER 16

6. Install the handrails.

1) Install handrails (29) (2 pieces) with bolts (31) and
washers (32). 29
Bolt (31): Width across flats 24 mm, M16, L65 mm
Tightening torque of bolt (31): 235 to 285 Nm
{23.5 to 29.5 kgm}
31, 32

123
A-20 Assembling of blade unit-1 (Machine with superdozer blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
C Wrench Commercially available 14 mm 1
D Wrench Commercially available 17 mm 1
E Wrench Commercially available 10 mm 1

Part list
Part No. Part name Q'ty Part state
70 203-62-21740 NIPPLE 1
71 198-68-11640 NIPPLE 1
72 198-68-14270 GREASING HOSE 1
73 07020-00000 FITTING 1
74 04434-51712 CLAMP 8
75 07095-20211 CUSHION 8
76 01024-81225 BOLT 8
77 198-72-86610 COVER 1
78 198-72-86620 COVER 1
79 198-72-86630 COVER 1
80 01024-81225 BOLT 8

1. Install the greasing hose.

70 72
1) Install nipples (70), (71) and connect the greasing
hose (72).
Nipple (70), (71): Width across flats 14 mm
Greasing hose (72): Width across flats 17 mm
Tightening torque of nipple (70), (71): 3.9 to 6.9 Nm
{0.4 to 0.7 kgm}
Tightening torque of greasing hose (72): 13.2 to
16.2 Nm {1.3 to 1.7 kgm} 71

2) Install the fitting (73).

Fitting (73): Width across flats 10 mm
Tightening torque of fitting (73): 3.9 to 6.9 Nm {0.4
to 0.7 kgm}

73

124
3) Install the clamps (74).
74, 75, 76
Bolts (76): Width across flats 19 mm, M12
Tightening torque of bolts (76): 98 to 123 Nm {10 to
12.5 kgm}

4) Install the covers (77), (78), (79).

80 78
Bolts (80): Width across flats 19 mm, M12

Tightening torque of bolts (80): 98 to 123 Nm {10 to

12.5 kgm}

77 79

125
A-20 Assembling of blade unit-2 (Machine with superdozer blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Wire rope sling Commercially available φ32 mm× 5 m 4
B Shackle Commercially available BB28-S 2
C Wooden block - 4 350 mm × 350 mm × 400 mm
D Plate Commercially available 1
E Belt sling Commercially available 1 Width 50 mm × 4 m
F Crane - 45 t 1
G Socket Commercially available 36 mm 1
H Air impact Commercially available 1 Torque 980 Nm (100 kgm) or more
I Wooden block - 2 350 mm × 350 mm × 750 mm

Part list
Part No. Part name Q'ty Part state
81 198-72-51810 PIN 1
82 198-72-86440 PIN 1
83 09257-11219 LOCK 2
84 01010-82455 BOLT 8
85 01643-32460 WASHER 8

1. Stand delivered blade (1) vertically on the assembly

place according to the following procedure.

REMARKS Stand the blade with its back (a) at 90 degrees to 1

the ground. a

90°

126
 1) Sling blade (1) with the crane. Raise blade (1)
gradually until it is vertical to the ground by A
b
simultaneously operating main hook (b) and
auxiliary hook (c). c
2
REMARKS ꞏ Install the wire rope sling (A) of main hook (a) to the B
blade lift cylinder mounting pin (2). d
ꞏ Install the rope sling (A) of auxiliary hook (b) to
lifting holes (d) at both ends of the blade top 1
through shackles (B).

ꞏ Use wire rope slings JIS B8817 or equivalent, the

using load of which is 84 kN {8.56 t} or higher. A b
ꞏ Use shackles JIS B2801 or equivalent, the using
c
load of which is 49 kN {5 t} or higher. A
Weight of superdoser blade: 14t B

Wire rope sling: φ32 mm x 5 m (4 pcs.) 1

Shackle: BB28-S (2 pcs.)

CAUTION When adding the spill guard to the blade, add it before standing the blade vertically.
For installation (welding) procedure, see “Appendix-1: Installation of spill guard”.
2. Take measures so that the blade does not fall down
even if wire rope slings (A) are loosened. A
1) Place the wooden blocks (C) (2 pieces) under the
center link bracket.

Wooden block (C): Width 350 mm × length 400 mm

C C

2) Place the wooden block (C) under the straight frame D

bracket.

Wooden block (C): Width 350 mm × length 400 mm

3) If it is difficult to stand the blade vertically only with
the wooden blocks (C) on step 1) and 2) , perform
fine adjustment by adding the plate (D).

4) Check that the blade is stable, then loosen and C

remove slings (A).

3. Weld the straight frame.

1) Check that the joint is installed in correct direction
(e).

REMARKS If the joint is not installed in the correct direction (f),

reinstall it in correct direction (e).

e f

127
 2) Remove bolt (84) and lock (83), and remove blade
left side connecting pin (81), blade right side
connecting pin (82).
REMARKS Remove all rust preventive oil, and add grease.
Bolt (84): Width across flats 36 mm, M24, L 55 mm

81, 82

84, 85
83

3) Sling the straight frame horizontally with belt sling

(E).
E
REMARKS ꞏ If the straight frame is not slung horizontally, the
joint does not easily go into the bracket yoke. Be
sure to sling it horizontally.

ꞏ Belt sling (E) is made of synthetic fibers. It can

prevent damage to the product and protect paint.

Weight of straight frame (R.H.): 2600 kg

Weight of straight frame (L.H.): 1900 kg
Belt sling (E): 50 mm wide, 4 m long (2 pieces)
4) Sling the straight frame, insert its joint end into the blade bracket yoke, and align the connecting pin
holes.

5) Install blade left side connecting pin (81), blade right 81, 82
side connecting pin (82) with bolt (84) and lock (83).
Bolt (84): Width across flats 36 mm, M24, L 55 mm
Tightening torque of bolt (84): 785 to 980 Nm {80 to 100
kgm}

83 84, 85

6) Sling by using the belt sling (E), and place the

wooden block (I) on the rear end of the straight E
frame.

REMARKS Adjust the trunnion mounting portion of machine to

height (g).
g
Height (g): Approx. 1085 mm (height to the center of
the trunnion) I

Wooden block (I): Width 350 mm × length 750 mm

(2 pieces for right and left)

7) Connect the straight frame on the opposite side

according to steps 1) to 2).
8) Sling the right and left straight frames again and h
adjust them so that they are symmetrical to the
blade to make the center width of the trunnion
spherical surface (h) approximately 4,000 mm.
REMARKS Clean each connection.

128
A-20 Assembling of blade unit-3 (Machine with superdozer blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Belt sling Commercially available 2 Width 25 mm × 3 m
B Wooden block - 2 350 mm × 350 mm × 750 mm
C Socket Commercially available 46 mm 1
D Socket Commercially available 50 mm 1
E Air impact Commercially available 1 Torque 2940 Nm (300 kgm) or more
F Belt sling Commercially available 1 Width 100 mm × 4 m
G Crane - 45 t 1

Part list
Part No. Part name Q'ty Part state
1 198-71-85751 BOLT 12
2 01643-33380 WASHER 12
3 198-71-85450 SHIM (2 mm) 2
4 198-71-85460 SHIM (1 mm) 4
5 198-71-85470 SHIM (0.5 mm) 4
6 198-71-85130 PIN 1
7 198-71-85120 LOCK 1
8 01010-83065 BOLT 4
9 01643-33080 WASHER 4
10 07049-02025 PLUG 1
90 198-72-85351 CENTER BRACE 1

4. Install the center brace.

Tightening lightly
1) Sling the center brace with the belt sling (A). A
2) Remove bolts (1), washers (2), and shims (3), (4),
and (5) which are lightly installed to spherical seat
(a) of the center bracket.

Bolt (1): Width across flats 50 mm, M33, L 175 mm

Detail of part A
90
2 1
3
4
5

129
 3) Remove pin (6), bolt (8), washer (9), and lock (7)
which are lightly installed to connection (b) of the 8, 9
straight frame. 10

Bolt (8): Width across flats 46 mm, M30, L 65 mm 7

90 6 b
4) Remove and clean paint from the ball joint.
REMARKS Check that the ball joint moves smoothly. 90
2 1
5) Sling and adjust center brace (90) to the installation 3
5 4
location.

Weight of center brace (90): 650 kg/piece

REMARKS Adjust the thickness by combining (c) and (d) of the
same thickness.

d
c

View Z

6) Install center brace (90) to connection (b) of the

straight frame with pin (6), bolt (8), washer (9), and 8, 9
lock (7).
10
Bolt (8): Width across flats 46 mm, M30, L 65 mm 7
Tightening torque of bolt (8): 1520 to 1910 Nm {155
to 195 kgm}

90 6 b

7) Lightly install center brace (90) with bolts (1),

washers (2), and shims (3), (4), and (5). Ball cap
3, 4, 5
Bolt (1): Width across flats 50 mm, M33, 175 mm 1, 2
long

REMARKS ꞏ Adjust and insert the shims so that their total

thickness is +0.5 mm when bolts (1) (4 pieces) are
tightened evenly lightly. Tighten bolts (1) to the
specified torque, and check that the blade moves 90
smoothly. e

ꞏ Insert each shim set 4.5 mm thick in total into the upper and lower 2 places. (2 mm shim: 1 piece, 1
mm shim: 2 pieces, 0.5 mm shim: 1 piece)

Standard shim thickness: 4.5 mm

ꞏ Lightly tighten bolts (1) until the spherical seat, shims, and ball cap are fitted.

130
 8) Add a little amount of grease through grease fitting
(f).

REMARKS Use GS-LI. See “Coating materials list”.

90

Checking shim thickness

9) Sling the R.H. straight frame with belt sling (F), and
slowly move it up and down. F g
Width of stroke (g): 300 to 400 mm
REMARKS ꞏ While moving straight frame up and down, check
that the ball joint of center brace moves smoothly
without making unusual noise.

ꞏ Check that there is no interference inside the ball

joint.

10) If there is any problem in the ball joint, adjust the shims again according to “Shim adjustment
(Addition of shims)”.

Tighten to specified torque

11) Tighten bolts (1) to the specified torque.
REMARKS Evenly tighten bolts (1) in the normal order.
1, 2
Tightening torque of bolt (1): 1960 to 2450 Nm {200
to 250 kgm}

Shim adjustment (Addition of shims)

12) If there is any problem (interference of the ball joint)
in step 7), remove bolts (1) and washers (2), and 3, 4, 5
add a 0.5 mm shim. 1, 2

13) Lightly install center brace (90) with bolts (1),

washers (2), and shims (3), (4), and (5).

REMARKS Adjust the thickness by combining (c) and (d) of the

same thickness. 90
e
Bolt (1): Width across flats 50 mm, M33, L 175 mm

d d
c c

View Z V

131
 Adjustment of distance between tilt cylinder mounting pin holes
14) Sling the straight frame with the belt sling(F), and
adjust distance (h) between tilt cylinder mounting F
pin holes to below. h
Left side: 1810 mm
Right side: 1780 mm
15) To make the adjusted distance between the holes
(h) constant, adjust the wooden block (B) position,
and release slinging of the straight frame.

16) Adjust on both right and left sides.

B

132
A-20 Assembling of blade unit-4 (Machine with superdozer blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Belt sling Commercially available 1 Width 25 mm × 3 m
B Wooden block - 1 350 mm × 350 mm × 400 mm
C Socket Commercially available 17 mm 1
D Socket Commercially available 19 mm 1
E Socket Commercially available 30 mm 1
F Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
G Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more
H Socket Commercially available 45 t 1
I Wrench Commercially available 36 mm 2

Part list
Part No. Part name Q'ty Part state
88 707-G1-07080 TILT CYLINDER 2
89 198-72-62570 TUBE (L.H) 1
90 198-72-62580 TUBE (R.H) 1
91 07000-F3030 O-RING 6
92 07372-21045 BOLT 4
93 01643-51032 WASHER 4
94 07372-21060 BOLT 4
95 01643-51032 WASHER 4
96 198-72-62550 BLOCK (L.H) 1
97 198-72-62560 BLOCK (R.H) 1
98 07372-21035 BOLT 8
99 01643-51032 WASHER 8
100 01010-81095 BOLT 8
101 01643-51032 WASHER 8
102 198-71-86811 COVER 2
103 01011-82025 BOLT 2
104 01010-82040 BOLT 12
105 01643-32060 WASHER 14
106 198-72-52110 HOSE 4
107 07000-F3025 O-RING 8
108 01010-82050 BOLT 4
109 01643-32060 WASHER 4
110 197-71-21561 PIN 2
111 197-71-21620 LOCK 2
112 198-72-52100 HOSE 4
113 198-71-86871 FLANGE 2
114 07371-30640 FLANGE 16
115 07375-21035 BOLT 32
116 01010-82055 BOLT 2
117 01010-82045 BOLT 2

133
 5. Install the tilt cylinder.
110 116 118
1) Remove bolts (108), remove lock (111), and then 111 117
remove pin (110).
Bolt (108): Width across flats 30 mm, M20, L 50 mm

2) Remove bolts (116), (117), and remove cover (118).

Bolt (116): Width across flats 30 mm, M20, L 55 mm

Bolt (117): Width across flats 30 mm, M20, L 45 mm

108, 109

3) Sling tilt cylinder (88) with piping side up, and align
100
it with the mounting pin hole in the straight frame. 98, 99 94, 95
101
Weight of tilt cylinder (88): 495 kg 92, 93
4) Connect tilt cylinder (88) by using pin (110), lock
(111), bolts (108), and washers (109) .

Bolt (108): Width across flats 30 mm, M20, L 50 mm 89, 90

Tightening torque of bolt (108): 455 to 565 Nm {46.5

to 58 kgm} 96, 97 88
5) Install tubes (89) (90).
REMARKS ꞏ Blocks (96), (97) and bolts (100) are pre-installed
on each hydraulic cylinder.

ꞏ When installing the hydraulic hoses, do not reuse the sleep head (oil stop cover) install to the
hydraulic cylinder.

ꞏ Replace O-rings (22), (25) with brand-new ones, as a rule.

Bolts (92), (94): Width across flats 14 mm, M10
Bolt (98): Width across flats 14 mm, M10
Bolt (100): Width across flats 17 mm, M10
Tightening torque of bolts (92), (94): 59 to 74 Nm {6.0 to 7.5 kgm}
Tightening torque of bolt (98): 59 to 74 Nm {6.0 to 7.5 kgm}
Tightening torque of bolt (100): 59 to 74 Nm {6.0 to 7.5 kgm}
6) Connect hose (112) to blocks (96), (97).
96, 97
REMARKS Be sure to install O-ring.
107 114 115
Bolt (115): Width across flats 14 mm, M10
Tightening torque of bolt (115): 59 to 74 Nm {6.0 to
7.5 kgm}
107

112

134
 7) Place the wooden block (B) between the tilt
hydraulic cylinder (88) and the straight frame, and A a
loosen the belt sling (A) to remove it.
CAUTION When connecting the hose, collect waste oil by 88
a waste oil container in order not to release oil
on the ground.
REMARKS At this time, do not install head side (a) pin of tilt
cylinder (88). Head side (a) will be installed in “A-21
Installation of blade unit (Machine with superdozer
blade)”. B

8) Connect hoses (112) to the elbows on the flange.

R. H
REMARKS ꞏ Be sure to install O-ring.
113
ꞏ When connecting the hoses, remove the oil head
115 114 107
(Part No.: 07378-10600) installed to the elbows on
the flange in advance.
Bolt (115): Width across flats 14 mm, M10
Tightening torque of bolt (115): 59 to 74 Nm {6.0 to
7.5 kgm}
107
112

L. H
113
115 114 107

107

112

9) Install the cover (118) removed in step 1).

104
Bolt (103): Width across flats 30 mm, M20, L 25 mm
103 118
Bolt (104): Width across flats 30 mm, M20, L 40 mm 116
117
Bolt (116): Width across flats 30 mm, M20, L 55 mm
104
Bolt (117): Width across flats 30 mm, M20, L 45 mm

Tightening torque of mounting bolts (103), (104):

455 to 565 Nm {46.5 to 58 kgm}
Tightening torque of mounting bolt (116): 455 to 565
Nm {46.5 to 59 kgm}
Tightening torque of mounting bolt (117): 455 to 565
Nm {46.5 to 60 kgm}

135
A-20 Assembling of blade unit-5 (Machine with superdozer blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 24 mm 1
B Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more

Part list
Part No. Part name Q'ty Part state
118 198-71-85680 HANDRAIL 2
119 01010-81660 BOLT 4
120 01643-31645 WASHER 4

6. Install the handrails.

1) Install handrails (118) (2 pieces) with bolts (119)
and washers (120). 118 119
120
Bolt (119): Width across flats 24 mm, M16, L 65 mm

Tightening torque of bolt (119): 235 to 285 Nm {23.5

to 29.5 kgm}

136
 Installation of blade assembly
A-21
(Machine with semi-U blade/full-U blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 50 mm 1
B Air impact Commercially available 1 Torque 2940 Nm (300 kgm) or more
C Wrench Commercially available 36 mm 1
D Socket Commercially available 30 mm 1
E Wooden block Commercially available 1 350 mm × 350 mm ×750 mm
F Wooden block Commercially available 1 350 mm × 350 mm × 400 mm
G Wooden block Commercially available 1 350 mm × 350 mm × 400 mm
H Belt sling Commercially available 1 Width 25 mm × 3 m
J Transportation sling bracket - 2
K Blade cylinder lock - 2
L Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more
M Socket Commercially available 24 mm 1
N Crane - 45 t 1
P Torque wrench Commercially available 1 Torque 2060 Nm (210 kgm) or more

Coating materials
Komatsu code Part No.
G2-LI SYG2-400LI, SYG2-350LI, SYG2-400LI-A, SYG2-160LI, SYGA-160CNLI
1
G0-LI (For cold district) SYG0-400LI-A (For cold district), SYG0-16CNLI (For cold district)

Part list
Part No. Part name Q'ty Part state
1 - BLADE ASSEMBLY - See Assembly procedure "A-20"
2 198-71-85341 BUSHING 2
3 198-71-85360 PLATE 4
4 198-71-85391 INSTALL TRUNNION CAP 1
5 195-71-11510 NUT 4 Must be installed in correct direction
6 21K-46-42340 BOLT 4
7 01643-33380 WASHER 4
8 - FLANGE 2
9 02789-00522 NUT 4
10 07376-50522 PLUG 4
11 198-71-85241 COVER 2
12 01010-82050 BOLT 12
13 01643-32060 WASHER 12
14 198-72-62140 CONNECTING PIN 2
15 198-72-62170 LOCK 2
16 01010-81635 BOLT 4
17 01643-31645 WASHER 4

137
Part list
Part No. Part name Q'ty Part state
18 09255-06295 PIN 2
19 09257-09014 LOCK 2
20 01010-82045 BOLT 4
21 01643-32060 WASHER 4
Preparations
ꞏ Before starting the following work, confirm that “Assembly procedure A-20 Assembling of blade unit”
is completed.

ꞏ Before starting the following work, confirm that the engine can be started and the machine can
travel.

F
b
a

G E

1. Set the blade assembly in the installation position.

1) Adjust the installation position of the blade assembly with wooden blocks (E) and (F).
Dimension “a”: Approx. 1085 mm
Dimension “b” (Distance between spherical surface centers): Approx. 4,000 mm
REMARKS ꞏ Dimension “a” in the table is set on the assumption that the machine is used on a hard ground
where the track shoe grousers do not sink. If the machine is used on a ground where the grousers
sink, the trunnion height decreases by the sinking distance. Accordingly, dimension “a” must be
lowered by the decrease of the trunnion height.
ꞏ Leave wooden block (G) set to erect the blade vertically in assembly procedure "A-20" as it is.
2. Connect the blade assembly and machine.
Fig. 3
1) Remove and clean the paint from the spherical
surfaces of trunnion.
Seated.
Coating Spherical surface of trunnion: Grease (G2-LI)
2) Set the machine within distance “b” of the blade
assembly, and move it forward so that the
clearances on the right and left sides are the same.

3) Move the machine forward until the trunnion is seated in the trunnion holder (bushing) of the blade
assembly (straight frame).

REMARKS If the trunnion and trunnion holder are different in height, trunnion holder bushing (2) may move
when the trunnion is pressed. If the trunnion and trunnion holder are different in height, sling the
straight frame of the blade assembly with a crane etc. and adjust their heights.

138
 6 Installation direction of nut (5)
7
4
3
2
5

3
Adjust chamfered part of nut
(5) to rounded corner.
1

3. Install trunnion-related parts (2), (3), (4), (5), and (7) to the blade assembly with bolts (6).
Bolt (6): Width across flats 50 mm, M33, L 320 mm
Tightening torque of bolt (6): 1960 to 2450 Nm {200 to 250 kgm}
Target tightening torque of bolt (6): 1960 Nm {200 kgm}
4. Remove wooden block (E).
5. Connect the hydraulic hoses for tilt dozer.
Fig. 5
1) Remove the plug at the end of the hydraulic hose
coming out of the center hole of trunnion.

REMARKS Take care not to lose hose O-ring (Part No. 02896-
61018).

2) Remove nuts (9) and plugs (10) from the upper and
lower nipples of flange (8) on the blade assembly 8
side.

3) Connect the hydraulic hoses to the nipples of the flange.

CAUTION When connecting the hose, collect waste oil by a waste oil container in order not to release
oil on the ground.

REMARKS ꞏ Be sure to install O-ring (Part No. 02896-11015).

ꞏ Connect the hydraulic hoses as follows.
Connect to UPPER nipple: Hose with red band at the hose tip
Connect to LOWER nipple: Hose with blue band at the hose tip
ꞏ The following plugs and nuts are removed from the nipples.
Dual tilt dozer: Nut (9) (4 pieces), Plug (10) (4 pieces) (2 pieces each on right and left sides)
ꞏ For the dual tilt dozer, install to the left side similarly as well.
6. Install protective cover (11) for the tilt dozer
hydraulic hoses with bolts (12).
1 12,13 11 4
Bolt (12): Width across flats 30 mm, M20, L 50 mm
Tightening torque of bolt (12): 455 to 565 Nm {46.5
to 58 kgm}

Target tightening torque of bolt (12): 460 Nm {47

kgm}

REMARKS Before installing the protective cover, check the

operation of the tilt cylinder in the blade adjustment
work described later and check that no oil leaks
from the tilt hose connections.

139
 7. Connect the blade assembly to the lift cylinder.
1) Sling the hydraulic cylinder with belt sling (H), and
remove transportation sling bracket (J). H
REMARKS Connect the hydraulic cylinder on one side at a
time.

2) With the shank point on the ground, check that the

hydraulic oil is at the specified level.

CAUTION If the hydraulic oil level is low, add hydraulic oil

according to Operation and Maintenance Manual. (If J
the hydraulic oil level is low, the work equipment
pump may be damaged.)

3) Start the engine and operate the blade control lever

to extend/retract the hydraulic cylinder rod and align
it with the connecting hole (joint link) of the blade
assembly.

CAUTION The work shall be performed by the machine

operator, crane operator, and "signalman". The
signalman must arrange the signaling method in
advance and give proper directions to both
operators.
4) Insert connecting pin (14) in portion “c”.
5) Stop the engine.
6) Install lock (15) to the connecting pin head with bolt c
14
(16) and washer (17).

Bolt (16): Width across flats 24 mm, M16, L 35 mm

Tightening torque of bolt (16): 235 to 285 Nm {23.5 16
to 29.5 kgm} 15 17
Target tightening torque of bolt (16): 235 Nm {23.5
kgm}

140
 7) Install sling bracket (J) to outside of the cylinder.
20 21 19
8. Connect the blade assembly to the tilt cylinder.
1) Remove pins (18), locks (19), bolts (20), and
washers (21) at the R.H. and L.H. hydraulic cylinder
connections of blade.
18
Bolt (20): Width across flats 30 mm, M20, L 50 mm

2) The bottom side (clevis side) of the hydraulic

cylinder is connected to the straight frame already. A P
Raise one end of hydraulic cylinder (15) with belt
sling (A) and remove wooden block (B) placed 15
under it. Q

3) With the hydraulic cylinder raised, start the engine

and operate the blade control lever to extend/retract
B
the hydraulic cylinder rod and align its pin hole (P)
with the pine hole (Q) of the blade.

CAUTION The machine operator, crane operation, and

signalman must work in cooperation during the 18
work. The signalman must arrange the signaling 19
method in advance and give proper directions to 20
both operators. 21
4) After aligning, stop the engine. Install pin (18), lock
(19), and washer (21) with bolt (20).

Bolt (20): Width across flats 30 mm, M20, L 50 mm

Tightening torque of bolt (20): 455 to 565 Nm {46.5
to 58 kgm}
Target tightening torque of bolt (20): 460 Nm {47 kgm}
5) Work similarly on the opposite side as well.
6) Loosen and remove the sling from the hydraulic cylinder.
7) Start the engine, and operate the blade control lever and raise the whole blade assembly.
8) Remove all wooden blocks under the blade.
9) Lower the blade to the ground and stop the engine.
9. Check operation of the blade assembly.
1) Check the hydraulic oil level, and add oil as necessary.
REMARKS ꞏ Check the oil level after lowering the ripper shank and blade to the ground and setting the back of
the blade perpendicular to the ground.
ꞏ For the oil type, etc., see “Assembly procedure A-10 Inspection of oil level and coolant level”.
ꞏ If the blade assembly is operated with the hydraulic oil level low, the work equipment pump may be
damaged.
2) Check each part for interference.
ꞏ Move the blade slowly and check each part for interference or unusual noise.
ꞏ Check for interference with the machine (radiator guard) when the blade is raised to the maximum
height and tilted maximum.
ꞏ Confirm that there is sufficient clearances between the straight frames of the blade assembly and
the tracks of the undercarriage when the blade is tilted maximum.

141
 3) Check of operation of dozer.
ꞏ Check that the blade is "raised" or "lowered" UP
according to the operation of the blade control lever.

ꞏ Check that the blade is "right-tilted" or "left-tilted"

according to the operation of the blade control lever.
DOWN

ꞏ Check that the blade is "pitched back" or "pitched

forward" according to the operation of the blade
control lever.
Right tilt

ꞏ Check that the blade is "left-dual-tilted" or "right-

dual-tilted" according to the operation of the blade
control lever.
Left tilt
ꞏ Check according to attached “Field assembly
inspection check sheet”.
Back pitch
4) Readjust the ball joint shims at both ends of the
center brace.
Forward
ꞏ When the blade is tilted to the right or left, if pitch
abnormal sound comes from either of the ball joints
at both ends of the center brace, remove the ball
cap of the ball joint which produces the abnormal
sound and add the thinnest shim (0.5 mm)
according to assembly procedure "A-20 Assembling
of blade unit" and tilt the blade again to check.

10. Bleed air from the hydraulic circuit.

CAUTION If bleed air is bled while the hydraulic oil level is low, the work equipment pump may be damaged.
Accordingly, bleed air carefully and check the hydraulic oil level each time, and add oil as
necessary.
1) Run the engine at low idle.
2) Extend and retract each cylinder and stop it about 100 mm before the stroke end 4 to 5 times.
REMARKS Do not relieve the oil at each stroke end.
3) Next, move the cylinder to each stroke end 6 to 7 times.
4) Lower the blade to the ground.
5) Lower the shank point to the ground and check the hydraulic oil level. If the hydraulic oil level is low,
add hydraulic oil according to the Operation and Maintenance Manual.

6) Check that each cylinder hose moves freely and oil does not leak through each joint.

142
A-21 Installation of blade assembly (Machine with superdozer blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 50 mm 1
B Air impact Commercially available 1 Torque 2940 Nm (300 kgm) or more
C Wrench Commercially available 36 mm 1
D Socket Commercially available 30 mm 1
E Wooden block Commercially available 1 350 mm × 350 mm ×750 mm
F Wooden block Commercially available 1 350 mm × 350 mm × 400 mm
G Wooden block Commercially available 1 350 mm × 350 mm × 400 mm
H Belt sling Commercially available 1 Width 25 mm × 3 m
J Transportation sling bracket - 2
K Blade cylinder lock - 2
L Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more
M Socket Commercially available 24 mm 1
N Crane - 45 t 1
P Torque wrench Commercially available 1 Torque 2060 Nm (210 kgm) or more

Coating materials
Komatsu code Part No.
G2-LI SYG2-400LI, SYG2-350LI, SYG2-400LI-A, SYG2-160LI, SYGA-160CNLI
1
G0-LI (For cold district) SYG0-400LI-A (For cold district), SYG0-16CNLI (For cold district)

Part list
Part No. Part name Q'ty Part state
1 - BLADE ASSEMBLY - See Assembly procedure "A-20"
2 198-71-85341 BUSHING 2
3 198-71-85360 PLATE 4
4 198-71-85391 TRUNNION CAP 1
5 195-71-11510 NUT 4 Must be installed in correct direction
6 21K-46-42340 BOLT 4
7 01643-33380 WASHER 4
8 - FLANGE 2
9 02789-00522 NUT 4
10 07376-50522 PLUG 4
11 198-71-85241 COVER 2
12 01010-82050 BOLT 12
13 01643-32060 WASHER 12
14 198-72-62140 CONNECTING PIN 2
15 198-72-62170 LOCK 2
16 01010-81635 BOLT 4
17 01643-31645 WASHER 4

143
Part list
Part No. Part name Q'ty Part state
18 198-72-51720 PIN 2
19 09257-09014 LOCK 2
20 01010-82045 BOLT 4
21 01643-32060 WASHER 4
Preparations
ꞏ Before starting the following work, confirm that “Assembly procedure A-20 Assembling of blade unit”
is completed.

