KOMATSU D475A-5E0 D475ASD-5E0 BULLDOZER FIELD ASSEMBLY INSTRUCTION MANUAL (SN:30001 & UP) KOMATSU D4

GEN00051-05

Field Assembly Instruction

BULLDOZER

-5E0 D475A D475ASD -5E0 SERIAL NUMBERS

30001

and up

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

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

Many units are large in size and heavy in weight and may be handled in a dangerous place or posture and many workers may have to work together to sling them with cranes.

Accordingly, before starting the assembly work, the work supervisor is required to hold a safety meeting to oblige the workers to put on protective gear and appoint a work leader and a crane work signal man and allot roles to all the workers for safe work.

In particular, the above meeting is more important when worker of different languages and customs work together.

The following is a reference supervision system diagram.

(Instruction system) Work leader Work supervisor

Crane director

Director and deputy director

Operator for assembly Liaison man Mechanics

Sharing of work

Interpreter

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

Accordingly, before installing the work equipment, inspect and maintain the machine thoroughly.

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

If you have any question when dividing and transporting the machine by yourself in future, ask one of our distributors.

CONTENTS SPECIFICATIONS...........................................................................................................................

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

DISPOSAL OF REMOVED PARTS ................................................................................................

ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE.................................

KIT LAYOUT DIAGRAM ..................................................................................................................

STYLE FOR TRANSPORTATION ..................................................................................................

TOOLS LIST FOR FIELD ASSEMBLY............................................................................................

SKETCH OF TOOLS .......................................................................................................................

TIGHTENING TORQUE ..................................................................................................................

COATING MATERIALS ...................................................................................................................

1 3 4 5 6 7 13 16 25 29

A. ASSEMBLY PROCEDURE ......................................................................................................... 31 A- 1. Setting of track shoe ........................................................................................................... 32 A- 2. Setting of the machine ........................................................................................................ 33 A- 3. Installation of blade lift hydraulic cylinder ........................................................................... 36 A- 4. Installation of undercarriage ............................................................................................... 42 A- 5. Adding oil to pivot chamber ................................................................................................ 58 A- 6. Check of oil and coolant levels ........................................................................................... 59 A- 7. Installation of ripper ............................................................................................................ 61 A- 8. Installation of trunnion ........................................................................................................ 66 A- 9. Installation of track shoe..................................................................................................... 67 A-10. Check track tension ............................................................................................................ 70 A-11. Assembly of blade .............................................................................................................. 72 A-12. Installation of blade ............................................................................................................ 92 A-13. Installation of operator's cab............................................................................................... 100 A-14. Installation of ROPS ........................................................................................................... 120 A-15. Installing direction of exhaust pipe ..................................................................................... 121 A-16. Installation of giant ripper shank......................................................................................... 122 A-17. Adjustment of arm joint (U-blade)....................................................................................... 123 A-18. Installation of counterweight ............................................................................................... 124 A-19. Procedure for adjusting blade tilt angle limit....................................................................... 125 A-20. Method of checking auto-reset system (Superdozer)......................................................... 134 A-21. Installation of ORBCOMM antenna and wiring harness ..................................................... 135 A-22. Installing lunchbox band (if equipped) ................................................................................ 136 A-23. Greasing each part of work equipment .............................................................................. 138 A-24. Bleeding air from hydraulic cylinders.................................................................................. 141 A-25. Air bleeding from work equipment pump and fan pump ..................................................... 142 M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY ..................

M- 1. Check and adjustment of operator’s cab ...........................................................................

M- 2. Inspection of machine monitor ...........................................................................................

M- 3. No-injection cranking of engine..........................................................................................

M- 4. Setting procedure of user adjust mode ..............................................................................

M- 5. Replacement of return filter (Replacement of standard filter → special flushing parts) ....

M- 6. Flushing of hydraulic circuit, and bleeding air from hydraulic cylinders (Part 1) ................

M- 7. Replacement of return filter (Replacement of special flushing parts → standard filter) .....

M- 8. Bleeding air from hydraulic cylinders (Part 2) ....................................................................

143 144 151 164 167 170 172 173 175

APPENDIX 1 INSTALLATION OF SPILL GUARDS APPENDIX 2 PRECAUTIONS FOR INITIALIZATION PROCEDURES FOR VHMS CONTROLLER FIELD ASSEMBLY INSPECTION REPORT (U-DOZER SPECIFICATION) FIELD ASSEMBLY INSPECTION REPORT (SUPERDOZER SPECIFICATION)

SPECIFICATIONS Item

Unit

Semi-U-tiltdozer + Variable giant ripper

Full U-tiltdozer + Variable giant ripper

Superdozer + Counterweight

Operating weight (excluding operator's weight)

kg

Blade weight (including cylinders)

kg

Ripper weight (including cylinders)

kg

Counterweight

kg

Engine model

–

Komatsu SAA12V140E-3 diesel engine

kW/rpm {HP/rpm}

664/2,000{890/2,000}

Rated engine output Overall length

mm

Overall height (with ROPS)

mm

Overall width

mm

108,310

(*1)

16,500

11,560

113,120 (*2) 18,800

20,900

7,360

–

–

6,040

11,950

10,525

4,546 (4,646) 5,265

6,205

Travel speed

Forward

km/h

3.5/6.3/10.9

(1st/2nd/3rd)

Reverse

km/h

4.7/8.4/14.3

*1: Blade + ripper + ROPS cab + air conditioner *2: Superdozer + counterweight + ROPS cab + air conditioner

• Semi-U-tiltdozer + variable giant ripper

• Full U-tiltdozer + variable giant ripper

1

6,465

• Superdozer + counterweight

2

PRECAUTIONS FOR FIELD ASSEMBLY 1. Selection of work place 1) When selecting a work place, consider the following.

• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout drawing.)

• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)

• Is the ground flat? (The ground surface must not be uneven or sloping.)

• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?

2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.

3) Avoid working outdoors while strong wind is blowing or it is raining.

4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.

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

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

3. Preparation and check of protective gear, slings and tools The work supervisor or the work leader must perform the following checks about protective gear, slings and tools.

1) Are all the workers wearing helmets and other protective gear which they are obliged to wear?

If special protective gear is necessary, check that it is prepared and can be used without problem.

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

4. k Check during actual work The work supervisor or the work leader must check the following items constantly and make all the workers observe them.

1) Are the parking brakes of the trailer and crane truck applied securely and are their wheels locked with chocks during work? Are outriggers, if installed, used securely?

2) Are the temperature and pressure of the engine, hydraulic oil, coolant, etc. lowered sufficiently during work?

3) Is horn or another signal is made to warn around when the engine is started? In addition, is it checked that work equipment control lever and other control levers are in neutral and the fuel control dial (or fuel control lever) is in the low idle position?

4) Is the balance of the slung item checked extremely during sling work with the crane?

5) Is entry prohibition for outsiders to the work place observed?

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

6. Precautions for starting engine When the engine is started for the first time after assembled in the field, its inside must be lubricated with engine oil. Lubricate according to “M-3 No-injection cranking of engine” in this manual.

3

DISPOSAL OF REMOVED PARTS As described in "Preface", when this machine is transported, it is divided into some units such as the body, undercarriage, cab, work equipment, etc. according to the transportation measure, regulations, etc.

Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydraulic devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt and dust, and damage during transportation.

In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to facilitate loading, unloading and crane work.

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

4

Setting of track shoe Setting of the machine (Unloading of other parts)

Installation of blade lift hydraulic cylinder Installation of undercarriage Replacement of return filter Adding oil to pivot chamber Check of oil and coolant levels Installation of ripper Installation of trunnion Installation of track shoe Check track tension Assembly of blade Installation of blade Installation of operator's cab Installation of ROPS Installation of exhaust pipe Installation of giant ripper shank Adjustment of arm joint (U-blade) Installation of counterweight Procedure for adjusting blade tilt angle limit Method of checking auto reset system Installation of ORBCOMM antenna and wiring harness Installing lunchbox band Greasing each part of work equipment Bleeding air from hydraulic cylinders Air bleeding from work equipment pump and fan pump Inspection Assembly Workers Welding Crane (With operator)

3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 –

Schedule

5 4 45 ton × 1

45 ton × 2

2nd day

4

1st day

4 (2) 45 ton × 1

3rd day

45 ton × 1

4

4th day

45 ton × 1

4

5th day

• •

1 2

No. Item

ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE A change of the schedule caused by weather is not considered.

The special work in the field shall be adjusted separately.

KIT LAYOUT DIAGRAM

Approx. 30 m

Accessories CAB assembly ROPS guard

6

Approx. 30 m

Chassis

Ripper parts

Right straight frame Truck crane (45 ton)

Left straight frame

Right track

Track

Track

Blade

Left track

•

When selection the work site, see "Precautions for field assembly", too.

The delivered kits (components) should be arranged as shown in the layout below after unloaded from the trailer and truck.

However, since the layout below is a reference image of a work site about 30 m by 30 m, decide the actual layout according to the area and land form of the work site, considering the transportation packaging of each kit (component) explained later.

Truck crane (45 ton)

• •

STYLE FOR TRANSPORTATION Since the machine can be divided for transportation, ask us or our service shop before transportation.

■ Style of each KIT. • Body

A

Overall length (mm)

6,600

B

Overall height (mm)

3,300

C

Overall width (mm) Weight (kg)

3,320 43,000

Note: The blade lift cylinder may be installed before delivery.

• Track frame

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

A

Overall length (mm)

4,800

B

Overall height (mm)

1,500

C

Overall width (mm)

982

Weight (kg)

12,200

• WORK EQUIPMENT (1) U-blade

A

Overall length (mm)

6,205

B

Overall height (mm)

2,615

C

Overall width (mm)

2,170

Weight (kg)

7

14,000

(2) Semi U-blade

A

Overall length (mm)

5,263

B

Overall height (mm)

2,610

C

Overall width (mm)

1,760

Weight (kg)

13,000

A

Overall length (mm)

6,465

B

Overall height (mm)

2,690

C

Overall width (mm)

• Super blade

Weight (kg)

2,180 14,000

fl Refer to the Appendix 1 for welding of spill guard.

• Track shoe

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

8

Shoe width

810

A (mm)

4,500

B (mm)

1,400

Weight (kg)

6,770 (1/2)

• Straight frame

a Right and left straight frames are prepared for each machine.

A B C

Overall length (mm) Overall height (mm) Overall width (mm) Weight (kg)

Semi-U, U 4,857 674 638 1,770

Super 5,020 682 681 1,868

A C

Overall length (mm) Overall width (mm) Weight (kg)

Semi-U, U 1,930 351 504

Super 1,754 351 508

• Hydraulic cylinder (1) Pitch, tilt cylinder

a One set of this part is used for single tilt-dozer and two sets for dual tilt-dozer.

(2) Blade lift cylinder

A B C

Overall length (mm) Overall height (mm) Overall width (mm) Weight (kg)

2,900 630 435 500

Note: May be installed to chassis before delivery.

9

(3) Ripper cylinder

a Both for lifting and tilting, each one set of this part is used on both left and right sides.

A C

Overall length (mm) Overall width (mm) Weight (kg)

Lift 1,748 304 389

Tilt 1,698 304 394

• Giant ripper beam

A B C

Overall length (mm) Overall height (mm) Overall width (mm) Weight (kg)

1,545 1,930 1,535 2,400

A B C

Overall length (mm) Overall height (mm) Overall width (mm) Weight (kg)

2,290 580 1,781 1,750

• Giant ripper arm, multi ripper arm

a Connecting pin with the beam is attached in this part in advance.

10

• Giant ripper shank assembly

A B C

Overall length (mm) Overall height (mm) Overall width (mm) Weight (kg)

115 2,800 940 1,000

a Protector and point is attached in this part in advance.

• Multi ripper beam

A B C

Overall length (mm) Overall height (mm) Overall width (mm) Weight (kg)

1,210 1,930 3,065 3,450

Overall length (mm) Overall height (mm) Overall width (mm) Weight (kg) Q’ty

115 2,170 775 740 3

• Multi ripper shank assembly (machine with multi ripper specification only)

A B C

a Protector and point is attached in this part in advance.

11

• Operator cab assembly

A B C

Overall length (mm) Overall height (mm) Overall width (mm) Weight (kg)

1,875 1,680 1,740 500

A B C

Overall length (mm) Overall height (mm) Overall width (mm) Weight (kg)

2,100 1,411 585 918

• ROPS

a For ROPS, see "Specifications".

• Counterweight

A B C1 C2

Overall length (mm) Overall height (mm) Overall width (mm) Weight (kg)

12

1,950 1,300 1,361 1,290 7,300

TOOLS LIST FOR FIELD ASSEMBLY No.

Specification

Q'ty

1

Truck crane

Maximum lifting capacity: 441 kN {45 t}

2

2

Air compressor

Discharge pressure: 0.69 MPa {7 kg/cm2} Discharge flow: 15 m3/min

1

3

Welding machine (see remarks)

It is used when spill guard (if equipped) Determine the specification and quantity in is to be added to the blade of work accordance with the drawings mentioned in the equipment. remarks.

For drawing see "Attached sheet".

4

Chain lever hoist (Chain block)

5

6

Part name

Wire rope sling

Belt sling: (Made by synthetic fibers)

Rated load: 15.7 kN {1.6 t}

2

Rated load: 31.4 kN {3.2 t}

2

ø12 mm × 2 m (11 kN {1.2 t})

4

ø12 mm × 4 m (11 kN {1.2 t})

1

ø16 mm × 2 m (21 kN {2.1 t})

4

ø20 mm × 5 m (32 kN {3.3 t})

4

ø20 mm × 6 m (32 kN {3.3 t})

4

ø24 mm × 2 m (47 kN {4.8 t})

2

ø32 mm × 5 m (84 kN {8.56 t})

4 2

For lifting the machine

1

For lifting the machine

Width: 25 mm × 1.5 m (4.9 kN: {0.5 t})

1

Width: 25 mm × 3 m (4.9 kN: {0.5 t})

2

Width: 50 mm × 3 m (9.8 kN: {1 t})

2

Width: 50 mm × 4 m (9.8 kN: {1 t})

2

Width: 100 mm × 4 m (19.6 kN: {2 t})

2

Wire diameter: 12.5 mm × 1.5 m (49 kN: {5 t})

1

8

Hydraulic wrench

Tightening capacity (torque): 5890 Nm {600 kgm} or more

1

9

Hydraulic wrench socket

10

16-times power wrench

11

Socket for 16-times power wrench

12

Pneumatic impact wrench

15

• Vertical lifting capacity is shown in parentheses.

• JIS B8817 or equivalent • The rope is 24A of JIS G3525 or equivalent

ø52 mm × 3 m (238 kN {24.3 t})

Load chain

14

JIS B8819 or equivalent

ø65 mm × 5 m (373 kN {38 t})

7

13

Remarks

Nominal width across flats: 50 mm 1 Tightening capacity (torque): 1 4400 Nm {450 kgm} or more Nominal width across flats (mm): 1 each 50, 46, 41, 36 Tightening capacity (torque): 1 2940 Nm {300 kgm} or more 980 Nm {100 kgm} or more 1 315 Nm {32 kgm} or more

1

160 Nm {16 kgm} or more

1

140 Nm {14 kgm} or more

1

Nominal width across flats (mm): Socket 50, 46, 41, 36, 32 (for pneumatic impact wrench) 30, 27, 24, 22, 19 600 mm long Extension bar 300 mm long Tightening capacity (torque): 2060 Nm {210 kgm} or more 1375 Nm {140 kgm} or more Torque wrench 590 Nm {60 kgm} or more

1 1 1 1 1 1

180 Nm {18 kgm} or more

1

Spanner

Nominal width across flats (mm) : 17, 19, 22, 24, 27, 30 32, 36, 41, 46, 50

17

Pneumatic hose and coupler (for pneumatic tools)

Inner diameter 6 to 10 mm × length 30 m Service pressure: 0.69 MPa {7 kg/cm2}

13

For tightening master link bolts of the track shoes

1 each

412 Nm {42 kgm} or more

16

• Vertical lifting capacity is shown in parentheses.

• Class I, type E of JIS B8818 or equivalent

2 each

1

Extending bar for pneumatic impact wrench • Prepare torque wrench so that the socket for air impact wrench could be used commonly.

• If torque wrench is not available, prepare the socket for torque wrench.

The width across flats is the same with the socket for pneumatic impact wrench.

For tightening hydraulic hose mouthpiece nut • The size of couplers on both sides are to be same as that of air compressor, pneumatic impact wrench, grease pump and oil feeding pump.

No.