ꞏ Before starting the following work, confirm that the engine can be started and the machine can
travel.

F
b
a

G E

1. Set the blade assembly in the installation position.

1) Adjust the installation position of the blade assembly with wooden blocks (E) and (F).
Dimension “a”: Approx. 1085 mm
Dimension “b” (Distance between spherical surface centers): Approx. 4,000 mm
REMARKS ꞏ Dimension “a” in the table is set on the assumption that the machine is used on a hard ground
where the track shoe grousers do not sink. If the machine is used on a ground where the grousers
sink, the trunnion height decreases by the sinking distance. Accordingly, dimension “a” must be
lowered by the decrease of the trunnion height.
ꞏ Leave wooden block (G) set to erect the blade vertically in assembly procedure "A-20" as it is.
2. Connect the blade assembly and machine.
Fig. 3
1) Remove and clean the paint from the spherical
surfaces of trunnion.
Seated.
Coating Spherical surface of trunnion: Grease (G2-LI)
2) Set the machine within distance “b” of the blade
assembly, and move it forward so that the
clearances on the right and left sides are the same.

3) Move the machine forward until the trunnion is seated in the trunnion holder (bushing) of the blade
assembly (straight frame).

REMARKS If the trunnion and trunnion holder are different in height, trunnion holder bushing (2) may move
when the trunnion is pressed. If the trunnion and trunnion holder are different in height, sling the
straight frame of the blade assembly with a crane etc. and adjust their heights.

144
 6 Installation direction of nut (5)
7
4
3
2
5

3
Adjust chamfered part of nut
(5) to rounded corner.
1

3. Install trunnion-related parts (2), (3), (4), (5), and (7) to the blade assembly with bolts (6).
Bolt (6): Width across flats 50 mm, M33, L 320 mm
Tightening torque of bolt (6): 1960 to 2450 Nm {200 to 250 kgm}
Target tightening torque of bolt (6): 1960 Nm {200 kgm}
4. Remove wooden block (E).
5. Connect the hydraulic hoses for tilt dozer.
Fig. 5
1) Remove the plug at the end of the hydraulic hose
coming out of the center hole of trunnion.

REMARKS Take care not to lose hose O-ring (Part No. 02896-
61018).

2) Remove nuts (9) and plugs (10) from the upper and
lower nipples of flange (8) on the blade assembly 8
side.

3) Connect the hydraulic hoses to the nipples of the flange.

CAUTION When connecting the hose, collect waste oil by a waste oil container in order not to release
oil on the ground.

REMARKS ꞏ Be sure to install O-ring (Part No. 02896-11015).

ꞏ Connect the hydraulic hoses as follows.
Connect to UPPER nipple: Hose with red band at the hose tip
Connect to LOWER nipple: Hose with blue band at the hose tip
ꞏ The following plugs and nuts are removed from the nipples.
Dual tilt dozer: Nut (9) (4 pieces), Plug (10) (4 pieces) (2 pieces each on right and left sides)
ꞏ For the dual tilt dozer, install to the left side similarly as well.
6. Install protective cover (11) for the tilt dozer
hydraulic hoses with bolts (12).
1 12,13 11 4
Bolt (12): Width across flats 30 mm, M20, L 50 mm
Tightening torque of bolt (12): 455 to 565 Nm {46.5
to 58 kgm}

Target tightening torque of bolt (12): 460 Nm {47

kgm}

REMARKS Before installing the protective cover, check the

operation of the tilt cylinder in the blade adjustment
work described later and check that no oil leaks
from the tilt hose connections.

145
 7. Connect the blade assembly to the lift cylinder.
1) Sling the hydraulic cylinder with belt sling (H), and
remove transportation sling bracket (J). H
REMARKS Connect the hydraulic cylinder on one side at a
time.

2) With the shank point on the ground, check that the

hydraulic oil is at the specified level.
J
CAUTION If the hydraulic oil level is low, add hydraulic oil
according to Operation and Maintenance Manual. (If
the hydraulic oil level is low, the work equipment
pump may be damaged.)

3) Start the engine and operate the blade control lever

to extend/retract the hydraulic cylinder rod and align
it with the connecting hole (joint link) of the blade
assembly.

CAUTION The work shall be performed by the machine

operator, crane operator, and "signalman". The
signalman must arrange the signaling method in
advance and give proper directions to both
operators.
4) Insert connecting pin (14) in portion “c”.
5) Stop the engine.
c
6) Install lock (15) to the connecting pin head with bolt 14
(16) and washer (17).

Bolt (16): Width across flats 24 mm, M16, L 35 mm

Tightening torque of bolt (16): 235 to 285 Nm {23.5 16
to 29.5 kgm} 15 17

Target tightening torque of bolt (16): 235 Nm {23.5

kgm}

146
 7) Install sling bracket (J) to outside of the cylinder. 19 20
21
8. Connect the blade assembly to the tilt cylinder.
1) Remove pins (18), locks (19), bolts (20), and
washers (21) at the R.H. and L.H. hydraulic cylinder
connections of blade.

Bolt (20): Width across flats 30 mm, M20, L 50 mm

18

2) The bottom side (clevis side) of the hydraulic

P
cylinder is connected to the straight frame already. A
Raise one end of hydraulic cylinder (15) with belt
sling (A) and remove wooden block (B) placed 15
under it. Q
3) With the hydraulic cylinder raised, start the engine
and operate the blade control lever to extend/retract
the hydraulic cylinder rod and align its pin hole (P)
with the pine hole (Q) of the blade.
B

CAUTION The machine operator, crane operation, and

signalman must work in cooperation during the
18
work. The signalman must arrange the signaling
19
method in advance and give proper directions to
20
both operators.
4) After aligning, stop the engine. Install pin (18), lock
21
(19), and washer (21) with bolt (20).

Bolt (20): Width across flats 30 mm, M20, L 50 mm

Tightening torque of bolt (20): 455 to 565 Nm {46.5
to 58 kgm}
Target tightening torque of bolt (20): 460 Nm {47 kgm}
5) Work similarly on the opposite side as well.
6) Loosen and remove the sling from the hydraulic cylinder.
7) Start the engine, and operate the blade control lever and raise the whole blade assembly.
8) Remove all wooden blocks under the blade.
9) Lower the blade to the ground and stop the engine.
9. Check operation of the blade assembly.
1) Check the hydraulic oil level, and add oil as necessary.
REMARKS ꞏ Check the oil level after lowering the ripper shank and blade to the ground and setting the back of
the blade perpendicular to the ground.
ꞏ For the oil type, etc., see “Assembly procedure A-10 Inspection of oil level and coolant level”.
ꞏ If the blade assembly is operated with the hydraulic oil level low, the work equipment pump may be
damaged.
2) Check each part for interference.
ꞏ Move the blade slowly and check each part for interference or unusual noise.
ꞏ Check for interference with the machine (radiator guard) when the blade is raised to the maximum
height and tilted maximum.
ꞏ Confirm that there is sufficient clearances between the straight frames of the blade assembly and
the tracks of the undercarriage when the blade is tilted maximum.

147
 3) Check of operation of dozer.
ꞏ Check that the blade is "raised" or "lowered" UP
according to the operation of the blade control lever.

ꞏ Check that the blade is "right-tilted" or "left-tilted"

according to the operation of the blade control lever.
DOWN

ꞏ Check that the blade is "pitched back" or "pitched

forward" according to the operation of the blade
control lever. Right tilt

ꞏ Check that the blade is "left-dual-tilted" or "right-

dual-tilted" according to the operation of the blade
control lever.
Left tilt
ꞏ Check according to attached “Field assembly
inspection check sheet”. Back pitch

4) Readjust the ball joint shims at both ends of the

center brace.
Forward
pitch
ꞏ When the blade is tilted to the right or left, if
abnormal sound comes from either of the ball joints
at both ends of the center brace, remove the ball
cap of the ball joint which produces the abnormal
sound and add the thinnest shim (0.5 mm)
according to assembly procedure "A-20 Assembling
of blade unit" and tilt the blade again to check.

10. Bleed air from the hydraulic circuit.

CAUTION If bleed air is bled while the hydraulic oil level is low, the work equipment pump may be damaged.
Accordingly, bleed air carefully and check the hydraulic oil level each time, and add oil as
necessary.
1) Run the engine at low idle.
2) Extend and retract each cylinder and stop it about 100 mm before the stroke end 4 to 5 times.
REMARKS Do not relieve the oil at each stroke end.
3) Next, move the cylinder to each stroke end 6 to 7 times.
4) Lower the blade to the ground.
5) Lower the shank point to the ground and check the hydraulic oil level. If the hydraulic oil level is low,
add hydraulic oil according to the Operation and Maintenance Manual.

6) Check that each cylinder hose moves freely and oil does not leak through each joint.

148
A-22 Installation of KOMTRAX antenna

Part list
Part No. Part name Q'ty Part state
1 01024-81225 BOLT 3
2 - ANTENNA ASSEMBLY 1

1. Remove bolts (1) (3 pieces), and remove

KOMTRAX antenna assembly (2). P

P
2

1
2

2. Install KOMTRAX antenna assembly (2) with bolts

(1) (3 pieces).
REMARKS Install the cable, and put its excess in grommet 2
holes (a).
1
Bolt (1): Width across flats 19mm, M12
Tightening torque of bolt (1): 98 to 123 Nm {10 to
12.5 kgm}

149
A-23 Installation of ROPS

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Torque wrench Commercially available 210 kgm 1
B Socket Commercially available 50 mm 1
C Air impact Commercially available 1 Torque 2940 Nm (300 kgm) or more
D Crane - 45 t 1
E Wire rope sling Commercially available φ12 × 2 m 2
F Shackle Commercially available SD16-SM 2

Part list
Part No. Part name Q'ty Part state
1 01011-83320 BOLT 16
2 01643-33380 WASHER 16

1. Sling and adjust ROPS (3) with the crane to the

installation location.
3
REMARKS Direct stamp “FRONT” on part (a) forward.
Weight of ROPS (3): 740 kg

2. Install ROPS (3) with bolts (1) (16 pieces).

Bolt (1): Width across flats 50mm, M33
Tightening torque of bolt (1): 1960 to 2450 Nm {200
to 250 kgm} 1
2

1
a 2

150
 Installation of engine air intake port hood
A-24
(When engine air intake port hood is not installed)

Part list
Part No. Part name Q'ty Part state
1 6128-11-5180 HOOD 2

REMARKS This operation may not be necessary depending on destination.

1: Air intake port hood 2: Engine hood

1. Remove the dust and water preventive seals from the air intake port hoods on engine hood (2)
shown in the figure.

2. Fully insert air intake port hoods (1) (2 pieces) into the air intake port hood mounting openings.
REMARKS The hoods may be inserted in any direction.
3. Tighten bolts (3) installed to air intake port hoods (1) (2 pieces).
REMARKS Tighten until dimension (a) becomes 0.
Bolt (3): Width across flats 17 mm, M10, L 45 mm
a

151
 Installation of pre-cleaner (optional)
A-25
(When pre-cleaner is not installed)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 17 mm 1
B Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more

Coating materials
Komatsu code Part No.
1 SEALANT 198-Z11-3960

Part list
Part No. Part name Q'ty Part state
1 198-01-51320 PRE-CLEANER (Sy-klone Int) 2
2 198-54-57170 DUCT (Sy-klone Int) 2
3 01016-51045 BOLT 2
4 01643-31032 WASHER 2
5 01580-11008 NUT 2
6 198-01-51340 PRE-CLEANER (Enginairer) 2
7 198-54-57282 DUCT (Enginairer) 2
8 01016-51045 BOLT 2
9 01643-31032 WASHER 2
10 01580-11008 NUT 2

REMARKS This operation may not be necessary depending on destination.

1. Remove the dust and water preventive seals from the air intake port hoods on the engine hood.
2. Apply sealant to only duct (7) of Enginaire pre-
cleaner. a
7
REMARKS ꞏ Apply the sealant all around without breakage in
dimensions (a) and (b) shown in the figure.
Dimension (a): 3 mm b
Dimension (b): 5 mm A
ꞏ Install duct (7) to the air intake port hood before the
A
sealant sets. A-A

3. Fully insert ducts (2) and (7) into the air intake port mounting openings.
REMARKS The hoods may be inserted in any direction.
4. Tighten the bands installed to the duct with bolts (3)
and (8), washers (4) and (9), and nuts (5) and (10).
REMARKS Tighten until dimension (a) becomes 0.
Bolt (3): Width across flats 17 mm, M10, L45 mm
a

152
 For Sy-kline Int
5. Fully insert pre-cleaner (1) into duct (2).
REMARKS Install R.H. pre-cleaner (1) with discharge slot (c) Sy-klone Int
toward the front of machine, and L.H. pre-cleaner
(1) with discharge slot (c) toward the right of c
machine.

For Enginaire
6. Fully insert pre-cleaner (6) into duct (7).
REMARKS Install R.H. pre-cleaner (6) with discharge slot (c)
toward the front of machine, and L.H. pre-cleaner
(1) with discharge slot (c) toward the right of
machine.
Enginaire

153
 Installation of engine exhaust pipe
A-26
(When engine exhaust pipe is not installed)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 17 mm 1
B Socket Commercially available 19 mm 1
C Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more

Part list
Part No. Part name Q'ty Part state
1 198-01-75161 EXHAUST PIPE 2
2 01010-D1240 BOLT 12
3 17A-54-42370 WASHER 12
4 198-01-75720 Rain cap 2

CAUTION This operation may not be necessary depending on destination.

1. Install exhaust pipes (1) (2 pieces) with bolts (1) (12
pieces).
Bolt (1): Width across flats 19 mm, M12, L40 mm
Tightening torque of bolt (1):
98 to 123 Nm {10 to 12.5 kgm}

2. Install rain caps (4) horizontally at the front of the machine.

154
A-27 Installation of headlamp (When headlamp is not installed)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more

Part list
Part No. Part name Q'ty Part state
1 - L.H. HEADLAMP ASSEMBLY 1
2 - R.H. HEADLAMP ASSEMBLY 1
3 01024-D1230 BOLT 14
4 198-54-85331 L.H. COVER 1
5 198-54-85310 R.H. COVER 1

REMARKS This operation may not be necessary depending on destination.

2, 3
1, 3

5, 3
4, 3

1. Install L.H. headlamp (1) and R.H. headlamp (2) with bolts (3).
Bolt (3): Width across flats 19 mm, M12, L30 mm
Tightening torque of bolt (3): 98 to 123 Nm {10 to 12.5 kgm}
2. Remove L.H. cover (4) and R.H. cover (5), connect the lamp connectors, and install the covers
again.
Bolt (3): Width across flats 19 mm, M12, L30 mm
Tightening torque of bolt (3): 98 to 123 Nm {10 to 12.5 kgm}

155
A-28 Installation of giant ripper shank

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Crane - 45 t 1
B Wire rope sling Commercially available φ12 x 4 m 1
C Shackle Commercially available SD22-M 1
D Block - 1

Part list
Part No. Part name Q'ty Part state
1 - RIPPER 1
2 - SHANK ASSEMBLY 1
3 - SHANK MOUNTING PIN 1

1. Operate the machine so that the distance between

Fig. 1
the ripper beam bottom and ground becomes (a).
REMARKS ꞏ Set the shank holder hole of ripper beam
perpendicular to the ground.
ꞏ An example of method is shown below. Actually, D
a
work according to the site conditions.
Dimension (a): 2700 mm min.
1) Float the rear of machine by running over wooden blocks, etc.
2) Raise the ripper arm to the maximum height, and set the shank holder hole perpendicular to the
ground by operating the ripper beam.
2. Place ripper shank (2) on the ground under ripper
(1) beam. A
REMARKS Bring the lifting ring at the ripper shank top to right
under the shank holder hole of the ripper beam.
B
3. Install rope sling (B) to crane (A), insert it from
above into the shank holder hole of ripper (1) beam,
and hang it to the ground.

REMARKS For details of rope sling (B) (φ12 mm x 4 m), see

“List of tools for field assembly”. 1
C
4. Connect rope sling (B) to the lifting ring of ripper
shank with shackle (C).
2
REMARKS For details of shackle: (C) (SD22-M), see “List of
tools for field assembly”.
Weight of shank assembly (2): Approx. 9.8 kN
{1000 kg}
5. Lift the ripper shank with crane (A), and pass it through the shank holder hole of ripper shank.

156
 6. Align the pin holes of ripper shank and ripper beam,
and fix them by inserting shank mounting pin (3).
REMARKS When installing the multi-shank ripper, install it
almost similarly to the above.

157
 Adjustment of blade tilt control angle
A-29
(Machine with semi-U blade/full-U blade)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Angle gauge 799-402-3800 1

REMARKS For selection method, see M-1 “Operating method of service mode”.
CAUTION ꞏ When the blade and blade cylinder
3
potentiometer were removed and installed or
when the machine controller was replaced,
adjust the blade tilt control angle according to
the following procedure.
2
ꞏ If this adjustment is not performed, the blade 1
may not tilt sufficiently or may tilt too much and
interfere with the track shoe. Accordingly, be
sure to perform this adjustment.

ꞏ Perform this adjustment on a level ground.

1. Adjust mounting dimension (a) of rod (1), and
connect the rod to potentiometer lever (2) and yoke
(3).

Dimension (a): 425 mm

Correction of angle sensor output
1. Start the engine.
2. Park the machine on a level surface.
1) Press F1 and enter the dual tilt mode.
3. Select "Adjustment" on "Service Menu" screen.
4. After "Adjustment" screen is displayed, select "Tilt
Limit Setting" with the function switches or numeral
input switches.

5. After "Tilt Limit Setting" screen is displayed, select

"Correction of Angle Sens Output" using the
function switch or numeral input switches.

6. After “Correction of Angle Sens Output (1/2)” screen

is displayed, follow the directions displayed on the
screen.

158
 F3: Go to next step.
F5: Return to “Tilt Limit Setting” screen.
1) Adjust the R.H. and L.H. blade lift cylinder rod
lengths to 425 mm.
2) Press F3 and go to the next step.
7. After “Correction of Angle Sens Output (2/2)” screen
is displayed, follow the directions displayed on the
screen.

F5: Return to “Correction of Angle Sens Output

(1/2)” screen.
F6: Record work equipment position.
1) Set the blade level.
2) Pitch the blade back to the stroke end.
3) Raise the blade cutting edge to a height of 100 mm above the ground.
4) Hold down F6 and check that the alarm buzzer sounds.
Correction of left tilt limit position
1. Return to “Tilt Limit Setting” screen, and select
“Correction of Left Tilt Limit” with the function switch
or numeral input switches.

2. After “Correction of Left Tilt Angle (1/2)” screen is

displayed, follow the directions displayed on the
screen.

F3: Go to next step.

F5: Return to “Tilt Limit Setting” screen.
1) While pitching back the blade to the stroke end,
raise the blade cutting edge to a 1000 mm above
the ground.

2) Press F3 and go to the next step.

3. After “Correction of Left Tilt Angle (2/2)” screen is
displayed, follow the directions displayed on the
screen.

F5: Return to “Correction of Left Tilt Limit (1/2)”

F6: Record work equipment position.
1) Set the left tilt angle to 12 degrees.
REMARKS Correctly set with angle gauge A.

159
 2) Hold down F6 and check that the alarm buzzer
sounds.

Correction of right tilt limit position

1. Return to “Tilt Limit Setting” screen, and select
“Correction of Right Tilt Limit” with the function
switch or numeral input switches.

2. After “Correction of Right Tilt Angle (1/2)” screen is

displayed, follow the directions displayed on the
screen.

F3: Go to next step.

F5: Return to “Tilt Limit Setting” screen.
1) Pitch the blade forward to the stroke end.
2) Level frame (A) on the screen.
3) Press F3 and go to the next step.
3. After “Correction of Right Tilt Angle (2/2)” screen is
displayed, follow the directions displayed on the
screen.

F5: Return to “Correction of Right Tilt Limit (1/2)”

screen.
F6: Record work equipment position.
1) Set the right tilt angle to 12 degrees.
REMARKS Correctly set with angle gauge A.
2) Hold down F6 and check that the alarm buzzer sounds.
4. Lower the work equipment to the ground and stop the engine.
5. Start the engine.
6. Tilt the blade to the right and left, and check that it does not interfere with the track shoe at any
position.

160
 Adjustment of blade tilt control angle
A-30
(Machine with superdozer)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Angle gauge 799-402-3800 1

REMARKS For selection method, see M-1 “Operating method of service mode”.
CAUTION ꞏ When the blade and blade cylinder
3
potentiometer were removed and installed or
when the machine controller was replaced,
adjust the blade tilt control angle according to
the following procedure.
2
ꞏ If this adjustment is not performed, the blade 1
may not tilt sufficiently or may tilt too much and
interfere with the track shoe. Accordingly, be
sure to perform this adjustment.

ꞏ Perform this adjustment on a level ground.

1. Adjust mounting dimension (a) of rod (1), and
connect the rod to potentiometer lever (2) and yoke
(3).

Dimension (a): 425 mm

Correction of angle sensor output
1. Start the engine.
2. Park the machine on a level surface.
1) Press F1 and enter the dual tilt mode.
3. Select "Adjustment" on "Service Menu" screen.
4. After "Adjustment" screen is displayed, select "Tilt
Limit Setting" with the function switches or numeral
input switches.

5. After "Tilt Limit Setting" screen is displayed, select

"Correction of Angle Sens Output" using the
function switch or numeral input switches.

6. After “Correction of Angle Sens Output (1/2)” screen

is displayed, follow the directions displayed on the
screen.

161
 F3: Go to next step.
F5: Return to “Tilt Limit Setting” screen.
1) Adjust the R.H. and L.H. blade lift cylinder rod
lengths to 425 mm.
2) Press F3 and go to the next step.
7. After “Correction of Angle Sens Output (2/2)” screen
is displayed, follow the directions displayed on the
screen.

F5: Return to “Correction of Angle Sens Output

(1/2)” screen.
F6: Record work equipment position.
1) Set the blade level.
2) Pitch the blade back to the stroke end.
3) While keeping the edge of the blade level, and hold it 100 mm above the ground.
4) Hold down F6 and check that the alarm buzzer sounds.
Correction of left tilt limit position
1. Return to “Tilt Limit Setting” screen, and select
“Correction of Left Tilt Limit” with the function switch
or numeral input switches.

2. After “Correction of Left Tilt Angle (1/2)” screen is

displayed, follow the directions displayed on the
screen.

F3: Go to next step.

F5: Return to “Tilt Limit Setting” screen.
1) Set the blade cutting edge at 52 degrees and raise
it to 200 to 300 mm above the ground.
2) Raise the blade cutting edge to 1000 mm above the ground.
3) Press F3 and go to the next step.
3. After “Correction of Left Tilt Angle (2/2)” screen is
displayed, follow the directions displayed on the
screen.

F5: Return to “Correction of Left Tilt Limit (1/2)”

F6: Record work equipment position.
1) Set the left tilt angle to 7 degrees.
REMARKS Correctly set with angle gauge A.

162
 2) Hold down F6 and check that the alarm buzzer
sounds.

Correction of right tilt limit position

1. Return to “Tilt Limit Setting” screen, and select
“Correction of Right Tilt Limit” with the function
switch or numeral input switches.

2. After “Correction of Right Tilt Angle (1/2)” screen is

displayed, follow the directions displayed on the
screen.

F3: Go to next step.

F5: Return to “Tilt Limit Setting” screen.
1) Set the blade cutting edge at 52 degrees and raise
it to 200 to 300 mm above the ground.
2) Raise the blade cutting edge to 1000 mm above the ground.
3) Press F3 and go to the next step.
3. After “Correction of Right Tilt Angle (2/2)” screen is
displayed, follow the directions displayed on the
screen.

F5: Return to “Correction of Right Tilt Limit (1/2)”

screen.
F6: Record work equipment position.
1) Set the right tilt angle to 7 degrees.
REMARKS Correctly set with angle gauge A.
2) Hold down F6 and check that the alarm buzzer sounds.
4. Lower the work equipment to the ground and stop the engine.
5. Start the engine.
6. Tilt the blade to the right and left, and check that it does not interfere with the track shoe at any
position.

163
 Blade pitch current value correction
A-31
(Machine with superdozer)
Check and adjust various settings of the machine by the adjustment ID.
By “Blade Pitch Current Value Correction”, adjust the speed of the left tilt cylinder to eliminate any unintended
blade tilt during the blade pitch operation.
This is an adjustment function available only with the super dozer specification.
1. Start the engine.
2. Park the machine on a flat ground.

3. On the “Service Menu” screen, select the “Adjustment”.

REMARK
For details about how to select, see “SERVICE MODE”.

4. On the “Adjustment” screen, select the “Input ID” with func-

tion switches or numeral input switches.
REMARK
For details about how to select, see “SERVICE MODE”.

5. On the “Input ID” screen, input the adjustment ID “8090” by

using the numeral input switches.
F5: The screen goes back to the “Adjustment” screen.
F6: Enters the inputted adjustment ID.
REMARK
• For adjustment ID and adjustment items, see “AD-
JUSTMENT ITEM TABLE”.
• If the inputted adjustment ID is incorrect, “Incorrect ID”
is shown. “Input ID” screen does not proceed to the
next screen. (Adjustment ID can be inputted again on
this screen display.)
6. On the “Adjustment” screen, select the object to adjust by
using the function switches.
F3: Switches between the operations “PITCH BACK” and
“PITCH DUMP”.
F4: Switches between the operations “PITCH BACK” and
“PITCH DUMP”.
F5: The screen goes back to the “Input ID” screen.
F6: Accepts the selected operation.
1) Push F3, or F4 to display the object to adjust.
2) Push F6 to confirm the object to adjust.

*

164
7. After you OOPS! the object to adjust, record the adjust-
ment value with function switches.
F3: Adjustment value “Current Offset” decreases.
F4: Adjustment value “Current Offset” increases.
F5: The screen goes back to the “Input ID” screen.
F6: Records the adjustment value.
1) Push F3 or F4 to increase or decrease the adjustment
value.
REMARK
• If it has been adjusted, the adjusted value is
shown. But you can adjust it as many times as you
*
need.
• When the “Current Offset” side is increased, the
speed of the left tilt cylinder is increased.
• When the “Current Offset” is decreased, the speed
of the left tilt cylinder is decreased.
• The value is adjustable by steps of 1 mA within the
range of ±30 mA.
2) Push F6 to confirm the object to adjust.
REMARK
• You can adjust the “Current Offset” while you do the blade pitch operation.
• Even when you turn the starting switch to the OFF position after the adjustment is complete, the
recorded adjustment value remains effective.
• Because this adjustment function is available only with the super dozer specification, BLADE TYPE
MISMATCHED is shown with the blade or dual tilt dozer specifications other than the super dozer
specification, and the screen does not proceed to the “Adjustment” screen.
8. Operate the blade operation lever and visually check that the blade does not tilt during blade pitch dump
and pitch back operations.