18

19

20

21

22

Part name

Eyebolt

Shackle for sling

Master link for lifting

Pinch bar (lever bar)

Sling bar (steel rod)

23

Sledge hammer

24

Jack

25

Tap (for repairing thread)

Specification

Q'ty

Adaptable screw: M12 Using load: 2.16 kN {220 kg} Adaptable screw: M16 Using load: 4.41 kN {450 kg} Suitable screw: M24 Using load: 9.32 kN {950 kg} SD16-M, using load 9.8 kN {1 t}

2

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

4 2

SB36-S, using load 122.6 kN {12.5 t}

2

SB50-S, using load 245.2 kN {25 t}

1

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

O type, using load 125 kN {12.7 t}

2

O type, using load 160 kN {16.3 t}

1

2 1

ø25 mm × 700 mm

2

ø19 mm × 300 mm

1

Double-headed: 4.5 kg (10 lbs) Thread type Using load: 147.1 kN {15 t} M24 × pitch 3

1

M30 × pitch 3

1

M33 × pitch 2

1

• For master link of track shoes • For adjusting the tilt limit angle of the blade (see A-19 in assembly procedure)

2

27

Grease pump

Pneumatic supplying type

1

30

Drain oil receiver (made of steel sheet)

Manual type or pneumatic supplying type Capacity: Approx. 5 l Height × width × depth (mm) Approx. 1000 × 700 × 150 Approx. 700 × 400 × 150

• JCMAS P018 or equivalent • See Fig. 9 for the shapes • S53C (JIS G4051) or equivalent is suitable for its material.

• For assembly of the undercarriage

1

1

Oil jack

• O type of JIS B8817 or equivalent • See Fig. 3 and Fig. 5 for the using positions.

ø25 mm × 1 m

2

With leveler with a smallest scale of one degree

29

• JIS B2801 or equivalent • Symbols show the type, nominal size and class in order. (See Fig. 8.)

Diameter of grip × full length of tool ø13 mm × 400 mm or equivalent ø25 mm × 900 mm or equivalent

Angle meter

Oil feed pump

• JIS B1168 or equivalent • The using load is the load for vertical lifting

1

26

28

Remarks

1 1 2 each

Approx. 300 × 300 × 100 Front stand (see Fig. 1)

1

Rear stand (see Fig. 2) Thickness × height × width (mm) 16 × 1000 × 500 t25 × T300 (mm)

1

t25 × 300 × 600 (mm)

4

See Fig. 3 and Fig. 4

1

31

Chassis stand (for fixing the machine body)

32

Floor plate made by steel (for setting chassis stand)

33

Steel plate

34

Sling jig A

35

Sling jig B

See Fig. 5 and Fig. 6

1

36

Sling jig C

See Fig. 5 and Fig. 7

1

14

4

• Weld lifting hook to the corner

1 • For slinging track frame assembly • For slinging final drive assembly and pivot shaft • For slinging final drive assembly

No.

37

Part name

Wooden bar

Specification Height × width × depth (mm) 350 × 350 × 750 350 × 350 × 670

Q'ty

Remarks

4 2

350 × 350 × 400

4

300 × 300 × 600

2

100 × 100 × 750

4

95 × 95 × 180 to 200

2

350 × 350 × 800

2

38

Stand for high lift work

Height 2 m with stairs and handrail

1

39

Safety belt

Trunk belt type

40

Goggles

41

Safety rope and "No Entrance" board

42

Resin tube (Vinyl tube)

43

Lubricating oil and grease

See A-6 of assembly procedure

44

Seizure preventing agent

Molybdenum disulfide grease (LM-P)

45

Cleaning oil

For removing of preservative

40 l

46

Paint remover

5l

47

Repair paint

For removing of phthalic acid coating materials See the list of coating materials.

48

Glass cleaner

Liquid cleaner

49

Waste cloth

50

Adhesive cloth tape

Width × Length × Color 50 mm × 25 m × Not specified

1 wrap

51

Wire (metal wire)

ø3.2 mm × length approx. 2 m

1

For the number For high lift works of workers

For welding For protecting from spray • Rope of yellow ground color with black stripes • Standing signboard Inner diameter 8 mm × thickness 1 mm × length 3 m Soft and transparent

Necessary quantity Necessary quantity 1

For preventing outsiders from entering the working area For checking air tightness (internal pressure) of operator's cab

— 200 g

See the list of coating materials.

3 each For cleaning of the Proper quantity windshield glass of operator’s cab 1 kg

JIS G3532 #10 or equivalent

a General tools for manual works (such as box wrench, driver, pliers, etc.) are not listed in this list.

Prepare general tools if necessary.

15

Only movable part

Only movable part

No. 01 02 03 04 05 06 07 08 09 10 11 12 13

16 Material SS400C SS400C SS400C SS400C SS400C SS400C SS400C SS400B SS400 SS400 SS400 SS400 SS400

Q'ty 4 2 2 2 2 2 2 4 4 4 10 2 2

Material t12

Remarks C150×75×t9-1332 C150×75×t9-829 C150×75×t9-829 C150×75×t9-510 C150×75×t9-548 C150×75×t9-453 C150×75×t9-355 T50-500 t25×180×250 t12×200×655 t12×60×128 t16×124×130 t25×70×85

Fig.1

SKETCH OF TOOLS

• For jigs that are not available from the market, see jig drawings (Fig. 1 to Fig. 7) and make them in the field. a But Komatsu does not take the responsibility of manufacturer for the jigs made in accordance with Fig. 1 to Fig. 7

1. Chassis stand (Front side)

17 Only movable part

Only movable part

No. 01 02 03 04 05 06 07 08 09 10 11 12 13

Material SS400C SS400C SS400C SS400C SS400C SS400C SS400C SS400B SS400 SS400 SS400 SS400 SS400

Total weight

Material t12

Q'ty 4 2 2 2 2 2 2 4 4 4 10 2 2

Remarks C150×75×t9-1282 C150×75×t9-829 C150×75×t9-829 C150×75×t9-510 C150×75×t9-548 C150×75×t9-453 C150×75×t9-355 T50-500 t25×180×250 t12×200×655 t12×60×128 t16×124×130 t25×70×85

Fig.2

2. Chassis stand (Rear side)

• • •

Track frame assembly

Clane

18

Straight shackle

04

Bow shackle

Master link

03

06

Bow shackle

02

Master link

Sling jig A

01

05

Material

No.

Fig. 3 shows the example of using of sling jig A. Bow shackle (Fig No.06) in Fig. 3 is for installing the leveling sling of the lifting object (track frame assembly).

See Fig. 4 for the details of sling jig A (Fig No.01).

1

2

4

1

1

1

Q'ty

Using load: 35.3 kN {3.6 t} BB24 (M level) of JIS B2801 or equivalent

Using load: 125 kN {12.7 t} JIS B8817 or equivalent

Using load: 122.6 kN {12.5 t} SB36 (S level) of JIS B2801 or equivalent

Using load: 160 kN {16.3 t} JIS B8817 or equivalent

Using load: 157 kN {16 t} BB36 (T level) of JIS B2801 or equivalent

Remarks

Fig.3

3. Sling jig A (Track frame assembly)

19

2 places

2-36 drill

Weight: Approx. 345 kg The scale is indefinite.

2 places 2 places

2-44 drill

Plate Plate Plate

02 03

Part name 01

44 drill

SS400

SS400

SS400

Material

2

1

1

Q’ty

t36

t36

t36

Remark

Fig.4

3.1 Details of sling jig A

4. Sling jig B (final drive assembly and pivot shaft) • Fig. 5 shows the example of slinging of final drive assembly.

Fig.5

Crane

Master link • Using load: 80 kN {8.16 t} • JIS B8817 or equivalent

Sling jig B

Bow shackle • Using load: 78.5 kN {8 t} • BB28 (S level) of JIS B2801 or equivalent

Straight shackle • Using load: 78.5 kN {8 t} • BB28 (S level) of JIS B2801 or equivalent

Sling jig C

Final drive assembly

a For details of sling jigs B and C, see Fig. 6 and 7. a For example of slinging pivot shaft, see "Assembly procedure A-5".

20

Apply chamfering on the ridges and corners so that they would not hurt hands.

21 The scale is indefinite.

Plate Plate

02

Part name 01

No.

Weight: Approx. 175 kg

36 drill

2-36 drill

SS400

SS400

Material

1

1

Q’ty

t22

t28

Remark

Fig.6

4.1 Details of sling jig B

2-33 drill

2-36 drill

22 Part name Plate Boss

01 02

SS400

SS400

Material

Weight : Approx. 14.5 kg No.

The scale is indefinite.

2

1

Q’ty

Before welding

Apply chamfering on the ridges so that they would not hurt hands.

ø56

t32

Remark

Fig.7

4.2 Details of sling jig C

5. Selecting table of shackles (extracted from JIS B2801-1996)

Fig.8

Straight shackle

Type SB

Type Nominal

Type SD

Dimension (Unit: mm)

Using load

t

B

d

D

L

d1

M level

S level

T level

16

16

32

ø16

36

64

ø20

9.8 kN {1 t}

—

—

22

22

44

ø22

50

88

ø27

19.6 kN {2 t}

—

—

28

28

43

ø28

70

112

ø34

47.1 kN {4.8 t}

78.5 kN{8 t}

98.1 kN {10 t}

36

36

54

ø36

90

144

ø42

78.5 kN {8 t}

122.6 kN {12.5 t}

156.9 kN {16 t}

50

50

75

ø50

125

200

ø60

156.9 kN {16 t}

245.2 kN {25 t}

308.9 kN {31.5 t}

SD

SB

Bow shackle Type BB

Type Nominal

BB

Dimension (Unit: mm)

Using load

t

B

d

D

L

d1

B1

M level

S level

24

24

39

ø28

62

126

ø30

70

35.3 kN {3.6 t}

61.8 kN {6.3 t}

28

28

43

ø32

70

144

ø34

80

47.1 kN {4.8 t}

78.5 kN {8 t}

36

36

54

ø42

90

190

ø42

105

78.5 kN {8 t}

23

T level

98.1 kN {10 t}

122.5 kN {12.5 t} 156.9 kN {16 t}

6. Pinch bar

Fig.9

Dimension (Unit: mm) Type L (Overall length)

d (Outer diameter of grip) [For round ones]

Small

400

13

Big

900

25

a This tool is equivalent to P018-1978 (pinch bar) of JCMAS (Japan Construction Mechanization Association Standard).

Similar parts are acceptable if the quality is not below this tool.

P019-1978 (ply bar) of JCMAS is also acceptable for tools of smaller type. a You can read the information about JCMAS on the website.

24

TIGHTENING TORQUE 1. Tightening torque for bolts Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified torque.

Part No. of bolt

TTTTT-TTTTT

Part No. of washer

EEEEE-EEEEE

Bolt specification

Thread × Bolt length Thread sizediameter (Diameter, pitch, length) Applicable socket size

Tool (Socket) Tightening torque

Nm {QQQ kgm}

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

Remarks 1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 20 26 mm is expressed as M20.

The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit: mm).

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

3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. correspond to dimension b in Fig. 1, an applicable socket can be selected from Table 1, too.

4. Tightening torque is expressed as QQQ – www or QQQ ± RR. If the target tightening torque is set, expression of QQQ ± RR is applied.

Fig. 1

a b c d

: Bolt thread diameter (Nominal diameter) : Width across flats of bolt head : Bolt length : Threaded part of bolt

25

Table 1 Tightening torque for bolts not specified in text Unit: Nm {kgm} Tightening torque

Nominal size of thread × pitch a (mm)

Width across flats (= Socket size) b (mm)

Unit : Nm

Unit : {kgm}

6×1

10

12 {1.2}

8.8 – 14.7 {0.9 – 1.5}

8 × 1.25

13

25 {2.5}

14.7 – 34 {1.5 – 3.5}

10 × 1.5

17

54 {5.5}

34 – 74 {3.5 – 7.5}

12 × 1.75

19

89 {9}

54 – 123 {5.5 – 12.5}

14 × 2

22

137 {14}

84 – 196 {8.5 – 20}

16 × 2

24

230 {23.5}

147 – 309 {15 – 31.5}

18 × 2.5

27

315 {32}

201 – 427 {20.5 – 43.5}

20 × 2.5

30

460 {47}

319 – 608 {32.5 – 62}

22 × 2.5

32

650 {66.5}

471 – 829 {48 – 84.5}

24 × 3

36

810 {82.5}

588 – 1030 {60 – 105}

27 × 3

41

1180 {120}

883 – 1470 {90 – 150}

30 × 3

46

1520 {155}

1130 – 1910 {115 – 195}

33 × 3

50

1960 {200}

1470 – 2450 {150 – 250}

36 × 3

55

2450 {250}

1860 – 3040 {190 – 310}

39 × 3

60

2940 {300}

2260 – 3630 {230 – 370}

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

26

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

2.1 If the male screw is made of mild steel or cast iron, apply Table 2.

Table 2 Unit: Nm {kgm} Material of female thread

Steel

Cast iron

Light alloy

1/8

3.9 – 6.9 {0.4 – 0.7}

2.9 – 5.9 {0.3 – 0.6}

2.0 – 3.9 {0.2 – 0.4}

1/4

5.9 – 11.8 {0.6 – 1.2}

4.9 – 9.8 {0.5 – 1.0}

3.9 – 7.8 {0.4 – 0.8}

3/8

16.7 – 26.5 {1.7 – 2.7}

13.7 – 21.6 {1.4 – 2.2}

9.8 – 16.7 {1.0 – 1.7}

1/2

32.3 – 52.9 {3.3 – 5.4}

26.5 – 43.1 {2.7 – 4.4}

19.6 – 32.3 {2.0 – 3.3}

3/4

51.0 – 85.3 {5.2 – 8.7}

42.1 – 70.6 {4.3 – 7.2}

31.4 – 52.9 {3.2 – 5.4}

1

86.2 – 173.5 {8.8 – 17.7}

72.5 – 146.0 {7.4 – 14.9}

54.9 – 111.7 {5.6 – 11.4}

Nominal size (in)

2.2 If the male screw is made of refined steel (heat-treated hard steel), apply Table 3.

Table 3 Unit: Nm {kgm} Material of female thread

Steel

Cast iron

Light alloy

1/8

16.7 – 29.4 {1.7 – 3.0}

9.8 – 19.6 {1.0 – 2.0}

6.9 – 14.7 {0.7 – 1.5}

1/4

19.6 – 44.1 {2.0 – 4.5}

16.7 – 37.2 {1.7 – 3.8}

12.7 – 28.4 {1.3 – 2.9}

3/8

44.1 – 93.1 {4.5 – 9.5}

37.2 – 77.4 {3.8 – 7.9}

27.4 – 58.8 {2.8 – 6.0}

1/2

98.0 – 188.2 {10.0 – 19.2}

83.3 – 157.8 {8.5 – 16.1}

60.8 – 115.6 {6.2 – 11.8}

3/4

170.5 – 316.5 {17.4 – 32.3}

141.1 – 247.0 {14.4 – 25.2}

105.8 – 186.2 {10.8 – 19.0}

1

367.5 – 612.5 {37.5 – 62.5}

309.7 – 514.5 {31.6 – 52.5}

235.2 – 392.0 {24.0 – 40.0}

Nominal size (in)

27

3. Tightening torque for hydraulic hose connecting nut For the connecting nuts installed to the hydraulic hose adapters in relatively low pressure systems, apply tightening torque in Table 4.

Table 4 Tightening torque (Nm {kgm})

Outside diameter of hose (mm)

Width across flatse. (mm)

Range

Target

Approx. 6

19

35 – 63 {3.5 – 6.5}

44 {4.5}

22

54 – 93 {5.5 – 9.5}

74 {7.5}

24

59 – 98 {6.0 – 10.0}

78 {8.0}

Approx. 13

27

84 – 132 {8.5 – 13.5}

103 {10.5}

Approx. 16

32

128 – 186 {13.0 – 19.0}

157 {16.0}

Approx. 20

36

177 – 245 {18.0 – 25.0}

216 {22.0}

Approx. 10

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

4. Proper socket sizes for bolts of M39 and larger (Reference) For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and larger, see Table 5.

Table 5 Unit: mm Thread diameter

Proper sizes of sockets or spanners

M42

65

M45

70

M48

75

M52

80

M56

85

M60

90

M64

95

28

COATING MATERIALS a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this list.

Category

Komatsu code

Part No.

Q'ty

Container

Main applications, features

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

Polyethylene container

• Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.

LT-2

09940-00030

50 g

Polyethylene container

• Features: Resistance to heat and chemicals • Used for anti-loosening and sealant purpose for bolts and plugs.

LT-3

790-129-9060 (Set of adhesive and hardening agent)

Adhesive: 1 kg Hardening agent: 500 g

Can

LT-4

790-129-9040

250 g

Polyethylene container

Holtz MH 705

790-126-9120

75 g

Tube

• Used as heat-resisting sealant for repairing engine.

Three bond 1735

790-129-9140

50 g

Polyethylene container

• Quick hardening type adhesive • Cure time: within 5 sec. to 3 min.

• Used mainly for adhesion of metals, rubbers, plastics and woods.

Adhesives

• Used as adhesive or sealant for metal, glass and plastic.

• Used as sealant for machined holes.

Aron-alpha 201

790-129-9130

2g

Polyethylene container

• Quick hardening type adhesive • Quick cure type (max. strength after 30 minutes) • Used mainly for adhesion of rubbers, plastics and metals.

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

• Resistance to heat, chemicals • Used at joint portions subject to high temperatures.

LG-1

790-129-9010

200 g

Tube

• Used as adhesive or sealant for gaskets and packing of power train case, etc.

LG-5

790-129-9080

1 kg

Can

• Used as sealant for various threads, pipe joints, flanges.

• Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

Tube

• Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread.

• Used as sealant for oil pan, final drive case, etc.

LG-6

790-129-9020

200 g

Gasket sealant LG-7

790-129-9070

1 kg

Tube

• Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Three bond 1211

790-129-9090

100 g

Tube

• Used as heat-resisting sealant for repairing engine.

Tube

• Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material • Used as sealing material for transfer case

Three bond 1207B

419-15-18131

100 g

29

Category

Molybdenum disulphide lubricant

Grease

Komatsu code

Part No.

Q'ty

Container

Main applications, features

LM-G

09940-00051

60 g

Can

• Used as lubricant for sliding portion (to prevent from squeaking).

Tube

• Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting.

• Used as lubricant for linkage, bearings, etc.

LM-P

09940-00040

G2-LI

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI

G2-CA

SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

Molybdenum disulphide grease LM-G (G2-M)

SYG2-400M SYG2-400M-A SYGA-16CNM

Hyper White Grease G2-T G0-T (*) *: For use in cold district

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)

Biogrease G2B G2-BT (*) *: For high temperature and large load

SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

200 g

• General purpose type Various

Various

Various

Various

400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can

400 g 16 kg

400 g 16 kg

• Used for normal temperature, light load bearing at places in contact with water or steam.

• Used for heavy load portion

• Seizure resistance and heat resistance higher than molybdenum diBellows type sulfide grease Can • Since this grease is white, it does not stand out against machine body.

• Since this grease is decomposed by bacteria in short period, it has Bellows type less effects on microorganisms, Can animals, and plants.

SUNSTAR PAINT PRIMER 580 SUPER

20 ml

Glass container

SUNSTAR GLASS PRIMER 580 SUPER

20 ml

Glass container

• Used as primer for cab side (Expiration date: 4 months)

Primer

Caulking material

SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"

320 ml

Polyethylene container

Adhesive for cab glass

Adhesive

417-926-3910

• Used as primer for glass side (Expiration date: 4 months) • "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass.

(Expiration date: 4 months) • Used as adhesive for glass.

(Expiration date: 6 months)

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene container

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml

Polyethylene container

SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml

Polyethylene container

GE TOSHIBA SILICONES TOSSEAL 381

22M-54-27220

333 ml

Cartridge

Natural yellow

SYPA-U03PNY

–

Spray can

Black gray

SYPA-U03PBG

–

Spray can

• Used to seal joints of glass parts.

(Expiration date: 4 months) • Used to seal front window.

(Expiration date: 6 months) • Used to seal joint of glasses.

Translucent white seal.

(Expiration date: 12 months)

Paint

30

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

Example:

(1) (2) (3) (4) (5) (6)

2.

Plate Collar Washer Bolt Bolt Washer

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

Front

Left hand

Right hand

Operator's seat Sprocket Rear

31

Assembly procedure

Setting of track shoe

A-1

1. Place two sets of track shoes to the place planned in the kit layout above, and expand one set on the left side of the machine while the other set on the right side as shown in Fig. 1.

Left track

Parallel

Front Right track

Front end

Symbol Dimension (mm) W

2,770

A

2,060

B

710

N

13,066

Remarks When shoe width is B

a Only master shoes are removed previously (one piece on each side, i.e. two pieces for each machine).

Number of shoes: 40

a When the track shoes are placed, they are folded as the shape in Fig. 2, so pay attention to the front and rear directions when expanding them.

a When the track shoes are placed on the ground, the joint portion with the master link on the tip of front side shoes faces to the ground. (Fig. 3)

Abutment joints Ground

32

Assembly procedure

Setting of the machine (1/3)

A-2 1. Installation of chassis stand

Place the steel plates between the tracks spread in parallel on the ground and install the chassis stands on them. a Arrange the chassis stands and steel plates as shown in the figure. a The chassis stands for the front side and rear side are different from each other. a The steel plates are required when the ground is soil. They are not required when the ground is covered with steel plates.

Chassis stand (rear)

Chassis stand (front)

Track (Left)

Steel plate

Track (Right)

Front end

Chassis stand (rear) Steel plate

Steel plate

Chassis stand (front) Ground

Symbol H1 H2 t L1 L2

Dimension (mm) 1,105 1,020 16 2,800 3,300 2,450

Remarks

Recommended thickness of steel plate

33

Assembly procedure

A-2

Setting of the machine (2/3)

2. Setting of the machine

(1) Front tow hook (hole diameter : 70 mm) (installed on the machine previously )

(7) Wire rope sling (ø52 mm × 3 m × 2 pieces)

(2) Shackle (equivalent to JIS SB50 [class 5])

(8) The second crane (45 t specification)

(3) Damage preventing pad (rubber or felt plate)

(9) Equalizer bar (installed on the machine previously)

(4) Wire rope sling (ø36 mm × 5 m × 1 piece) (5) The first crane (45 t specification)

(10) Hull frame (main frame of the machine)

(6) Tilt cylinder mounting pin for the ripper (installed on the machine previously)

(11) Front chassis stand (12) Rear chassis stand

a See the part of machine itself in above-mentioned "Style for transportation" for the machine weight.

34

Assembly procedure

A-2

Setting of the machine (3/3)

As shown in Fig. 4, set wire rope sling on the machine, one in the front and two in the rear, lift the machine up with two cranes together (one sling by one crane in the front, two slings by another crane in the rear), put down the machine from the trailer, and set it on the chassis stand on the ground. a Install the front wire rope sling by using tow hook on the under cover installed on the machine with suitable shackle.

At this time, set rubber or felt pad in the portions that the machine and the sling interfere with each other to prevent damage of the machine. a Install the rear wire rope sling to the tilt cylinder mount of the ripper attached on the machine previously.

There is one pin on each right and left side of the mount, so set one sling to each pin. a Set the equalizer bar, attached on the machine previously, on the front chassis stand, and set the hull frame (main frame of the machine ) on the rear chassis stand.

At this time, set the machine while confirming that the chassis stand is at the center of the width of the machine. a Before releasing the lift, set wooden bars (13) on left and right sides in the clearance between equalizer bar (9) and main frame (10) of the machine as shown in Fig. 5. <Specification of wooden bar> Section: 95 mm, square Length: 180 to 200 mm a Steel bar of the same shape can be used instead of wooden bar.

(9) Equalizer bar (10) Main frame of the machine (11) Front chassis stand (13) Wooden bar

35

Assembly procedure

A-3

Installation of blade lift hydraulic cylinder (1/6)

1. Make the counter mark from cylinder stay yoke (1) on the front top of the machine to cap (2), then remove them.

(Fig.1) a Specification of bolt (3) M30, length 140 mm a Remove bushings (5) and (6) held by cap (2) at the same time. At this time, disconnect greasing hose connected to the elbow of bushing (5).

(1) Cylinder stay yoke (2) Cap (3) Bolt

(4) Washer (5) Bushing (top) (6) Bushing (bottom)

2. To sling and install hydraulic cylinder horizontally (Fig. 3), turn cylinder stay yoke to keep its posture as shown in Fig. 2. a Set the mounting side of greasing hose connected to the bushing to the rear side.

Greasing hose

3. Lift up hydraulic cylinder with belt sling as shown in Fig. 3, and set it on the mounting portion of cylinder stay yoke. a Lifting load: 4.9 kN {500 kg} a Adjust the posture of hydraulic cylinder to be horizontal during lifting. a Set the rod side of hydraulic cylinder to the front side. a Tubes of hydraulic cylinder (A) on both left and right sides are on the outer and lower side of cylinder.

36

Assembly procedure

A-3

Installation of blade lift hydraulic cylinder (2/6)

4. Insert bushing (5) [Sealing welded plate on which the elbow connecting greasing hose is attached] into the trunnion shaft that becomes top of hydraulic cylinder. a Dust seal is embedded in the end of inserting port on bushing side. Carefully insert the bushing after applying grease (G2-LI), etc. in order to prevent damaging the lip of this seal.

Trunnion shaft

5. After that, install it to cylinder stay yoke by using bolts (3) and washers (4) so that bushing (5) is pressed by cap (2). a Align the dowel pin (knock pin) installed previously on the cap with the hole on bushing side. a Temporarily tighten the bolts at this time.

6. Insert bushing (6) (Sealing welded plate on which greasing nipple is attached) into trunnion shaft under hydraulic cylinder from the bottom, press it with cap (2) on the top in the same way, and install it to cylinder stay yoke by using bolts (3) and washers (4).

(2) Cap (3) Bolt (M30) (4) Washer (5) Bushing (top) (6) Bushing (bottom) (7) Blade lift hydraulic cylinder

7. Tighten bolts (3) on top and bottom firmly.

Bolt specification

M30, length 140 mm

Necessary socket

46 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

37

Assembly procedure

A-3

Installation of blade lift hydraulic cylinder (3/6)

8. Loosen bolt (9), and remove fixing jig (8) installed on hydraulic cylinder (7). (Fig. 5) a Specification of bolt (9) M16, length 35 mm a Fixing jig (8): It is a special jig for supporting hydraulic cylinder when front work equipment (blade) is not installed, and is mainly used when the machine is operated as a tractor.

9. After that, change the direction of fixing jig (8), reinstall hydraulic cylinder (7), and install the other side to the machine body by using bolts (11) and washers (12) as shown in Fig. 6.

Then hydraulic cylinder is fixed at nearly horizontal posture.

Rotating center of cylinder stay yoke

a Bolts (11) and washers (12) are installed on the machine in advance, and the part numbers are listed below as a reference.

No. 11 12

Part No. 01010-81630 21T-09-11330

Part Name Bolt Washer

Q'ty 1 1

a Specification of bolt (11) M16, length 30 mm 10. Release the slinging.

11. Reconnect greasing hose disconnected in Item 1 to the elbow of bushing (5).

38

Assembly procedure

Installation of blade lift hydraulic cylinder (4/6)

A-3 12. Installation of hydraulic hoses

1) Confirm the necessary quantity of parts by Fig. 7 and the table below. a The quantity shown in the table below is for one machine, and the necessary quantity for left and right hydraulic cylinder are both one half of the quantity for one machine. a Reuse flange (16) and sems bolt (17) of the cover part (see Fig. 8) removed in 2).

Piping on machine side

a This figure shows left hydraulic cylinder.

Right hydraulic cylinder is laterally symmetric with this figure.

No. 13 14 15 16 17

Part No. 07098-01218 07098-01219 07000-F3038 07371-51260 07375-21250

Part Name Hose Hose O-ring Flange Sems bolt

Q'ty 2 2 8 16 32

Remarks Length: 1,800 mm Length: 1,900 mm

Bolt with washer

a Specification of sems bolt (17) M12, length 50 mm Width across flats of bolt head: 17 mm (Special dimension)

39

Assembly procedure

A-3

Installation of blade lift hydraulic cylinder (5/6)

2) Remove cover parts (16 to 19) installed on hydraulic hose mounting portion of hydraulic cylinder and hydraulic hose mounting portion of machine piping for preventing oil leak during transportation and dust entrance into hydraulic circuit. (Fig.8) a But flange (16) and sems bolt (17) are to be reused for installing hydraulic hose.

Piping on machine side

No. 18 19

Part No. 07378-11210 07000-F3038

Part Name Head O-Ring

3) Install hydraulic hoses (13) (14) to hydraulic cylinder. a See Fig. 7 and Fig. 9 for mounting position and direction of left hydraulic cylinder.

For right hydraulic cylinder, install the parts laterally symmetrically as shown in Fig. 10.

Bolt specification

M12, length 50 mm

Necessary socket

17 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

(Bottom)

(Head)

a This figure shows View Y in Fig. 8 for left hydraulic cylinder.

40

Q'ty 1 1

Assembly procedure

Installation of blade lift hydraulic cylinder (6/6)

A-3

a Reference As shown in Fig. 9 and Fig. 10, the installation of hydraulic hose is laterally symmetric for left and right cylinders, but the hydraulic flow of left and right cylinders is different as shown in the following table.

Hydraulic cylinder Left Right

Hydraulic hose No. 13

Hydraulic cylinder connecting port Head

14

Bottom

13

Bottom

14

Head

(Head)

(Bottom)

4) Connect the other side of hydraulic hose with piping parts on machine side (see Fig. 7 or Fig. 8).

Connecting procedures, such as tightening torque of bolts, etc. are the same with 3). a Avoid interference between hydraulic hoses or between hydraulic hose and machine during installation.

13. Items 1 to 12 are mainly described on left hydraulic cylinder. Install right hydraulic cylinder with the same procedure.

Avoid interference

41

Assembly procedure

A-4

Installation of undercarriage (1/16)

1. Preparations 1) Removal of accessories Remove the following 10 parts (the bolts are not counted in) from the track frame as shown in the photo.

No. 1 2 3 4 5 6 7 8 9 10

Part No. 198-30-69530 198-30-61360 198-50-61370 198-50-61150 198-30-69460 198-30-69470 198-30-62311 198-30-62321 198-50-51390 198-30-51430 198-30-51440 198-50-31270 198-50-51220 195-30-31260 198-30-69850 198-30-69860

Part Name Cover Cover (L.H.) Cover (R.H.) Shaft (Side pin) Cover (L.H.) Cover (R.H.) Cover (L.H.) Cover (R.H.) Cover Cover (L.H.) Cover (R.H.) Spacer Cover assembly Cover Cover (L.H.) Cover (R.H.)

2) Maintenance of track frame pivot and application of grease Apply grease (G2-LI) to the O-ring groove and fit the Oring to the groove.

No. 11

Part No. 07000-15355

Part Name O-ring

3) Check of seal for damage, maintenance of shaft, and application of grease Apply grease (G2-LI) to the (P) and (Q) surfaces.

Torsion seal

42

Assembly procedure

Installation of undercarriage (2/16)

A-4 2. Sling work of track frame assembly

Track frame assembly Lifting jig A

Chain lever hoist Crane

Crane

Lifting jig A Lifting jig A

Chain lever hoist Track frame assembly Hook

Pivot shaft hole

Track frame assembly

Hook

Horizontally sling track frame assembly by using sling jig A and chain lever hoist (referred as chain block hereafter) as shown in Fig. 5, and move it close to machine. a See "Tools list for field assembly" for lifting jig A and chain block.

Use two chain blocks with rated capacity of 31.4 kN (3.2 t). a U-hook is welded to the lifting portion of track frame assembly in advance.

The center hook (for slinging jig A) is set to a position a little backward (approximately 100 mm) to the center of gravity of track frame assembly, so adjust track frame assembly to be horizontal by chain block. a Lifting load: approximately 124 kN (12.65 t) (Track frame assembly + lifting jig A + chain block (2 sets))

43

Assembly procedure

A-4

Installation of undercarriage (3/16)

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

2) Keep track frame assembly horizontally slung, move it closer to machine (Fig. 6) until the pin holes of side pin of equalizer bar are aligned. (Fig. 7)

Pin holes

Equalizer bar

44

Assembly procedure

Installation of undercarriage (4/16)

A-4

3) Confirm that the track frame assembly is completely moved to the machine, and confirm that inner thread seal (12) pressed and fixed into pivot shaft in advance contacts with the mounting surface of O-ring (11) on track frame described in 1-2). (Fig. 8)

Pivot shaft

Track frame Machine (11) O-ring (12) Inner torsion seal (13) Seal pressing cover

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

There is UP mark

(3) Side pin 2) Connect the grease tube.

Grease tube

Mudguard for pin

3) Install the side pin fixing bolt.

Part No. of bolt Part No. of washer Part No. of washer Length of bolt Necessary socket Tightening torque

198-50-61410 (2 pieces on each side) 01643-33380 (4 piece on each side) 19M-09-12890 (2 pieces on each side) M33, Length 320 mm 50 mm 2450 â&#x20AC;&#x201C; 2700 Nm {250 â&#x20AC;&#x201C; 275 kgm}

4) Install the attached cover and tighten the bolt. a Refer to the Table 1, "Tightening Torques".

45

a Insert the pin fixing bolt from below and install the nut to the upper side.

Assembly procedure

Installation of undercarriage (5/16)

A-4 5. Assembly of end portion of pivot shaft

1) Set spacer (8) removed in "1. Preparations" on the tip portion (Fig. 11) of pivot shaft inserted into track frame assembly. Install smaller O-ring (15) on the tip side of pivot shaft and larger O-ring (16) on torsion seal assembly (17) side. Set torsion seal assembly (17) to press spacer and O-rings. Install inner washer to pivot shaft by using bolts (18) and washers (19), and install outer washer to track frame by using bolts (20) and washers (21).

a Torsion seal assembly (17) is included in parts (8) removed in "1. Preparations".

No.

Part No.

8

198-50-31270

Spacer

1 each on right and left sides

15

07000-05190

O-ring

1 each on right and left sides

07000-05315

O-ring

16

198-50-31160 17

198-50-31241 198-50-52171

Part Name

Q'ty

Remarks

1 each on right and left sides The quantity shows the number of parts for dual tilt 1 each on right and left sides dozer specification.

1 each on right and left sides For single tilt dozer, the quantity shows only for one 13 each on right and left sides side (right side).