165
A-32 Installation of platform-1

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Socket Commercially available 24 mm 1
C Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
D Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more

Part list
Part No. Part name Q'ty Part state
1 198-54-87111 STEP 1
2 198-54-87130 HANDRAIL 1
3 198-54-79161 BRACKET 10
4 01034-81230 BOLT 40
5 198-54-89221 STEP 1
6 198-54-89241 HANDRAIL 1
7 198-54-89671 BRACKET 1
8 01034-81230 BOLT 11
9 195-54-56171 BRACKET 2
10 198-54-89181 BRACKET 1
11 01010-81650 BOLT 8
12 01010-81640 BOLT 8
13 21T-54-16150 WASHER 16

1. Assemble the L.H. platform.

1) Install handrail (2) to step (1) with brackets (3).
2 1

Bolt (4): Width across flats 19 mm, M12, L30 mm

Tightening torque of bolt (4): 98 to 123 Nm {10 to
12.5 kgm}
3, 4

3, 4

166
 2. Assemble the rear platform.
1) Install handrail (6) to step (5) with brackets (3). 6
Bolt (4): Width across flats 19 mm, M12, L30 mm
Tightening torque of bolt (4): 98 to 123 Nm {10 to
12.5 kgm}
2) Install bracket (7) to step (5) with bolts (8). 3, 4
Bolt (8): Width across flats 19 mm, M12, L30 mm
Tightening torque of bolt (8): 98 to 123 Nm {10 to
12.5 kgm}
3, 4 5
7, 8 3, 4

3. Install the platform.

1) Install brackets (9) and (10) to the fender with bolts
(11) and (12). 9, 12, 13

REMARKS Tighten bolts (11) and (12) so that no gap is made

on mounting faces (a) of brackets (9) and (10). 10, 11, 13

Bolt (11): Width across flats 24 mm, M16, L50 mm

Bolt (12): Width across flats 24 mm, M16, L40 mm
Tightening torque of bolts (11), (12): 235 to 285
Nm {23.5 to 29.5 kgm}

167
A-32 Installation of platform-2

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Socket Commercially available 24 mm 1
C Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
D Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more

Part list
Part No. Part name Q'ty Part state
4 01034-81230 BOLT 4
13 21T-54-16150 WASHER 12
14 01010-81660 BOLT 12
15 198-54-87671 BRACKET 1
16 198-54-87681 BRACKET 1
17 01034-81240 BOLT 20
18 01034-81250 BOLT 6
19 198-54-87660 STEP 1
20 198-54-87121 STEP 1

2) Install brackets (15) and (16) with bolts (14).

Bolt (14): Width across flats 24 mm, M16, L60 mm 14, 15 14, 16
Tightening torque of bolt (14): 235 to 285 Nm
{23.5 to 29.5 kgm}

168
3) Install the L.H. platform assembly with bolts (17).
Bolt (17): Width across flats 19 mm, M12, L40 mm
Tightening torque of bolt (17): 98 to 123 Nm {10 to
12.5 kgm}

17

17

4) Install the rear platform assembly with bolts (18).

Bolt (18): Width across flats 19 mm, M12, L50 mm
Tightening torque of bolt (18): 98 to 123 Nm {10 to
12.5 kgm}

18 18

5) Install steps (19) and (20) with bolts (4) and (17).
Bolt (4): Width across flats 19 mm, M12, L30 mm 19
Bolt (17): Width across flats 19 mm, M12, L40 mm
Tightening torque of bolt (4): 98 to 123 Nm {10 to 4 4
12.5 kgm}
20
Tightening torque of bolt (17): 98 to 123 Nm {10 to
12.5 kgm} 17
17

169
A-32 Installation of platform-3

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more

Part list
Part No. Part name Q'ty Part state
3 198-54-79161 BRACKET 3
4 01034-81230 BOLT 12
21 198-54-87141 HANDRAIL 1
22 07094-31024 CLAMP 6
23 07095-01033 CUSHION 6
24 04089-01230 SEAT 3
25 01024-81280 BOLT 6

6) Install handrail (21) with brackets (3).

Bolt (4): Width across flats 19 mm, M12, L30 mm 22, 23, 24, 25
Tightening torque of bolt (4): 98 to 123 Nm {10 to
6
12.5 kgm}
7) Mount handrails (2), (6), and (21) with clamps (22).
Bolt (25): Width across flats 19 mm, M12, L80 mm 21
Tightening torque of bolt (25): 98 to 123 Nm {10 to
12.5 kgm}
3, 4
2

170
A-32 Installation of platform-4

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 17 mm 1
B Socket Commercially available 19 mm 1
C Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more

Part list
Part No. Part name Q'ty Part state
26 195-54-89250 PLATE 1
27 195-54-56660 PLATE 5
28 198-54-89251 PLATE 1
29 07283-33450 CLIPS 14
30 07283-53444 SEAT 14
31 22P-70-12160 NUT 28
32 01643-31032 WASHER 28
33 195-54-56261 HANDRAIL 3
34 01024-81250 BOLT 6

8) Install plates (26) and (27) to handrail (2).

33, 34
Clip (29): Width across flats 17 mm
Tightening torque of clip (29): 59 to 74 Nm
{6 to 7.5 kgm}
9) Install handrails (33) to step (5) with bolts (34). Bolt
(34): Width across flats 19 mm, M12, L50 mm 5
Tightening torque of bolt (34): 98 to 123 Nm {10 to
26, 29, 30, 31, 32
12.5 kgm}

27, 29, 30, 31, 32

10) Install plates (27) to handrail (6).

Clip (29): Width across flats 17 mm 28, 29, 30, 31, 32 6
Tightening torque of clip (29): 59 to 74 Nm
{6 to 7.5 kgm}
11) Install plates (28) to handrail (6).
Clip (29): Width across flats 17 mm
Tightening torque of clip (29): 59 to 74 Nm
{6 to 7.5 kgm}
21 27, 29, 30, 31, 32

171
A-33 Greasing each part

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 24 mm 1
B Air impact Commercially available 1 Torque 315 Nm (32 kgm) or more
C Grease pump Commercially available 1 Air supply type

1. Add grease to each portion.

Portion a
1) Blade lift cylinder support yoke (1) (4 places) (2 2
places each on each right and left)
2) Blade lift cylinder support shaft (2) (2 places) (1
place each on each right and left)

Portion b
3) Blade arm ball joint (3)

172
 Portion c
4) Ripper tilt cylinder bottom pin (4) (2 places)
5) Ripper lift cylinder bottom pin (5) (2 places)
6) Ripper arm pin on machine side (6) (2 places)
4 4

5
5
6

Portion d
7) Ripper tilt cylinder bottom pin (7) (2 places) (1 place
each on right and left) 7
8) Ripper lift cylinder bottom pin (8) (2 places) (1 place
each on right and left)
8
9) Ripper arm pin on beam side (9) (2 places) (1 place
each on right and left)
9

Portion e
CAUTION ꞏ Never open or close cover (12) while you are
right under cover (12). 11

ꞏ When removing bolts (11), work from back of

cover (12) so that the cover will not touch you. 12

ꞏ Remove the starting key or take other measures

so that no one starts the engine by mistake. FWD
10
10) Remove bolts (10) (2 pieces) on the front side of
machine.
Bolt (10): Width across flats 24 mm, M16, L100 mm
11) While supporting cover (12) with your elbow, remove bolts (11) (2 pieces) on the rear side of
machine.
Bolt (11): Width across flats 24 mm, M16, L100 mm
Weight of cover (12): Approx. 50kg
12) Gradually open cover (12).

12

FWD

173
 13) Universal joint (2 places)
REMARKS Do not use molybdenum disulfide grease.

View Z

Portion f
14) Equalizer bar side pin (13) (2 places) (1 place each
on right and left)
13

15) Both ends of equalizer bar (14) (2 places) (1 place

each on right and left)
REMARKS Remove the cover and add grease. 14

16) Suspension (Equalizer bard center shaft) (15) (1

place on right side of engine compartment)

15
FWD

174
A-34 Bleeding air from hydraulic cylinder

REMARKS After disassembling for transportation, 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.

Blade lift cylinder (with piston valve)

1 Start and run the engine at low idle for approximately 5 minutes.
2. While running the engine at low idle, extend and retract the cylinder 4 to 5 times.
REMARKS ꞏ Do not move the cylinder to each stroke end.
ꞏ Stop the cylinder approximately 100 mm before each stroke end.
ꞏ Do not relieve the circuit under any conditions.
3. While running the engine at low idle, retract the cylinder and stop 100 mm before each stroke end.
Then, slowly retract the cylinder to the stroke end (take at least 10 seconds). Hold the lever down
for approximately 3 minutes under this condition.

4. While running the engine at high idle, retract the cylinder and stop 100 mm before each stroke end.
Then, slowly retract the cylinder to the stroke end (take at least 10 seconds). Hold the lever down
for approximately 1 minutes under this condition.

Blade tilt cylinder (without piston valve)

1. Start and run the engine at low idle for approximately 5 minutes.
2. While running the engine at low idle, extend and retract the cylinder 4 to 5 times.
REMARKS ꞏ Do not move the cylinder to each stroke end.
ꞏ Stop the cylinder approximately 100 mm before each stroke end.
ꞏ Do not relieve the circuit under any conditions.
3. Repeat this operation while running the engine at high idle. Decrease the engine speed to low idle,
and move the cylinder to the stroke end and relieve the oil.

CAUTION ꞏ 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.
ꞏ Check the oil level, and add oil to the specified level if necessary.

175
A-35 Bleeding air from work equipment pump and fan pump

a: Air bleeder of fan pump (2 places) b: Air bleeder of work equipment pump
(1 place)

1. Bleed air from the pumps.

1) Before starting the engine, loosen the air bleeding port plugs.
2) Keep the air bleeding ports open until oil containing no bubble flows out.
3) When bubbles do not come out any more, tighten the plugs.

176
A-36 Installation of quick charge piping (optional)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 17 mm 1
B Socket Commercially available 19 mm 1
C Socket Commercially available 30 mm 1
D Air impact Commercially available 1 Torque 140Nm(14kgm) or more
E Air impact Commercially available 1 Torque 980Nm(100kgm) or more

Coating materials
Komatsu code Part No.
1 LG-5 790-129-9080

Part list
Part No. Part name Q'ty Part state
1 07371-32076 FLANGE 4
2 07375-21240 BOLT 8
3 07283-36163 CLIPS 3
4 07283-56170 SEAT 3
5 01643-31032 WASHER 6
6 22P-70-12160 NUT 6
7 198-04-66161 PLATE 1
8 198-04-75330 TUBE 1
9 198-04-66170 RECEIVER 1
10 198-04-75280 HOSES 1
11 07000-12060 O-RING 2
12 42C-16-11510 CLAMP 2
13 07095-02062 CUSHION 1
14 01011-81210 BOLT 2
15 01643-31232 WASHER 2
16 01010-82040 BOLT 2
17 01643-32060 WASHER 2
18 21T-04-31130 VENT Ass'y 1
19 02761-24119 HOSES 1
20 07281-00609 CLAMP 1
21 198-61-44220 CLAMP 4
22 198-61-44130 CUSHION 2
23 01024-81290 BOLT 2
24 07000-13048 O-RING 1

177
 1. Remove the plug at the left top of fuel tank, and
connect hose (10).
REMARKS ꞏ Reuse flanges (1) and bolts (2).
ꞏ Be sure to install the O-ring (24).
Bolt (2): Width across flats 17 mm, M12, L40 mm
Tightening torque of bolt (2): 59 to 74 Nm
{6 to 7.5 kgm}
2. Install plate (7).
REMARKS Make sure that the hose (10) and the (a) part of the
catwalk do not interfere, and then install the plate
(7).

Bolt (16): Width across flats 30 mm, M20, L40 mm

Tightening torque of bolt (16): 455 to 565 Nm {46.5
to 58 kgm}
3. Lightly install tube (8) with clips (3).

Nut (6): Width across flats 17 mm

4. Connect hose (10) to tube (8).
Bolt (2): Width across flats 17 mm, M12, L40 mm
Tightening torque of bolt (2): 59 to 74 Nm
{6 to 7.5 kgm}
5. Fix hose (10) to the fuel tank with clamp (12).
Bolt (14): Width across flats 19 mm, M12, L110 mm
Tightening torque of bolt (14): 98 to 123 Nm {10 to
12.5 kgm}

6. Tighten clips (3) to the specified torque.

REMARKS ꞏ Tube (8) and receiver (9) are made as a unit.
ꞏ Install tube (8) and receiver (9) at the angle shown
in the figure.
Angle (a): 15°
Threads of receiver (9): LG-5 (Liquid gasket)
Nut (6): Width across flats 17 mm
Tightening torque of nut (6): 59 to 74 Nm
{6 to 7.5 kgm}
Tightening torque of receiver (9): 147.2 to 196.2Nm
{15 to 20 kgm}

178
7. Remove the plug on the upper right of the fuel tank,
and temporarily install the breather hose (19) with
the clamp (20).
Clamp (20) bolt: Width across flats 7 mm
8. Fix hose (19) to the fuel tank with clamp (21). Bolt
(23): Width across flats 19 mm, M12, L90 mm
Tightening torque of bolt (23): 98 to 123 Nm {10 to
12.5 kgm}
9. Tighten the clamp (20).
Clamp (20) bolt: Width across flats 7 mm
Clamp (20) bolt tightening torque: 5.9 ± 0.49 Nm
{0.6 ± 0.05 kgm}

179
A-37 Installation of ladder - 1 (For machine with ladder)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Crane - 45 t 1
Width 25
B Belt sling Commercially available 1
mm × 3 m
C Extension bar Commercially available 1
D Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
E Wrench Commercially available 19 mm 1

Part list
Part No. Part name Q'ty Part state
1 X21-2697130 LADDER ASSEMBLY 1
2 01643-31645 WASHER 11
3 01011-81615 BOLT 4
4 01011-81600 BOLT 3
5 01010-81640 BOLT 4

1. Install the ladder.

1) Before starting the work, remove the transportation
cover.

2, 4
2, 5 2, 3

2) Lift and install ladder assembly (1) with bolts (3), (4), and (5).

180
 Bolt (3): Width across flats 24 mm, M16, L115 mm
Bolt (4): Width across flats 24 mm, M16, L100 mm
Bolt (5): Width across flats 24 mm, M16, L40 mm
Weight of ladder assembly (1): 470 kg
Tightening torque of bolts (3), (4) (5): 235 to 285 Nm {23.5 to 29.5 kgm}

2. Connect the hydraulic hoses.

1) 1) Remove the plugs of the hydraulic hoses coming
out of the machine.
REMARKS Do not lose O-rings (8).
2) Remove the plugs and nuts from the nipples on the
ladder side.
3) Connect hoses (6) and (7).
REMARKS ꞏ Reuse O-rings (8) removed in Step 2).
ꞏ The removed plugs and nuts are unnecessary after
the hoses are connected. However, keep them
since they necessary for transportation.

Hoses (6), (7): Width across flats 19 mm

Tightening torque of hoses (6), (7): 98 to 123 Nm
{10 to 12.5 kgm}

3. Connect the wiring harness.

1) Remove bolts (9), and remove cover (10).
Bolt (9): Width across flats 19 mm, M12, L30 mm
9
9

10

2) Connect connectors CN-S0 and CN-S1.

Connector CN-S0: Gray CS-S1
Connector CN-S1: Black

CS-S0

181
A-37 Installation of ladder - 2 (For machine with ladder)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more

Part list
Part No. Part name Q'ty Part state
10 01024-81225 BOLT 8
11 195-54-52471 COVER 1
12 195-54-52431 COVER 1
13 198-54-89441 COVER 1
14 195-54-52481 COVER 1
15 198-54-88181 COVER 1
16 X21-2370011 BOLT 1
17 01024-81020 BOLT 2
18 01024-81240 BOLT 1
19 15B-54-14220 COLLAR 1
20 175-54-27351 SPRING 2
21 209-54-14650 WASHER 1
22 175-54-28770 RING 1

1. Adjust dials (1) and (2) of the hydraulic oil flow

control valve and set the ladder speed control as
follows.

Rising speed dial (1): 10.0 (2.0 at delivery)

Lower speed dial (2): 1.6 (2.0 at delivery)
1
2

1) Set the lowering line (2) of the ladder raise/lower

speed adjustment dial to “1.6”.
2

182
REMARKS ꞏ The datum line of the gauge is (h).
ꞏ 1 graduation (g) is “1”.

2) Set the raising line (11) of the ladder raise/lower

speed adjustment dial to “10”.
REMARKS 1 graduation (g) is “1”.
1

2. Install the cover.

1) Install cover (15) with bolts (10).
15
Bolt (10): Width across flats 19 mm, M12, L25 mm
Tightening torque of bolt (10): 98 to 123 Nm {10 to
12.5 kgm}

10

183
2) Install cover (11) with bolts (10).
Bolt (10): Width across flats 19 mm, M12, L25 mm 14, 17 18, 19, 20, 21, 22
Tightening torque of bolt (10): 98 to 123 Nm {10 to
12.5 kgm}
3) Install cover (12) with bolts (10).
Bolt (10): Width across flats 19 mm, M12, L25 mm
Tightening torque of bolt (10): 98 to 123 Nm {10 to
10, 11 10, 12 10, 13
12.5 kgm}
4) Install cover (13) with bolts (10) and (18).
Bolt (10): Width across flats 19 mm, M12, L25 mm
Bolt (18): Width across flats 19 mm, M12, L40 mm
Tightening torque of bolts (10) and (18): 98 to 123 Nm {10 to 12.5 kgm}
5) Install cover (14) with bolts (17).
Bolt (17): Width across flats 17 mm, M10, L20 mm
Tightening torque of bolt (17): 59 to 74 Nm {6 to 7.5 kgm}
3. Move the mounting plate from position (a) to
position (b).
Mounting plate mounting bolt: Width across flats: 19
mm, M12, L35 mm

184
A-37 Installation of ladder - 3 (For machine with ladder)

1. Set the machine specifications.

1) On the standard screen, display “Service Menu”
with the numeral input switches.
Switch operation (Press the following switches in
order while pressing "4"): 4 + 1 -> 2 -> 3

1 2

4 3

2) Select “Default” on “Service Menu” screen.

3) When “Default” screen is displayed, input “40” with

the numeral input switches and press F6, and
“Machine Specification Setting Menu” is displayed.

4) When “Machine specification Setting Menu” is

displayed, select “Power Ladder”, and set “Use”.

5) After setting, turn the starting switch to OFF position, then to ON position, and the set contents are
saved in the controller.

185
A-37 Installation of ladder - 4 (For machine with ladder)

1. If the ladder does not function normally, adjust the limit switches according to the following
procedure.
Check the limit switch functions.
1) Display “02710 option controller SW input 1” and
“02711 option controller SW input 2” on “Service
Menu” of the monitor.

REMARKS To display “Service Menu” screen, see2 Inspection

of machine monitor (2/7)”.

2) Operate the ladder and check the status of limit

switches.

Limit switch status

Ladder Clamp
Ladder position
Lower position limit Upper position limit Open position limit Close position limit
switch switch switch switch

Stowage OFF ON OFF ON

Clamp center OFF ON OFF OFF
Between top and bottom OFF OFF ON OFF
Lowest position ON OFF ON OFF

3) If any limit switches do not work normally, adjust

them.

1 Ladder lower position limit switch

2 Ladder upper position limit switch
3 Open open position limit switch
4 Clamp close position limit switch 1

3 2

186
A-37 Installation of ladder - 5 (For machine with ladder)

1. Bleed air from the ladder cylinder.

Bleed air from the ladder cylinder circuit according to the following procedure.
2. With the ladders stowed, check the pump oil level.
1) If the oil level is below specified level (a), add oil
according to the following procedure.
ꞏ Operate the switches and extend or retract to each
stroke end. (Approx. 3 to 4 times)
ꞏ Check the air bleeding status through the inspection
window or oil filler port of the ladder pump, and
bleed until no air is left.

REMARKS If the oil level is low, the pump may be damaged.

Bleed air carefully, check the oil level, and add oil
as necessary.

Applicable oil: TO10

Oil capacity: Approx. 3.0 L (When ladder is stowed)
a

187
A-38 Installation of ladder - 1 (For machine with retrofitting ladder)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 19 mm 1
B Socket Commercially available 30 mm 1
C Extension bar Commercially available 1

Part list
Part No. Part name Q'ty Part state
1 198-54-85590 COVER 1 Reused for installation
2 01024-81230 BOLT 4 Reused for installation
3 198-54-88840 CLAMP 2 Discard after remove
4 198-54-88880 CLAMP 2 Discard after remove
5 07095-01033 CUSHION 1 Discard after remove
6 07095-0042B CUSHION 1 Discard after remove
7 198-54-88870 BRACKET 1 Discard after remove
8 01024-81290 BOLT 2 Discard after remove
9 01024-81270 BOLT 2 Discard after remove
10 X21-2767210 COVER 1 Reused for installation
11 21N-53-31870 CAP 2 Reused for installation
12 01034-81230 BOLT 7 Reused for installation
13 X21-2509262 COVER 1 Reused for installation
14 01024-81230 BOLT 6 Reused for installation
15 198-54-88541 BRACKET 1 Discard after remove
16 01010-82075 BOLT 4 Discard after remove
17 01643-32060 WASHER 4 Discard after remove
18 01024-81240 BOLT 6 Discard after remove
19 198-54-88830 PLATE 2 Discard after remove
20 17A-61-13391 BRACKET 1 Discard after remove
21 01024-81240 BOLT 1 Discard after remove
22 04434-53412 CLIP 1 Discard after remove
23 07095-20627 CUSHION 1 Discard after remove
24 01024-81230 BOLT 1 Discard after remove
25 195-06-55170 CAP 1 Discard after remove
26 01010-82040 BOLT 7 Discard after remove
27 01643-32060 WASHER 7 Discard after remove
CAUTION Keep the parts that will be reused during installation so that parts will not be lost.

This work may not be necessary depending on the destination or the specifications of the machine.
Refer to this work when installing the ladder on a machine with a retrofitted ladder.
After completing this work, refer to "A-37" to complete the installation of the ladder.

188
 1. Remove cover (1), (10), (13), handrail (29) and
harness clip. P
10,11,12
1) Remove bolts (8), (9), and remove bracket (7).
Bolt (8): Width across flats 19mm, M12, L90 mm 28
Bolt (9): Width across flats 19mm, M12, L70 mm
2) Remove bolts (2), (12), (14), and remove cover (1),
(10), (13), (28).
Bolt (2), (12), (14): Width across flats 19mm, M12,
L30 mm

13,14 1,2

3,4,5,6,7,8,9

3) Remove bolts (26). Z

Bolt (26): Width across flats 30mm, M20, L40 mm
4) Remove bolts (21), (24), and remove bracket (20).
Bolt (21): Width across flats 19mm, M12, L40 mm
Bolt (24): Width across flats 19mm, M12, L30 mm
5) Remove bolts (18), and remove plate (19).
Bolt (18): Width across flats 19mm, M12, L40 mm
6) Remove bolts (16), and remove bracket (15).
REMARKS Remove bracket (15) at the same time as handrail 26,27 29
15,16,17
(29).
Bolt (16): Width across flats 30mm, M20, L75 mm
20,21,22,23,
18,19
24,25

View Z

189
A-38 Installation of ladder - 2 (For machine with retrofitting ladder)

Symbol Part name Part No. Specification Q'ty Remarks

A Socket Commercially available 19 mm 1
B Socket Commercially available 30 mm 1
C Extension bar Commercially available 1

Part No. Part name Q'ty Part state

1 198-54-87951 BRACKET 1 Reused for installation
2 01010-82065 BOLT 4 Reused for installation
3 01643-32060 WASHER 4 Reused for installation
4 198-54-87941 BRACKET 1 Reused for installation
5 01010-82065 BOLT 6 Reused for installation
6 01643-32060 WASHER 6 Reused for installation
7 198-54-87980 PLATE 1 Reused for installation
8 01024-81230 BOLT 4 Reused for installation
9 07049-01215 PLUG 3 Reused for installation
10 01010-82045 BOLT 6 Reused for installation
11 01643-32060 WASHER 6 Reused for installation
12 425-43-27491 BRACKET 1 Reused for installation
13 01024-81240 BOLT 1 Reused for installation
14 07049-01215 PLUG 4
15 07049-01012 PLUG 1
CAUTION Keep the parts that will be reused during installation so that parts will not be lost.
1) Install brackets (1), (4) with bolts (2), (5), (10).
Bolt (2), (5): Width across flats 30mm, M20, L65 mm 9
4
Bolt (10): Width across flats 30mm, M20, L45 mm Z

Tightening torque of bolts (2), (5): 455 to 565 Nm 1

{46.5 to 58 kgm}
2) Install plug (9).
3) Install plate (7) with bolts (8).
2,3 5,6 7,8
Bolt (8): Width across flats 19mm, M12, L35 mm
Tightening torque of bolt (8): 98 to 123 Nm
{10 to 12.5 kgm} View Z 9
9
10,11

190
4) Install bracket (12) with bolt (13).
View Y
Bolt (13): Width across flats 19mm, M12, L40 mm
Tightening torque of bolt (13): 98 to 123 Nm 12,13
{10 to 12.5 kgm}

5) Remove plugs (14), (15).

14
Right

Front

15
View from above

191
A-38 Installation of ladder - 3 (For machine with retrofitting ladder)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 13 mm 1
B Socket Commercially available 17 mm 1
C Socket Commercially available 19 mm 1
D Extension bar Commercially available 1
E Wrench Commercially available 27 mm 1

Part list
Part No. Part name Q'ty Part state
1 195-61-58700 PUMP ASSEMBLY 1
2 195-06-76891 BRACKET 1
3 01024-80825 BOLT 4
4 198-61-85970 BRACKET 1
5 01024-81025 BOLT 2
6 07270-21515 TUBE 1
7 07281-00197 CLAMP 1
8 02775-003A3 HOSE 1
9 02896-61008 O-RING 2
10 07000-12016 O-RING 1
11 427-62-27180 NIPPLE 1
12 08028-EH030 CABLE 1
13 01024-81020 BOLT 1
14 21W-62-43980 ELBOW 2
15 07000-12011 O-RING 2
16 02896-61008 O-RING 2
17 02789-00210 PLUG 2
18 195-61-58820 PLUG 1
19 07002-61023 O-RING 1

1. Assemble the ladder pump assembly.

1) Install pump assembly (1) to bracket (2) with bolts (3). 1
Bolt (3): Width across flats 13 mm, M8, L25 mm
Tightening torque of bolt (3): 27 to 34 Nm 3
{2.8 to 3.5 kgm}
2

192
2) Install bracket (4) with bolt (5).
Bolt (5): Width across flats 17 mm, M10, L20 mm 8,9
Tightening torque of bolt (5): 59 to 74 Nm
{6 to 7.5 kgm}
4,5
3) Install tube (6) with clamp (7).
Clamp (7): Width across flats 7 mm
Tightening torque of clamp (7): 4.4 ± 0.49 Nm
{0.45 ± 0.05 kgm}
4) Connect hose (8). 6,7
Hose (8): Width across flats 22 mm
Tightening torque of hose (8): 54 to 93 Nm
{5.5 to 9.5 kgm}
5) Install nipple (11).
Z
Nipple (11): Width across flats 27 mm
Tightening torque of nipple (11): 14.7 ± 0.5 Nm 18,19
{1.50 ± 0.05 kgm}
6) Install plug (18).
Plug (18): Width across flats 17.3 mm
Tightening torque of plug (18): 9.8 to 12.7 Nm
{1.0 to 1.3 kgm}
10,11

7) Install cable (12) with bolt (13).

View Z
Bolt (13): Width across flats 17 mm, M10, L20 mm
Tightening torque of bolt (13): 59 to 74 Nm
{6 to 7.5 kgm}
12,13

14,15,16,17

193
A-38 Installation of ladder - 4 (For machine with retrofitting ladder)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 17 mm 1
B Socket Commercially available 19 mm 1
C Extension bar Commercially available 1
D Wrench Commercially available 27 mm 1

Part list
Part No. Part name Q'ty Part state
1 195-06-78191 BRACKET 1
2 01580-11008 NUT 4
3 198-06-81590 CUSHION 8
4 198-06-81750 COLLAR 4
5 415-64-13120 WASHER 8
6 01010-81070 BOLT 4
7 01024-81235 BOLT 4
8 04434-51712 CLIP 1
9 07095-20211 CUSHION 1
10 01024-81230 BOLT 1
11 01024-81220 BOLT 1
12 08038-04030 CAP 1
13 02789-01210 PLUG 2 Discard after remove
14 02753-002A4 HOSE 1
15 198-61-85420 HOSE 1
16 195-61-58861 SOCKET 2
17 07000-12011 O-RING 2
18 02896-61008 O-RING 2
19 195-61-58871 ADAPTER 2

194
1. Install the ladder pump assembly. Z
1) Install collar (4), cushion (3), washer (5) to bracket
(1) with bolt (6) and nut (2).
Bolt (6): Width across flats 17 mm, M10, L70 mm
Tightening torque of bolt (6): 59 to 74 Nm
{6 to 7.5 kgm}
A

1
A

View A-A 2
3
5 4

5
6

View Z

2) Install ladder pump assembly with bolts (7), (10),

(11). 7 C 8,9,10
B
Bolt (7): Width across flats 19 mm, M12, L35 mm 20
Bolt (10): Width across flats 19 mm, M12, L30 mm C
Bolt (11): Width across flats 19 mm, M12, L20 mm
B
Tightening torque of bolts (7), (10), (11): 98 to 123
Nm {10 to 12.5 kgm}
11
3) Connect the pump connector (20) and CN-C2.