3 each on right and left sides

Inner washer

1 each on right and left sides

Torsion seal Torsion seal assembly Outer washer

18

01010-81665

Bolt

19

01643-31645

Washer

20

01011-82005

Bolt

10 each on right and left sides

21

01643-32060

Washer

10 each on right and left sides

2) Tightening bolts Bolt

Specifications

18

M20, length 105 mm

Nominal size of socket wrench to be used 30 mm

20

M16, length 65 mm

24 mm

a Set the track frame parallel with the machine.

46

Tightening torque Refer to Table 1, "Tightening Torques" in this manual.

Assembly procedure

A-4

Installation of undercarriage (6/16)

6. Fixing of torsion seal on the larger diameter side of pivot shaft

Seal pressing cover Torsion seal

Track frame O-ring Machine

Pivot shaft

Fix torsion seal on the larger diameter side (inner side of track frame assembly) of pivot shaft by using the seal pressing cover at the further portion (inner side).

Set the cutting portion of seal pressing cover downwards (to the ground), and install it to the track frame by using bolts (25) and washers (26).

No. 25 26

Part No. 01010-81640 01643-31645

Part Name Bolt Washer

Q'ty 6 each on left and right sides 6 each on left and right sides

Bolt specification

M16, length 40 mm

Necessary socket

24 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

47

Assembly procedure

Installation of undercarriage (7/16)

A-4 7.

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

Structure Specification

Tilt hose piping Left side of machine

Right side of machine

Not installed

Installed

Dual tiltdozer

Installed

Installed

Super dozer

Installed

Installed

Single tiltdozer

2) Work when tilt hose piping is installed 2-1) If the tilt hose piping is installed, 2 tilt hoses are projected from the pivot shaft end as shown in the figure.

2-2) Install the unions, elbows and plugs for the tilt piping to the pivot shaft end cover. a1. Take care not to forget to set the O-rings. a2. Direct the elbows to the rear. a3. If these parts have been installed when delivered, the above work is not necessary.

No. 31 32 33 34 35

Part Name Cover Union Plug Elbow O-ring

Part No. 198-50-51390 02781-00628 07040-12412 02782-1062A 07002-22434

Tightening torque of union, plug and elbow

Q'ty 2 pcs. (common to right and left) 2 pcs. (for each cover) 2 pcs. (for each cover) 2 pcs. (for each cover) 6 pcs. (for each cover) 128 â&#x20AC;&#x201C; 186 Nm {13 â&#x20AC;&#x201C; 19 kgm}

a Parts (31) to (35) are components of (6) and (7) removed in "1. Preparations".

48

Assembly procedure

Installation of undercarriage (8/16)

A-4

3) Install hoses (36) and (37) to the elbows of the cover assembly described in step 2) to connect to the work equipment piping. a1. Take care not to forget to set the Orings (38). a2. Install the red-banded hose to the elbow that will be on the upper side when the cover assembly is installed to the machine and the blue banded hose to the elbow that will be on the lower side. a3. Set the opposite side of each hose free.

No. 6 36 37 38

Part Name Part No. Cover Assembly in step 2.2) Hose 198-71-62171 Hose 198-71-62270 O-ring 02896-21018 Tightening torque of hydraulic hose (The quantity is for 1 cover assembly) 4) Remove the plugs from the tilt hoses projected from the pivot shaft end (2 places).

Reference Plug

07376-70628

O-ring

02896-11018

49

Q'ty – 1 1 2

Remarks Red-banded Blue-banded 177 – 245 Nm {18 – 25 kgm}

Assembly procedure

Installation of undercarriage (9/16)

A-4

5) Install the tilt hoses projected from the pivot shaft end to the cover assembly described in step 2). a1. Take care not to forget to set the O-rings.

O-ring

02896-21018

2 pcs.

a2. Install the red-banded hose to the union that will be on the upper side when the cover assembly is installed to the machine and the blue banded hose to the union that will be on the lower side.

6) Tighten cover assembly in item 5) together with the large washer of torsion seal assembly installed in 5) and install it.

(41) Cover assembly in 5) (45) Hose in 3) (46) Hose in 3) (47) Mounting seat of trunnion (see A-8) P: Hydraulic hose with identification color mark Q: Hydraulic hose without identification color mark

No. Part Name Part No. 42 Bolt 01010-81695 43 Bolt 01011-81625 44 Washer 01643-31645 Note) The quantity is for 1 cover assembly.

Q'ty 9 1 10

Remarks For tightening torque of bolts, see refer to Table 1, "Tightening Torques" in this manual.

7) Installation of plug to the tilt hose end.

Install the oil stopper plugs to the tilt hose end (P, Q in Fig. 19) from the trunnion mounting portion.

50

Assembly procedure

A-4

Figure No.

Part Name

Installation of undercarriage (10/16)

Qâ&#x20AC;&#x2122;ty

Part No.

For single tilt dozer

For dual tilt dozer

77

Plug

07376-70522

Only two for the right side

Two each on left and right sides

78

O-ring

02896-11015

Only two for the right side

Two each on left and right sides

a Be sure to install this plug in advance.

It is because that hydraulic oil pressure of work equipment may apply on the hose before front work equipment (blade assembly) is installed when rear work equipment (ripper) is reused in "A-9 Installation of track shoe" below. a Plugs (77) removed in step 4.1.1) can be reused.

8) Pass hoses (45) and (46) through the track frame and pull them out of the hole of the trunnion mounting seat.

9) Install the mud cover to the front of cover assembly (41) described in step 6).

The covers for the right and left sides of the machine have different part Nos.

No. 51 52 53 54

Part Name Cover (Right) Cover (Left) Bolt Washer

Part No. 198-30-51440 198-30-51430 01010-81635 01643-31645

Q'ty 1 1 3 3

Remarks For tightening torque of bolts, see refer to Table 1, "Tightening Torques" in this manual.

Note) The quantity of bolts and washers shows for each one cover.

51

Assembly procedure

A-4

Installation of undercarriage (11/16)

10) Work when tilt hose piping is not installed 10.1) As described in 1), the tilt hose is not installed to the left end of the pivot shaft of the single tiltdozer specification. (Part A in Fig. 22) Install the cover described in 10.2) and 10.3) (Fig. 23) 10.2) Install cover (61) together with the outer washers of the twist seal assembly installed in steps 5).

10.3) Close the square hole at the front of cover (61) with plate (64).

No. 61 62 63 64 65 66

Part Name Cover Bolt Washer Plate Bolt Washer

Part No. 198-30-51220 01010-81695 01643-31645 198-30-51330 01010-81635 01643-31645

Q'ty 1 10 10 1 3 3

Remarks

For tightening torque of bolts, see refer to Table 1, "Tightening Torques" in this manual.

52

Assembly procedure

A-4

Installation of undercarriage (12/16)

8. Release of slinging If the works in 7 are completed, loosen and remove the sling. a When the installation of track frame assembly on one side is completed, and the installation on the other side is to be started, set jack or wooden bar under the installed track frame assembly in order to prevent dropping when the slinging by crane is finished. (Fig.24)

Jack

Set two or more jacks or wooden bars to keep the track frame assembly to be longitudinally horizontal.

9. Lowering of the machine (removing chassis stand) 1) Sling only the front of the machine by crane in accordance with the same procedure in "A-2 Setting of the Machine", and draw out the front chassis stand from under the machine. (Fig.25) a Lifting load: Approximately 343 kN {35 t} 2) After that, draw out the wooden bar set between the equalizer bar described in Fig. 5 of the same procedure and the machine.

3) Slowly lower the front side of the machine, and place the idler of track frame assembly on the track shoes.

4) Release the slinging works for front side of the machine.

53

Assembly procedure

A-4

Installation of undercarriage (13/16)

5) After that, lift only the rear side of the machine by crane in accordance with the same procedure of "A-2 Setting of the machine", and draw out the rear chassis stand from under the machine.

Wire rope sling

a Lifting load: Approx 343 kN {35 t} 6) In order to keep enough working space for the works in 7), insert the wooden bar put between steel plates, between rear track roller and track shoes on the ground. a Set wooden bars for the track rollers in the same positions on left and right sides. a Wooden bars: T300 × 600 (mm) – 2 pieces Steel plates: t25 × 300 × 600 (mm) – 4 pieces

54

Assembly procedure

A-4

Installation of undercarriage (14/16)

7) Sling the rear of the machine again, and draw out wooden bars and steel plates.

8) After that, slowly lower the rear of the machine, and set all track rollers on track shoe links. (Fig. 27) 9) Release the slinging of the rear side of the machine.

10. Removal of bogie fixing jig 1) Remove the bogie fixing jig (L) for track frame assembly. (Fig. 28) 2) As shown in Fig. 29 (the next page), the fixing jigs are installed on four places on the outer side of left and right track frame assemblies. (Among the four places, only one jig has the different size.) a Removal is to be performed after lowering the machine on the track shoes.

If the machine is remained on chassis stand, the track roller will hang down, interfering the following works. a This fixing jig is used for transporting, preventing the track roller from hanging down when track frame assembly is placed on trailer, etc. or lifted up by using crane when unloading. a Follow the intention of the customer or the judgment of service department for the storage of removed jigs.

Necessary socket

50 mm

55

Assembly procedure

Installation of undercarriage (15/16)

A-4

Figure No. Part Name

Part No.

Qâ&#x20AC;&#x2122;ty

75

Plate

198-30-69280

3

76

Collar

198-30-66190

3

77

Washer

19M-54-11770

3

78

Bolt

01011-62710

3

79

Bolt

01010-62765

3

80

Washer

01643-32780

3

81

Plate

198-30-68950

1

82

Collar

198-30-68960

1

83

Washer

19M-54-11770

2

84

Bolt

01011-62710

2

Remarks

Removal parts

Reinstall them in different places.

Removal parts

a The quantity shows the number of parts for each one side of left and right track frame assemblies.

56

Assembly procedure

A-4

Installation of undercarriage (16/16)

3) For the portions without bolts and washers after fixing jigs are removed, supply mounting bolts and washers (79), (80), (85), (86) to triangle cover and install it.

(Fig. 30) a Among the supplied bolts and washers, reuse bolts (79) and washers (80) for mounting fixing jigs on triangle covers (3 places) in track roller bogie assembly.

(See Fig. 29) Necessary socket

41 mm

Tightening torque

883 â&#x20AC;&#x201C; 1,470 Nm {90 â&#x20AC;&#x201C; 150 kgm}

Figure No. 79 80 85 86

Part Name Bolt Washer Bolt Washer

Part No. 01010-62765 01643-32780 01010-62765 01643-32780

Q'ty 3 3 2 2

Remarks Reuse Reuse Newly supply Newly supply

a The quantity shows the number of parts for each one side of left and right track frame assemblies.

4) For the portions without bolts and washers after fixing jigs are removed, knock cork plug (87) into thread holes without the following installation to protect them. (Fig. 31) Figure No. Part Name 87 Plug

Part No. 07049-02734

Q'ty 3

a The quantity shows the number of parts for each one side of left and right track frame assemblies.

57

Assembly procedure

A-5 â&#x20AC;˘

Adding oil to pivot chamber

Pivot chamber Add engine oil through the hole of plug (1).

a Quantity of oil: 26 l/each side a Oil level (B): 10 â&#x20AC;&#x201C; 30 mm from oil level (2) a For using oil type, see "A-6 Check of oil and coolant levels" in assembly procedure.

58

Assembly procedure

A-6

Check of oil and coolant levels (1/2)

a For details of the notes (Note. 1, 2, 3, 4) in the table, see the Operation and Maintenance Manual.

The details refer to an Operation and Maintenance Manual about Recommended Komatsu fluids again.

â&#x20AC;˘

ASTM: American Society of Testing and Material

59

Assembly procedure

A-6

Check of oil and coolant levels (2/2)

Precautions

Tools required Name

Others

.If any oil level or coolant level is low, add oil or coolant.

60

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Installation of ripper (1/5)

A-7 1. Preparation •

Removal of paint and rust prevention oil from mounting parts

•

Do not remove the arm pin but pull it out to the state shown in the photo.

•

Arm pin lock bolt

Part No. of washer

01010-82040 (2 pieces on each side) 01643-32060 (2 pieces on each side)

Bolt specification

M20, Length 40 mm

Necessary socket

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

Part No. of bolt

•

Style

It is necessary to start the engine to perform the following step "8. Connection of cylinder", so prepare to start the engine.

2. Installation of arm •

Sling the arm by 3 points. Set its right and left parts in parallel accurately.

•

Set a wood block under the arm as shown in the photo.

3. Installation of lift cylinder •

Lift cylinder connecting pin lock bolt

Block

Part No. of washer

01010-82045 (2 pieces on each side) 01643-32060 (2 pieces on each side)

Bolt specification

M20, Length 45 mm

Necessary socket

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

Part No. of bolt

61

Assembly procedure

Installation of ripper (2/5)

A-7 4. Installation of tilt cylinder •

Tilt cylinder connecting pin lock bolt

Part No. of washer

01010-82045 (2 pieces on each side) 01643-32060 (2 pieces on each side)

Bolt specification

M20, Length 45 mm

Necessary socket

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

Part No. of bolt

5. Installation of right and left lift hoses and tilt hoses • •

Direct the hoses as shown in the photo.

Part No. of hose : 07097-01012 (Common to 8 hoses on right and left sides) Straight openings

L-adapters

6. Sub beam •

Assemble the right and left grease hoses and elbows before installing them to cylinder head pin. a Connect the pin portion after the installation.

7. Installation of beam assembly • •

Sling the beam assembly by the 3 points of the shank pin and cylinder pin.

Beam connecting pin lock bolt

Part No. of washer

01010-82040 (2 pieces on each side) 01643-32060 (2 pieces on each side)

Bolt specification

M20, Length 40 mm

Necessary socket

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

Part No. of bolt

62

Assembly procedure

Installation of ripper (3/5)

A-7 •

Set a block (Height: 670 mm) under the beam so that the arm will be horizontal.

8. Connection of cylinder 1) Start the engine in low idle, and confirm the movement of the lift cylinder rod and the tilt cylinder rod.

•

If the movement of rods is abnormal, confirm the amount of hydraulic oil and fill oil.

2) Install lift cylinder while adjusting by moving the rod of the cylinder.

3) Install tilt cylinder while adjusting by moving the rod of the cylinder.

•

Connecting pin lock bolt on cylinder rod side

Bolt specification

01010-82045 (2 pieces on each side) 01643-32060 (2 pieces on each side) M20, Length 45 mm

Necessary socket

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this mannual.

Part No. of bolt Part No. of washer

Note) If the engine is started for the first time in this work, lubricate it before starting according to "M-3 No-injection cranking of engine".

63

Assembly procedure

A-7

Installation of ripper (4/5)

9. Installation of pin puller hoses â&#x20AC;˘ Clamping positions of hoses 1. Between clamp on side of beam and cylinder: 990 mm 2. Between connecting part of chassis and clamp A: 1,060 mm

A

3. Between clamp A and clamp on side of beam: 1,370 mm

â&#x20AC;˘ Detail of installation of pin puller hoses

64

Assembly procedure

A-7

Installation of ripper (5/5)

10. Installation of grease supply hoses

â&#x20AC;˘

Method of installing centralized greasing unit on mount side

â&#x20AC;˘

After completing assembly, check the operation and confirm that the hose is not abnormally slackened or tensed.

65

Assembly procedure

Installation of trunnion

A-8 •

Sling and install the trunnion.

•

Remove the paint from both trunnion mounting faces.

a Weight of trunnion: 1.37 kN {140 kg}

•

Trunnion mounting bolts

Part No. of washer

01011-83005 (12 pieces on each side) 01643-33080 (12 pieces on each side)

Bolt specification

M30, Length 105 mm

Necessary socket

46 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

Part No. of bolt

•

Track frame

Trunnion Washer Bolt

If there are tilt hoses, pull them out of the center of the trunnion as shown in the figure.

Trunnion

66

Tilt hose

Assembly procedure

A-9

Installation of track shoe (1/3)

The cooperation of crane operator, machine operator and signal worker is required for installing track shoes.

Therefore, make communication between the three persons to clarify the signals.

The signaler should give out signals at a position where he could be clearly seen by the operators of the machine and the crane.

1. Sling the front end of track shoes by crane, and roll the track shoes on the idler. (Fig. 1) After that, set wooden bar on the grouser of track shoes to prevent the track shoes from rewinding, and loosen the sling.

Wire rope slings

Slinging bar

Wooden bars

a Slinging bar: steel rod ø25 mm × 1 m (one piece) a Wire rope slings: ø24 mm × 2 m (2 pieces) Using load: 47 kN {4.8 t} a Wooden bars: T300 mm × 600 mm (2 pieces) a Properly set steel plates between track shoes and grouser to slightly adjust the height of wooden bar.

2. Start the engine, operate the ripper to vertically raise ripper beam a little, and set wooden bar under ripper beam.

Then set steel plate on the top of wooden bar, and set ripper beam onto it. (Fig. 2)

Steel plate

Wire rope slings

a Steel plate: t25 mm × T300 mm a Wooden bar: T300 mm × 600 mm (1 piece)

Inserted

3. Move ripper beam downwards to raise the rear side of machine until the sprocket completely falls off the track shoes. (Fig. 2)

Floated Wooden bars

4. Sling one side of the front end of the rear of track shoes (sprocket side) as shown in Fig. 3, and move it close to the sprocket.

Crane.

Main hoisting

a Slinging bar: steel rod ø25 mm × 700 mm (one piece) a Load chain: wire diameter 12.5 mm × 1.5 m (one piece) Using load: 49 kN {5 t}

Load chain

Outside

Inside

Sling bar

5. As shown in Fig. 4, connect the belt sling with track shoes by using the subsidiary crane, and pull the track shoes until it goes beyond the sprocket. a Sling bar: steel rod ø25 mm × 700 mm (one piece) a Belt sling: width 75 mm × 5 m Using load: 19.6 kN {2 t}

Crane.

Main hoisting

Belt sling Sling bar

Sprocket

Track shoes

67

Carrier roller

Crane.

Subsidiary hoisting

Assembly procedure

Installation of track shoe (2/3)

A-9

6. After that, move it forward until the fifth link pin interlocks with sprocket, completely set track shoes on the sprocket, and then loosen the sling on subsidiary crane to lower the track shoes.

7. Clean the mating surface of master link to remove all harmful sand, metal scraps, etc. a Also clean the master link on the idler described in item 1.

8. Start the engine, and rotate the sprocket to slowly move the track shoes forward.

After that, make the master links on the front end and on the idler interlock with each other. (Fig. 6)

Interlocking of master links

a In this work, be sure to keep cooperation between crane operator, machine operator and signaler.

Wooden bar

9. The lifting of track shoes is finished when the master links interlock with each other.

10. Set the interlocked master link on master shoe (1), install and temporarily tighten four master bolts (3) to make the master links firmly contact with each other. a If the shoe bolts are tightened forcibly before the contact surfaces of the master link are fitted, the threads of them and master link may be damaged.

11. Confirm that the interlock surface is firmly contacted, and then loosen master bolts (3) to remove master shoe (1).

12. Apply seizure preventing agent (LM-P) on the thread portion of shoe bolts. a See "Coating materials".

No. 1 2 3

Part No. 198-32-31483 19M-32-11450 198-32-31341

Part Name Master shoe Key Master bolt

Q'ty (1 pieces on each side) (2 pieces on each side) (4 pieces on each side)

68

Assembly procedure

A-9

Installation of track shoe (3/3)

13. Control of bolt tightening torque 1) Install master shoe (1) and key (2) to the master link again, and screw-in the master bolt (3).

2) Tighten the bolts to torque of 980 ± 98 Nm {100 ± 10 kgm} first and check that the mating faces of the link are fitted.

3) Make counter marks to bolt head and shoe with white paint, etc., so that the original position of the bolt head is identified.

4) After making counter marks, further tighten them by using impact wrench to set the angle between counter marks 180 ± 10° from the original position.

a Tightening order Tighten the bolts in the order shown in Fig. 9. a To adjust the track tension, refer to the section A-10.

14. Remove the wooden bars set in steps 1 and 2.

69

Assembly procedure

Check track tension (1/2)

A-10

WHEN INCREASING TENSION 1. First remove both bolts (1) and then remove the cover (2).

2. Pump in grease through the grease fitting (3) with a grease pump.

3. To check that the correct tension has been achieved, move the machine backwards and forwards.

4. Check the track tension again, and if the tension is not correct, adjust it again.

WHEN LOOSENING TENSION 1. Remove both bolts (1), then remove cover (2).

2. Loosen plug (4) gradually to release the grease.

3. Turn plug (4) a maximum of one turn.

4. If the grease does not come out smoothly, move the machine backwards and forwards a short distance.

5. Tighten plug (4).

6. To check that the correct tension has been achieved, move the machine backwards and forwards.

7. Check the track tension again, and if the tension is not correct, adjust it again.

Precautions

Name

Others

NOTICE • Grease inside the adjusting mechanism is under high pressure.

Grease coming from plug (4) under pressure can penetrate the body causing injury or death. For this reason, do not loosen plug (4) more than one turn.

Do not loosen any part other than plug (4).

Furthermore, do not bring your face in front of the grease fitting.

If the track tension is not relieved by this procedure, please contact your Komatsu distributor.

• When removing cover (2), be careful not to let any dirt get inside.

• There is a safety label stuck to the back of cover (2). Be careful not to damage the safety label.

Tools required

70

Equipment required Q’ty

Name

Q’ty

Assembly procedure

Check track tension (2/2)

A-10

INSPECTION Stop the machine on level ground (stop with the transmission in FORWARD while applying the brake slowly). Then place a straight bar on the track shoes between the carrier roller and the idler as shown in the figure, and measure the clearance is 20 to 30 mm, the tension is standard.

If the track tension is not at the standard value, adjust it in the following manner. a Set the track tension to 30 mm for the first 100 operating hours to fit the bushings and pins.

Precautions

Tools required

Others

Name

71

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

A-11

Assembly of blade (1/20)

1. Installation of blade Stand the delivered blade vertically on the assembly ground according to the following procedure. a Stand the blade means to set the back of the blade at 90° to the ground as shown in (Fig. 1).

[1] Sling the blade with the crane. While operating the main and auxiliary hoists, stand the blade gradually as shown in (Fig. 2) and (Fig. 3) until it stands vertically on the object position (ground).

Auxiliary hoist side Main hoist side

a Install the rope slings of the main hoist to the blade lift hydraulic cylinder mounting pin. a Install the rope slings of the auxiliary hoist to the lifting holes at both ends of the blade top through shackles.

Weight of semi U-blade Weight of full U-blade Weight of Super dozer Wire rope sling Shackle

13 t 14 t 12 t ø32 mm × 5 m (4 pieces) SD34 (2 pieces)

a Use rope slings of JIS B8817 or equivalent having the lifting capacity of at least 84 kN {8.56 t}. a Use shackles of JIS B2801 or equivalent having the lifting capacity of at least 49 kN {5 t}.

Reference: Additionally weld spill guard on the blade before setting the blade vertical.

See "Appendix: Installation of Spill Guard" for the installing (welding) procedure.

72

Assembly procedure

Assembly of blade (2/20)

A-11

2. Measures to prevent blade from falling (Set the blade so that it will stand vertically and stably even after the slings are loosened.)

[1] Set wooden blocks under the center link brackets. (Fig. 4) a Wooden block: T350 mm × length 400 mm – 2 pieces [2] Set wooden blocks under the straight frame brackets on both sides. (Fig. 5)

2 parts

a Wooden block: T350 mm × length 400 mm – 2 pieces [3] If it is difficult to stand the blade vertically with only the wooden blocks in steps [1] and [2], add plates to adjust finely. (Fig. 5) [4] After confirming that the blade stands stably, loosen and remove the slings.

Plate

[5] Install eye bolts (2) to center link (1).

Wooden block (Insert on both sides)

a Remove cork plugs knocked into the thread holes in advance, and then install eye bolts.

[6] Turn center link (1) by using eye bolts (2) and crane, and set it to a position as shown in Fig. 6 (upwards).

Set bar (4) on the top of mud cover (5) welded on the back surface of the blade on top of center link. Connect eye bolt and bar with wire (3), and twist the wire to fix the center link.

No. 1

Part Name Center link

2

Eyebolt

3

Wire (metal wire)

4

Sling bar

5

Mud cover

—

Shackle

Remarks Components of blade assembly M24, using load: 9.32 kN {950 kg} (JIS B1168 or equivalent) #10 wire, ø3.2 mm × approximate length 2 m (JIS G3532 or equivalent) SS400B, ø19 mm × 300 mm (JIS G3532 or equivalent) Welded on the back surface of the blade already SD16, using load: 9.81 kN {1 t} (JIS B2801).

To be used for slinging by crane

73

Assembly procedure

Assembly of blade (3/20)

A-11

3. Connection of straight frames to right and left of blades [1] Check that the joints at the ends of the straight frames are installed in the correct directions. (Fig. 7)

Joint

a If the joints are installed in wrong directions, correct their directions.

Good

[2] Remove the connecting pins installed to the straight frame brackets on the blade. (Fig. 8) No. 81 84 85 86

Part Name Pin Lock Bolt Washer

Part No. 198-72-51810 09257-11219 01010-82455 01643-32460

Q'ty 2 2 8 8

Bolt specification

M24, Length 55 mm

Tool (Socket)

36 mm

a The quantity is the number of parts necessary to 1 machine (1 blade).

74

Wrong

Assembly procedure

A-11

Assembly of blade (4/20)

[3] Sling the straight frame horizontally with belt slings.

(Fig. 9) Belt sling

•

•

Lifting load : Approx. 1770 kg for each side : Approx. 1850 kg for each side (for super dozer) Belt sling: Both ends eye type 100 mm wide, 4 m long (2 pieces) Using load: 19.6 kN {2 t} JIS B8818 or equivalent Connection

a If the straight frame slants to the right or left, the joint described in [1] will not be inserted in the bracket yoke easily.

Accordingly, keep the straight frames horizontally.

Wooden block

Reference: A belt sling means a belt made of synthetic fibers used to sling heavy things.

It is used to prevent damage on the products and protect the paint during sling work.

[4] While slinging the straight frame, insert the joint at its end in the bracket yoke on the blade and align the connecting pin holes. (Fig. 9) [5] Insert pin (81) removed in step [2] and fix it to the bracket on the blade with lock (83), bolt (84) and washer (85). (Fig. 9)

Belt sling

a For tightening torque of bolt, see Table 1, "Tightening Torque".

[6] Set a wooden block under the rear end of the straight frame (on the opposite side to the joint) and adjust the height (H) of the trunnion mounting portion (center) of the machine above the ground to approx. 1,085 mm.

(Fig. 10)

Wooden block

a Wooden block: T350 mm × length 800 mm – 1 piece [7] Perform steps [1] – [6] on both right and left sides.

[8] Sling the straight frames again and set the right and left straight frames symmetrically about the blade and adjust the distance between both straight frames (dimension W) to approx. 3,810 mm. (Fig. 11) a Clean each connecting part.

75

Assembly procedure

Assembly of blade (5/20)

A-11 4. Installation of center brace

4.1 Temporary installation [1] Remove the shims, bolts and washers installed temporarily in advance to part (F) (spherical seat) of the center link and part (G) (spherical seat) of the straight frame. (Fig. 12) No. 1 2 3 4 5

Part Name Bolt Washer Shim (2 mm) Shim (1 mm) Shim (0.5 mm)

Part No. 01011-83335 01643-33380 198-71-31450 198-71-31460 198-71-31470

Q'ty 8 8 2 4 4

a "Q'ty" in above table indicates the number for each spherical seat.

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

Detail P

a When adjusting the thickness of 4.5 mm, keep each combination of (A) and (B). (Fig. 14)

View Z [2] Install the belt sling to the center of center brace (90).

While slinging the center brace with the crane, put the balls of the ball joints respectively to the spherical seat (part F) of the center link and that (part G) of the straight frame. (Fig. 12) No. 90

Part Name Center brace

Part No. 198-72-51350

Q'ty 2

a "Q'ty" in above table indicates the number for each machine. a Weight of center brace: Approx. 340 kg/piece a Belt sling: Both ends eye type 50 mm wide, 4 m long (2 pieces) Using load: 9.81 kN {1 t} JIS B8818 or equivalent

76

Assembly procedure

Assembly of blade (6/20)

A-11

[3] Temporarily install the ball caps of center brace (90) to the spherical seats of the center link and straight frame (parts (F) and (G) in (Fig. 12)) with bolts (1) and washers (2) removed in step [1], while inserting shims (3), (4) and (5) removed in step [1] in parts A. (Fig. 15) and (Fig. 16) Bolt specification

M33, Length 135 mm

Tool (Socket)

50 mm

Ball cap

a Insert the sets of shims 4.5 mm thick in total (One 2-mm shim, Two 1-mm shims and One 0.5-mm shim) in the Two upper and lower places. a Tighten the bolts until the spherical seat, shims and ball cap are fitted to each other, although they are being installed temporarily.

[4] Install the center brace on the opposite side similarly (according to steps [1] â&#x20AC;&#x201C; [3]). a To perform the same procedure for the opposite side, remove the eye bolts, washers and bar already installed in step 2-[6].

Knock the cork plug into the thread hole to which the eye bolt is installed.

Part Name Plug

Part No. 07049-02430

Q'ty 1

[5] Supply a little amount of grease through part (M) (1 place) and parts (N) (1 place each on the right and left sides). (Fig. 16) a Use grease G2-LI (See the coating material list).

[6] Install the belt sling to either of the right and left straight frames and move the straight frame end up and down slowly for several times with the crane as shown in (Fig. 17). (Stroke: 300 â&#x20AC;&#x201C; 400 mm) While moving up and down, check the ball joints of the center brace for abnormal sound and ensure that the ball joints move smoothly (check the balls for internal interference).

Perform this check on both right and left straight frames.

Belt sling

a If no problem is detected, go to step 4.2. If any problem is detected, adjust the shims again (add new shims) according to step 4.3.

77

Assembly procedure

Assembly of blade (7/20)

A-11

4.2 Permanent installation [1] If no problem is detected in step 4.1-[6], tighten the ball cap bolts at both ends of the center brace (1) in (Fig. 15) permanently.

Necessary socket

41 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

a Tighten all the bolts evenly in the diagonal order.

[2] After tightening permanently, go to step 4.4.

4.3 Shim adjustment (Addition of shims) [1] If any problem is detected (interference of the ball is felt) in step 4.1-[6], remove bolts (1) and washers (2) which are fixing the ball caps temporarily at both ends of the center brace and add 0.5-mm thick shim (5) to the shim set in part (A), and then install the ball caps temporarily with bolts (1) and washers (2) according to step 4.1-[3]. (Fig. 18) No. 5

Part Name Shim (0.5 mm)

Part No. 198-71-31470

Shim Bolt Washer

Ball joint

Q'ty 2

a Numbers in above fig. show the quantity required for each spherical seat. a When adjusting the thickness of 4.5 mm, keep each combination of (A) and (B). (Fig. 14)

View Z 4.4 Adjustment of distance between tilt cylinder mounting pin holes [1] Sling the straight frame again with the belt sling as shown in (Fig. 19) and adjust the distance between the mounting pin holes of the tilt cylinder (dimension K) (or the brace assembly on the left side in step 6 for the single tilt dozer specification) to about 1,845 mm.

Then, adjust the position of the wooden block under the straight frame so that the distance between the holes will be stabilized and then remove the sling. a Perform this adjustment on the right and left sides.

Belt sling

Wooden block

78

Assembly procedure

Assembly of blade (8/20)

A-11 5. Installation of tilt hydraulic cylinders

5.1 In case of dual tiltdozer specification [1] Install hydraulic hoses and hose protection covers to the right and left hydraulic cylinders. (Fig. 20) No. 6 7 8 9 ª 10 ª 11 ª 12 13 14 15

Part Name Hydraulic cylinder Hydraulic hose (Overall length: 1,650 mm) Hydraulic hose (Overall length: 1,130 mm) O-ring Flange Bolt Washer Cover Bolt Washer

Part No. 707-01-0X760

Q'ty 2

198-71-62131

2

198-71-62121

2

07000-23025 07371-30640 07372-21035 01643-51032 198-71-62211 01010-82045 01643-32060

4 8 16 16 2 12 12

Bolt specification

Tool (Socket)

M10

17 mm

M20

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

a Flange (10), bolt (11) and washer (12) are installed to each hydraulic cylinder in advance.

(Marked ª) However, do not reuse the sleeve head (oil stop cover) installed to the hydraulic cylinder with (10), (11) and (12) when installing the hydraulic hoses. a Replace O-ring (9) with new one, as a rule.

When assembling, make sure that the shorter hose (bottom side) has been located on R.H. side of the cylinder (both R.H. and L.H. cylinders).

79

Assembly procedure

Assembly of blade (9/20)

A-11

[2] Remove the covers and hydraulic cylinder mounting pins installed to the hydraulic cylinder mounting sections of the right and left straight frames. (Fig. 21) (Same as super dozer specification) Bolt specification

Tool (Socket)

M12

19 mm

M20

30 mm

[3] While slinging hydraulic cylinder (6) with belt sling (20), with the cover side (hydraulic hose side) up, align the mounting pin hole on the bottom side (clevis side) with that of the straight frame.

Then, insert mounting pin (16) removed in step [2] and fix it to the straight frame with lock (17), bolt (18) and washer (19). (Fig. 21)

â&#x20AC;˘

Sling weight (Weight of hydraulic cylinder assembly) R.H. and L.H. sides, approx. 510 kg each

Bolt specification

M20, Length 50 mm

Tool (Socket)

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

â&#x20AC;˘

Belt sling: The same with 4.1-[2]

[4] Set a wooden block between hydraulic cylinder (hydraulic hose protection cover) and straight frame so that hydraulic cylinder (6) will be positioned as shown in (Fig. 22), and then loosen and remove the sling.

Wooden block TIE

a Do not connect the head side of hydraulic cylinder (6) (part (R) in Fig. 22) at this time.

Connect it after installing the blade assembly to the machine. See "assembly procedure A-12"

80

Assembly procedure

Assembly of blade (10/20)

A-11

[5] Connect the free ends of hydraulic hoses (7) and (8) installed to hydraulic cylinder (6) in step [1] to the elbows of flange (21) installed to the straight frame.