4) Connect the cable terminal CN-C1 to the pump

terminal (21). View B-B
12
Install cap (12). 15

21

195
5) Pass the drain tube through hole in the fender.

22

View C-C
6) Remove plug(13).

13

7) Connect hoses (14), (15).

8) Install socket (16), O-ring (17), (18) and adapter 14 P
(19).

15

View P

19
16,17,18

196
A-38 Installation of ladder - 5 (For machine with retrofitting ladder)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 10 mm 1
B Socket Commercially available 19 mm 1
C Extension bar Commercially available 1

Part list
Part No. Part name Q'ty Part state
1 195-54-55190 COVER 1 Discard after remove
2 01024-81240 BOLT 4 Discard after remove
3 11Y-54-13620 CAP 1 Discard after remove
4 07049-01215 PLUG 3 Discard after remove
5 08192-19832 CONNECTOR 1 Discard after remove
6 2A8-06-11320 LIGHT 1
7 198-06-73870 BRACKET 1
8 01024-81230 BOLT 2
9 04434-50612 CLIP 1
10 01024-81220 BOLT 1
11 363-06-36150 GROMMET 1
12 195-06-76840 GROMMET 2
13 21N-53-3870 CAP 1
14 198-06-86911 WIRING HARNESS 1
15 04434-51712 CLIP 1
16 01024-81220 BOLT 1
17 01024-D0620 BOLT 4
18 195-06-76821 SWITCH BOX 1
19 01024-81240 BOLT 4
20 01024-81220 BOLT 1
21 04434-51712 CLIP 1
22 02024-81220 BOLT 1
23 04434-51212 CLIP 1

197
1. Install the ladder switch on the floor side.
1) Remove bolts (2) and cover (1).
4 3
Bolt (2): Width across flats 19 mm, M12, L40 mm
2) Remove plugs (4) and cap (3).
4
4 1,2

3) Install clip (21) with bolt (20) and clip (23) with bolt
(22).
View Z
Bolt (20), (22): Width across flats 19 mm, M12, L20
mm
Tightening torque of bolts (20), (22): 98 to 123 Nm
{10 to 12.5 kgm}
4) Install the grommet (12).
5) Connect the connector (5) to the CN-LS1.

20,21 22,23

CN-LS1
12
Z

198
 6) Install wiring harness (14) with bolts (16), (17).
Bolt (16): Width across flats 19 mm, M12, L20 mm 14
Bolt (17): Width across flats 10 mm, M6, L20 mm 15,16
17
Tightening torque of bolt (16): 98 to 123 Nm
{10 to 12.5 kgm}
18
Tightening torque of bolt (17): 11.8 to 14.7 Nm 12
{1.2 to 1.5 kgm}
19
7) Install grommet (12).
8) Install cap (13), and install switch box (18) with bolt
(19).
9) Connect CN-AL10.
13 P

CN-AL10
View Z

10) Install grommet(11).

11) Install light (6) with bolts (8), (10).
6,7,8
P
Bolt (8): Width across flats 19 mm, M12, L30 mm
Bolt (10): Width across flats 19 mm, M12, L20 mm 9,10
Tightening torque of bolts (8), (10): 98 to 123 Nm
{10 to 12.5 kgm}

11

199
A-38 Installation of ladder - 6 (For machine with retrofitting ladder)

Tools/Equipment
Symbol Part name Part No. Specification Q'ty Remarks
A Socket Commercially available 10 mm 1
B Socket Commercially available 17 mm 1
C Socket Commercially available 19 mm 1
D Extension bar Commercially available 1

Part list
Part No. Part name Q'ty Part state
1 195-54-55662 BRACKET 1 Reused for installation
2 01024-81230 BOLT 4 Reused for installation
3 14X-54-59160 CONNECTOR 1 Discard after remove
4 195-06-55140 PLATE 1 Discard after remove
5 01024-80620 BOLT 4 Discard after remove
6 195-06-76951 BRACKET 1
7 195-06-76961 BRACKET 1
8 01023-70414 SCREW 4
9 08501-21507 SWITCH 1
10 08504-10000 CAP 1
11 195-06-76913 WIRING HARNESS 1
12 01024-80620 BOLT 4
13 04434-51412 CLIP 1
14 01024-81225 BOLT 1
15 198-54-85590 COVER 1 Reused for installation
16 01024-81230 BOLT 4 Reused for installation
17 X21-2509262 COVER 1 Reused for installation
18 01024-81230 BOLT 6 Reused for installation
19 X21-2510082 COVER 1 Reused for installation
20 21N-53-31870 CAP 2 Reused for installation
21 01034-81230 BOLT 7 Reused for installation
CAUTION Keep the parts that will be reused during installation so that parts will not be lost.
1. Install the ladder switch on the ground side.
1) Remove cover (1) and bolts (2). 1,2
Bolt (2): Width across flats 19 mm, M12, L30 mm
2) Remove plate (4) and bolts (5).
Bolt (5): Width across flats 10 mm, M6, L20 mm

4,5

200
3) Install connector (3), harness (11), and switch (9) to
bracket (6) in the direction shown in view z.

4) Install cover (7) with screws (8) and install cap (10).

5) Install the ladder switch on the ground side with

bolts (12).
Bolt (12): Width across flats 10 mm, M6, L20 mm
Tightening torque of bolt (12): 11.8 to 14.7 Nm
{1.2 to 1.5 kgm}

12

6) Install clip (13) with bolt (14).

Bolt (14): Width across flats 19 mm, M12, L25 mm
CN-ES6
Tightening torque of bolt (14): 98 to 123 Nm
{10 to 12.5 kgm}
Angle (a): 30° a
7) Connect the connector CN-ES6.

13,14

201
8) Install cover (1) with bolts (2).
Bolt (16): Width across flats 19 mm, M12, L30 mm
Tightening torque of bolt (16): 98 to 123 Nm
{10 to 12.5 kgm}

1,2

2. Install cover.
1) Install cover (19) with bolts (21).
19,20,21
Bolt (21): Width across flats 19 mm, M12, L30 mm
Tightening torque of bolt (21): 98 to 123 Nm
{10 to 12.5 kgm}
2) Install cover (17) with bolts (18).
Bolt (18): Width across flats 19 mm, M12, L30 mm
Tightening torque of bolt (18): 98 to 123 Nm 17,18
{10 to 12.5 kgm}
15,16
3) Install cover (15) with bolts (16).
Bolt (16): Width across flats 19 mm, M12, L30 mm
Tightening torque of bolt (16): 98 to 123 Nm
{10 to 12.5 kgm}

202
A-38 Installation of ladder - 7 (For machine with retrofitting ladder)

Part list
Part No. Part name Q'ty Part state
1 09824-K0641 PLATE 2
2 198-00-81250 PLATE 2
3 195-98-58410 PLATE 1
4 195-98-58420 PLATE 1

1. Install the caution plates.

REMARKS ZD: Straight up (View ZD) PG
ZJ: Straight up (View ZJ)

ZJ

ZD
REMARKS Dimension (a): 5 mm

PG 1

REMARKS ZF: Straight up (View ZF)

View ZD
View ZF
3
2

ZF

203
REMARKS Dimension (a): 25 mm
Dimension (b): 15 mm View ZJ

b
a 4

After completing this work, refer to "A-37" to complete the installation of the ladder.

204
A-39 Installation of access light and additional work lamp (optional)

Tools/Equipment
Symbol Parts name Parts No. Specification Q'ty Remarks
A Socket Commercially available 17 mm 1
B Socket Commercially available 19 mm 1
C Air impact Commercially available 1 Torque 140 Nm (14 kgm) or more
D Torque wrench Commercially available 1 Torque 180 Nm (18 kgm) or more

Parts list
Parts No. Parts name Q'ty State of parts
1 2A8-06-11320 LIGHT (LED) 2 Unit shipment
1 17A-06-17931 LIGHT (HALOGEN) 2 Unit shipment
2 427-06-45810 LIGHT (LED) 2 Unit shipment
2 17A-06-17931 LIGHT (HALOGEN) 2 Unit shipment
3 427-06-45810 LIGHT (LED) 2 Unit shipment
3 17A-06-17931 LIGHT (HALOGEN) 2 Unit shipment
4 2A8-06-11320 LIGHT (LED) 1 Unit shipment
4 17A-06-17931 LIGHT (HALOGEN) 1 Unit shipment

How to install access light

1. Install the lights (1) (2 pieces).

How to install left side access light
1) Install the left light (1).
Install the light so that the light (1) and the bracket
form the angle shown as (a) in the figure.
Angle (a): 30°
Light (1) tightening torque: 45 to 65 Nm
{4.7 to 6.7 kgm}

2) Connect the connector CN-AL8.

205
REMARK Install the light so that the light (1) and Q part of the
bracket are parallel.

How to install right side access light

3) Install the right light (1).
REMARK Install the light so that the light (1) and P part of the
bracket are parallel.
Light (1) tightening torque: 45 to 65 Nm
{4.7 to 6.7 kgm}

4) Connect the connector CN-AL9.

How to install front additional work lamp

2. Install the lights (2) (2 pieces).

REMARK There are halogen type and LED type for the light (2). The figure shows the LED type.
How to install left side additional work lamp
1) Install the left light (2).
REMARK Install the light so that the light (2) and the bracket
form the angle shown as (b) in the figure.
Angle (b): 27°
Light (2) tightening torque: 45 to 65 Nm {4.7 to
6.7 kgm} (LED type)
Light (2) tightening torque: 59 to 74 Nm {6 to 7.5
kgm} (halogen type)
2) Connect the connector CN-AFL1.

206
REMARK Install the light so that the light (2) and the bracket
form the angle shown as (c) in the figure.
Angle (c): 22°

How to install right side additional work lamp

3) Install the right light (2).
REMARK Install the light so that the light (2) and the bracket
form the angle shown as (d) in the figure.
Angle (d): 32°
Light (2) tightening torque: 45 to 65 Nm {4.7 to
6.7 kgm} (LED type)
Light (2) tightening torque: 59 to 74 Nm {6 to 7.5
kgm} (halogen type)
4) Connect the connector CN-AFR1.

How to install rear additional work lamp and access light

3. Install the lights (3) and (4).

REMARK • There are halogen type and LED type for the light (3). The figure shows the LED type.
• Light (4) may not be provided depending on the machine type.
• There are halogen type and LED type for the light (4). The figure shows the halogen type.

207
 How to install left side additional work lamp
1) Install the left light (3).
REMARK Install the light so that the light (3) and the bracket
form the angle shown as (e) in the figure.
Angle (e): 30°
Light (3) tightening torque: 45 to 65 Nm {4.7 to
6.7 kgm} (LED type)
Light (3) tightening torque: 59 to 74 Nm {6 to 7.5
kgm} (halogen type)
2) Connect the connector CN-CBRL.

REMARK Install the light so that the light (3) and the bracket
form the angle shown as (f) in the figure.
Angle (f): 10°

How to install right side additional work lamp

3) Install the right light (3).
REMARK Install the light so that the light (3) and the bracket
form the angle shown as (g) in the figure.
Angle (g): 30°
Light (3) tightening torque: 45 to 65 Nm {4.7 to
6.7 kgm} (LED type)
Light (3) tightening torque: 59 to 74 Nm {6 to 7.5
kgm} (halogen type)
4) Connect the connector CN-CBRR.

REMARK Install the light so that the light (3) and the bracket
form the angle shown as (h) in the figure.
Angle (h): 10°

208
 How to install access light
5) Install the light (4).
REMARK • This operation is not necessary depending on the
machine type.
• Install the light so that the light (4) and Q part of the
bracket are parallel.
Light (4) tightening torque: 45 to 65 Nm {4.7 to 6.7
kgm} (LED type)
Light (4) tightening torque: 59 to 74 Nm {6 to 7.5
kgm} (halogen type)
6) Connect the connector CN-AL7.
REMARK Install the light so that light (4) and bracket form the
angle in the figure.
Angle (J): 25°

How to check illumination

4. Operate the switch to check the illumination of the access lights and additional work lamps.
How to check illumination of access lights
1) By using the access light switch, light up the access
lights.

How to check illumination of additional work lamps

2) By using the additional work lamp switch, light up
the additional work lamps.

209
M. CHECK AND MAINTENANCE PROCEDURES
AFTER COMPLETION OF ASSEMBLY

211
M-1 Checking machine monitor - 1

Check that the "machine monitor" on the front panel can be set in the "service mode" with its
special function and the "failure codes" can be displayed normally in that mode.
REMARKS The "Service mode" is used in "Initialization of KOMTRAX PLUS" of the VHMS specification
described later in "M-7". Accordingly, understand the operating procedure thoroughly.

About switches

1 2 3 4 5 6 7 8

(1) Engine compartment lamp switch (Optional)

(2) Rear lamp switch
(3) Headlamp or working lamp switch
(4) Machine monitor
(5) Monitor switch section (Air conditioner panel or heater panel)
(6) Starting switch
(7) Additional lamp switch (Optional)
(8) Access lamp switch (Optional)
Explanation of each device in machine monitor section

13
11

1
10

EE: Warning or Error screen, DD: Guidance screen

(9) Warning display section (12) Guidance icon display section
(10) Monitor switch section (13) Pilot display section
(11) Guidance display section

212
M-1 Checking machine monitor - 2
About service mode
Operation method in service mode
To change the operator mode to the service mode, perform the following operation.
This operation is always required when you use the service mode.
1. Perform the following operation with the numeral B4D27902
keys on the standard screen.
Switch operation (Press the following switches in
order while pressing "4"): 4 + 1 -> 2 -> 3
REMARKS This operation of the switches is accepted only
while the standard screen is displayed.

2. When the "Service Menu" screen is displayed, the B4P29628

service mode is selected. Select a service menu
you use by using the function switches or numeral
input switches.

F3: Move to lower item

F4: Move to upper item
[F5] Return to standard screen (operator mode)
F6: Enter selection
REMARKS ꞏ You may enter a code (2-digit) with the numeral
input switches to select the menu of that code and
confirm it with F6.

ꞏ Items with codes (2-digit ) are the menus displayed

on the Service menu screen. The items on their
right are the menus on the next hierarchy.

213
M-1 Checking machine monitor - 3
Method for checking abnormality record (Mechanical systems)
The machine monitor classifies and logs the failures which occurred in the past or which are
occurring at present into the mechanical system abnormality, and electrical system abnormality.
To check the “mechanical system abnormality record”, perform the following procedures.
1. Select “Abnormality Record” on the “Service Menu” B4P29639
REMARKS For selecting method, see “Operating method of
service mode” in “SERVICE MODE”.

2. After the "Abnormality Record" screen is displayed, B4P29640

select "Mechanical Systems" with the function
switches or numeral input switches.

F3: Move to lower item

F4: Move to upper item
F5: Return to "Service Menu" screen
F6: Enter selection
REMARKS You may enter a code (2-digit) with the numeral
input switches to select the item of that code and
confirm it with F6.

3. On the "Mechanical Systems Abnormality Record” B4P30860

screen, the following information is displayed.
Check it.

a: Occurrence order of abnormalities from latest

one/Total number of records
b: Failure code
c: Contents of failure
d: Number of occurrences (displayable range: 0 to
65535 times)
e: Service meter reading at first occurrence
f: Service meter reading at last occurrence
F1: Move to next page (screen) (When all data cannot be displayed on 1 screen, function switch
becomes effective)
F2: Return to previous page (screen) (When all data cannot be displayed on 1 screen, function
switch becomes effective)
F3: Move to lower item
F4: Move to upper item
F5: Return to “Abnormality record” screen
F6: Scroll displayed contents of failure to left again
REMARKS ꞏ If no abnormality is recorded, "No abnormality record" is displayed.
ꞏ In the mechanical system abnormality record screen, up to 50 cases currently stored are displayed.

214
ꞏ When the number of occurrences is 1 (first occurrence), the service meter reading at the first
occurrence and that at the last occurrence are the same. When the latest service meter reading is
recovered, the value at the recovery time is displayed, thus the above readings may not be the
same.

ꞏ If “E” is displayed on the left of a failure code, the abnormality is still occurring or restoration of it has
not been confirmed.
ꞏ For the contents of all failure codes that the machine monitor can record, see Troubleshooting,
"Failure codes table".
ꞏ When many characters are used to describe the failure contents, the character string strolls.
ꞏ The contents of mechanical system abnormality record cannot be clearing.

215
M-1 Checking machine monitor - 4
Method for checking abnormality record (Electrical systems)
The machine monitor classifies and logs the failures which occurred in the past or which are
occurring at present into the mechanical system abnormality, and electrical system abnormality.
To check the “electrical system abnormality record”, perform the following procedures.
For all failure codes that the machine monitor can record, see Troubleshooting, "Failure codes
table".
1. Select “Abnormality Record” on the “Service Menu” B4P29639
REMARKS For selecting method, see “Operating method of
service mode” in “SERVICE MODE”.

2. After the "Abnormality Record" screen is displayed, B4P2942

select "Electrical Systems" with the function
switches or numeral input switches.

F3: Move to lower item

F4: Move to upper item
F5: Return to "Service Menu" screen
F6: Enter selection
REMARKS You may enter a code (2-digit) with the numeral
input switches to select the item of that code and
confirm it with F6.

3. On the "Electrical Systems Abnormality Record” B4P30808

screen, the following information is displayed.
Check it.

a: Occurrence order of abnormalities from latest

one/Total number of records
b: Failure code
c: Contents of failure
d: Number of occurrences (displayable range: 0 to
65535 times)
e: Service meter reading at first occurrence
f: Service meter reading at last occurrence
F1: Move to next page (screen) (When all data cannot be displayed on 1 screen, function switch
becomes effective)
F2: Return to previous page (screen) (When all data cannot be displayed on 1 screen, function
switch becomes effective)
F3: Move to lower item
F4: Move to upper item
F5: Return to “Abnormality record” screen
F6: Scroll displayed contents of failure to left again

216
REMARKS ꞏ If no abnormality is recorded, "No abnormality record" is displayed.
ꞏ Up to 20 of the saved electrical system abnormality records are displayed. When the number of
records exceeds 21, the latest occurrence code is displayed and the oldest record is deleted.
ꞏ When the number of occurrences is 1 (first occurrence), the service meter reading at the first
occurrence and that at the last occurrence are the same.
ꞏ If “E” is displayed on the left of a failure code, the abnormality is still occurring or restoration of it has
not been confirmed.
ꞏ For the contents of all failure codes that the machine monitor can record, see Troubleshooting,
"Failure codes table".
ꞏ When many characters are used to describe the failure contents, the character string strolls.

4. To clear the abnormality record, perform the B4P30809

following operation with the numeral input switches
on the “Electrical Systems Abnormality Record”
screen.

1) Switch operation (Press the following switches in B4D22856

order while pressing "4"): 4 +1 -> 2 -> 3

2) Check that the screen is set in the clear mode, and

then clear the items one by one or together with the
function switches.

REMARKS When the screen is in the clear mode, "CLEAR" is

displayed in F2.
F2: Clear all abnormality record information
F3: Move to lower item
F4: Move to upper item
F5: Return to “Abnormality record” screen
F6: Clear selected abnormality record information
REMARKS ꞏ To clear selected abnormality records, select abnormality records to be cleared with F3 or F4, then
press F6, and the selected abnormality records are cleared.
ꞏ To clear all abnormality records, press [F2], and all the items are cleared, regardless of the selection
status.
ꞏ If “E” is displayed on the left of a failure code, the clearing operation is accepted but the information
is not cleared.
3) After the "Electrical Systems Abnormality Record Clear" screen is displayed, clear the records with
the function switches.
F5: Return to “Electrical Systems Abnormality Record” (Clear mode)
F6: Clear

217
REMARKS ꞏ This screen is for clearing selected abnormality B4P30861
records.

ꞏ This screen is for clearing all abnormality records. B4P30046

4) If the screen to notify the completion of clearing is displayed and then the "Electrical System
Abnormality Record (clear mode)" screen is displayed again, clearing of abnormality record is
completed.

REMARKS ꞏ This screen is displayed when selected abnormality B4P30862

records are cleared.

ꞏ This screen is displayed when all abnormality B4P30049

records are cleared.

218
M-1 Checking machine monitor - 5
Failure codes
As described above, the "failure codes“ are classified and displayed into the "electrical system
failure codes" and "mechanical system failure codes". For details of each code, see "Testing and
adjusting" or “Troubleshooting” in the shop manual.
The major "failure codes" are listed on the following pages.
REMARKS ꞏ In this table, failure codes are listed in the alphabetical order.
ꞏ A component in charge is a controller in charge of the system check.
MON: Machine monitor ENG: Engine controller
Check that the oil level is between the H and L lines on sight gauge (G).
If it is below the L line, add hydraulic oil.
KPLUS: KOMTRAX Plus terminal
ꞏ The failure codes that do not have numbers in the action level columns are not displayed on the
standard screen even when a failure related to them occurs. They are simply recorded in the
abnormality record (electrical system or mechanical system) of the service menu.

ꞏ The record category column shows into which system each failure is classified, the electrical
system or mechanical system, when it is recorded in the abnormality record.

219
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
1500L0 T/M Clutches Double Engagement L03 PT Electrical
system
15B0NX T/M Oil Filter Clogging L01 MON Mechanical
system
15SAL1 ECMV Release Trouble (Forward) L03 PT Electrical
system
15SALH ECMV Engage Trouble (Forward) L03 PT Electrical
system
15SBL1 ECMV Release Trouble (Reverse) L03 PT Electrical
system
15SBLH ECMV Engage Trouble (Reverse) L03 PT Electrical
system
15SEL1 ECMV Release Trouble (1st) L03 PT Electrical
system
15SELH ECMV Engage Trouble (1st) L03 PT Electrical
system
15SFL1 ECMV Release Trouble (2nd) L03 PT Electrical
system
15SFLH ECMV Engage Trouble (2nd) L03 PT Electrical
system
15SGL1 ECMV Release Trouble (3rd) L03 PT Electrical
system
15SGLH ECMV Engage Trouble (3rd) L03 PT Electrical
system
15SJL1 ECMV Release Trouble (Lock Up Clutch) L03 PT Electrical
system
15SJLH ECMV Engage Trouble (Lock Up Clutch) L03 PT Electrical
system
1800MW P/T Clutch Slip L03 PT Electrical
system
2201L1 ECMV Release Trouble (RH Clutch) L04 PT Electrical
system
2201LH ECMV Engage Trouble (RH Clutch) L04 PT Electrical
system
2202L1 ECMV Release Trouble (LH Clutch) L04 PT Electrical
system
2202LH ECMV Engage Trouble (LH Clutch) L04 PT Electrical
system
2300NR Brake Thermal Load Abnormality - PT Mechanical
system
2301L1 ECMV Release Trouble (RH Brake) L04 PT Electrical
system
2301LH ECMV Engage Trouble (RH Brake) L04 PT Electrical
system

220
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
2301NR Steering Brake RH Thermal Load Abnormality - PT Mechanical
system
2301NT Steering brake too hot (right) - PT Mechanical
system
2302L1 ECMV Release Trouble (LH Brake) L04 PT Electrical
system
2302LH ECMV Engage Trouble (LH Brake) L04 PT Electrical
system
2302NR Steering Brake LH Thermal Load Abnormality - PT Mechanical
system
2302NT Steering brake too hot (left) - PT Mechanical
system
851PKA R/C Steering Lever Front-Back Neutral SW:Open L03 OPT Electrical
Circuit or Ground Fault system
851PKX R/C Steering Lever Front-Back Signal Error - OPT Electrical
system
851QKA R/C Steering Lever Left-Right Neutral SW:Open L03 OPT Electrical
Circuit or Ground Fault system
851RKA R/C Center Control Lever Front-Back Neutral L03 OPT Electrical
SW:Open Circuit or Ground Fault system
851RKX R/C Center Control Lever Front-Back Signal Error - OPT Electrical
system
851SKA R/C Center Control Lever Left-Right Neutral L03 OPT Electrical
SW:Open Circuit or Ground Fault system
851SKX R/C Center Control Lever Left-Right Signal Error - OPT Electrical
system
851TKA R/C W/E Control Lever Front-Back Neutral L03 OPT Electrical
SW:Open Circuit or Ground Fault system
851TKX R/C Work Equipment Control Lever Front-Back Sig- - OPT Electrical
nal Error system
851UKA R/C W/E Control Lever Left-Right Neutral SW:Open L03 OPT Electrical
Circuit or Ground Fault system
851UKX R/C Work Equipment Control Lever Left-Right Sig- - OPT Electrical
nal Error system
851VKA R/C Shift Up-Down Lever Front-Back Neutral L03 OPT Electrical
SW:Open Circuit or Ground Fault system
851XKA R/C Decel/Brake Lever Front-Back Neutral L03 OPT Electrical
SW:Open Circuit or Ground Fault system
851XKX R/C Decel/Brake Lever Front-Back Signal Error - OPT Electrical
system
852RKR R/C Receiver Defective Communication L03 OPT Electrical
system
8590KA R/C Mode Change SW 1(CAB) or 2(GND):Open L03 OPT Electrical
Circuit or Ground Fault system

221
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
8590KY R/C Mode Change SW 1(CAB) or 2(GND):Hot L03 OPT Electrical
Short Circuit system
879AKA A/C Recirculation Air Temperature Sensor Open - MON Electrical
Circuit system
879AKB A/C Recirculation Air Temperature Sensor Short - MON Electrical
Circuit system
879BKA A/C Fresh Air Temperature Sensor Open Circuit - MON Electrical
system
879BKB A/C Fresh Air Temperature Sensor Short Circuit - MON Electrical
system
879CKA Ventilating Sensor Open Circuit - MON Electrical
system
879CKB Ventilating Sensor Short Circuit - MON Electrical
system
879DKZ Sunlight Sensor Open Circuit or Short Circuit - MON Electrical
system
879EMC Ventilation Damper Malfunction L01 MON Electrical
system
879FMC Air Mix Damper Malfunction L01 MON Electrical
system
879GKX Refrigerant Pressure Input Signal Out of Range L01 MON Electrical
system
989L00 Engine Controller Lock Caution 1 - MON Electrical
system
989M00 Engine Controller Lock Caution 2 - MON Electrical
system
989N00 Engine Controller Lock Caution 3 - MON Electrical
system
A900FR Abrupt Engine Stop by Auto Idling Stop 3 L03 MON Mechanical
system
A900N6 Abrupt Engine Stop by Auto Idling Stop 1 - MON Mechanical
system
A900NY Abrupt Engine Stop by Auto Idling Stop 2 L01 MON Mechanical
system
AA10NX Air Cleaner Clogging L01 MON Mechanical
system
AB00KE Charge Voltage Low L03 MON Mechanical
system
B@BAZG Engine Oil Pressure Low L03 ENG Mechanical
system
B@BAZK Eng Oil Level Low L01 MON Mechanical
system
B@BCNS Engine Coolant Overheat L02 ENG Mechanical
system

222
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
B@BCZK Engine Coolant Level Low L01 MON Mechanical
system
B@CENS Power Train Oil Overheat L02 PT Mechanical
system
B@HANS Hydraulic Oil Overheat L02 WE Mechanical
system
B@HAZK Hydraulic Oil Level Low L03 MON Mechanical
system
CA115 Engine NE and Backup Speed Sensor Error L04 ENG Electrical
system
CA122 Charge Air Pressure Sensor High Error L03 ENG Electrical
system
CA123 Charge Air Pressure Sensor Low Error L03 ENG Electrical
system
CA131 Throttle Sensor High Error L03 ENG Electrical
system
CA132 Throttle Sensor Low Error L03 ENG Electrical
system
CA135 Engine Oil Pressure Sensor High Error L01 ENG Electrical
system
CA141 Engine Oil Pressure Sensor Low Error L01 ENG Electrical
system
CA144 Coolant Temperature Sensor High Error L01 ENG Electrical
system
CA145 Coolant Temperature Sensor Low Error L01 ENG Electrical
system
CA153 Charge Air Temperature Sensor High Error L03 ENG Electrical
system
CA154 Charge Air Temperature Sensor Low Error L03 ENG Electrical
system
CA187 Sensor 2 Supply Voltage Low Error L03 ENG Electrical
system
CA212 Eng Oil Temp Sensor High Error L01 ENG Electrical
system
CA213 Eng Oil Temp Sensor Low Error L01 ENG Electrical
system
CA221 Ambient Pressure Sensor High Error L03 ENG Electrical
system
CA222 Ambient Pressure Sensor Low Error L03 ENG Electrical
system
CA227 Sensor 2 Supply Voltage High Error L03 ENG Electrical
system
CA234 Engine Overspeed - ENG Electrical
system