(Fig. 23) Connect according to the letters stamped on the flange.

Stamp H B

Hose to be connected Longer hydraulic hose (Head side) Shorter hydraulic hose (Bottom side)

a Take care not to forget to install O-rings (22).

No. 22

Part Name O-ring

Part No. 02896-11018

Q'ty 4

a When connecting the hydraulic hoses, remove the oil plugs (Part No.: 02789-00628) installed to the elbows of the flange in advance.

81

Assembly procedure

Assembly of blade (11/20)

A-11

5.2 In case of single tiltdozer specification a For the single tiltdozer specification, install the tilt hydraulic cylinder to only the right side.

[1] Install the hydraulic hoses and hose protection cover to the hydraulic cylinder. (Fig. 24) No. 31 32 33 34 ª 35 ª 36 ª 37 38 39 40

Part Name Hydraulic cylinder Hydraulic hose (Overall length: 1,650 mm) Hydraulic hose (Overall length: 1,130 mm) O-ring Flange Bolt Washer Cover Bolt Washer

Part No. 707-01-0X760

Q'ty 2

198-71-62121

2

198-71-62131

2

07000-23025 07371-30640 07372-21035 01643-51032 198-71-62211 01010-82045 01643-32060

4 8 16 16 2 12 12

Bolt specification

Tool (Socket)

M10

17 mm

M20

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

a Flange (35), bolt (36) and washer (37) are installed to hydraulic cylinder (31) in advance.

(Marked ª) However, do not reuse the sleeve head (oil stop cover) installed to the hydraulic cylinder with (35), (36) and (37) when installing the hydraulic hoses. a Replace O-ring (34) with new one, as a rule.

When assembling, make sure that the shorter hose (bottom side) has been located on R.H. side of the cylinder

82

Assembly procedure

Assembly of blade (12/20)

A-11

[2] Remove the covers and hydraulic cylinder mounting pin (41) installed to the tilt hydraulic cylinder mounting section of the right straight frame. (Fig. 25) Bolt specification

Tool (Socket)

M12

19 mm

M20

30 mm

[3] While slinging tilt hydraulic cylinder (31) with belt sling (20), with the hydraulic hose cover side down, align the mounting pin hole on the bottom side (clevis side) with that of the straight frame.

Then, insert mounting pin (41) removed in step [2] and fix it to the straight frame with lock (42), bolt (43) and washer (44). (Fig. 25)

â&#x20AC;˘

Sling weight (Weight of hydraulic cylinder assembly): Approx. 510 kg each

Bolt specification

M20, Length 50 mm

Tool (Socket)

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

â&#x20AC;˘

Belt sling: The same with 4. 1-[2]

[4] Set a wooden block between hydraulic cylinder (hydraulic hose protection cover) and straight frame so that the hydraulic cylinder (31) will be positioned as shown in (Fig. 26), and then loosen and remove the sling.

Wooden block TIE

a Do not connect the head side of the hydraulic cylinder (31) (part (R) in Fig. 26) at this time.

Connect it after installing the blade assembly to the machine.

(See "Assembly procedure A-12")

83

Assembly procedure

Assembly of blade (13/20)

A-11

[5] Connect the free ends of hydraulic hoses (32) and (33) installed to the hydraulic cylinder (31) in step [1] to the elbows of flange (46) installed to the straight frame. (Fig. 27) Connect according to the letters stamped on the flange.

Stamp

Hose to be connected Longer hydraulic hose (Head side) Shorter hydraulic hose (Bottom side)

H B

a Take care not to forget to fit O-rings (47).

No. 47

Part Name O-ring

Part No. 02896-11018

Q'ty 4

a When connecting the hydraulic hoses, remove the oil plugs (Part No.: 02789-00628) installed to the elbows of the flange in advance.

[6] Reinstall the covers removed in step [2].

Bolt specification Tool (Socket) Tightening torque

M12 Length 25 mm 19 mm

M20 Length 40 mm 30 mm

Refer to Table 1, "Tightening Torques" in this manual.

84

Assembly procedure

Assembly of blade (14/20)

A-11 5.3 For super dozer specification

[1] Install tube and tube protection covers to the right and left hydraulic cylinders.

No. 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107

Part Name Hydraulic cylinder (For super dozer) Tube (L.H.) Tube (R.H.) O-ring Bolt Washer Bolt Washer Block (L.H.) Block (R.H.) Bolt Washer Bolt Washer Cover Bolt Bolt Washer Hose O-ring

Part No.

Q'ty

707-01-0X990

2

198-72-62570 198-72-62580 07000-F3030 07372-21045 01643-51032 07372-21060 01643-51032 198-72-62550 198-72-62560 07372-21035 01643-51032 01010-81095 01643-51032 198-72-62590 01011-82025 01010-82040 01643-32060 198-72-52110 07000-F3025

1 1 6 4 4 4 4 1 1 8 8 8 8 2 2 12 14 4 4

Bolt specification

Tool (Socket)

M10

17 mm

M20

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

85

Assembly procedure

Assembly of blade (15/20)

A-11

[2] Set the cover side of hydraulic cylinder (88) facing upwards, lift the cylinder up by using belt sling (20), and align the mounting pin holes on the bottom side (Clevis side) of the cylinder and on straight frame.

Then, insert mounting pin (110) removed in step [2] and fix it to the blade with lock (111), bolt (108) and washer (109).

â&#x20AC;˘

Sling weight (Weight of hydraulic cylinder assembly) R.H. and L.H. sides, approx. 510 kg each

Bolt specification

M20, Length 50 mm

Tool (Socket)

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

â&#x20AC;˘

Belt sling: The same with 4. 1-[2]

[3] Set a wooden block between hydraulic cylinder and straight frame so that hydraulic cylinder (88) will be positioned as shown in (Fig. 26), and then loosen and remove the sling. a Do not connect the head side of hydraulic cylinder (88) (part (R) in Fig. 26) at this time.

Connect it after installing the blade assembly to the machine.

(See "assembly procedure A-12")

86

Assembly procedure

Assembly of blade (16/20)

A-11

[4] Connect flange (114), bolt (115) and washer (116) to joint of flange (113), which the free side of hose (112) is installed to hydraulic cylinder (88) in step [1]. a Take care not to forget to fit O-rings (117).

No. 117

Part Name O-ring

Part No. 07000-F3025

Bolt specification

Tool (Socket)

M10

17 mm

Q'ty 4

a When connecting the hydraulic hoses, remove the oil head (Part No.: 07378-10600) installed to the joint in advance.

[5] Reinstall the covers removed in step [2].

Bolt specification

M12

M20

Tool (Socket)

19 mm

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

87

Assembly procedure

Assembly of blade (17/20)

A-11 6. Installation of brace assembly

a The brace assembly is applied to the single tilt dozer specification in the portion shown in Fig. 28.

Not necessary for super dozer

[1] Remove covers (51 – 54) and brace assembly mounting pins (55 – 58) installed to the brace assembly mounting section of the left straight frame in advance.

(Fig. 29) Bolt specification of 53, 57

M20

Tool (Socket)

30 mm

[2] Remove brace assembly mounting pins (59 – 62) installed to the brace assembly mounting section of the blade in advance. (Fig. 30)

88

Assembly procedure

Assembly of blade (18/20)

A-11

[3] The brace assembly consists of the following parts.

(Fig. 31) No. 63 64 65 66 67 68 69 70 71 72

Part Name Brace Fitting Seal Screw Screw Bushing Ring Handle Bolt Washer

Part No. 198-72-53260 07020-00000 2989-01-2580 198-71-21280 198-71-21272 195-71-51254 195-71-52360 198-71-32150 01010-81660 01643-31645

Q'ty 1 2 1 1 1 1 1 1 2 2

[4] Supply grease (See step [9]) through fitting (64) installed to brace (63) and rotate brace (63) with attached lever (73) to adjust dimension (L) between the holes at both ends of brace assembly to approximately 1,850 mm. (Fig. 32) Reference If brace (63) is rotated with lever (73) while screws (66) and (67) at both ends are fixed, dimension (L) increases or decreases by 12.7 mm performance turn.

Accordingly, if only one side screw in the both end screws is rotated by a half turn, dimension (L) can be adjusted by 3.175 mm.

89

Assembly procedure

Assembly of blade (19/20)

A-11

[5] While slinging brace assembly with the belt sling, with the handle (70) up, align the mounting pin hole of the brace assembly with that of the straight frame. Then, insert mounting pin (55) removed in step [1] and fix it to the straight frame with lock (56), bolt (57) and washer (58). (Fig. 33) â&#x20AC;˘

Sling weight (Weight of brace assembly): Approx. 280 kg

Bolt specification

M20, Length 50 mm

Tool (Socket)

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

â&#x20AC;˘

Belt sling: The same with 4. 1-[2]

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

If brace (63) is rotated with lever (73) to adjust dimension (L), the direction of handle (70) changes. According, do not apply this method.

Then, insert mounting pin (59) removed in step [2] and fix it to the blade with lock (60), bolt (61) and washer (62). (Fig. 33) Bolt specification

M20, Length 50 mm

Tool (Socket)

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

[7] Loosen and remove the sling.

90

Assembly procedure

Assembly of blade (20/20)

A-11

[8] Reinstall covers (51) â&#x20AC;&#x201C; (54) removed in step [1].

No.

53

57

Tool (Socket)

M20 M20 Length 40 mm Length 50 mm 30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

Bolt specification

[9] Greasing

Single tiltdozer After finishing installation, supply grease to the 5 places indicated with the arrows in (Fig. 34) until it comes out.

Single tiltdozer Dual tiltdozer Super dozer

6 places indicated by arrows 4 places indicated by arrows 4 places indicated by arrows

a G2-LI in "Coating material list" in this manual is recommended as grease for the above purpose.

Dual tiltdozer, Super dozer

91

Assembly procedure

A-12

Installation of blade (1/8)

Condition 1) Before starting the following work, complete "Assembly procedure A-11".

2) Before starting the following work, set the engine so that it can run to move the machine.

1) Posture of blade assembly before installation

Adjust the posture of the blade assembly before installation with wooden blocks (E) and (F) as shown in (Fig. 1) and (Fig. 2).

Dimension (b) (Disconnect between sphere centers) Approx. 1,085 mm Approx. 3,810 mm Dimension (a)

a Dimension (a) in the table is set on the assumption that the machine is used on a hard ground where the track shoe grousers will not sink. If the machine is used on a ground where the grousers sink, the trunnion height decreases by the sinking distance. Accordingly, dimension (a) must be lowered by the decrease of the trunnion height. a If the center link falls, dimension (b) increases. To prevent this, set wooden block (F) under the center link or arm. a Leave wooden block (G) set to erect the blade vertically in "assembly procedure A-11" as it is.

2) Connection of blade assembly and machine 2.1)

Peel off the paint from the spherical part of the trunnion and clean its surface.

a Apply grease [G2-LI] to the spherical part of the trunnion.

G2-LI : See [Coating materials]

Seat

2.2)

Set the machine within dimension (b) of the blade assembly and move it forward so that the right and left clearances will be the same.

2.3)

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

92

Assembly procedure

Installation of blade (2/8)

A-12

a If the trunnion and trunnion holder are different in height, trunnion holder bushing (2) in (Fig. 4) may move when the trunnion is pressed.

If the trunnion and trunnion holder are different in height, sling the straight frame of the blade assembly with a crane etc. and adjust their heights.

2.4)

No. 1 2 3 4 5 6 7

Set the trunnion parts (Fig. 4) and tighten the bolts.

Part Name Straight frame Bushing Plate Cap Nut Bolt Washer

Part No. â&#x20AC;&#x201D; 198-71-51340 198-72-00110 198-71-51390 195-71-11510 198-61-11250 01643-33380

Q'ty â&#x20AC;&#x201D; 2 4 1 4 4 4

Bolt specification

M33, Length 305 mm

Tool (Socket)

50 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

Remarks See "assembly procedure A-11"

2.5) Remove wooden block (E) set under the straight frame in step 1).

93

Assembly procedure

Installation of blade (3/8)

A-12

3) Connection of hydraulic hoses for tiltdozer and super dozer 3.1)

Remove the plug at the tip of the hydraulic hose coming out from the center hole of trunnion.

a Take care not to lose the "O-rings".

3.2)

Remove the upper and lower plugs from the nipples of the flange (7) in (Fig. 5) on the blade assembly side.

3.3)

Connect the hydraulic hoses to the nipples of the above flange. (Fig. 5)

a When connect it, certainly assemble O-ring (02896-11018) removed in step 3.1). a Connect the hydraulic hoses according to the following table.

Hose indentification Color identification mark (red) at the tip of hose Color identification mark (blue) at the tip of hose

Selection of connecting nipple Connect to upper nipple.

Connect to lower nipple.

a The part Nos. of the plug and nut removed from the nipple of the flange in step 2) are shown below for reference.

Part name/Part No. Plug

02789-00628

Dual tiltdozer Q'ty 2 pieces each on right and left

Single tiltdozer Q'ty 2 pieces on only right

Super dozer Q'ty 2 pieces each on right and left

This part is not necessary any more after the blade assembly is installed to the machine.

Keeping this part is recommended, however, since it is necessary again when the blade assembly is removed from the machine and stored. a When the front work equipment is the single tiltdozer, perform this work only on the right side.

94

Assembly procedure

Installation of blade (4/8)

A-12

4) Installation of tiltdozer hydraulic hose protection cover Install tiltdozer hydraulic hose protection cover (8) (Fig. 6) connected in step 3).

No. 1 4 8 9 10

Part Name Blade assembly Trunnion cap Cover Bolt Washer

Part No. — — 198-71-21240 01010-82050 01643-32060

Q'ty — — 1 each on right and left 6 each on right and left 6 each on right and left

Bolt specification

M20, Length 50 mm

Tool (Socket)

30 mm

Tightening torque

Refer to Table 1, "Tightening Torques" in this manual.

Remarks See 2.4) of this procedure

a Before installing the protection cover, check the operation of the tilt cylinder in the blade adjustment work described later and confirm that there is not oil leakage or another problem in the tilt hose connection.

95

Assembly procedure

Installation of blade (5/8)

A-12

5) Connection of blade assembly and blade lift cylinders 5.1)

Sling the hydraulic cylinder with the belt sling and remove the transportation sling bracket.

(Fig. 7), (Fig. 8)

Belt sling Sling bracket a Connect the hydraulic cylinders one by one.

5.2)

Start the engine and operate the blade control lever to extend/retract the hydraulic cylinder rod and align it with the connecting hole (joint link) of the blade assembly. Part (A) in (Fig. 9)

a The work shall be performed by the machine operator, crane operator, and "signalman". The signalman must arrange the signaling method in advance and give proper directions to both operators.

5.3)

Insert the connecting pin in part (A). (Fig. 9)

5.4)

Stop the engine.

5.5)

Set the lock to the connecting pin head and bolt it to the joint link. (Fig. 9)

Connecting pin part No. Part No. of lock Part No. of bolt Part No. of washer Bolt specification Tool (Socket) Tightening torque

5.6)

198-72-62140 (1 piece each on right and left) 198-72-62170 (1 piece each on right and left) 01010-81635 (2 pieces each on right and left) 01643-31645 (2 pieces each on right and left) M16, Length 45 mm 24 mm Refer to Table 1, "Tightening Torques" in this manual.

Install blade cylinder holdfast (11) on the upper side of the cylinder facing inside of cylinder to fix the cylinder.

96

Assembly procedure

Installation of blade (6/8)

A-12

6) Connection of blade assembly and blade tilt hydraulic cylinder 6.1)

Remove the pins from the right and left of the cylinder connecting side (blade). (Fig. 11)

a For the single tiltdozer, remove the pin from only the right side. For the left side, see "assembly procedure A-11" Installation of brace assembly.

No. 12 13 14 15

â&#x20AC;˘

Part Name Pin Lock Bolt Washer

Part No. 09255-06295 09257-09014 01010-82045 01643-32060

Q'ty 1 each 1 each 4 each 4 each

Bolt specification

M20, Length 45 mm

Tool (Socket)

30 mm

For super dozer

No. 12 13 14 15

Part Name Pin Lock Bolt Washer

Part No. 198-72-51720 09257-09014 01010-82045 01643-32060

Q'ty 1 each 4 each 4 each 4 each

6.2)

The bottom side (clevis side) of the hydraulic cylinder has been connected to the straight frame already. See "assembly procedure A-11".

Raise one end of this hydraulic cylinder with the belt sling and remove the wooden block placed under it. (Fig. 12)

6.3)

With the hydraulic cylinder raised, start the engine and operate the blade control lever to extend/retract the hydraulic cylinder rod and align its pin hole (P) with the pin hole (Q) of the blade. (Fig. 12)

cylinder

a The work shall be performed by the machine operator, crane operator, and "signalman". The signalman must arrange the signaling method in advance and give proper directions to both operators.

97

Assembly procedure

A-12 6.4)

Installation of blade (7/8)

After aligning the pin holes, stop the engine and insert pin (12) removed in step 6.1) and fix it to the blade with lock (13), bolt (14) and washer (15).

(Fig. 13)

a Perform the work from step 6.2) to step 6.4) on the right and left sides.

However, perform on only the right side for the single tiltdozer. a For the tightening torque of bolt (14), see "Tightening torque", Table 1 in this manual.

6.5)

Loosen and remove the slings of the hydraulic cylinder.

6.6)

Start the engine again and operate the blade control lever to raise the whole blade assembly.

Then, remove all the wooden blocks placed under the blade.

6.7)

Lower the blade to the ground and stop the engine.

7) Confirmation of operation of blade assembly 7.1)

Check of hydraulic oil level and supply of new oil

[1] Check the hydraulic oil level again and supply new oil, if necessary. a Confirm the oil level after lowering the ripper shank and blade to the ground and set the back of the blade perpendicular to the ground. a About the kind of used fluids refer to "Assembly procedure A-6" Check on the amount of lubricants and coolant.

7.2)

Check of each part for interference

[1] Move the blade slowly and check that each part does not make interference or abnormal sound.

If abnormal sounds seem to come from the ball joints at both ends of the center brace, see step 7.5).

[2] Confirm that the blade does not interfere with the machine (radiator guard) when it is tilted to the maximum (or dual-tilted to the maximum for the dual tiltdozer) at the maximum lifting height.

[3] Confirm that there is sufficient clearances between the straight frames of the blade assembly and the tracks of the undercarriage when the blade is tilted to the maximum (or dual-tilted to the maximum for the dual tiltdozer).

98

Assembly procedure

A-12 7.3)

Installation of blade (8/8)

Confirmation of operation of blade

[1] Confirm that the blade is "raised" and "lowered" according to the operation of the blade control lever.

(Fig. 14) [2] Confirm that the blade is "right-tilted" and "left-tilted" according to the operation of the blade control lever.

(Fig. 15) [3] Inspect according to the "Field assembly inspection check sheet" attached to the end of this manual. a If the lateral balance or the clearance between blade assembly and machine needs to be adjusted and the brace assembly length must be adjusted consequently as a result of the check, return to "assembly procedure A-11" Assembly of blade, 6.

Installation of brace assembly, and readjust those items.

â&#x20AC;˘

Confirmation of operation of dual tiltdozer

[4] In addition to [1] and [2] of the single tiltdozer specification, ensure that the blade is "pitched back" and "pitched forward" according to the operation of the blade control lever. (Fig. 16) [5] Furthermore, confirm that the blade is "left-dual-tilted" and "right-dual-tilted" according to the operation of the blade control lever.

[6] Inspect according to the "Field assembly inspection check sheet" attached to the end of this manual. a For super dozer, this corfirmation of operation of dual tiltdozer is not necessary.

7.4)

Readjustment of ball joint shims at both ends of center brace When the blade is tilted to the right or left, if abnormal sound comes from either of the ball joints at both ends of the center brace, remove the ball cap of the ball joint which produces the abnormal sound and add the thinnest shim (0.5 mm) according to "assembly procedure A-11" Assembly of blade, step 4, and tilt the blade again to check.

99

Assembly procedure

A-13

Installation of operator's cab (1/20)

1) Installation of open lock striker Install right and left open lock striker mounting brackets (1) and (2) with sems bolts (3), washers (4) as shown in (Fig. 1). (5 pieces on each side) a Strikers (5), nuts (6), washers (7), stopper rubbers (8), and nuts (9) are installed to the bracket when delivered.

After mounting the operator's cab on the chassis, check the inspection items.

2) Installation of cab mounting bracket (L-shaped plate) Temporarily tighten the bracket (10) (L-shaped plate for indoor use) and bracket (11) (for outdoor use) to the position shown in [Fig. 2] by using sems bolts (12) and washers (13) (3 pieces on each side).

Loosen the sems bolts (12) before installation of the cab.

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Part Name Bracket (L.H.) Bracket (R.H.) Bolt Washer Striker Nut Washer Stopper Nut Bracket Bracket Bolt Washer

Part No. 198-Z11-3341 198-Z11-3351 01010-D1230 01643-71232 14X-911-1921 01580-11008 01643-31032 09453-00002 01580-01210 198-Z11-3571 198-Z11-3581 01010-D1230 01643-71232

Q'ty 1 1 10 10 2 8 8 2 2 1 1 12 12

Remarks Left Right

100

Assembly procedure

A-13

Installation of operator's cab (2/20)

3) Installation of rubber seals (14) to dashboard bracket 3.1)

Apply paste seal (55) to the mating faces of the dashboard bracket and floor as shown in (Fig. 3).

3.2)

Fit rubber seal (14) to the guide plate of the dashboard bracket and apply paste seal (55) as shown in (Fig. 4).

3.3)

Apply grease (G2-LI) to the outside of rubber seal (14) (joint face to the cap) as shown in (Fig. 5).

Remark 1: Apply grease so that the cab and rubber seal (14) will slip well against each other and rubber seal (14) will not be shifted or deformed when the cab is installed.

Remark 2: For the ease of assembly, remove both of right and left covers (A) before installing the cab and reinstall them after installing the cab.

Apply G2-LI

No. 14 55

Part Name Rubber seal Paste seal

Part No. 198-Z11-3540 198-Z11-3960

Q'ty 1 1

Remarks Sponge rubber

101

Assembly procedure

A-13

Installation of operator's cab (3/20)

4) Installation of rubber seals to mating face of operator cab bottom (Fig. 6) 4.1)

Weight of operator cab assembly: Approx. 500 kg

4.2)

Remove dirt, oil and grease from the rubber seal sticking faces of operator cab bottom.

4.3)

Peel off the release paper of rubber seals (15), (16) and (17) and stick those seals, referring to (Fig. 7) on the next page.

Remark : Since the rubber seals are made a little longer than required, cut them properly when sticking.

No. 15 16 17-1 17-2

Part Name Rubber seal Rubber seal Rubber seal Rubber seal

Part No. 14X-911-5911 198-Z11-7420 198-Z11-7410 198-Z11-7430

Q'ty 3 2 1 1

102

Assembly procedure

A-13

Installation of operator's cab (4/20)

Fig. 7 How to stick seals (View from bottom of operator's cab)

17

17

16 17 20

16 16

20

15

Remark : For the base seal shown in the figure, see the next page.

103

Assembly procedure

Installation of operator's cab (5/20)

A-13

⑯ ⑮ ⑰ ⑯ Apply paste seal (55) to clearance

⑮ Apply paste seal (55) to clearance No. 55

Part Name Paste seal

Part No. 198-Z11-3960

Q'ty 1

104

Assembly procedure

A-13

Installation of operator's cab (6/20)

5) Installation of operator cab (hereinafter referred to as cab) 5.1)

Lower the operator's cab assembly slowly onto the floor frame.

After installing cab, check that there is not clearance at each corner.

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

Lower cab in direction of arrow.

a Eliminate the clearance between the rubber seal of the air conditioner duct on the cab side and the air conditioner duct on the dashboard side.

Remark: For the machine monitor, see "assembly procedure M-2".

5.2)

Tighten bolts (18) and (20) and washers (19) temporarily. See (Fig. 15)

a The bolts at the cab door inlet have different length.

Take care.

After installing cab, check that there is not clearance at each corner.

Lower cab in direction of arrow.

5.3)

Confirm if there is a clearance between the mating part (a) of the rubber seal and floor frame. (Fig. 14)

a If there is a clearance as a result of the confirmation, sling the cab again and repeat the procedure from step 5.1).

If the clearance is very narrow, however, fill it with paste seal (55).

Flange Cab

Dashboard Bracket

105

Assembly procedure

Installation of operator's cab (7/20)

A-13

Operator cab assembly

15 parts

6 parts

Floor frame assembly Lower part of door

No. 18 19 20 55

Part Name Bolt Washer Bolt Paste seal

Part No. 01010-81275 124-54-26540 01010-81245 198-Z11-3960

106

Q'ty 15 21 6 1

Assembly procedure

A-13

Installation of operator's cab (8/20)

5.4)

Check that the clearance between the air conditioner duct on the cab side and monitor is even on the right and left sides. At the same time, check that the air conditioner duct seal on the cab side is fitted to faces (C) on the right and left sides of the air conditioner duct on the dashboard side and it is not moved to the right or left.

5.5)

If the clearance between the air conditioner duct on the cab side and monitor is not even, loosen the air conditioner duct mounting screws on the cab side and move the air conditioner duct so that the clearance will be even.

If the duct on the cab side or air conditioner side is moved to the right or left, adjust it similarly.

5.6)

Permanently tighten bolts (10), (18) and (20) which were tightened temporarily in step 5.2) above .

5.7)

Permanently tighten mounting bolts (12) of Lplates (11) which were installed temporarily in step 5.4 above.

107

Assembly procedure

Installation of operator's cab (9/20)

A-13 5.8)

Install plates (21) with bolts (22) and washers (23). (2 pieces on each side)

5.9)

Install right and left foot rests (24) and (25) with bolts (26) and washers (27).

5.10) Install pedal caps (28) to the foot rests.

Part P No. 21 22 23 24 25 26 27 28

Part Name Plate Bolt Washer Foot rest (left) Foot rest (right) Bolt Washer Pedal cap

Part No. 198-Z11-2961 01010-D1230 01643-71232 14X-911-5711 14X-911-5721 01010-D1230 01643-71232 203-43-56450

108

Q'ty 2 4 4 1 1 4 4 2

Assembly procedure

A-13

Installation of operator's cab (10/20)

5.11) The bundle of window washer tubes and the power supply wiring harness for cab (A) in (Fig. 20) come out of the bottom of the cab left side pillar (pillar at the left door hinge) into the cab. Take them out of the cab through the hole on the floor frame (B) in (Fig. 20).

Operator cab

5.12) Fit the grommet of the rubber boot protecting above bundle (A) to hole (B) and connect the boot to the cab and floor frame. (Fig. 21) 5.13) Connect bundle of the window washer tubes and power supply wiring harness for cab (A) pulled out in step 5.11) to the window washer tubes and power supply wiring harness for cab installed to the machine in advance at a place out of hole (B) indicated with Xo in (Fig. 20). (Fig. 22), (Fig. 23)

Floor frame

a The window washer tubes and power supply wiring harness for cab have connector No. indicating rings at their ends as shown in (Fig. 22).

Connect the tubes having the same color marks and the connectors having the same Nos. together respectively.

Grommet

109

Assembly procedure

Installation of operator's cab (11/20)

A-13

Identification color marks • Red • Blue • Black • —

For right door For left door For rear window For front window

Window washer tubes

Connectors No.

1 Phase 1 Phase 3 Phase

Wiring harness connectors

4 Phase Connector No. indicating ring

Window washer tubes

Wiring harness for cab power source

No. 29 30 31

Part Name Clip Clip Sems bolt

Part No. 198-Z11-2961 01010-D1230 01643-71232

110

Q'ty 1 1 1

Assembly procedure

A-13

Installation of operator's cab (12/20)

6. Installation of left parking brake lever knob 6.1)

Before installing the garnish, remove the lever knob.

6.2)

After installing the garnish, apply adhesive (LT-2) to the thread part of the knob, and then install the knob to the lever.

Garnish

Knob (Lever)

a When installing the garnish, be sure to install the screws shown in the figure.

Screw

Screw

111

Assembly procedure

A-13

Installation of operator's cab (13/20)

7. Installation of bellows bracket 7.1)

Pull and remove bellows (101) and bellows bracket (102) of blade lever as shown in the photo.

7.2)

Similarly, remove bellows (103) and bellows bracket (104) of ripper lever.

7.3)

Install cover (33).

7.4)

Install the bellows bracket to fixing spring (105).

â&#x20AC;˘

Installing condition of cover (33) (Fig. 30)

Fig. 30

Correct

Wrong

112

Assembly procedure

A-13

Installation of operator's cab (14/20)

8) Installation of interior parts 8.1)

Install floor covers (35), (36), and (37) with screws (40) (14 pieces).

8.2)

Install covers (38), (39), and (41) with button (43). (16 places)

8.3)

Install cup holder (46) with screws (47) to plate (42).

Then, install ashtray (44) and cigarette lighter (45) to plate (42) with screws (47) and washers (48).

8.4)

Install grille (50).

8.5)

Install rubber chutes (51) and (52).

No. 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Precautions

Tools required Name

1. Install plate (42) on cover (38) as shown in the photo.

2. Install cover (38) first, and then install plate (42).

Match the mounting holes of cover (38) before installing plate (42). After plate (42) is installed, the position of cover (38) cannot be adjusted. (Fig. 33, Fig. 34)

Others

3. If the band to fix the optional lunch box is selected, see also A-22.

113

Part No. 198-Z11-6170 198-Z11-6190 198-Z11-6150 198-54-61511 198-54-61531 01024-D0820 198-54-61521 198-Z11-6160 23D-950-4450 20Y-06-21751 20Y-06-23472 17A-Z11-3180 01245-00616 01643-70623 01370-40408 201-979-7820 198-Z11-6230 198-Z11-6241

Q'ty 1 1 1 1 1 14 1 1 16 1 1 1 4 4 2 2 1 1

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

A-13

Installation of operator's cab (15/20)

Correct installation

Wrong installation

Plate (42) is installed under cover (38).

114

Assembly procedure

A-13

Installation of operator's cab (16/20)

8.6)

Install sensor (62) to cover (61), connect CN-SLS, and then install them with screws (63) and washers (64). (4 pieces)

8.7)

Install plates (57) and (58) with screws (59) and washers (60). (8 pieces)

8.8)

Install cab door plate (65). (On both sides).

8.9)

After installing cab door plate (65), apply liquid sealant (55) all around the plate. (On both sides) Before opening and closing the door, wait until the sealant dries up.

CN-SLS is fixed to dashboard wiring harness with band.

Cut band and connect.

Sensor

Section of central part of cab

115

No. 55 57 58 59 60 61 62 63 64 65 75 76

Part No. 198-Z11-3960 198-Z11-2941 198-Z11-2951 01245-00616 01643-70623 198-Z11-6280 20Y-979-6161 01245-00616 01643-70623 198-Z11-6410 01010-D0645 01643-70623

Q'ty 1 1 1 8 8 1 1 4 4 2 6 6

Assembly procedure

A-13

Installation of operator's cab (17/20)

8.10) Install cushion (67) and install mat (68) on it.

8.11) Install mat (69).

8.12) Install plate (65). (On both sides, See Fig. 36)

No. 67 68 69 70 71 72 73 74

Precautions

Tools required

Others

Name

116

Part No. 198-54-75681 198-54-15791 198-54-75770 198-54-75620 198-54-75610 198-54-74950 198-54-74941 198-54-74862

Q'ty 1 1 1 1 1 1 1 1

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

Installation of operator's cab (18/20)

A-13

8) Install floor mat (74) while holding down its right and left ends with plates (81) and (82) attached to the bottom of the operator cab doorway. (See Fig. 39)

Section A-A

No. 81 82

Part Name Plate (Left) Plate (Right)

Part No. 198-Z11-6410 198-Z11-6410

117

Q'ty 1 1

Remarks

Assembly procedure

Installation of operator's cab (19/20)

A-13

10) Installation of rear view mirror (if equipped)

No. 91 92 93 94

Part Name Mirror Bracket Bolt Washer

Part No. 14X-911-6140 198-Z11-3670 01010-D0845 01643-70823

Q'ty 1 1 2 2

Remarks

10.1) Install rear view mirror (91) to bracket (92).

10.2) Install bracket (92) to the front duct top of the operator cab with bolts (93) and washers (94). a The rear view mirror is an optional part, which is not installed to the operator cab of the standard specification. a Each operator cab to be equipped with the rear view mirror is delivered with the rear view mirror installed, as a rule.

Accordingly, this work is required only when the rear view mirror is delivered uninstalled.

118

Assembly procedure

A-13

Installation of operator's cab (20/20)

11) Change of installed angle of radio antenna

Loosen the wing bolt at the center of rotation of the radio antenna, rotate the antenna from position (T) indicated with the broken line to position (P) indicated with the solid line, and stand it vertically.

Tighten the wing bolt again to fix the antenna. a Loosen and tighten the wing bolt with the hand. a The radio antenna is set to position (T) indicated with the broken line for packing when the operator cab is transported from the factory to the field.

119

Assembly procedure

Installation of ROPS

A-14

Sling the ROPS with the crane and install it to the mounting position.

4 ROPS: 918 kg

3 Mounting bolt (1): 1,960 – 2,450 Nm {200 – 250 kgm}

Set stamp F on the front side.

Precautions

Tools required Name

120

T)

No.

Part No.

Q'ty

1

01011-83310

16

2

01643-33380

16

Equipment required Q’ty

Torque wrench (2,059 Nm {210 kgm}) Socket 50 mm (38.1

Others

•

1 1

Name

Q’ty

Assembly procedure

A-15

Installing direction of exhaust pipe

• After installing the exhaust pipe, connect komaclone tube (4), using gasket (1), bolt (2), and washer (3).

Right of chassis

Install rain caps 20¡ rotated.

Left of chassis

Front of chassis

Precautions

Tools required

Others

Name

121

No.

Part No.