223
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
CA238 NE Speed Sensor Supply Voltage Error L01 ENG Electrical
system
CA239 NE Speed Sensor Supply Voltage High Error L01 ENG Electrical
system
CA271 IMV or PCV 1 Short Circuit Error L03 ENG Electrical
system
CA272 IMV or PCV 1 Open Circuit Error L03 ENG Electrical
system
CA273 PCV 2 Short Circuit Error L03 ENG Electrical
system
CA274 PCV 2 Open Circuit Error L03 ENG Electrical
system
CA322 Injector #1 (L#1) Open Circuit Error or Short Circuit L03 ENG Electrical
Error system
CA323 Injector #5 (L#5) Open Circuit Error or Short Circuit L03 ENG Electrical
Error system
CA324 Injector #3 (L#3) Open Circuit Error or Short Circuit L03 ENG Electrical
Error system
CA325 Injector #6 (L#6) Open Circuit Error or Short Circuit L03 ENG Electrical
Error system
CA331 Injector #2 (L#2) Open Circuit Error or Short Circuit L03 ENG Electrical
Error system
CA332 Injector #4 (L#4) Open Circuit Error or Short Circuit L03 ENG Electrical
Error system
CA343 Engine Controller Internal Failure L04 ENG Electrical
system
CA351 Injectors Drive Circuit Error L03 ENG Electrical
system
CA352 Sensor 1 Supply Voltage Low Error L03 ENG Electrical
system
CA356 MAF Sensor High Error L03 ENG Electrical
system
CA357 MAF Sensor Low Error L03 ENG Electrical
system
CA386 Sensor 1 Supply Voltage High Error L03 ENG Electrical
system
CA428 Water in Fuel Sensor High Error L01 ENG Electrical
system
CA429 Water in Fuel Sensor Low Error L01 ENG Electrical
system
CA441 Power Voltage Low Error L04 ENG Electrical
system
CA442 Power Voltage High Error L04 ENG Electrical
system

224
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
CA449 Common Rail Pressure High Error 2 L03 ENG Electrical
system
CA451 Common Rail Pressure Sensor High Error L03 ENG Electrical
system
CA452 Common Rail Pressure Sensor Low Error L03 ENG Electrical
system
CA515 Common Rail Pressure Sensor Supply Voltage High L03 ENG Electrical
Error system
CA516 Common Rail Pressure Sensor Supply Voltage Low L03 ENG Electrical
Error system
CA553 Common Rail Pressure High Error 1 L01 ENG Electrical
system
CA555 Crankcase Pressure High Error 2 L01 ENG Electrical
system
CA556 Crankcase Pressure High Error 3 L03 ENG Electrical
system
CA559 Common Rail Pressure Low Error 1 L01 ENG Electrical
system
CA595 Turbocharger Speed High Error 2 L01 ENG Electrical
system
CA687 Turbocharger Speed Low Error L01 ENG Electrical
system
CA689 Engine NE Speed Sensor Error L01 ENG Electrical
system
CA691 Intake Air Temperature Sensor High Error L01 ENG Electrical
system
CA692 Intake Air Temperature Sensor Low Error L01 ENG Electrical
system
CA697 Engine Controller Internal Temperature Sensor High L01 ENG Electrical
Error system
CA698 Engine Controller Internal Temperature Sensor Low L01 ENG Electrical
Error system
CA731 Engine Backup Speed Sensor Phase Error L01 ENG Electrical
system
CA778 Engine Backup Speed Sensor Error L01 ENG Electrical
system
CA1117 Engine Controller Partial Data Lost Error L04 ENG Electrical
system
CA1135 CEN Communication Error L03 ENG Electrical
system
CA1257 Multi-controller ID Harness Key Error L03 ENG Electrical
system
CA1695 Sensor 5 Supply Voltage High Error L03 ENG Electrical
system

225
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
CA1696 Sensor 5 Supply Voltage Low Error L03 ENG Electrical
system
CA1843 Crankcase Pressure Sensor High Error L01 ENG Electrical
system
CA1844 Crankcase Pressure Sensor Low Error L01 ENG Electrical
system
CA1942 Crankcase Pressure Sensor In Range Error L01 ENG Electrical
system
CA2185 Throttle Sensor Supply Voltage High Error L03 ENG Electrical
system
CA2186 Throttle Sensor Supply Voltage Low Error L03 ENG Electrical
system
CA2249 Common Rail Pressure Low Error 2 L03 ENG Electrical
system
CA2265 Fuel Feed Pump Open Circuit Error L01 ENG Electrical
system
CA2266 Fuel Feed Pump Short Circuit Error L01 ENG Electrical
system
CA2765 Injector Trim Data Mismatch L01 ENG Electrical
system
CA4952 System Operating Lamp Short Circuit (Navigation - ENG Electrical
Controller) system
CB115 Engine NE and Backup Speed Sensor Error_2 L04 ENG Electrical
system
CB122 Charge Air Pressure Sensor High Error_2 L03 ENG Electrical
system
CB123 Charge Air Pressure Sensor Low Error_2 L03 ENG Electrical
system
CB153 Charge Air Temperature Sensor High Error_2 L03 ENG Electrical
system
CB154 Charge Air Temperature Sensor Low Error_2 L03 ENG Electrical
system
CB187 Sensor 2 Supply Voltage Low Error_2 L03 ENG Electrical
system
CB227 Sensor 2 Supply Voltage High Error_2 L03 ENG Electrical
system
CB238 NE Speed Sensor Supply Voltage Error_2 L01 ENG Electrical
system
CB239 NE Speed Sensor Supply Voltage High Error_2 L01 ENG Electrical
system
CB271 IMV or PCV 1 Short Circuit Error_2 L03 ENG Electrical
system
CB272 IMV or PCV 1 Open Circuit Error_2 L03 ENG Electrical
system

226
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
CB273 PCV 2 Short Circuit Error_2 L03 ENG Electrical
system
CB274 PCV 2 Open Circuit Error_2 L03 ENG Electrical
system
CB343 Engine Controller Internal Failure_2 L04 ENG Electrical
system
CB351 Injectors Drive Circuit Error_2 L03 ENG Electrical
system
CB352 Sensor 1 Supply Voltage Low Error_2 L03 ENG Electrical
system
CB386 Sensor 1 Supply Voltage High Error_2 L03 ENG Electrical
system
CB441 Power Voltage Low Error_2 L04 ENG Electrical
system
CB442 Power Voltage High Error_2 L04 ENG Electrical
system
CB449 Common Rail Pressure High Error 2_2 L03 ENG Electrical
system
CB451 Common Rail Pressure Sensor High Error_2 L03 ENG Electrical
system
CB452 Common Rail Pressure Sensor Low Error_2 L03 ENG Electrical
system
CB515 Common Rail Pressure Sensor Supply Voltage High L03 ENG Electrical
Error_2 system
CB516 Common Rail Pressure Sensor Supply Voltage Low L03 ENG Electrical
Error_2 system
CB553 Common Rail Pressure High Error 1_2 L01 ENG Electrical
system
CB559 Common Rail Pressure Low Error 1_2 L01 ENG Electrical
system
CB689 Engine NE Speed Sensor Error_2 L01 ENG Electrical
system
CB691 Intake Air Temperature Sensor High Error_2 L01 ENG Electrical
system
CB692 Intake Air Temperature Sensor Low Error_2 L01 ENG Electrical
system
CB697 Engine Controller Internal Temperature Sensor High L01 ENG Electrical
Error_2 system
CB698 Engine Controller Internal Temperature Sensor Low L01 ENG Electrical
Error_2 system
CB731 Engine Backup Speed Sensor Phase Error_2 L01 ENG Electrical
system
CB778 Engine Backup Speed Sensor Error_2 L01 ENG Electrical
system

227
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
CB1117 Engine Controller Partial Data Lost Error_2 L04 ENG Electrical
system
CB1257 Multi-controller ID Harness Key Error_2 L03 ENG Electrical
system
CB1548 Injector #7 (R#1) Open Circuit Error or Short Circuit L03 ENG Electrical
Error system
CB1549 Injector #8 (R#2) Open Circuit Error or Short Circuit L03 ENG Electrical
Error system
CB1551 Injector #10 (R#4) Open Circuit Error or Short Cir- L03 ENG Electrical
cuit Error system
CB1552 Injector #11 (R#5) Open Circuit Error or Short Cir- L03 ENG Electrical
cuit Error system
CB1553 Injector #12 (R#6) Open Circuit Error or Short Cir- L03 ENG Electrical
cuit Error system
CB1622 Injector #9 (R#3) Open Circuit Error or Short Circuit L03 ENG Electrical
Error system
CB1695 Sensor 5 Supply Voltage High Error_2 L03 ENG Electrical
system
CB1696 Sensor 5 Supply Voltage Low Error_2 L03 ENG Electrical
system
CB2249 Common Rail Pressure Low Error 2_2 L03 ENG Electrical
system
CB2765 Injector Trim Data Mismatch_2 L01 ENG Electrical
system
CB4952 Operating Lamp Short Circuit(ENG Con)_2 - ENG Electrical
system
D130KA Neutral Safety Relay Open Circuit L01 PT Electrical
system
D130KB Neutral Safety Relay Short Circuit L01 PT Electrical
system
D141KA Engine Starting Relay Open Circuit L03 OPT Electrical
system
D141KB Engine Starting Relay Ground Fault L03 OPT Electrical
system
D141KY Engine Starting Relay Hot Short Circuit L03 OPT Electrical
system
D162KA R/C Horn Relay Open Circuit L03 OPT Electrical
system
D162KB R/C Horn Relay Ground Fault L03 OPT Electrical
system
D162KY R/C Horn Relay Hot Short Circuit L03 OPT Electrical
system
D16CKA Fire Suppression Relay Open Circuit L03 OPT Electrical
system

228
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
D16CKB Fire Suppression Relay Ground Fault L03 OPT Electrical
system
D16CKY Fire Suppression Relay Hot Short Circuit L03 OPT Electrical
system
D182KZ Preheater Relay Open Circuit or Short Circuit L01 PT Electrical
system
D19CKA Red Revolving Light Relay Open Circuit L03 OPT Electrical
system
D19CKB Red Revolving Light Relay Ground Fault L03 OPT Electrical
system
D19CKY Red Revolving Light Relay Hot Short Circuit L03 OPT Electrical
system
D19EKA Blue Revolving Light Relay Open Circuit L01 OPT Electrical
system
D19EKB Blue Revolving Light Relay Ground Fault L01 OPT Electrical
system
D19EKY Blue Revolving Light Relay Hot Short Circuit L01 OPT Electrical
system
D19FKA Green Revolving Light Relay Open Circuit L01 OPT Electrical
system
D19FKB Green Revolving Light Relay Ground Fault L01 OPT Electrical
system
D19FKY Green Revolving Light Relay Hot Short Circuit L01 OPT Electrical
system
D19GKA R/C Working Lamp Relay Open Circuit L01 OPT Electrical
system
D19GKB R/C Working Lamp Relay Ground Fault L01 OPT Electrical
system
D19GKY R/C Working Lamp Relay Hot Short Circuit L01 OPT Electrical
system
D19JKZ Personal Code Relay Open or Short L03 MON Electrical
system
D1D5KA Engine Controller ACC Signal Cut/Hold Relay Open L04 WE Electrical
Circuit system
D1D5KB Engine Controller ACC Signal Cut/Hold Relay Short L04 WE Electrical
Circuit system
D1D5KY Engine Controller ACC Signal Cut/Hold Relay Hot L03 WE Electrical
Short system
D1EFKA Pre-lubrication Motor Relay Open Circuit L01 PT Electrical
system
D1EFKB Pre-lubrication Motor Relay Short Circuit L01 PT Electrical
system
D1EWKA Ladder Electrical Pump Open Circuit L01 OPT Electrical
system

229
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
D1EWKB Ladder Electrical Pump Short Circuit L01 OPT Electrical
system
D1EWKY Ladder Electrical Pump Hot Short Circuit L01 OPT Electrical
system
D862KA GPS Antenna Open Circuit - KOM- Electrical
TRAX system
DAF0MB Monitor ROM Abnormality - MON Electrical
system
DAF0MC Monitor Malfunction - MON Electrical
system
DAF8KB Camera Power Supply Short Circuit L03 MON Electrical
system
DAF9KQ Model Selection Signal Mismatch (Monitor) L03 MON Electrical
system
DAFGMC GPS Module Malfunction - KOM- Electrical
TRAX system
DAFLKA System Operating Lamp Open Circuit (Monitor) - MON Electrical
system
DAFLKB System Operating Lamp Short Circuit (Monitor) - MON Electrical
system
DAFQKR CAN 2 Defective Communication (Monitor) - KOM- Electrical
TRAX system
DAZ9KQ Model Selection Signal Mismatch (A/C) - MON Electrical
system
DAZQKR CAN 2 Defective Communication (A/C ECU) L01 MON Electrical
system
DB2QKR CAN 2 Defective Communication (Engine Control- L03 MON Electrical
ler) system
DB2RKR CAN 1 Defective Communication (Engine Control- L03 PT Electrical
ler) system
DB90KT W/E Controller Internal Abnormality L01 PT Electrical
system
DB90MC W/E Controller Malfunction - WE Electrical
system
DB91KK W/E Controller Source Voltage Low Error L04 PT Electrical
system
DB92KK W/E Controller Solenoid Power Voltage Low Error L04 PT Electrical
system
DB95KK W/E Controller 5V Sensor 0 Power Voltage Out of L03 PT Electrical
Range system
DB97KK W/E Controller 5V Sensor 1 Power Voltage Out of L01 PT Electrical
Range system
DB99KQ Model Selection Signal Mismatch (W/E Controller) L04 WE Electrical
system

230
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DB9LKA System Operating Lamp Open Circuit (W/E Control- - WE Electrical
ler) system
DB9LKB System Operating Lamp Short Circuit (W/E Control- - WE Electrical
ler) system
DB9QKR CAN 2 Defective Communication (W/E Controller) L03 MON Electrical
system
DB9RKR CAN 1 Defective Communication (W/E Controller) L03 PT Electrical
system
DBE0KT P/T Controller Internal Abnormality L01 PT Electrical
system
DBE0MC P/T Controller Malfunction - PT Electrical
system
DBE1KK P/T Controller Source Voltage Low Error L04 PT Electrical
system
DBE2KK P/T Controller Solenoid Power Voltage Low Error L04 PT Electrical
system
DBE5KK P/T Controller 5V Sensor 0 Power Voltage Out of L03 PT Electrical
Range system
DBE6KK P/T Controller 24V Sensor Power Voltage Out of L03 PT Electrical
Range system
DBE7KK P/T Controller 5V Sensor 1 Power Voltage Out of L03 PT Electrical
Range system
DBE9KQ Model Selection Signal Mismatch (P/T Controller) L04 PT Electrical
system
DBELKA System Operating Lamp Open Circuit (P/T Control- - PT Electrical
ler) system
DBELKB System Operating Lamp Short Circuit (P/T Control- - PT Electrical
ler) system
DBEQKR CAN 2 Defective Communication (P/T Controller) L03 MON Electrical
system
DBERKR CAN 1 Defective Communication (P/T Controller) L03 WE Electrical
system
DBU0KR GNSS Receiver Internal Abnormality L01 NAV Electrical
system
DBUSKR GNSS Receiver LAN Defective Communication L01 NAV Electrical
system
DBUTKA GNSS Receiver Antenna :Open - NAV Electrical
system
DBUTKN GNSS Receiver Antenna Over Current L01 NAV Electrical
system
DBV0MC KOMTRAX Plus Malfunction - KPLUS Electrical
system
DBV1KK Drop in KOMTRAX Main Power Source L01 KPLUS Electrical
system

231
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DBV5KB 5V Power Source 1 Failure (KOMTRAX Plus) - KPLUS Electrical
system
DBV6KB 24V Power Supply Ground Fault (KOMTRAX Plus) - KPLUS Electrical
system
DBVLKA System Operating Lamp Open Circuit (KOMTRAX - KPLUS Electrical
Plus) system
DBVLKB System Operating Lamp Short Circuit (KOMTRAX - KPLUS Electrical
Plus) system
DBVQKR CAN2 Discon (KOMTRAX Plus) - MON Electrical
system
DBVRKR CAN1 Discon (KOMTRAX Plus) - MON Electrical
system
DBVVKR LAN1 Discon - KPLUS Electrical
system
DBVWKR LAN2 Discon - KPLUS Electrical
system
DD12KA Shift Up SW Open Circuit L03 PT Electrical
system
DD12KB Shift Up SW Short Circuit L03 PT Electrical
system
DD13KA Shift Down SW Open Circuit L03 PT Electrical
system
DD13KB Shift Down SW Short Circuit L03 PT Electrical
system
DD14KA Parking Brake Lever SW Open Circuit L03 PT Electrical
system
DD14KB Parking Brake Lever SW Short Circuit L03 PT Electrical
system
DDDDKA Brake Pedal SW Open Circuit L03 PT Electrical
system
DDDDKB Brake Pedal SW Short Circuit L03 PT Electrical
system
DDDDKX Brake Pedal SW Signal Mismatch L03 PT Electrical
system
DDDHKB Ladder Operation Switch 2 (Ground Level) Hot L01 OPT Electrical
Short Circuit system
DDDKKA Ladder Operation Switch 1 (Side of the Cab) Raise L01 OPT Electrical
Open Circuit system
DDDKKB Ladder Operation Switch 1 (Side of the Cab) Raise L01 OPT Electrical
Hot Short Circuit system
DDDLKA Ladder Operation Switch 1 (Side of the Cab) Lower L01 OPT Electrical
Open Circuit system
DDDLKB Ladder Operation Switch 1 (Side of the Cab) Lower L01 OPT Electrical
Hot Short Circuit system

232
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DDE2KA Pre-lubrication Oil Pressure SW Open Circuit L01 PT Electrical
system
DDK4KA FNR Switch Open Circuit or Hot Short Circuit L03 PT Electrical
system
DDK4KB FNR Switch Ground Fault L03 PT Electrical
system
DDKAKA Blade Float SW Open Circuit L01 WE Electrical
system
DDKAKB Blade Float SW Short Circuit L01 WE Electrical
system
DDKBKA Blade Auto Pitch SW Open Circuit L01 WE Electrical
system
DDKBKB Blade Auto Pitch SW Short Circuit L01 WE Electrical
system
DDKCL4 Ripper Tilt In SW Signal Mismatch L01 WE Electrical
system
DDKEL4 Ripper Tilt Back SW Signal Mismatch L01 WE Electrical
system
DDKHKA iB SW Open Circuit L01 WE Electrical
system
DDKHKB iB SW Short Circuit L01 WE Electrical
system
DDKQKA Offset Switch UP :Open or Hot Short Circuit L01 NAV Electrical
system
DDKQKB Offset Switch UP :Short L01 NAV Electrical
system
DDKRKA Offset Switch DOWN :Open or Hot Short Circuit L01 NAV Electrical
system
DDKRKB Offset Switch DOWN :Short L01 NAV Electrical
system
DDKSKA Back Grade Mode SW:Open L01 WE Electrical
system
DDKSKB Back Grade Mode SW:Short L01 WE Electrical
system
DDN7L4 Blade Pitch Back SW Signal Mismatch L01 WE Electrical
system
DDN8L4 Blade Pitch Dump SW Signal Mismatch L01 WE Electrical
system
DDNLKA W/E Lock SW Open Circuit L03 PT Electrical
system
DDNLKB W/E Lock SW Short Circuit L03 PT Electrical
system
DDT5KQ S/T Lever Spec Setting Mismatch L04 PT Electrical
system

233
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DDTSL1 Stator Clutch Release Trouble L03 PT Electrical
system
DDTSLH Stator Clutch Engage Trouble L03 PT Electrical
system
DFA4KX Blade Lift Lever Potentiometer 1 and 2 Open Circuit L01 WE Electrical
or Hot Short Circuit system
DFA4KZ Blade Lift Lever Potentiometer 1 and 2 Open Circuit L01 WE Electrical
or Hot Short Circuit system
DFA4L8 Blade Lift Lever Potentiometer 1 or 2 Signal Abnor- L01 WE Electrical
mality system
DFA5KA Blade Lift Lever Potentiometer 1 Open Circuit L01 WE Electrical
system
DFA5KY Blade Lift Lever Potentiometer 1 Hot Short Circuit L01 WE Electrical
system
DFA6KA Blade Lift Lever Potentiometer 2 Open Circuit L01 WE Electrical
system
DFA6KY Blade Lift Lever Potentiometer 2 Hot Short Circuit L01 WE Electrical
system
DFA7KX Blade Tilt Lever Potentiometer 1 and 2 Open Circuit L01 WE Electrical
or Hot Short Circuit system
DFA7KZ Blade Tilt Lever Potentiometer 1 and 2 Open Circuit L01 WE Electrical
or Hot Short Circuit system
DFA7L8 Blade Tilt Lever Potentiometer 1 or 2 Signal Abnor- L01 WE Electrical
mality system
DFA8KA Blade Tilt Lever Potentiometer 1 Open Circuit L01 WE Electrical
system
DFA8KY Blade Tilt Lever Potentiometer 1 Hot Short Circuit L01 WE Electrical
system
DFA9KA Blade Tilt Lever Potentiometer 2 Open Circuit L01 WE Electrical
system
DFA9KY Blade Tilt Lever Potentiometer 2 Hot Short Circuit L01 WE Electrical
system
DFAAKX Ripper Lift Lever Potentiometer 1 and 2 Open Cir- L01 WE Electrical
cuit or Hot Short Circuit system
DFAAKZ Ripper Lift Lever Potentiometer 1 and 2 Open Cir- L01 WE Electrical
cuit or Hot Short Circuit system
DFAAL8 Ripper Lift Lever Potentiometer 1 or 2 Signal Abnor- L01 WE Electrical
mality system
DFABKA Ripper Lift Lever Potentiometer 1 Open Circuit L01 WE Electrical
system
DFABKY Ripper Lift Lever Potentiometer 1 Hot Short Circuit L01 WE Electrical
system
DFACKA Ripper Lift Lever Potentiometer 2 Open Circuit L01 WE Electrical
system

234
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DFACKY Ripper Lift Lever Potentiometer 2 Hot Short Circuit L01 WE Electrical
system
DGS1KA Hydraulic Oil Temperature Sensor Open Circuit L01 PT Electrical
system
DGS1KX Hydraulic Oil Temperature Sensor Input Signal Out L01 PT Electrical
of Range system
DGT1KA T/C Oil Temperature Sensor Open Circuit L01 PT Electrical
system
DGT1KX T/C Oil Temperature Sensor Input Signal Out of L01 PT Electrical
Range system
DGTUKY Hot Short Circuit of Exhaust Temperature Sensor - KPLUS Electrical
(Left Front) system
DGTUKZ Ground Fault of Exhaust Temperature Sensor (Left - KPLUS Electrical
Front) system
DGTVKY Hot Short Circuit of Exhaust Temperature Sensor - KPLUS Electrical
(Right Front) system
DGTVKZ Ground Fault of Exhaust Temperature Sensor - KPLUS Electrical
(Right Front) system
DGTWKY Hot Short Circuit of Exhaust Temperature Sensor - KPLUS Electrical
(Left Rear) system
DGTWKZ Ground Fault of Exhaust Temperature Sensor (Left - KPLUS Electrical
Rear) system
DGTXKY Hot Short Circuit of Exhaust Temperature Sensor - KPLUS Electrical
(Right Rear) system
DGTXKZ Ground Fault of Exhaust Temperature Sensor - KPLUS Electrical
(Right Rear) system
DH22KA W/E Pump Pressure Sensor Open Circuit L01 WE Electrical
system
DH22KY W/E Pump Pressure Sensor Hot Short Circuit L01 WE Electrical
system
DH23KA W/E Pump Pressure Sensor 2 Open Circuit L01 WE Electrical
system
DH23KY W/E Pump Pressure Sensor 2 Hot Short Circuit L01 WE Electrical
system
DHA4KA Air Cleaner Clog Sensor Open Circuit L01 MON Electrical
system
DHT2L6 T/M Oil Filter Clogging Sensor Open Circuit L01 MON Electrical
system
DHT3KX T/M Oil Pressure Sensor Error - KPLUS Electrical
system
DHT5KA T/C Inlet Pressure Sensor Open Circuit L03 PT Electrical
system
DHT5KY T/C Inlet Pressure Sensor Hot Short Circuit L03 PT Electrical
system

235
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DHT7KA T/C Outlet Pressure Sensor Open Circuit L03 PT Electrical
system
DHT7KY T/C Outlet Pressure Sensor Hot Short Circuit L03 PT Electrical
system
DHZ1KX Operator Presence Switch Voltage Error L03 PT Electrical
system
DK01KA Left Yoke Angle Sensor Open Circuit L01 WE Electrical
system
DK01KY Left Yoke Angle Sensor Hot Short Circuit L01 WE Electrical
system
DK03KA Right Yoke Angle Sensor Open Circuit L01 WE Electrical
system
DK03KY Right Yoke Angle Sensor Hot Short Circuit L01 WE Electrical
system
DK10KA Fuel Control Dial Open Circuit L03 PT Electrical
system
DK10KB Fuel Control Dial Short Circuit L03 PT Electrical
system
DK30KA S/T Potentiometer 1 Open Circuit L03 PT Electrical
system
DK30KX S/T Potentiometer 1 and 2 Open Circuit or Hot L04 PT Electrical
Short Circuit system
DK30KY S/T Potentiometer 1 Hot Short Circuit L03 PT Electrical
system
DK30KZ S/T Potentiometer 1 and 2 Open Circuit or Hot L04 PT Electrical
Short Circuit system
DK30L8 S/T Potentiometer 1 or 2 Signal Abnormality L03 PT Electrical
system
DK31KA S/T Potentiometer 2 Open Circuit L03 PT Electrical
system
DK31KY S/T Potentiometer 2 Hot Short Circuit L03 PT Electrical
system
DK40KA Brake Pedal Potentiometer Open Circuit L03 PT Electrical
system
DK40KY Brake Pedal Potentiometer Hot Short Circuit L03 PT Electrical
system
DK55KX F/R Potentiometer 1 and 2 Open Circuit or Hot L04 PT Electrical
Short Circuit system
DK55KZ F/R Potentiometer 1 and 2 Open Circuit or Hot L04 PT Electrical
Short Circuit system
DK55L8 F/R Potentiometer 1 or 2 Signal Abnormality L03 PT Electrical
system
DK56KA F/R Potentiometer 1 Open Circuit L03 PT Electrical
system

236
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DK56KY F/R Potentiometer 1 Hot Short Circuit L03 PT Electrical
system
DK57KA F/R Potentiometer 2 Open Circuit L03 PT Electrical
system
DK57KY F/R Potentiometer 2 Hot Short Circuit L03 PT Electrical
system
DK60KA Acceleration Sensor Open Circuit L01 PT Electrical
system
DK60KY Acceleration sensor Hot Short Circuit L01 PT Electrical
system
DK80KR IMU Defective Communication L01 NAV Electrical
system
DK80KT IMU Internal Failure L01 NAV Electrical
system
DKH1KA Inclination Angle Sensor Open Circuit L03 PT Electrical
system
DKH1KY Inclination Angle Sensor Hot Short Circuit L03 PT Electrical
system
DKSGL8 Right Lift Stroke Sensor: Signal Mismatch L01 WE Electrical
system
DKSHKA Right lift Stroke sensor A:Open L01 WE Electrical
system
DKSHKB Right lift Stroke sensor A:Hot Short L01 WE Electrical
system
DKSJKA Right lift Stroke sensor B:Open L01 WE Electrical
system
DKSJKB Right Lift Stroke Sensor B: Hot Short L01 WE Electrical
system
DKSKKA Right lift Reset sensor :Open L01 WE Electrical
system
DKSKKB Right Lift Reset Sensor: Hot Short L01 WE Electrical
system
DKSKMB Right Lift Reset Sensor: Signal Mismatch - WE Electrical
system
DKSLL8 Left Lift Stroke Sensor: Signal Mismatch L01 WE Electrical
system
DKSMKA Left lift Stroke sensor A:Open L01 WE Electrical
system
DKSMKB Left lift Stroke sensor A:Hot Short L01 WE Electrical
system
DKSNKA Left lift Stroke sensor B:Open L01 WE Electrical
system
DKSNKB Left lift Stroke sensor B:Hot Short L01 WE Electrical
system

237
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DKSPKA Left lift Reset sensor :Open L01 WE Electrical
system
DKSPKB Left lift Reset sensor :Hot Short L01 WE Electrical
system
DKSPMB Left Lift Reset Sensor: Signal Mismatch - WE Electrical
system
DKR2KA Return Filter Bypass Valve Stroke Sensor1 Open - KPLUS Electrical
Circuit system
DKR2KB Return Filter Bypass Valve Stroke Sensor1 Short - KPLUS Electrical
Circuit system
DKW0KX Right S/T Lever Potentiometer 2 Open Circuit or L03 PT Electrical
Hot Short Circuit system
DKW0KZ Right S/T Lever Potentiometer 2 Open Circuit or L03 PT Electrical
Hot Short Circuit system
DKW0L8 Right S/T Lever Potentiometer 1 or 2 Signal Abnor- L03 PT Electrical
mality system
DKW1KA Right S/T Lever Potentiometer 1 Open Circuit L03 PT Electrical
system
DKW1KY Right S/T Lever Potentiometer 1 Hot Short Circuit L03 PT Electrical
system
DKW2KA Right S/T Lever Potentiometer 2 Open Circuit L03 PT Electrical
system
DKW2KY Right S/T Lever Potentiometer 2 Hot Short Circuit L03 PT Electrical
system
DKW3KX Left S/T Lever Potentiometer 2 Open Circuit or Hot L03 PT Electrical
Short Circuit system
DKW3KZ Left S/T Lever Potentiometer 2 Open Circuit or Hot L03 PT Electrical
Short Circuit system
DKW3L8 Left S/T Lever Potentiometer 1 or 2 Signal Abnor- L03 PT Electrical
mality system
DKW4KA Left S/T Lever Potentiometer 1 Open Circuit L03 PT Electrical
system
DKW4KY Left S/T Lever Potentiometer 1 Hot Short Circuit L03 PT Electrical
system
DKW5KA Left S/T Lever Potentiometer 2 Open Circuit L03 PT Electrical
system
DKW5KY Left S/T Lever Potentiometer 2 Hot Short Circuit L03 PT Electrical
system
DLM3KA Fan Speed Sensor Open Circuit L01 PT Electrical
system
DLM3MB Fan Speed Sensor Function Deterioration L01 PT Electrical
system
DLT3KA T/M Output Speed Sensor Open Circuit L03 PT Electrical
system

238
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DLT3KB T/M Output Speed Sensor Ground Fault L03 PT Electrical
system
DNDAMC Ladder Limit Switch Abnormality L01 OPT Electrical
system
DNDBKA Ladder Raise Limit Switch Open Circuit L01 OPT Electrical
system
DNDBKB Ladder Raise Limit Switch Hot Short Circuit L01 OPT Electrical
system
DNDCKA Ladder Lower Limit Switch Open Circuit L01 OPT Electrical
system
DNDCKB Ladder Lower Limit Switch Hot Short Circuit L01 OPT Electrical
system
DNDDKA Ladder Clamp Open Limit Switch Open Circuit L01 OPT Electrical
system
DNDDKB Ladder Clamp Open Limit Switch Hot Short Circuit L01 OPT Electrical
system
DNDEKA Ladder Clamp Close Limit Switch Open Circuit L01 OPT Electrical
system
DNDEKB Ladder Clamp Close Limit Switch Hot Short Circuit L01 OPT Electrical
system
DR21KX Camera 2 Picture Reverse Drive Input Out of L01 MON Electrical
Range system
DR31KX Camera 3 Picture Reverse Drive Input Out of L01 MON Electrical
Range system
DV20KB Back Alarm Buzzer Short Circuit L01 PT Electrical
system
DW4BKA Parking Lock Solenoid Open Circuit L03 PT Electrical
system
DW4BKB Parking Lock Solenoid Ground Fault L03 PT Electrical
system
DW7BKA Fan Reverse Solenoid Open Circuit L01 PT Electrical
system
DW7BKB Fan Reverse Solenoid Short Circuit L01 PT Electrical
system
DWJ0KA Flow Merge Solenoid Open Circuit L01 WE Electrical
system
DWJ0KB Flow Merge Solenoid Short Circuit L01 WE Electrical
system
DWJ0KY Flow Merge Solenoid Hot Short Circuit L01 WE Electrical
system
DWN3KA Sudden Stop Prevention Valve Solenoid Open Cir- L04 PT Electrical
cuit system
DWN3KB Sudden Stop Prevention Valve Solenoid Short Cir- L04 PT Electrical
cuit system

239
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DWN3KY Sudden Stop Prevention Valve Solenoid Hot Short L04 PT Electrical
Circuit system
DWN5KA Fan Control Solenoid 1 Open Circuit L03 PT Electrical
system
DWN5KB Fan Control Solenoid 1 Short Circuit L03 PT Electrical
system
DWN5KY Fan Control Solenoid 1 Hot Short Circuit L01 PT Electrical
system
DWNCKA Fan Control Solenoid 2 Open Circuit L03 PT Electrical
system
DWNCKB Fan Control Solenoid 2 Short Circuit L03 PT Electrical
system
DWNCKY Fan Control Solenoid 2 Hot Short Circuit L01 PT Electrical
system
DWNVKA Ladder Raise Solenoid Open Circuit L01 OPT Electrical
system
DWNVKB Ladder Raise Solenoid Short Circuit L01 OPT Electrical
system
DWNWK Ladder Lower Solenoid Open Circuit L01 OPT Electrical
A system
DWNWK Ladder Lower Solenoid Short circuit L01 OPT Electrical
B system
DWNXKA Ladder Clamp Open Solenoid Open Circuit L01 OPT Electrical
system
DWNXKB Ladder Clamp Open Solenoid Short Circuit L01 OPT Electrical
system
DWNYKA Ladder Clamp Close Solenoid Open Circuit L01 OPT Electrical
system
DWNYKB Ladder Clamp Close Solenoid Short circuit L01 OPT Electrical
system
DXE0KA LS Solenoid Open Circuit L01 WE Electrical
system
DXE0KB LS Solenoid Short Circuit L01 WE Electrical
system
DXE0KY LS Solenoid Hot Short Circuit L01 WE Electrical
system
DXH1KA Lockup Clutch ECMV Solenoid Open Circuit L03 PT Electrical
system
DXH1KB Lockup Clutch ECMV Solenoid Short Circuit L03 PT Electrical
system
DXH1KY Lockup Clutch ECMV Solenoid Hot Short Circuit L03 PT Electrical
system
DXH4KA T/M 1st Clutch ECMV Solenoid Open Circuit L03 PT Electrical
system

240
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DXH4KB T/M 1st Clutch ECMV Solenoid Short Circuit L03 PT Electrical
system
DXH4KY T/M 1st Clutch ECMV Solenoid Hot Short Circuit L03 PT Electrical
system
DXH5KA T/M 2nd Clutch ECMV Solenoid Open Circuit L03 PT Electrical
system
DXH5KB T/M 2nd Clutch ECMV Solenoid Short Circuit L03 PT Electrical
system
DXH5KY T/M 2nd Clutch ECMV Solenoid Hot Short Circuit L03 PT Electrical
system
DXH6KA T/M 3rd Clutch ECMV Solenoid Open Circuit L03 PT Electrical
system
DXH6KB T/M 3rd Clutch ECMV Solenoid Short Circuit L03 PT Electrical
system
DXH6KY T/M 3rd Clutch ECMV Solenoid Hot Short Circuit L03 PT Electrical
system
DXH7KA T/M Reverse Clutch ECMV Solenoid Open Circuit L03 PT Electrical
system
DXH7KB T/M Reverse Clutch ECMV Solenoid Short Circuit L03 PT Electrical
system
DXH7KY T/M Reverse Clutch ECMV Solenoid Hot Short Cir- L04 PT Electrical
cuit system
DXH8KA T/M Forward Clutch ECMV Solenoid Open Circuit L03 PT Electrical
system
DXH8KB T/M Forward Clutch ECMV Solenoid Short Circuit L03 PT Electrical
system
DXH8KY T/M Forward Clutch ECMV Solenoid Hot Short Cir- L04 PT Electrical
cuit system
DXH9KA Right S/T Clutch ECMV Solenoid Open Circuit L03 PT Electrical
system
DXH9KB Right S/T Clutch ECMV Solenoid Short Circuit L03 PT Electrical
system
DXH9KY Right S/T Clutch ECMV Solenoid Hot Short Circuit L04 PT Electrical
system
DXHAKA Left S/T Clutch ECMV Solenoid Open Circuit L03 PT Electrical
system
DXHAKB Left S/T Clutch ECMV Solenoid Short Circuit L03 PT Electrical
system
DXHAKY Left S/T Clutch ECMV Solenoid Hot Short Circuit L04 PT Electrical
system
DXHBKA Right Brake ECMV Solenoid Open Circuit L04 PT Electrical
system
DXHBKB Right Brake ECMV Solenoid Short Circuit L04 PT Electrical
system

241
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
DXHBKY Right Brake ECMV Solenoid Hot Short Circuit L04 PT Electrical
system
DXHCKA Left Brake ECMV Solenoid Open Circuit L04 PT Electrical
system
DXHCKB Left Brake ECMV Solenoid Short Circuit L04 PT Electrical
system
DXHCKY Left Brake ECMV Solenoid Hot Short Circuit L04 PT Electrical
system
DXHRKA Blade Lift Raise EPC Solenoid Open Circuit L01 WE Electrical
system
DXHRKB Blade Lift Raise EPC Solenoid Short Circuit L01 WE Electrical
system
DXHRKY Blade Lift Raise EPC Solenoid Hot Short Circuit L03 WE Electrical
system
DXHSKA Blade Lift Lower EPC Solenoid Open Circuit L01 WE Electrical
system
DXHSKB Blade Lift Lower EPC Solenoid Short Circuit L01 WE Electrical
system
DXHSKY Blade Lift Lower EPC Solenoid Hot Short Circuit L03 WE Electrical
system
DXHTKA Blade Tilt Right Head EPC Solenoid Open Circuit L01 WE Electrical
system
DXHTKB Blade Tilt Right Head EPC Solenoid Short Circuit L01 WE Electrical
system
DXHTKY Blade Tilt Right Head EPC Solenoid Hot Short Cir- L03 WE Electrical
cuit system
DXHUKA Blade Tilt Right Bottom EPC Solenoid Open Circuit L01 WE Electrical
system
DXHUKB Blade Tilt Right Bottom EPC Solenoid Short Circuit L01 WE Electrical
system
DXHUKY Blade Tilt Right Bottom EPC Solenoid Hot Short Cir- L03 WE Electrical
cuit system
DXHWKA Ripper Lift Raise EPC Solenoid Open Circuit L01 WE Electrical
system
DXHWKB Ripper Lift Raise EPC Solenoid Short Circuit L01 WE Electrical
system
DXHWKY Ripper Lift Raise EPC Solenoid Hot Short Circuit L03 WE Electrical
system
DXHXKA Ripper Lift Lower EPC Solenoid Open Circuit L01 WE Electrical
system
DXHXKB Ripper Lift Lower EPC Solenoid Short Circuit L01 WE Electrical
system
DXHXKY Ripper Lift Lower EPC Solenoid Hot Short Circuit L03 WE Electrical
system

242
 Applicable
Failure History cate-
Failure (Shown on screen) Action level equip- Remarks
code gory
ment
F7ALKB System Operating Lamp Short Circuit (Navigation - NAV Electrical
Controller) system
F7AQKR CAN 2 Defective Communication (Navigation Con- L01 MON Electrical
troller) system
F7ARKR CAN 1 Defective Communication (Navigation Con- L01 MON Electrical
troller) system
F7ASKA Navigation Controller Ethernet Communication 1 L01 NAV Electrical
Open Circuit system
F7BSKR MMS PTX Controller Defective Communication L01 NAV Electrical
(Ethernet Communication 1) system
F7BTKR MMS PTX Controller Defective Communication L01 NAV Electrical
(CAN) system
F7C0KR MMS Clinometer Defective Communication L01 NAV Electrical
system
F7CRKT MMS Clinometer Internal Abnormality L01 NAV Electrical
system
F7FQKR CAN 2 Defective Communication (ID Key Control- L03 MON Electrical
ler) system
F9A0KT Optional Controller Memory Error L01 OPT Electrical
system
F9A0MC Optional Controller Malfunction - OPT Electrical
system
F9A1KK Optional Controller Source Voltage Low Error L04 OPT Electrical
system
F9A2KK Optional Controller Solenoid Power Voltage Low Er- L04 OPT Electrical
ror system
F9AQKR CAN 2 Defective Communication (Optional Control- L03 MON Electrical
ler) system
F9ARKR CAN 1 Defective Communication (Optional Control- L03 MON Electrical
ler) system
F9ATKA System Operating Lamp Open Circuit (Optional - OPT Electrical
Controller) system
F9ATKB System Operating Lamp Short Circuit (Optional - OPT Electrical
Controller) system
F9AUMC Optional Controller ACC Line Error L01 OPT Electrical
system

• In this table, failure codes are listed in the alphabetical sequence.

• Applicable equipment is the controller which examines the system.
MON: Machine monitor
ENG: Engine controller
PT: Power train controller
Work equipment controller
KOMTRAX: KOMTRAX terminal
KPLUS: KOMTRAX Plus terminal

243
M-2 Adjustment menu
Various adjustment methods of machine
Adjustment menu or adjustment ID is used to check the various settings of the machine.
When performing various adjustments, you can select adjustment items by the following 2 methods.
When selecting adjustment items form adjustment menu:
ꞏ The figure shows an example where adjustment B4D22874
menu “BRAKE PEDAL POTENTIO INITIAL SET” is
displayed.
ꞏ The functions given to function switches F3 to F6
vary depending on the adjustment item.

ꞏ For the method of operating each adjustment item,

see the explanation of its adjustment menu.

When selecting adjustment items by adjustment ID:

ꞏ The figure shows an example where adjustment ID B4D20072
“0002” is displayed.
ꞏ “000”, “00”, and “0” in the 1st to 3rd digits of
adjustment ID must be input. However, they are not
displayed on the “Adjustment” screen.

ꞏ The functions given to function switches F3 to F6

vary depending on the adjustment item.
ꞏ For the method of operating each adjustment item,
see the explanation of its adjustment ID.

The adjustment items are classified into “adjustment menu” and “adjustment ID” as described
above. For details of each item, see Shop Manual, “Testing and adjustment”.

244
M-3 Change of return filter (Standard filter  Flushing filter)

Part list
Part No. Part name Q'ty Part state
1 208-60-71170 ELEMENT 1 Flushing parts
2 21T-60-13730 PLATE 1 Flushing parts

Valve

Straner
With packing
Element

Hydraulic tank

Replacement of return filter

1. Replace the standard hydraulic oil return filter element, valve, and strainer with flushing element (1)
and plate (2).
REMARKS ꞏ When replacing the element, raise the element slowly so that dirt sticking to it does not fall in.
Remove dirt left in the case by hand.
ꞏ Check the installation state of element according to “Check of installation state of element”.
ꞏ When the atmospheric temperature is -15°C or below, do not replace plate (2) but replace only
element (1).
ꞏ After replacement, flush the hydraulic circuit while running the engine at low idle.
ꞏ Clean and keep the removed standard element (208-60-71123), strainer (07069-25400), and valve
(208-60-71160), as they will be reused after flushing.

245
 Element

Fig.1 Correct state Fig.2 Incorrect state

Check installation state of element

2. Insert the element, turn it by hand, and check that it turns smoothly.
REMARKS ꞏ Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig.
2.
ꞏ When the filter case is filled with oil, it is difficult to check if the element is inserted correctly. Turn
the element by hand after inserting it in the case. When it turns smoothly, judge that it is inserted
correctly.

246
M-4 Flushing hydraulic circuit and bleeding air from cylinder - 1

After assembling completely, flush the hydraulic circuit and bleed air from the hydraulic cylinders.
REMARKS ꞏ You do not need to perform “A-33 Bleed air from hydraulic cylinders" when performing this work (M3
to M5). However, bleed air in advance according to “A-21 Installation of blade assembly” and “A-11
Installation of ripper”.
ꞏ Do not run the engine at high idle to avoid the damage to the flushing elements.
ꞏ Do not move each cylinder to its stroke end before bleeding air, or the piston packing may be
damaged.
1. Flush the fan circuit.
1) Check the oil level in the hydraulic tank.
G
REMARKS ꞏ Check that the oil level is between the H and L lines
on sight gauge (G).
ꞏ If it is below the L line, add hydraulic oil.
2) Start and run the engine at low idle for
approximately 10 minutes.
3) Run at 1,000 to 1,200 rpm for approximately 30
minutes.
4) Check the oil level in the hydraulic tank.
REMARKS ꞏ Check that the oil level is between the H and L lines
on sight gauge (G).
H
ꞏ If it is below the L line, add hydraulic oil.

2. Air-bleed and flush the cylinder with piston valve (blade lift cylinder).
1) While running the engine at low idle, extend and retract the cylinder for 5 minutes.
REMARKS ꞏ Do not move the cylinder to each stroke end but stop is approximately 100 mm before the stroke
end.
ꞏ Do not relieve the circuit under any conditions.
2) While running the engine at low idle, retract the cylinder and stop it 100 mm before the stroke end.
Then, slowly retract the cylinder (take at least 10 seconds) to the stroke end. At this position, keep
the lever turned down for approximately 3 minutes.

3. Air-bleed and flush the cylinder without piston valve (blade tilt cylinder, ripper lift cylinder, ripper tilt
cylinder).
1) Check the oil level in the hydraulic tank.
REMARKS Check that the oil level is between the H and L lines on sight gauge (G). If it is below the L line, add
hydraulic oil.
2) While running the engine at low idle, extend and retract the cylinder for 5 minutes.
REMARKS ꞏ Do not move the cylinder to each stroke end but stop is approximately 100 mm before the stroke
end.
ꞏ Do not relieve the circuit under any conditions.

247
M-5 Change of return filter (Flushing filter → Standard filter)

Part list
Part No. Part name Q'ty Part state
3 208-60-71124 ELEMENT
4 07069-25400 STRAINER
5 208-60-71520 VALVE

2 Plate

3 With packing
1 Element

Replacement of return filter

1. Replace the flushing parts with the kept standard element (3), strainer (4), and valve (5).
REMARKS ꞏ When replacing flushing element (1), raise it slowly so that dirt sticking to it does not fall in. Remove
dirt left in the case by hand.
ꞏ Note that valve (5) and strainer (4) are not replaced with plate (2) when the ambient temperature is
-15°C or below.
ꞏ If the element is not installed correctly, its ability becomes imperfect. Check its installation state
according to “Check of installation state of element”.
ꞏ Discard used flushing element (1). (Observe the local regulations when discarding.)
ꞏ The strainer, valve, and replaced plate (2) are reusable. It is recommended to keep them for the
next flushing.

248
 Element

Fig.1 Correct state Fig.2 Incorrect state

Check installation state of element

2. Insert the element, turn it by hand, and check that it turns smoothly.
REMARKS ꞏ Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig.
2.
ꞏ When the filter case is filled with oil, it is difficult to check if the element is inserted correctly. Turn
the element by hand after inserting it in the case. When it turns smoothly, judge that it is inserted
correctly.

249
M-6 Bleeding air from cylinder - 2

1. Bleed air from the cylinder with piston valve (blade lift cylinder).
1) While running the engine at high idle, retract the cylinder and stop it 100 mm before the stroke end.
Then, slowly retract the cylinder (take at least 10 seconds) to the stroke end. At this position, keep
the lever turned down for approximately 1 minutes.

2. Bleed air from the cylinder without piston valve (blade tilt cylinder, ripper lift cylinder, ripper tilt
cylinder).
1) While running the engine at high idle, extend and retract the cylinder for 5 minutes.
2) While running the engine at low idle, move the cylinder to the stroke end and relieve the oil.
3. After bleeding air, leave the engine stopped for 1 hour.
1) Check the oil level in the hydraulic tank after leaving
the engine stopped for 1 hour. G
REMARKS ꞏ Check that the oil level is between the H and L lines
on sight gauge (G).
ꞏ If it is below the L line, add hydraulic oil.

250
 How to start operation of KOMTRAX terminal and how to initialize
M-7
KOMTRAX Plus controller

Perform the following procedure when using KOMTRAX.

For the procedure, see Shop Manual for D475A-8, “Testing and Adjusting”, “Electrical system:”
ꞏ How to start operation of KOMTRAX terminal
ꞏ How to initialize KOMTRAX Plus controller
ꞏ Initialization of wireless LAN modem
Excerpt from Shop Manual for reference

251
M-8 No-injection cranking of engine

When starting the engine for the first time, perform

its no-injection cranking to lubricate it in advance
according to the following procedure.

Before performing this work, check the oil levels

and complete inspection and maintenance of each
part.
Setting of No-Injection cranking must be performed
while the engine is stopped. The function of No-
Injection cranking will not be enabled while the
engine is running. This function can be selected
even when the engine is running. However, if you
execute No-Injection cranking, a message “Engine
is running. Please turn the key off.” is displayed on
the screen.

REMARKS Even if the confirmation screen is displayed and No-

Injection cranking is operated, the function does not
become enabled in the following cases. Turn the
starting switch OFF once to operate.

ꞏ The communication between the machine monitor

and engine controller is not normal.
ꞏ Engine starting operation was performed before
“No-injection cranking is possible.” Is displayed.
1. On “Service Menu” screen, select “No-Injection
Cranking”.
REMARKS For selecting method, see “METHOD FOR
OPERATING SERVICE MODE” in “SERVICE
MODE”.

2. When “No-Injection Cranking” screen is displayed,

confirmation for the execution of No-Injection
cranking is displayed. Select the action with the
function switch.

F5: Do not perform (Returns the screen to the

“Service Menu” screen)
F6: Perform

252
 3. “No-injection cranking is possible. Please turn the
key off after no-injection ends.” is displayed when
No-injection cranking (No-injection on all cylinder)
becomes available. Then, perform cranking of the
engine.
NOTICE Do not crank the engine for 20 seconds or
longer to protect the starting motor.
REMARKS "In preparation" screen is displayed during transition
to the screen shown in the figure.
4. After the cranking is completed, turn the starting
switch to OFF position.
You cannot change the screen described above to another screen.
5. Check that the system operating lamp is not lit.
REMARKS ꞏ Turning the starting switch key to OFF position does not disable the function until the engine
controller is shut down.
ꞏ Start it again after the shut-down (approximately in 60 minutes) of the engine controller.

253
 APPENDIX 1.

INSTALLATION OF SPILL GUARDS

1. Introduction ...................................................................................................................................... 254

2. Additional parts ................................................................................................................................ 254
3. Spill guard fabrication drawings ..................................................................................................... 255
3-1. For semi-U blade ....................................................................................................................... 255
3-2. For full-U blade .......................................................................................................................... 259
3-3. For superdozer blade ................................................................................................................. 263

4. Installation procedure ...................................................................................................................... 267

DESCRIPTION

1. Introduction
When installing the spill guards in field, refer to the installation procedure described in this installation
procedure.

2. Additional parts

Blade Part No. Part Name Q‘ty Weight (kg) Remarks

198-71-61710 Spill guard (center) 1 134.6
Semi-U 198-71-61720 Spill guard (left) 1 49.6
198-71-61730 Spill guard (right) 1 49.6
198-72-63910 Spill guard (center) 1 171 Refer to the fabrication
Full-U 198-72-63920 Spill guard (left) 1 56 drawing
198-72-63930 Spill guard (right) 1 56
198-72-87110 Spill guard (center) 1 222
Superdozer 198-72-87120 Spill guard (left) 1 34
198-72-87130 Spill guard (right) 1 34

254
3. Spill guard fabrication drawings
3-1. For semi-U blade
(1) Spill guard

255
256
(2) Spill guard (for semi-U, center) 198-71-61710 fabrication drawing

1. This drawing shown CO-gas welding groove

dimensions and leg length for manual welding
per KES 04.351
2. Flatness of surface A in drawing to be within 2.
Sym. Part Name Material Q‘ty Weight (kg) Remarks

01 PLATE SS400F 2 24.5 t 19 ✕ 65

02 PLATE SS400F 11 2.55 t 19 ✕ 65

03 PLATE SS400P 10 5.75 t 19

 1. This drawing shown CO-gas welding groove
dimensions and leg length for manual welding

257
per KES 04.351
2. Flatness of surfaces A, B, C, D and E in drawing
to be within 2.
Sym. Part Name Material Q‘ty Weight (kg) Remarks

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

258
1. This drawing shown CO-gas welding groove
dimensions and leg length for manual welding
per KES 04.351
2. Flatness of surfaces A, B, C, D and E in drawing
to be within 2.
(4) Spill guard (for semi-U, right) 198-71-61730 fabrication drawing

Sym. Part Name Material Q‘ty Weight (kg) Remarks

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

259
260
(2) Spill guard (for full-U, center) 198-72-63910 fabrication drawing

1. This drawing shown CO-gas welding groove

dimensions and leg length for manual welding
per KES 04.351
2. Flatness of surfaces A, B, C, D and E in drawing
to be within 2.
Sym. Part Name Material Q‘ty Weight (kg) Remarks

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

 1. This drawing shown CO-gas welding groove
dimensions and leg length for manual welding
per KES 04.351

261
2. Flatness of surfaces A, B, C, D and E in drawing
to be within 2.
Sym. Part Name Material Q‘ty Weight (kg) Remarks
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
 1. This drawing shown CO-gas welding groove
dimensions and leg length for manual welding
per KES 04.351

262
2. Flatness of surfaces A, B, C, D and E in drawing
to be within 2.
Sym. Part Name Material Q‘ty Weight (kg) Remarks
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
 (6360)
(1) Spill guard

ONLY DIMENSION MARKED

4 PLACES ONLY DIMENSION MARKED

3-3 For superdozer blade

2 1
3 4

3536

263
P Q
B A
R

B A
A-A B-B P

THIS DRAWINGS TO BE SAME AS 198-72-86120

EXCEPT SPECIFIED IN DRAWING.

(3076)
THIS DRAWINGS SHOWS CO2-GAS ARC WELDING
GROOVE DIMENSIONS AND LEG LENGTH.

WELDING QUALITY TO CONFORM TO KES 04.343.

MASS(kg)
 4 3 2
5

264
1

THIS DRAWING SHOWS CO2-GAS ARC WELDING

Q Q GROOVE DIMENSION AND LEG LENGTH.
(2) Spill guard (for superdozer, center) 198-72-87110 fabrication drawing

WELDING QUALITY TO CONFORM TO KES 04.343.

FLATNESS OF SURFACE A IN DRAWING TO BE WITHIN 10.

AND OF ADJOINING SURFACE TO BE WITHIN 2 AFTER WELDING.

MASS
(kg)
Z 198-72-87110-03

198-72-87110-04
(3) Spill guard (for superdozer, left) 198-72-87120 fabrication drawing

S
R

U
P

T
Q

9
7

Q
P
6
5
4

Z
Y

S
3
Z

R
Y

T
1

265
(4) Spill guard (for superdozer, right) 198-72-87130 fabrication drawing

U
R

S
P

U
1

T
Y

R
2
3

S
Y

Z
4
5
Z

Q
7

9
8

266
4. Installation procedure

4-1 For disassembly and assembly procedures which are not described in this manual, see the
Shop Manual.

4-2 Weld the spill guard to the blade according to the drawing.

4-3 Precautions for welding

4-3-1 Remove all dirt, rust, and paint from the parts to be removed with a grinder.

4-3-2 If the parts to be welded are wet, dry them with a gas burner.

4-3-3 Do not use anti-spatter agents.

4-3-4 Use coated welding rods specified by JIS 4316 (Low-hydrogen welding rod for mild steel)
or welding wires specified by JIS YGW11.

4-3-5 Before using coated welding rods, dry them at 300 - 350°C for 30 - 60 minutes.

4-3-6 Preheat the area about 50 mm from the beat to be laid at 150 - 200°C. When the ambient
temperature is below 10°C, post-heat the same area, too, at 150 - 200°C.

4-3-7 Set the welding current to the lower limit of the current range specified for the diameter
of the welding rod or wire.

4.3.8 When performing multi-layer welding, weave the welding rod.

4.3.9 Do not weld by letting the melted metal flow, but weld from below to above with sufficient
penetration. Keep the arc length as short as possible, and take care not to make an
overlap, undercut, etc.

4.3.10 Before welding the spill guard, remove all the paint (or rust) from the parts to be welded
with a grinder. Then, perform tack welding, permanent welding and finishing in order.

4.3.11 Connect the ground cable to a part of the blade where paint is removed or a part where
the ground cable can be connected securely electrically.

(Remark) If a painted part is welded, hydrogen in the paint will be mixed in the welded
part, and that can cause cold cracking.

267
 FIELD ASSEMBLY INSPECTION REPORT 1/7

Check sheet No.

FIELD ASSEMBLY INSPECTION REPORT

After assembling the machine, inspect it according to this check sheet to check its performance.
Please fill its results in the check sheets , and send the copy of these check sheets to "Inspection section, Osaka plant,
Komatsu Ltd."

E-Mail address：JP00MB_os_shaken@global.komatsu
Type - Specification Machine serial Nos. User unit No. Engine model Engine serial No.

D475A-8R SAA12V140E-7
Service meter reading (Hr) Inspection date Inspector Inspection place

Distributor's name Specification

Blade U Semi U Super

User name (Country name) Ripper or

VGR VMR CW ( ton)
counterweight

Address: Shoe width 910 mm 810 mm 710 mm

Others Enter options, locally procured items, etc., if any

Delivery report No. (Options, locally procured

items)

Comments:

Komatsu use only

Check sheet receiving date Recipient Remarks

Judgment entry method:

1. Enter as follow.

✔ --- Normal ○ --- Reworked

--- Abnormal --- Not applicable

Enter measured value in [ ].

Remarks:

Criteria are for factory shipment time

 FIELD ASSEMBLY INSPECTION REPORT 2/7

Measu
Cate Decis
Check item red Criterion
gory ion
value
Battery electrolyte
Between L and H
Battery

Battery unit
No grease, loose terminal, or crack

Radiator coolant level Above strainer bottom

Reservoir tank coolant level Betwen LOW and FULL
Coolant concentration
(%) 64 58 50 41 30 Coolant is mixed in
°C -50 -40 -30 -20 -10

Engine oil level

Between
Engine: Stopped
H and L

Power train oil level

For oil to be used, see Between Engine: At idle
Operation & Maintenance H and L (After 3 - 5 minutes)
Manual
Damper case oil level
Between
Engine: Stopped
H and L

Hydraulic oil level

ꞏ Between H and L
Pitch back to ground
Between horizontally
H and L Ripper point: On ground
Water and coolant levels

Engine: stopped

Final drive oil level

Left See Operation and
Between
Maintenance Manual
H-20 and H
Right Engine: Stopped

Pivot shaft oil level

Left
10 - 30 mm
See Operation and
from shaft
Maintenance Manual
For oil to be used, end
see Operation & Right
Maintenance
Manual
Recoil spring case oil level Clearance
between the
Left
oil surface
and the
See Operation and
lower end of
Maintenance Manual
grease niple
lock plate "a"
Right
= 0 to 30
mm

Window washer tank water level Left Full

Fuel tank Full (1920 L)

Sound of horn Free from chattering or hoarse sound

Backup alarm must sound when

Backup alarm (Engine: Running) transmission lever is in reverse position
without chattering or hoarse sound.

When switch is turned ON, monitor

comes on with buzzer sound, goes off
Acceptance

Monitor display
in 3 seconds, then instrument
positions light up.
Must not flash when all lamps are
Lighting of charge alarm lamp (Engine: Low idle)
turned on.
Lamps light up when switch is turned
Lighting (Headlamp, tail lamp, working lamp, ripper point lamp)
ON.

Check of failure code display on controller

Clear failure code after confirming it.
(Make sure that code is not displayed again)

Bleeding air from hydraulic cylinders Bleed air from hydraulic cylinders
 FIELD ASSEMBLY INSPECTION REPORT 3/7

Measu
Cate Decis
Check item red Criterion
gory ion
value
Does not function while machine is
Check of auto shift-down function
stopped.
Operation of parking brake switch Check following;
Engine does not start when parking
(L) Lock position: brake lever is in free (F) position.
Machine cannot start or shift gear when
lever is in lock (L) position. Parking
brake lever pilot lamp is turned on or
(F) Free position: off in pilot display section of monitor.

Controllability of travel lever

No sticking or unusual noise .Notch
ꞏ Gear shifting
must not be released.

ꞏ Forward and reverse No sticking or unusual noise. Must

travel return smoothly.

ꞏ Play of steering levers

(R.H. and L.H.) in position 10mm or less
“N”

Check of display of gear speed on monitor panel N F1 F2 F3 R1 R2 R3 N, F1, F2, F3,

ꞏ Must be able to be shifted to any position with engine at low idle and brake R1, R2 and R3 are displayed. No
turned on. display error.

Check of front-rear adjustment of travel lever box

ꞏ Position adjustment
ꞏ Check of lock lever of box (upper and lower)

Position must be adjustable.

Functions, operations

Lever must not when locked.

Check of armrest (R.H.) height adjustment

ꞏ 4-stage position adjustment
ꞏ Check of lock levers (R.H./L.H.) Position must be adjustable.
Lever must not when locked.

Operation of decelerator pedal

ꞏ Turn fuel control dial to MAX position and set decelerator pedal in high idle Must move smoothly.
position (Do not depress it).
Set decelerator pedal in low idle position (Fully press it), and check engine
speed.
High idle: 2000 ± 50 rpm

Low idle: 1050 ± 50 rpm

Operation of fuel dial Must move smoothly.

Check of tilting operation
Blade must move to left

Blade must move to right

Operation of isolator
ꞏ Check engine emergency stop switch

Switch must function normally.

 FIELD ASSEMBLY INSPECTION REPORT 4/7

Measu
Cate Decis
Check item red Criterion
gory ion
value
Check of tilting operation and pitching operation Backward pitch (D -> E) Blade must move backward.

Forward pitch (E -> D) Blade must move forward.

Tilt LEFT (A -> B) Blade must move to left

Tilt RIGHT (B -> ) Blade must move to right

Blade must be moved freely by external

force.
Float mode
(To enter “Float mode”, lower lever to
stroke end while pressing button (d).)
Functions, operations

Check of dual tilt mode pilot lamp (M)

Check dual tilt mode pilot lamp (M).

Lighting: ON (Dual tilt mode)

Check of tilt limit

Measure angle of cutting edge when tilt limit switch Tilt LEFT (Full U/Semi U) 12 ± 1°
operates.
Tilt RIGHT (Full U/Semi U) 12 ± 1°
Note: See manual of tilt
limit.
Tilt LEFT (Super) 7 ± 1°

Tilt RIGHT (Super) 7 ± 1°

Check of clearance between frame and track

Left Difference between right and left is 30
mm or less. (Measure on level surface)
Move blade up and down and stop 100
Right mm above ground, and then measure.

Function check of work equipment lock switch

When work equipment lock switch is

ON, no actuator operates.
Work equipment lock pilot lamp is lit on
monitor.

Operation check of quick drop valve

ꞏ Quickly move down blade from max. raise position. With engine at full, move blade lever to
LOWER position. When lever is moved
Work equipment

to N position after blade drops by 1000

mm, it must stop.

Main relief valve function (Engine: Low idle) Blade and ripper must brace.

Check of the accumulator function (blade, ripper) Operate immediately after stopping
engine. At this time, work equipment
must lower from max. raise position to
ground.

Blade cylinder OL
Left
ꞏ Damage to U-packing or rod, coming out of QDV tube, flange, or dust
seal. Not detected
Right

Tilt cylinder or pitch cylinder OL

Left
ꞏ Damage to U-packing or rod, coming out of tube, flange, or dust seal.
Not detected
Right

Check of end bit and cutting edge mounting nut and bolt Tightened correctly.

Check fitting between blade and stopper No gap

 FIELD ASSEMBLY INSPECTION REPORT 5/7

Measu
Cate Decis
Check item red Criterion
gory ion
value
Track tension adjustment
ꞏ With the gear in F1 and engine at low idle, travel for approximately 10
ꞏ Stretch string or bar
m, and when grouser comes above 1st carrier roller, stop machine
Left 20 - 30 mm between idler and first
slowly by depressing brake pedal.
carrier roller, and
measure distance
between string (bar) and
grouser.
(Difference between R.H.
and L.H.: 20 mm max.)
Right 20 - 30 mm ꞏ Target is 30 mm when
Undercarriage

new.

Flanges must not constantly rub

Alignment of carrier roller against links.
Left
ꞏ Travel on level surface with gear in F1 and R1 for approximately 10 m,
3 or 4 times, then stop slowly by depressing brake pedal. * Check only
when F/T is installed in the field (Check is not necessary when F/T is
installed already.) Right

Oil leakage from undercarriage

ꞏ Idler, carrier roller, track roller, bogie, pivot chamber, adjustment Left
cylinder, lubricated track (plug, seal), F/D mating faces, pivot mounting Not detected
portion Right

Chattering inside cab, chattering of external covers Not detected

Opening, closing, locking, and key operation of cab door Door must move smoothly and lock
securely. It must be lockable with key.

Operation of cab door open lock release lever Lever must operate smoothly and lock
securely.

Opening, closing, and locking R.H. and L.H. sliding glasses Must operate smoothly and lock
securely.

Lighting of room lamp Must come on/go off according to

switch operation.

Operation of windshield wiper and window washer Must operate according to switch
operation.
Wiper must operate smoothly (without
Cabin

chattering).

Operation of the radio and cassette system Must operate normally.

(Volume, tuning, AM/FM selection, cassette function)

Operation of cigarette lighter Must be heated red.

Ash tray installation Must be installed.

12 V power supply to cab (for options such as accessory socket) 12 V power is supplied
ꞏ Check by installing radio device

Operation of air conditioner Cold or warm air must be selected by

monitor operation. Air flow rate must be
adjustable.

Check of air conditioner vents Air comes out from each vent
ꞏ Louver must be smoothly switched

Reservoir Q'ty Example: Greasing to U-blade

ꞏ Equalizer bar side pin shaft 2

Greasing

ꞏ Equalizer bar center pin shaft 1

ꞏ Blade lift cylinder support shaft and yoke 6

ꞏ Blade oblique arm ball joint 1

 FIELD ASSEMBLY INSPECTION REPORT 6/7

Measu
Cate Decis
Check item red Criterion
gory ion
value
Check of ripper operation direction
(a) Raise

(b) Hold

(c) LOWER

(A) Angle (α) decreases

(B) Angle (α) increases

Oil leakage from ripper lift cylinder

· Damage to U-packing or rod, coming out of tube, flange, or dust seal. Left
Not detected
Right

Oil leakage from ripper tilt cylinder

· Damage to U-packing or rod, coming out of tube, flange, or dust seal. Left
Not detected
Right

Interference with hoses when ripper operates

(Check through operating range) No interference

Creak from the ripper link pin No creak

Check of operating direction of pin puller operation
switch
(A) Pull out
Operating direction of pin puller switch
Ripper

must conform to movement of pin

puller cylinder.
(B) Push in

Check of clamp position of pin puller cylinder hose No interference.

(Check through operation range) Hoses must not be pulled strongly.

Oil leakage from pin puller cylinder Not detected

· Damage to U-packing or rod, tube, flange

Reservoir Q'ty (Engraved, index) 給脂のこと （左右）

TL 7,8
・Ripper tilt cylinder bottom left TL 1
・Ripper lift cylinder bottom left LL

・Ripper arm pin left front AL 3

・Ripper arm pin righ front AR TR
LL
・Ripper lift cylinder bottom right LR AR 1
5
・Ripper tilt cylinder bottom right TR AL LR
5,6,9

・Ripper tilt cylinder head left 1

・Ripper tilt cylinder head right 2

・Ripper lift cylinder head left 3

・Ripper lift cylinder head right 4 2

・Ripper arm pin ｌeft rear 5
4
・Ripper arm pin ｒight rear 6

6
 FIELD ASSEMBLY INSPECTION REPORT 7/7

Recored sheet of tightening torque of ROPS

Sketch Record
1. Tightening torque of ROPS
From right to left of rear of machine: A to H
From right to left of front of machine: I to P (8 pieces at
rear, 8 pieces at front, 16 pieces in total)

Location Place Record Standard tightening torque

A
B

Rear of machine
C
D
E

A F
I G
H 200 to 250 kgm {1950 to
I 2450 Nm}

Front of machine
K

FWD H
L
M
P
N
O
P
 QUICK PM

QUICK PM
• “Quick Pm” means Pm Clinic done by “Snapshot” function of the machine monitor. If you use this function to
collect data on a regular basis, do the operation specified in Quick Pm.
• For details about how to handle the machine, see “PERFORM QUICK PM”.
Before you start the Quick Pm, set the machine under the condition that follows.
• Hydraulic oil temperature: 55 to 100 °C
• Power train oil temperature: 70 to 120 °C
• Engine coolant temperature: 60 to 100 °C
REMARK
• The manual Snapshot is recorded in the memory area that is shared with the error records automatically
collected in the KOMTRAX Plus controller. It is possible that the Snapshot cannot be recorded according to
the amount of recorded error. Download the data saved in KOMTRAX Plus controller into the personal com-
puter before you do the Snapshot, and delete the data saved in the controller.
• The data of manual Snapshot is recorded for only one time. The data is written over when the manual Snap-
shot is done again. After the manual Snapshot is done, save the recorded data and download them to a PC
to allow future use. For details about data download, see “DOWNLOAD DATA FROM KOMTRAX Plus CON-
TROLLER”.
• It takes 7 minutes and 30 seconds from the start of recording the manual Snapshot to the end of recording.
The sampling interval becomes shorter after the first 5 minutes of the recording.
During the first 5 minutes of the recording, a single sampling operation takes 10 seconds. Sampling is done
for 300 seconds (5 minutes), recording 30 samples.
From 5 minutes until 7 minutes and 30 seconds in the recording, a single sampling operation takes 1 sec-
ond. Sampling is done for 150 seconds (2 minutes and 30 seconds), recording 150 samples.

QUICK PM
1. Start the engine.
2. Set the operating mode to P mode.
3. Set to the manual gear shift mode.
4. Select “Snapshot” from the “Service Menu” screen.

5. On the “Snapshot” screen, check that each oil temperature

is in the range of the test condition and push the ENTER
switch (F1).
RETURN switch (F5): The screen goes back to the “Serv-
ice Menu” screen.
ENTER switch (F1): The screen goes to the record start
confirmation screen.

1
QUICK PM

6. On the “Start Snapshot?” screen, push the ENTER switch

(F6).
RETURN switch (F5): Stops recording and goes back to
the “Service Menu” screen.
ENTER switch (F6): Starts recording.

7. Operate the machine when recording started. See “OPER-

ATION TABLE OF MACHINE IN QUICK PM”.
REMARK
The progress of recording can be checked on the machine
monitor. For checking the recording process, see “SNAP
SHOT”.

2
 QUICK PM

Operation table of machine in Quick Pm

Operation of machine
Tim
e WOR
Star K Fuel Park-
No. End (se Transmis- Steer- Decelera- Brake
t Operation status EQUI control ing
con sion ing tor pedal pedal
ds) PMEN dial brake
T
12:
0:0 Re- Re-
1 40 40 Low idle N LH N LOW Release
0 lease lease
AM
12: 1:2
Re- Re-
2 40 0 40 Low idle N RH N LOW Release
lease lease
AM AM
1:2 2:0
Re- Re-
3 0 0 40 High idle N N N HI Release
lease lease
AM AM

2:0 2:4 • Deceleration

slow Fully Re- Re-
4 0 0 40 N N N HI
push lease lease
AM AM • High idle

2:4 3:1 • Work equipment

relief Ripper Re- Re-
5 0 0 30 N N HI Release
lift lease lease
AM AM • High idle

3:1 3:4 • Work equipment

relief Ripper Re- Re-
6 0 0 30 N N LOW Release
lift lease lease
AM AM • Low idle
N → F1 →
3:4 4:2 • Torque convert- F2 → F3
er stalled (*1) Fully Re-
7 0 0 40 → N → R1 N N LOW Release
push lease
AM AM • Low idle → R2 →
R3 → N
Fully
• Torque convert- N → F3
4:2 5:3 push →
er stall (F3) (*1) (high idle Fully Re-
8 0 0 70 N N HI Release
after (F3) push lease
AM AM • High idle (*2) after (F3)
shift)
shift
5:3 6:0
Re- Re-
9 0 0 30 High idle N N N HI Release
lease lease
AM AM

• Torque convert- Fully

N → F3
6:0 7:0 er stall + relief push →
(high idle Ripper Fully Re-
10 0 0 60 (*1) N HI Release
after (F3) lift push lease
AM AM after (F3)
• High idle shift)
shift
7:0 7:3
High idle → Low idle HI → Re-
11 0 0 30 N N N Release ON
(*3) LOW lease
AM AM

Make sure that the hydraulic oil temperature is min. 45 ˚C and then do the Snapshot.
*1: Stall until the power train oil temperature reaches 118 ˚C. For the torque converter stall, see “TEST EN-
GINE SPEED”, “TEST ENGINE SPEED AT TORQUE CONVERTER STALL”.
*2: Push the brake pedal fully, set the upshift switch to (F3), and set the engine speed to high idle.

3
QUICK PM

*3: Continue low idle until the oil temperature goes back to normal.
NOTICE
• During torque converter stall, do not set the engine speed to high idle when the gear speed is in
1st gear.
• During torque converter stall, monitor the power train oil temperature gauge to prevent overheat.
• The 60 seconds specified for torque converter stall is only a reference value. When the power
train oil temperature reaches 118 ˚C, immediately set the transmission back to (N) and the en-
gine speed to high idle to lower the oil temperature.
8. If Snapshot is completed. is shown after 7 minutes and 30
seconds have passed from the start of recording, the data
recording has been completed. Download the data to a
personal computer and use the data for diagnosis of the
machine.
REMARK
After 3 seconds passes since the recording has been com-
pleted, the screen returns to the starting screen of Snap-
shot.

4
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Pm-CLINIC
PM CLINIC SERVICE
Machine model Machine serial number Service meter
□ D475A-8R h
User name Date of inspection Inspector

Specifications
Front attachment Rear attachment Shoe width
□ Semi-U dozer □ Multi-shank ripper □ 710 mm □()
□ Full-U dozer □ Variable giant ripper □ 810 mm
□ Super dozer □ Counterweight ( kg) □ 910 mm
□

Work condition
Quarry, mining Construction Type of soil Contents of the work
□ Construction, civil engi-
□ Coal □ Rock □ Dozing %
neering
□ Gold □ Gravel □ Side cutting %
□ Road
□ Limestone □ Sand □ Ripping %
□ Tunnel
□ □ Clay □ Drive %
□

Check of the oil and coolant levels

□ Engine coolant When necessary
□ Oil level of the engine □ Oil level of the damper case □ Oil level of final drive
□ Oil level of the hydraulic tank □ Oil level of the power train □
Outside air temperature Altitude
°C m

Operator's comment

Result of the visual inspection

1
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Mechanical Sys Abnormality Record Electrical Sys Abnormality Record

2300NR Times/First time h/Latest h Times/First time h/Latest h
2301NR Times/First time h/Latest h Times/First time h/Latest h
2301NT Times/First time h/Latest h Times/First time h/Latest h
2302NR Times/First time h/Latest h Times/First time h/Latest h
A900FR Times/First time h/Latest h Times/First time h/Latest h
AA10NX Times/First time h/Latest h Times/First time h/Latest h
B@BAZG Times/First time h/Latest h Times/First time h/Latest h
B@BCNS Times/First time h/Latest h Times/First time h/Latest h
B@CENS Times/First time h/Latest h Times/First time h/Latest h
B@HANS Times/First time h/Latest h Times/First time h/Latest h
CA234 Times/First time h/Latest h Times/First time h/Latest h
DAQW00 Times/First time h/Latest h Times/First time h/Latest h
DKR2NX Times/First time h/Latest h Times/First time h/Latest h
F@BWNR Times/First time h/Latest h Times/First time h/Latest h
F@BWNS Times/First time h/Latest h Times/First time h/Latest h
F@BXNR Times/First time h/Latest h Times/First time h/Latest h
F@BXNS Times/First time h/Latest h Times/First time h/Latest h

Maximum range of the engine coolant temperature gauge

Coolant temperature Engine coolant tem- Lighting color of the
gauge level perature monitor (a)
W1 105°C
Red
W2 102°C
W3 100°C
W4 85°C Green
W5 60°C
W6 30°C White

Maximum range of power train oil temperature gauge

Oil temperature lev- Power train oil tem- Lighting color of the
el perature monitor (a)
P1 130°C
Red
P2 120°C
P3 118°C
P4 90°C Green
P5 50°C
P6 0°C White

2
30 TESTING AND ADJUSTING PM CLINIC SERVICE

PM CLINIC CHECK SHEET: D475A-8R

The standard value is the value which is normal.
NOTICE
Do the inspection after sufficient warm-up operation of the engine.
Machine serial
Machine model Service meter User name Date of inspection Inspector
number
D475A-8R

The standard value is the value which is normal.

Engine: SAA12V140E-7
Standard val- Meas- No
Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C
• Hydraulic oil temperature: 45 to
100 °C
• Operation mode: P (power
Engine mode)
speed at • Fuel control dial MAX (High idle) rpm 1950 to 2050 1950 to 2050
high idle (*1) • Joystick (steering, directional,
and gear shift lever) (PCCS lev-
er): NEUTRAL
• Preset mode: F3-R3
• Gear shift mode Automatic gear
shift mode or manual gear shift
mode
• Pre-defined Monitoring (01/23)
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C
• Hydraulic oil temperature: 45 to
100 °C
• Operation mode: P (power
Engine mode)
speed at low • Fuel control dial MIN (Low idle) rpm 610 to 710 610 to 710
idle (*1) • Joystick (steering, directional,
and gear shift lever) (PCCS lev-
er): NEUTRAL
• Preset mode: F3-R3
• Gear shift mode Automatic gear
shift mode or manual gear shift
mode
• Pre-defined Monitoring (01/23)

3
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C
• Hydraulic oil temperature: 45 to
100 °C
• Operation mode: P (power
Engine mode)
speed when
• Fuel control dial MAX (High idle)
decelerator rpm 1000 to 1100 1000 to 1100
pedal is • Joystick (steering, directional,
pushed (*1) and gear shift lever) (PCCS lev-
er): NEUTRAL
• Gear shift mode Automatic gear
shift mode or manual gear shift
mode
• Decelerator pedal Push the ped-
al fully to the stroke end
• Pre-defined Monitoring (01/23)
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C
• Hydraulic oil temperature: 55 to
100 °C
• Operation mode: P (power
Engine mode)
speed at tor- • Fuel control dial MAX (High idle) rpm 1640 to 1740 Min. 1590
que convert-
er stall (*1) • At torque converter stall
• Gear shift mode Manual gear
shift mode
• Preset mode: F3-R3
• Joystick (steering, directional,
and gear shift lever) (PCCS lev-
er): Forward
• Pre-defined Monitoring (01/23)

4
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C
• Hydraulic oil temperature: 55 to
100 °C
Engine • Operation mode: P (power
speed at full
mode)
stall (torque
converter • Fuel control dial MAX (High idle)
rpm 1515 to 1665 Min. 1490
stall and • At torque converter stall
work equip-
ment relief) • Gear shift mode Manual gear
(*1) shift mode
• Preset mode: F3-R3
• Joystick (steering, directional,
and gear shift lever) (PCCS lev-
er): Forward
• Ripper control lever: RAISE re-
lief

5
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine oil tempera- When the
ture: Min. 80 ºC gauge is
used MPa 0.39 to 0.54 0.29
• Engine coolant
(measure-
temperature: 60 to 2 {4.0 to 5.5} {3.0}
ment posi- {kg/cm }
100 °C tion: oil filter
• Gear shift mode outlet)
Manual gear shift
mode
• Operation mode: P
(power mode)
• Joystick (steering,
directional, and Monitoring
gear shift lever) display
(PCCS lever): (measure-
NEUTRAL ment posi-
kPa 290 to 440 200
tion: left
• Engine oil (*2) bank side
EOS5W30–LA piston cool-
EOS5W40–LA ing gallery)
EO10W30–LA
EO15W40–LA
• Pre-defined Moni-
Engine oil toring (01/23)
pressure
(*1) • Engine oil tempera- When the
ture: Min. 80 ºC gauge is
used MPa
• Engine coolant Min. 0.08 0.04
(measure-
temperature: 60 to 2 {Min. 0.8} {0.4}
ment posi- {kg/cm }
100 °C tion: oil filter
• Gear shift mode outlet)
Manual gear shift
mode
• Operation mode: P
(power mode)
• Fuel control dial
MIN (Low idle) Monitoring
display
• Joystick (steering,
(measure-
directional, and
ment posi-
gear shift lever) kPa Min. 80 40
tion: left
(PCCS lever): bank side
NEUTRAL piston cool-
• Engine oil (*2) ing gallery)
EOS5W30–LA
EOS5W40–LA
EO10W30–LA
EO15W40–LA

6
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C
• Hydraulic oil temperature: 55 to
100 °C
kPa
Blowby • Operation mode: P (power Min. 3.92 Min. 6.86
pressure mode) {mmH2O
{Min. 400} {Min. 700}
}
• At torque converter stall
• Preset mode: F3-R3
• Gear shift mode Manual gear
shift mode
• The KCCV circuit is disconnec-
ted.
• Engine coolant Gauge Min. 189.3 Min. 176.0
temperature: 60 to pressure {Min. 1250} {Min. 1150}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 55 to
100 °C
• Operation mode: P
(power mode)
• At torque converter
stall
• Preset mode: F3-
Boost pres- R3 kPa
sure (*1) {mmHg} Min. 268.0 Min. 254.7
• Gear shift mode Absolute
Manual gear shift pressure {Min. 2010} {Min. 1910}
mode
REMARK
• The gauge pressure
does not include at-
mospheric pressure.
• The absolute pres-
sure is the value
which is obtained by
adding 101.3 kPa
{760 mmHg} of am-
bient pressure at 0
m above sea level to
the gauge pressure.

7
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Left bank
Max. 700 Max. 750
temperature: 60 to side (LH)
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 55 to
Exhaust 100 °C
temperature °C
• Operation mode: P Right bank
(*1) Max. 700 Max. 750
(power mode) side (RH)
• At torque converter
stall
• Preset mode: F3-
R3
• Gear shift mode
Manual gear shift
mode

*1: Item that you can check with monitoring function of the machine monitor
*2: KES diesel engine oil

Cooling fan
Standard val- Meas- No
Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Hydraulic oil temperature: 55 to
100 °C
• Fuel control dial MAX (High idle)
• Operation mode: P (power
Cooling fan
mode) rpm 1025 to 1075 1025 to 1075
speed (*1)
• Gear shift mode Manual gear
shift mode
• Adjustment ID: 1005 “Fan 100%
Mode”
• Hydraulic oil temperature: 55 to
Cooling fan 100 °C
MPa 17.1 to 22.1 17.1 to 22.1
circuit oil • Fuel control dial MAX (High idle)
{kg/cm2} {175 to 225} {175 to 225}
pressure • Adjustment ID: 1005 “Fan 100%
Mode”

8
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Power train oil pressure

Standard val- Meas- No
Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Fuel control 2.65 to 2.98 2.55 to 3.04
temperature: 60 to dial MAX
(High idle) {27.0 to 30.4} {26.0 to 31.0}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
Transmis-
• Hydraulic oil tem-
sion main MPa
perature: 45 to
relief pres-
100 °C Fuel control {kg/cm2} 2.35 to 2.89 2.45 to 3.04
sure (TM)
(*1) • Operation mode: P dial MIN
(Low idle) {24.0 to 29.5} {25.0 to 31.0}
(power mode)
• Joystick (steering,
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL
• Engine coolant Fuel control 0.78 to 1.05 0.78 to 1.05
temperature: 60 to dial MAX
(High idle) {8.0 to 10.7} {8.0 to 10.7}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
Torque con- • Hydraulic oil tem-
verter inlet perature: 45 to MPa
pressure 100 °C Fuel control {kg/cm2}
(IN) (*1) 0.03 to 0.2 0.03 to 0.2
• Operation mode: P dial MIN
(Low idle) {0.3 to 2.0} {0.3 to 2.0}
(power mode)
• Joystick (steering,
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL
• Engine coolant Fuel control 0.39 to 0.64 0.39 to 0.64
temperature: 60 to dial MAX
(High idle) {4.0 to 6.5} {4.0 to 6.5}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
Torque con- • Hydraulic oil tem-
verter outlet perature: 45 to MPa
pressure 100 °C Fuel control {kg/cm2}
(OUT) (*1) 0.03 to 0.15 0.03 to 0.15
• Operation mode: P dial MIN
(Low idle) {0.3 to 1.5} {0.3 to 1.5}
(power mode)
• Joystick (steering,
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL

9
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C
• Hydraulic oil temperature: 45 to
100 °C
Torque con- • Operation mode: P (power
verter lock- mode)
up clutch MPa 1.34 to 1.59 1.34 to 1.59
• Fuel control dial MAX (High idle)
operation {kg/cm2} {13.7 to 16.2} {13.7 to 16.2}
pressure • Joystick (steering, directional,
(LU) and gear shift lever) (PCCS lev-
er): FORWARD (idle rotation)
• Gear shift mode Automatic gear
shift
• Preset mode: F2-R2
• Adjustment ID: 5535 “Both
Steering Clutch Release Mode”
• Engine coolant Fuel control 2.55 to 2.94 Min. 2.55
temperature: 60 to dial MAX
(High idle) {26.0 to 30.0} {Min. 26.0}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
Torque con- • Hydraulic oil tem-
verter stator perature: 45 to MPa
clutch pres- 100 °C Fuel control {kg/cm2} 2.25 to 2.94
sure (SC) Min. 2.45
• Operation mode: P dial MIN
(Low idle) {26.0 to 30.0} {Min. 25.0}
(power mode)
• Joystick (steering,
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL

10
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Fuel control 2.35 to 2.74 2.25 to 2.94
temperature: 60 to dial MAX
(High idle) {24.0 to 28.0} {23.0 to 30.0}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
Transmis- 100 °C
sion F clutch MPa
• Operation mode: P
operation
(power mode) Fuel control {kg/cm2} 2.35 to 2.74 2.25 to 2.94
pressure
(FWD) • Gear shift mode dial MIN
(Low idle) {24.0 to 28.0} {23.0 to 30.0}
Manual gear shift
(F3)
• Preset mode: F2-
R2
• Adjustment ID:
5535 “Both Steer-
ing Clutch Release
Mode”
• Engine coolant Fuel control 2.35 to 2.74 2.25 to 2.94
temperature: 60 to dial MAX
(High idle) {24.0 to 28.0} {23.0 to 30.0}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
Transmis- 100 °C
sion R MPa
• Operation mode: P
clutch oper-
(power mode) Fuel control {kg/cm2} 2.35 to 2.74 2.25 to 2.94
ation pres-
sure (REV) • Gear shift mode dial MIN
(Low idle) {24.0 to 28.0} {23.0 to 30.0}
Manual gear shift
(R3)
• Preset mode: F2-
R2
• Adjustment ID:
5535 “Both Steer-
ing Clutch Release
Mode”

11
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Fuel control 1.96 to 2.35 1.86 to 2.55
temperature: 60 to dial MAX
(High idle) {20.0 to 24.0} {18.9 to 26.0}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
Transmis- 100 °C
sion 1st MPa
• Operation mode: P
clutch oper-
(power mode) Fuel control {kg/cm2} 1.96 to 2.35 1.86 to 2.55
ation pres-
sure (1ST) • Gear shift mode dial MIN
(Low idle) {20.0 to 24.0} {18.9 to 26.0}
Manual gear shift
(F1)
• Preset mode: F1-
R1
• Adjustment ID:
5535 “Both Steer-
ing Clutch Release
Mode”
• Engine coolant Fuel control 2.35 to 2.74 2.25 to 2.94
temperature: 60 to dial MAX
(High idle) {24.0 to 28.0} {23.0 to 30.0}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
Transmis- 100 °C
sion 2nd MPa
• Operation mode: P
clutch oper-
(power mode) Fuel control {kg/cm2} 2.35 to 2.74 2.25 to 2.94
ation pres-
sure (2ND) • Gear shift mode dial MIN
(Low idle) {24.0 to 28.0} {23.0 to 30.0}
Manual gear shift
(F2)
• Preset mode: F2-
R2
• Adjustment ID:
5535 “Both Steer-
ing Clutch Release
Mode”

12
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Fuel control 2.35 to 2.74 2.25 to 2.94
temperature: 60 to dial MAX
(High idle) {24.0 to 28.0} {23.0 to 30.0}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
Transmis- 100 °C
sion 3rd MPa
• Operation mode: P
clutch oper-
(power mode) Fuel control {kg/cm2} 2.35 to 2.74 2.25 to 2.94
ation pres-
sure (3RD) • Gear shift mode dial MIN
(Low idle) {24.0 to 28.0} {23.0 to 30.0}
Manual gear shift
(F3)
• Preset mode: F2-
R2
• Adjustment ID:
5535 “Both Steer-
ing Clutch Release
Mode”

13
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Fuel control 2.65 to 2.98 2.45 to 3.18
temperature: 60 to dial MAX
(High idle) {27.0 to 30.4} {25.0 to 32.4}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
100 °C
• Operation mode: P
(power mode) MPa
• Gear shift mode Fuel control {kg/cm2} 2.35 to 2.89 2.25 to 3.04
Manual gear shift dial MIN
(Low idle) {24.0 to 29.5} {23.0 to 31.5}
mode
• Parking brake
switch: FREE posi-
tion
• Joystick (steering,
directional, and
gear shift lever)
Steering (PCCS lever):
R.H. brake NEUTRAL
operation
pressure • Engine coolant Fuel control 0.27 to 0.57 0.27 to 0.57
(RB) temperature: 60 to dial MAX
(High idle) {2.8 to 5.8} {2.8 to 5.8}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
100 °C
• Operation mode: P
(power mode) MPa
• Gear shift mode Fuel control {kg/cm2} 0.27 to 0.57 0.27 to 0.57
Manual gear shift dial MIN
(Low idle) {2.8 to 5.8} {2.8 to 5.8}
mode
• Parking brake
switch: FREE posi-
tion
• Joystick (steering,
directional and gear
shift lever) (PCCS
lever): RIGHT
stroke end

14
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Fuel control 0 to 0.1 0 to 0.1
temperature: 60 to dial MAX
(High idle) {0 to 1} {0 to 1}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
100 °C
• Operation mode: P
(power mode)
• Gear shift mode MPa
Manual gear shift Fuel control {kg/cm2} 0 to 0.1 0 to 0.1
mode dial MIN
(Low idle) {0 to 1} {0 to 1}
• Parking brake
switch: FREE posi-
tion
• Joystick (steering,
directional, and
gear shift lever)
(PCCS lever):
Steering NEUTRAL
R.H. brake • Brake pedal: Push
operation
to the stroke end
pressure
(RB) • Engine coolant Fuel control 0 to 0.1 0 to 0.1
temperature: 60 to dial MAX
(High idle) {0 to 1} {0 to 1}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
100 °C
• Operation mode: P
(power mode) MPa
• Gear shift mode Fuel control {kg/cm2} 0 to 0.1 0 to 0.1
Manual gear shift dial MIN
(Low idle) {0 to 1} {0 to 1}
mode
• Parking brake
switch: LOCK posi-
tion
• Joystick (steering,
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL

15
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Fuel control 2.65 to 2.98 2.45 to 3.18
temperature: 60 to dial MAX
(High idle) {27.0 to 30.4} {25.0 to 32.4}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Operation mode: P
(power mode)
• Gear shift mode MPa
Manual gear shift
Fuel control {kg/cm2} 2.35 to 2.89 2.25 to 3.04
mode
dial MIN
• Parking brake (Low idle) {24.0 to 29.5} {23.0 to 31.5}
switch: FREE posi-
tion
• Joystick (steering,
directional, and
gear shift lever)
Steering (PCCS lever):
L.H. brake NEUTRAL
operation
pressure • Engine coolant Fuel control 0.27 to 0.57 0.27 to 0.57
(LB) temperature: 60 to dial MAX
(High idle) {2.8 to 5.8} {2.8 to 5.8}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Operation mode: P
(power mode)
• Gear shift mode MPa
Manual gear shift
Fuel control {kg/cm2} 0.27 to 0.57 0.27 to 0.57
mode
dial MIN
• Parking brake (Low idle) {2.8 to 5.8} {2.8 to 5.8}
switch: FREE posi-
tion
• Joystick (steering,
directional and gear
shift lever) (PCCS
lever): LEFT stroke
end

16
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Fuel control 0 to 0.1 0 to 0.1
temperature: 60 to dial MAX
(High idle) {0 to 1} {0 to 1}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Operation mode: P
(power mode)
• Gear shift mode
Manual gear shift
mode MPa
• Parking brake Fuel control {kg/cm2} 0 to 0.1 0 to 0.1
switch: FREE posi- dial MIN
(Low idle) {0 to 1} {0 to 1}
tion
• Joystick (steering,
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL
Steering
L.H. brake • Brake pedal: Push
operation the pedal fully to
pressure the stroke end
(LB)
• Engine coolant Fuel control 0 to 0.1 0 to 0.1
temperature: 60 to dial MAX
(High idle) {0 to 1} {0 to 1}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Operation mode: P
(power mode)
• Gear shift mode MPa
Manual gear shift
Fuel control {kg/cm2} 0 to 0.1 0 to 0.1
mode
dial MIN
• Parking brake (Low idle) {0 to 1} {0 to 1}
switch: LOCK posi-
tion
• Joystick (steering,
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL

17
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Fuel control 2.65 to 2.98 2.45 to 3.18
temperature: 60 to dial MAX
(High idle) {27.0 to 30.4} {25.0 to 32.4}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
100 °C
MPa
• Operation mode: P
Fuel control {kg/cm2} 2.35 to 2.89 2.25 to 3.04
(power mode)
dial MIN
• Parking brake (Low idle) {24.0 to 29.5} {23.0 to 31.5}
switch: FREE posi-
tion
• Joystick (steering,
directional and gear
shift lever) (PCCS
Steering lever): RIGHT
R.H. clutch stroke end
operation
pressure • Engine coolant Fuel control 0 to 0.1 0 to 0.1
(RC) temperature: 60 to dial MAX
(High idle) {0 to 1} {0 to 1}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
100 °C
MPa
• Operation mode: P
Fuel control {kg/cm2} 0 to 0.1 0 to 0.1
(power mode)
dial MIN
• Parking brake (Low idle) {0 to 1} {0 to 1}
switch: FREE posi-
tion
• Joystick (steering,
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL

18
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant Fuel control 2.65 to 2.98 2.45 to 3.18
temperature: 60 to dial MAX
(High idle) {27.0 to 30.4} {25.0 to 32.4}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
100 °C
MPa
• Operation mode: P
Fuel control {kg/cm2} 2.35 to 2.89 2.25 to 3.04
(power mode)
dial MIN
• Parking brake (Low idle) {24.0 to 29.5} {23.0 to 31.5}
switch: FREE posi-
tion
• Joystick (steering,
directional and gear
shift lever) (PCCS
Steering lever): LEFT stroke
L.H. clutch end
operation
pressure • Engine coolant Fuel control 0 to 0.1 0 to 0.1
(LC) temperature: 60 to dial MAX
(High idle) {0 to 1} {0 to 1}
100 °C
• Power train oil tem-
perature: 70 to
120 °C
• Hydraulic oil tem-
perature: 45 to
100 °C
MPa
• Operation mode: P
Fuel control {kg/cm2} 0 to 0.1 0 to 0.1
(power mode)
dial MIN
• Parking brake (Low idle) {0 to 1} {0 to 1}
switch: FREE posi-
tion
• Joystick (steering,
directional, and
gear shift lever)
(PCCS lever):
NEUTRAL

19
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C
Transmis- • Hydraulic oil temperature: 45 to
sion lubri- 100 °C MPa 0.15 to 0.29 0.15 to 0.29
cating oil
pressure • Operation mode: P (power {kg/cm2} {1.5 to 3.0} {1.5 to 3.0}
(LUB) mode)
• Fuel control dial MAX (High idle)
• Joystick (steering, directional,
and gear shift lever) (PCCS lev-
er): NEUTRAL
• Power train oil temperature: 70
to 120 °C
• Fuel control dial: MAX (High
idle)
• Operating Mode: P (Power
mode)
Brake per- • Gear shift mode: Manual gear
- Machine must not move
formance shift (F2)
• Preset mode: F2 - R2
• Check that the monitor displays
(F2).
• Joystick (steering, directional,
and gear shift lever) (PCCS lev-
er): Travel FORWARD

*1: Item that you can check with monitoring function of the machine monitor

Oil pressure of the work equipment

Standard val- Meas- No
Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C
• Hydraulic oil temperature: 45 to
Unload 55 °C MPa 2.9 to 4.9 2.9 to 4.9
pressure
(*1) • Operation mode: P (power {kg/cm2} {30 to 50} {30 to 50}
mode)
• Fuel control dial MAX (High idle)
• Joystick (steering, directional,
and gear shift lever) (PCCS lev-
er): NEUTRAL

20
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Hydraulic oil temperature: 45 to
55 °C
• Operation mode: P (power
mode)
• Fuel control dial MAX (High idle)
Work equip-
ment pump • Joystick (steering, directional, MPa 26.0 to 28.8 26.0 to 28.8
pressure and gear shift lever) (PCCS lev-
{kg/cm2} {266 to 294} {266 to 294}
(*1) er): NEUTRAL
• Gear shift mode Manual gear
shift mode
• Work equipment control lever:
Ripper RAISE or blade pitch
back
Blade con- Work equipment pump out-
trol lever: let pressure (F), (R)
• Engine coolant RAISE
temperature: 60 to (U dozer, 25.6 to 28.4 25.6 to 28.4
100 °C semi-u doz-
er specifi- {261 to 289} {261 to 289}
• Power train oil tem-
cation)
perature: 70 to
Blade relief 120 °C Blade con- Work equipment pump out-
trol lever: MPa let pressure (F), (R)
pressure • Hydraulic oil tem-
(*1) Pitch dump {kg/cm2}
perature: 45 to
55 °C (Super doz- 26.0 to 28.8 26.0 to 28.8
er specifi- {266 to 294} {266 to 294}
• Operation mode: P cation)
(power mode)
Work equipment pump out-
• Fuel control dial Blade con- let pressure (F), (R)
MAX (High idle) trol lever:
26.0 to 28.8 26.0 to 28.8
LOWER
{266 to 294} {266 to 294}

21
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
Work equipment pump out-
let pressure (F)
26.0 to 28.8 26.0 to 28.8
Blade con- {266 to 294} {266 to 294}
trol lever:
LEFT tilt Work equipment pump out-
let pressure (R)
22.6 to 25.4 22.6 to 25.4
MPa {231 to 259} {231 to 259}
{kg/cm2} Work equipment pump out-
let pressure (F)
• Engine coolant 22.6 to 25.4 22.6 to 25.4
temperature: 60 to Blade con- {231 to 259} {231 to 259}
100 °C trol lever:
Work equipment pump out-
• Power train oil tem- RIGHT tilt
let pressure (R)
perature: 70 to
120 °C 26.0 to 28.8 26.0 to 28.8
Blade tilt re-
lief pressure • Hydraulic oil tem- {266 to 294} {266 to 294}
(*1) perature: 45 to Blade con- Work equipment pump out-
55 °C trol lever: let pressure (F), (R)
• Operation mode: P Pitch dump
(power mode) (U dozer, 23.1 to 25.9 23.1 to 25.9
• Fuel control dial semi-u doz-
er specifi- {236 to 264} {236 to 264}
MAX (High idle)
cation)
Blade con- Work equipment pump out-
trol lever: MPa let pressure (F), (R)
Pitch dump {kg/cm2}
(Super doz- 2.36 to 26.4 2.36 to 26.4
er specifi- {241 to 269} {241 to 269}
cation)
Work equipment pump out-
Blade con- let pressure (F), (R)
trol lever:
26.0 to 28.8 26.0 to 28.8
Pitch back
{266 to 294} {266 to 294}

22
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
Work equipment pump out-
Ripper con- let pressure (F), (R)
trol lever:
26.0 to 28.8 26.0 to 28.8
• Engine coolant RAISE
temperature: 60 to MPa {266 to 294} {266 to 294}
100 °C {kg/cm2} Work equipment pump out-
• Power train oil tem- Ripper con- let pressure (F), (R)
perature: 70 to trol lever:
26.0 to 28.8 26.0 to 28.8
120 °C LOWER
Ripper relief {266 to 294} {266 to 294}
pressure • Hydraulic oil tem-
(*1) perature: 45 to Work equipment pump out-
Ripper con- let pressure (F), (R)
55 °C
trol lever: N
• Operation mode: P 26.0 to 28.8 26.0 to 28.8
→ Tilt IN
(power mode) MPa {266 to 294} {266 to 294}
• Fuel control dial {kg/cm2} Work equipment pump out-
Ripper con-
MAX (High idle) let pressure (F), (R)
trol lever: N
→ Tilt 26.0 to 28.8 26.0 to 28.8
BACK {266 to 294} {266 to 294}
Blade con- 2.25 to 2.65 2.25 to 2.65
trol lever:
RAISE {23 to 27} {23 to 27}

Blade con- 2.25 to 2.65 2.25 to 2.65

trol lever:
LOWER {23 to 27} {23 to 27}

Blade con- 1.07 to 1.47 1.07 to 1.47

trol lever:
LEFT tilt MPa {11 to 15} {11 to 15}

• Engine coolant Blade con- {kg/cm2} 1.07 to 1.47 1.07 to 1.47

temperature: 60 to trol lever:
100 °C RIGHT tilt {11 to 15} {11 to 15}
• Power train oil tem- Blade con-
1.56 to 1.96 1.56 to 1.96
perature: 70 to trol lever:
120 °C Pitch dump {16 to 20} {16 to 20}
LS differen-
• Hydraulic oil tem- Blade con-
tial pressure 1.56 to 1.96 1.56 to 1.96
perature: 45 to trol lever:
55 °C Pitch back {16 to 20} {16 to 20}
• Operation mode: P Ripper con-
(power mode) 2.25 to 2.65 2.25 to 2.65
trol lever:
RAISE {23 to 27} {23 to 27}
• Fuel control dial
MAX (High idle) Ripper con- 2.25 to 2.65 2.25 to 2.65
trol lever:
LOWER {23 to 27} {23 to 27}
MPa
Ripper con-
{kg/cm2} 2.25 to 2.65 2.25 to 2.65
trol lever: N
→ Tilt IN {23 to 27} {23 to 27}

Ripper con-
trol lever: N 2.25 to 2.65 2.25 to 2.65
→ Tilt {23 to 27} {23 to 27}
BACK

23
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant temperature: 60
to 100 °C
• Power train oil temperature: 70
to 120 °C

Control cir- • Hydraulic oil temperature: 45 to

55 °C MPa 3.5 to 4.5 Min. 3.1
cuit oil pres-
sure • Operation mode: P (power {kg/cm2} {36 to 46} {Min. 32}
mode)
• Fuel control dial MAX (High idle)
• Blade control lever: NEUTRAL
• Ripper control lever: NEUTRAL
PA1: Ripper 2.5 to 2.8 2.5 to 2.8
lift (RAISE) {25.5 to 28.6} {25.5 to 28.6}
PA2: Ripper 3.06 to 3.35 3.06 to 3.35
tilt (tilt back) {31.2 to 34.2} {31.2 to 34.2}
PA3: Blade
2.4 to 2.7 2.4 to 2.7
LEFT tilt
{24.5 to 27.5} {24.5 to 27.5}
(LEFT tilt)
PA4: Blade
2.4 to 2.7 2.4 to 2.7
• Engine coolant RIGHT tilt
{24.5 to 27.5} {24.5 to 27.5}
temperature: 60 to (RIGHT tilt)
100 °C PA5: Blade 2.02 to 2.29 2.02 to 2.29
• Power train oil tem- lift (RAISE) {20.6 to 23.4} {20.6 to 23.4}
perature: 70 to PB1: Rip-
120 °C 2.5 to 2.8 2.5 to 2.8
EPC valve per lift MPa {25.5 to 28.6} {25.5 to 28.6}
outlet pres- • Hydraulic oil tem- (LOWER)
sure perature: 45 to {kg/cm2}
PB2: Rip-
55 °C 3.06 to 3.35 3.06 to 3.35
per tilt (tilt
{31.2 to 34.2} {31.2 to 34.2}
• Operation mode: P in)
(power mode)
PB3: Blade
• Fuel control dial 2.4 to 2.7 2.4 to 2.7
LEFT tilt
MAX (High idle) {24.5 to 27.5} {24.5 to 27.5}
(RIGHT tilt)
PB4: Blade
2.4 to 2.7 2.4 to 2.7
RIGHT tilt
{24.5 to 27.5} {24.5 to 27.5}
(LEFT tilt)
PB5: Blade
1.48 to 1.73 1.48 to 1.73
lift (LOW-
{15.1 to 17.6} {15.1 to 17.6}
ER)
PB5: Blade 2.81 to 3.11 2.81 to 3.11
lift (FLOAT) {28.7 to 31.7} {28.7 to 31.7}

24
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine coolant LOCK posi-
0 0
temperature: 60 to tion
100 °C
• Power train oil tem-
Work equip-
perature: 70 to
ment lock 120 °C
MPa
solenoid • Hydraulic oil tem- 3.5 to 4.5
valve outlet perature: 45 to FREE posi- {kg/cm2} Min. 3.1
tion {36 to 46}
pressure 55 °C {Min. 32} (*2)
(*2)
• Operation mode: P
(power mode)
• Fuel control dial
MAX (High idle)
• Engine coolant
temperature: 60 to
100 °C
• Power train oil tem-
Ripper pin
perature: 70 to
120 °C Pull on the 2.65 to 3.03
puller sole- MPa Min. 2.55
side of pin
noid valve • Hydraulic oil tem- {27.0 to 30.9}
puller cylin- {kg/cm2} {Min. 26} (*3)
outlet pres- perature: 45 to (*3)
der head
sure 100 °C
• Operation mode: P
(power mode)
• Fuel control dial
MAX (High idle)

*1: Item that you can check with monitoring function of the machine monitor
*2: Same as control circuit oil pressure.
*3: Same as R.H. and L.H. brake pressure (RB and LB).

25
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Speed of the work equipment

Standard val- Meas- No
Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Hydraulic oil tem- U dozer,
perature: 45 to semi-u doz-
4.5 to 5.5 Max. 6.0
55 °C er specifi-
cation
• Operation mode: P
(power mode)
• Fuel control dial
MAX (High idle)
• No load on blade
• See the STAND-
Blade ARD VALUE TA-
RAISE BLE, “MACHINE
POSTURE AND Super doz-
PROCEDURE FOR er specifi- 4.3 to 5.3 Max. 6.0
MEASURING PER- cation
FORMANCE”, Fig.
1.
• Time required to
operate the blade
from the ground
level to RAISE
stroke end
second
• Hydraulic oil tem- U dozer,
perature: 45 to semi-u doz-
1.5 to 2.1 Max. 2.5
55 °C er specifi-
cation
• Operation mode: P
(power mode)
• Fuel control dial
MAX (High idle)
• No load on blade
• See the STAND-
Blade LOW- ARD VALUE TA-
ER BLE, “MACHINE
POSTURE AND Super doz-
PROCEDURE FOR er specifi- 1.4 to 2.0 Max. 2.5
MEASURING PER- cation
FORMANCE”, Fig.
1.
• Time required to
operate the blade
from RAISE stroke
end to the ground
level

26
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Hydraulic oil tem- U dozer,
perature: 45 to semi-u doz-
3.3 to 4.3 Max. 5.0
55 °C er specifi-
cation
• Operation mode: P
(power mode)
• Fuel control dial
MAX (High idle)
• No load on blade
• Time required to
Blade LEFT operate the blade
from RIGHT tilt end second
tilt
to LEFT tilt end Super doz-
er specifi- 2.5 to 3.8 Max. 6.0
• See the STAND-
cation
ARD VALUE TA-
BLE, “MACHINE
POSTURE AND
PROCEDURE FOR
MEASURING PER-
FORMANCE”, Fig.
2.
Dual tilt
• Hydraulic oil tem- U dozer,
perature: 45 to semi-u doz-
3.3 to 4.3 Max. 5.0
55 °C er specifi-
cation
• Operation mode: P
(power mode)
• Fuel control dial
MAX (High idle)
• No load on blade
• Time required to
Blade
operate the blade second
RIGHT TILT
from LEFT tilt end Super doz-
to RIGHT tilt end er specifi- 2.8 to 4.1 Max. 6.0
• See the STAND- cation
ARD VALUE TA-
BLE, “MACHINE
POSTURE AND
PROCEDURE FOR
MEASURING PER-
FORMANCE”, Fig.
2.

27
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Hydraulic oil tem- U dozer, semi-u dozer specification
perature: 45 to
Fuel control
55 °C dial MAX 3.9 to 4.9 Max. 6.0
• Operation mode: P (High idle)
(power mode) second
Fuel control
• No load on blade dial MIN 8.1 to 11.1 Max. 13.0
• Time required to (Low idle)
Blade pitch move BACK end to Super dozer specification
DUMP DUMP end
Fuel control
• See the STAND- dial MAX 6.8 to 8.8 Max. 10.0
ARD VALUE TA- (High idle)
BLE, “MACHINE
POSTURE AND second
PROCEDURE FOR Fuel control
MEASURING PER- dial MIN 20.0 to 26.0 Max. 30.0
FORMANCE”, Fig. (Low idle)
3.
• Hydraulic oil tem- U dozer, semi-u dozer specification
perature: 45 to
Fuel control
55 °C dial MAX 3.6 to 4.6 Max. 6.0
• Operation mode: P (High idle)
(power mode) second
Fuel control
• No load on blade dial MIN 5.0 to 8.2 Max. 10.0
• Time required to (Low idle)
operate the blade Super dozer specification
Blade pitch from the DUMP
back end to BACK end Fuel control
dial MAX 6.2 to 8.2 Max. 9.5
• See the STAND- (High idle)
ARD VALUE TA-
BLE, “MACHINE
POSTURE AND second
Fuel control
PROCEDURE FOR dial MIN 14.0 to 18.0 Max. 23.0
MEASURING PER- (Low idle)
FORMANCE”, Fig.
3.

28
30 TESTING AND ADJUSTING PM CLINIC SERVICE

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Hydraulic oil tem- Time re-
perature: 45 to quired to
55 °C operate the
Ripper
ripper from 2.5 to 3.5 Max. 4.0
RAISE • Operation mode: P
the ground
(power mode) to RAISE
• Fuel control dial end
MAX (High idle)
• No load on ripper
(lowest shank hole) Time re- second

• See the STAND- quired to

ARD VALUE TA- operate rip-
Ripper
BLE, “MACHINE per from 2.5 to 3.5 Max. 4.0
LOWER
POSTURE AND RAISE end
PROCEDURE FOR to the
MEASURING PER- ground
FORMANCE”, Fig.
4.
• Hydraulic oil tem- Time re-
perature: 45 to quired to
55 °C operate the
Ripper TILT
ripper from 4.7 to 5.7 Max. 7.0
IN • Operation mode: P
TILT BACK
(power mode) end to TILT
• Fuel control dial IN end
MAX (High idle)
• No load on ripper second
Time re-
• See the STAND-
quired to
ARD VALUE TA-
operate the
Ripper TILT BLE, “MACHINE
ripper from 2.8 to 3.8 Max. 4.5
BACK POSTURE AND TILT IN end
PROCEDURE FOR to TILT
MEASURING PER- BACK end
FORMANCE”, Fig.
4.

Hydraulic drift of the work equipment

Standard val- Meas- No
Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Hydraulic oil temperature: 45 to
55 °C
• Engine is stopped

Hydraulic • Hydraulic drift of blade bottom

drift of lifted height (h) in 15 min. mm Max. 150 Max. 300
blade • See the STANDARD VALUE TA-
BLE, “MACHINE POSTURE
AND PROCEDURE FOR
MEASURING PERFORM-
ANCE”, Fig. 6.

29
PM CLINIC SERVICE 30 TESTING AND ADJUSTING

Standard val- Meas- No

Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Hydraulic oil temperature: 45 to
55 °C
• Engine is stopped
Hydraulic • Hydraulic drift of idler center
drift of ma- height (h) in 5 min. mm Max. 50 Max. 100
chine lifted
• See the STANDARD VALUE TA-
by blade
BLE, “MACHINE POSTURE
AND PROCEDURE FOR
MEASURING PERFORM-
ANCE”, Fig. 7.
• Hydraulic oil temperature: 45 to
55 °C
• Engine is stopped
Hydraulic • Hydraulic drift of track shoe bot-
drift of ma- tom height (h) in 5 min. mm Max. 50 Max. 100
chine tilted
• See the STANDARD VALUE TA-
by blade
BLE, “MACHINE POSTURE
AND PROCEDURE FOR
MEASURING PERFORM-
ANCE”, Fig. 8.
• Hydraulic oil temperature: 45 to
55 °C
• Engine is stopped

Hydraulic • Hydraulic drift of shank bottom

drift of lifted height (h) in 15 min. mm Max. 80 Max. 160
ripper • See the STANDARD VALUE TA-
BLE, “MACHINE POSTURE
AND PROCEDURE FOR
MEASURING PERFORM-
ANCE”, Fig. 9.
• Hydraulic oil temperature: 45 to
55 °C
• Engine is stopped
Hydraulic • Hydraulic drift of sprocket center
drift of ma- height (h) in 5 min. mm Max. 30 Max. 60
chine lifted
• See the STANDARD VALUE TA-
by ripper
BLE, “MACHINE POSTURE
AND PROCEDURE FOR
MEASURING PERFORM-
ANCE”, Fig. 10.

Final drive
Standard val- Meas- No
Judgment Goo
Item Test condition Unit ue for new ured val- goo
criteria value d
machine ue d
• Engine is stopped There must be no excessive
Final drive -
• Visual check of drain plug metallic powder

30
D475A-8R BULLDOZER
Form No. GEN00241-00

©2022 KOMATSU
All Rights Reserved
Printed in Japan 05-22 (01)