Q'ty

1

6162-13-5611

2

2

01010-81025

4

3

01643-51032

4

Equipment required Q’ty

Name

Q’ty

Assembly procedure

A-16

Installation of giant ripper shank

1. Operate the machine to make the distance from the bottom of ripper beam to the ground as dimension (H) shown in Fig. 1. a (H): 2700 mm or more a Make the hole for shank holder of ripper beam to be vertical to the ground.

The following is an example of the method. Choose proper method according to the conditions in the field.

1) Set the rear of the machine on blocks, etc. to raise it as shown in Fig. 1.

2) Raise ripper arm to the highest position, operate ripper beam, and set the hole for shank holder vertical to the ground.

2. Set ripper shank on the ground under ripper beam. At this time, the sling ring on the top of ripper shank should be right under the hole for shank holder of ripper beam.

3. Set lifting rope sling on the crane, and insert the rope sling into the hole for shank holder of ripper beam from the top to leave the front end of the rope sling on the ground.

Crane Rope sling

Ripper

a Rope sling: ø12 mm Ă&#x2014; 4 m See "Tools list for field assembly" 4. Connect the rope sling and the lifting ring of ripper shank with shackle. a Shackle: SD22-M See "Tools list for field assembly" a Weight of shank assembly: approx. 9.8 kN {1000 kg} 5. Sling ripper shank by using crane, and insert it into the hole for shank holder of ripper beam.

6. Align the pin holes of ripper shank and ripper beam, and insert shank mounting pin to fix it.

Reference: The procedure for multi-ripper specification is almost the same.

122

Shackle

Shank assembly

Assembly procedure

Adjustment of arm joint (U-blade)

A-17

Check of clearance in arm ball joint fl If the clearance in arm ball joint is adjusted properl y in Assembly procedure A-8, step 4, following check is not necessary.

Adjustment of shim 1. Remove shim (1) and tighten bolt (2) until the play of the ball joint is eliminated.

2. Measure clearance “A” and remove bolt (2).

3. Install shim (1) having thickness of “A + (0 to 1) mm”.

Shim (1) Bolt (2)

Standard thickness of shim: 4.5 mm

4. Tighten bolt (2). Then, check that the ball joint rotates smoothly.

Adjustment of shim

Adjustment of shim

Adjustment of shim

123

Assembly procedure

A-18

Installation of counterweight

(1) Sling the counterweight assembly and set it to the mounting position of the main frame.

Fig. 1

Weight of counterweight: 7,300 kg Lifting wire: ø20 mm ✕ 6 m ✕ 2 pieces

(2) Install the mounting pins as shown in Fig. 2.

Fig. 2

No.

Part name

Part No.

Q ty

1

Counterweight assembly

1

2

Main frame

—

3

Lifting wire

4

Pin

198-78-21180

2

5

Plate

205-70-61560

2

6

Bolt

01010-82045

4

7

Washer

01643-32060

4

2

8

Pin

198-78-21140

2

9

Plate

195-78-21171

2

10

Bolt

01010-82040

4

11

Washer

01643-32060

4

124

Assembly procedure

A-19

Procedure for adjusting blade tilt angle limit (1/9)

1. Dual-tiltdozer 1-1 Set the machine under the standard condition.

• Set the potentiometer rod to 425 mm.

• Keep the machine horizontally.

Run the engine at low idling and set the blade in the following standard position.

1) Set the tilt angle to 0°.

2) Set the pitch angle to the maximum pitch back.

3) Lower the blade to the ground and then raise it about 100 mm.

4) Set the toggle switch of the blade lever to the dual tilt position.

Pitch back

Tilt switch

Dual tilt

Precautions

Tools required Name

Others

1-2

125

Equipment required Q’ty

Name

Q’ty

Assembly procedure

A-19

Procedure for adjusting blade tilt angle limit (2/9)

1-3

Adjust mounting dimension "a" of rod (1) and connect the rod to potentiometer lever (2) and yoke (3).

• Mounting dimension "a": 425 mm

1-4

Mode and operation "Note 1" 1) Hold buzzer cancel switch (3) in the position for 2.5 seconds, and the maintenance mode is displayed.

2) Set the buzzer cancel switch to information switch (2), and the adjustment mode is selected.

3) Set the buzzer cancel switch in the position, and the adjustment mode selecting screen is displayed.

4) Operate the information switch to display the tilt limit setting screen.

5) Set the buzzer cancel switch in the select position ( ) to enter the tilt limit adjustment mode (User adjustment mode). If the pitchback button (lower button) of the work equipment control lever is pressed, the buzzer sounds and the reference position is saved.

6) Set the buzzer cancel switch in the cancel position ( ) to leave the adjustment mode temporarily.

Precautions

Tools required Name

Others

Note 1) For buzzer cancel switch and information switch, see "Assembly procedure M-2".

126

Equipment required Q’ty

Name

Q’ty

Assembly procedure

A-19

Procedure for adjusting blade tilt angle limit (3/9)

1-5

Raise the blade tip to about 1,000 mm above the ground.

1-6

Tilt the blade to the left with the blade control lever and set the left tilt angle to 12°. (User adjustment mode) a Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase too much. a Adjust the tilt angle accurately with angle gauge.

1-7

Set the toggle switch of the blade control lever in the single tilt position, and then set it in the dual tilt position again to save the left tilt limit in the system. a When the saving operation is finished, the buzzer sounds.

Tilt switch

Single tilt Dual tilt

Precautions

Tools required

Others

Name

127

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

A-19

Procedure for adjusting blade tilt angle limit (4/9)

1-8

Set buzzer cancel switch (3) in the cancel position ( ) once to leave the adjustment mode.

1-9

Set the blade in the maximum pitch type position.

(Set the work equipment horizontally.)

1-10 Set buzzer cancel switch (3) in the select position ( ) again to enter the tilt limit adjustment mode.

Precautions

Tools required

Others

Name

128

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

A-19

Procedure for adjusting blade tilt angle limit (5/9)

1-11 Tilt the blade to the right with the blade control lever and set the right tilt angle to 12°. a Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase too much. a Adjust the tilt angle accurately with angle gauge.

a 1-12 Set the toggle switch of the blade control lever in the single tilt position, and then set it in the dual tilt position again to save the right tilt limit in the system. a When the saving operation is finished, the buzzer sounds.

1-13 The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( mode, and then lower the work equipment to the ground and stop the engine.

) to leave the adjustment

1-14 Start the engine again and tilt the blade to the right and left and check that the blade does not interfere with the track shoe, regardless of its height.

Precautions

Tools required

Others

Name

129

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

A-19

Procedure for adjusting blade tilt angle limit (6/9)

2. Superdozer 2-1 Set the machine under the standard condition.

• Set the potentiometer rod to 425 mm.

• Keep the machine horizontally.

2-3

Run the engine at low idling and set the blade in the following standard position.

1) Set the tilt angle to 0°.

2) Set the pitch angle to the maximum pitch back.

3) Lower the blade to the ground and then raise it about 100 mm.

Pitch back

Adjust mounting dimension "a" of rod (1) and connect the rod to potentiometer lever (2) and yoke (3).

• Mounting dimension "a": 425 mm

Precautions

Tools required Name

Others

2-2

130

Equipment required Q’ty

Name

Q’ty

Assembly procedure

A-19

Procedure for adjusting blade tilt angle limit (7/9)

2-4

Mode and operation "Note 2" 1) Hold buzzer cancel switch (3) in the position for 2.5 seconds, and the maintenance mode is displayed.

2) Set the buzzer cancel switch to information switch (2), and the adjustment mode is selected.

3) Set the buzzer cancel switch in the position, and the adjustment mode selecting screen is displayed.

4) Operate the information switch to display the tilt limit setting screen.

5) Set the buzzer cancel switch in the select position ( ) to enter the tilt limit adjustment mode (User adjustment mode). If the pitchback button (lower button) of the work equipment control lever is pressed, the buzzer sounds and the reference position is saved.

6) Set the buzzer cancel switch in the cancel position ( ) to leave the adjustment mode temporarily.

2-5

Operate the blade according to the following procedure so that it can be tilted.

1) Raise the blade tip to 300 mm above the ground.

2) Set the blade angle to 52°. a Adjust the blade angle accurately with angle gauge.

Precautions

Tools required Name

Others

Note 1) For buzzer cancel switch and information switch, see "Assembly procedure M-4".

131

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

A-19

Procedure for adjusting blade tilt angle limit (8/9)

2-6

Set the buzzer cancel switch in the select position ( ) to enter the tilt limit adjustment mode (User adjustment mode).

2-7

Raise the work equipment about 1,000 mm without changing the blade pitch angle adjusted in step 25 and tilt it 8 ¹ 1° to the left. Under this condition, press the pitch-dump button (upper button), and the buzzer sounds and the left limit position is saved. a Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase too much. a Adjust the tilt angle accurately with angle gauge.

132

Assembly procedure

A-19 2-8

Operate the work equipment control lever to tilt the work equipment to the right. Under this condition, press the pitch-dump button (upper button), and the buzzer sounds and the right limit position is saved. a Since the tilt limiting function does not work, operate slowly so that the tilt angle (a) becomes the following angle in the chart. a Adjust the tilt angle accurately with angle gauge.

Shoe width 810 mm 910 mm

2-9

Procedure for adjusting blade tilt angle limit (9/9)

a

Tilt angle (a) 8 ± 1° 9 ± 1°

The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( mode, and then lower the work equipment to the ground and stop the engine.

) to leave the adjustment

2-10 Start the engine again and tilt the blade to the right and left, operate the blade following the procedure in section 25 and raise the blade about 1,000 mm, and check that the blade stops tilting to the right and left in the following range automatically.

• Automatic tilt stopping angle: 8 ± 1°

Precautions

Tools required

Others

Name

133

Equipment required Q’ty

Name

Q’ty

Assembly procedure

A-20

Method of checking auto-reset system (Superdozer)

System to return the blade to the digging position automatically 1.

2.

3.

4.

5.

6.

Auto pitch back switch : ON Pitch the blade forward.

Set the gear speed in R1 or R2.

Press the pitch-back button.

The blade is fully pitched back.

The blade returns to the digging position and horizontal position.

Auto pitch back switch

Pitch dump Pitch back

The auto-reset system is used to set the blade in the digging position automatically (to lower the blade to the ground and set its angle to 52°). To reset this system, press the pitch button.

Digging posture

Tilt forward

Controller

Valve Pitch back solenoid

Precautions

Tools required

Others

Name

134

Equipment required Q’ty

Name

Q’ty

Assembly procedure

A-21

Installation of ORBCOMM antenna and wiring harness

1. Remove left cover (6) (above the left fender).

2. Install the wiring harness and antenna (3) as shown in the following figure.

3. Install left cover (6).

No. 1 2 3 4 5

Precautions

Tools required Name

Others

ORBCOMM: The ORBCOMM terminal system is a communication system to use the satellite communication service of ORBCOMM Co., Ltd. (USA).

135

Part No. 01010-81220 04434-50612 8A13-10-2100 21N-54-38451 01010-81225

Q'ty 5 5 1 1 1

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

A-22

Installing lunchbox band (if equipped) (1/2)

Note) This part is optional. If not ordered, this part is not equipped. a When performing the following procedure, refer to A-13 Installing operator's cab, too.

1. After installing plate (1) to the operator's cab, pass the band through the rear U-hook as shown below.

2. Install cover (3).

Slide and position cover (3) to the rear U-hook as shown in the figure of part (P), and then fix it.

P

No. 1 2 3 Precautions

Tools required

Others

Name

136

Part No. 198-Z11-6170 198-911-7350 198-54-61511

Q'ty 1 2 1

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

A-22

Installing lunchbox band (if equipped) (2/2)

3. Referring to A-13 Installing operator's cab, install the lining and rubber plate.

4. Install the band as shown below.

After installing cover (3), pass band through front and side U-hooks.

Lining Front Rubber plate

Precautions

Tools required

Others

Name

137

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

A-23

Greasing each part of work equipment (1/3)

a For using oil type, see "A-6 Check of oil and coolant levels" in assembly procedure. a 1. Blade

Center ball joint

Center link pin

Left ball joint

Right ball joint

2. Blade lift cylinder support yoke

Cap upper side Cap lower side

138

Assembly procedure

A-23

Greasing each part of work equipment (2/3)

3. Blade lift cylinder support shaft

Support shaft LH and RH

4. Ripper

Cylinder bottom LH and RH

LH & RH

LH & RH

LH & RH

Arm bottom LH and RH

139

Assembly procedure

A-23

Greasing each part of work equipment (3/3)

5. Equalizer bar side pin

Equalizer bar side pin LH and RH

6. Equalizer bar both end.

Remove cover and lubricate both end.

7. Suspension (Equalizer bar center shaft) (1 place)

(Right side of engine room)

140

Assembly procedure

A-24

Bleeding air from hydraulic cylinders

a 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.

1. Blade lift Cylinder (with piston valve) 1) Start the engine and run at low idle for approx. 5 minutes.

2) While running the engine at low idling, extend and retract the cylinder four or five times without operating it to the end of its stroke. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

3) Keeping the engine at low idling, retract the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to retract the cylinder to the end of its stroke. While operating the lever, hold the cylinder in this position for 3 minutes.

4) With the engine at high idle, retract the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to retract the cylinder to the end of its stroke. While operating the lever, hold the cylinder in this position for 1 minute.

2. Blade tilt cylinder (without piston valve) 1) Start the engine and run at low idling for approx. 5 minutes.

2) With the engine at low idling, raise and lower the blade four or five times without operating the cylinder to the end of its stroke. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

3) Repeat this operation with the engine at full throttle; then run the engine at low idling and operate the piston rod to the end of its stroke to relieve the circuit.

k

If from the beginning the engine is run at full throttle; or the cylinders are operated to the end of their stroke, the piston packing may be damaged, so never operate in this way.

Check the oil level, and add oil to the specified level if necessary.

Precautions

Tools required Name

Others

k

141

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

A-25

Air bleeding from work equipment pump and fan pump

1. Bleeding air from pumps Procedure: Loosen air bleeding plug before starting the engine.

Start the engine, and leave the pump opened until no bubbles are found in the oil flowing out.

After that, tighten the plug.

1) Bleeding air from fan pump (1 place)

Tighten after air is bled

2) Bleeding air from work equipment pump

Precautions

Tools required Name

Others

Stop the engine before tightening work equipment pump.

Or there is danger of being caught into the universal joint.

142

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY

143

Assembly procedure

M-1

Check and adjustment of operator’s cab (1/7)

1. Measuring pressure in cab (1) Measure the pressure in the cab.

• Criterion: Measured value ≥ 98.1 Pa {10 mmH2O} • Testing condition : Run the engine at full throttle and set the engine fan to 100%. : Max. cooling fan speed. : Set the blower to the high (Hi). fl Set the maximum cooling fan speed of the USER ADJUST MODE of the machine monitor.

Use the USER ADJUST MODE according to Assembly procedure M-4. fl Operate the blower according to the following procedure.

1) Depress air outlet selector switch (2) on the air conditioner control panel to select the front-rearfoot area mode (shown at right).

2) Select the fresh air mode with the RECIRC/FRESH air selector switch (3).

3) Depress fan switch (1) to set the blower to the high (Hi).

Front-Rear-Foot area (including defroster) <Indication on LCD and air flow> Indication on LCD

Air flow Low Medium 1 Medium 2 Medium 3 Medium 4 High

fl If the standard pressure is not obtained, check the seals around the dashboard and the seals of the fitting faces of the cab and floor for an opening.

(Run water over outside to see if it enters the cab.)

If there is an opening, fill it with liquid seal.

144

Blower at high (Hi)

Assembly procedure

M-1

Check and adjustment of operator’s cab (2/7)

(2) Outlined below is a simplified method for the internal pressure measurement of the operator’s cab:

Lock lever mount hole

a) Prepare a transparent vinyl hose (of an outer diameter of 10 mm and 3,000 mm long). b) Pour water into the hose bore for about a half of the hose length.

10 mm or more

c) Remove the sliding windshield lock lever located on the side panel of the operator’s cab to insert one end of the vinyl hose before fastening an adjacent part of the hose to the top end of the back seat using packing tape. (See photo.) d) Seal the hole of lock lever with tape. e) Match the water levels of the beginning part and the ending part of the water cloumn inside the transparent vinyl hose at the outside of the operator’s cab. f)

Start the engine and run it at full speed to read the difference between the two water levels.

Inside the operator’s cab

Outside (Atmospheric pressure)

a Before measuring inner pressure, confirm that the grommet at the position shown in Fig. A is firmly locked.

Remove lock lever and insert vinyl hose.

Fig. A is the same with Fig. 21 in "Assembly Procedure A-14".

Fix vinyl hose to top end of back seat

Vinyl hose

145

Assembly procedure

M-1

Check and adjustment of operator’s cab (3/7)

2. Shower test for water-tightness (1) Close all the opening sections of the operator’s cab.

(2) Prepare to pour water of a flow of about 19 ¬/min. through a water hose.

(3) Pour water to the area around the hatched section in Fig. for about 10 minutes.

When doing this, it is not necessary to use pressurized water.

(4) Pour water horizontally to the sealed surface according to the “Cross-section A-A”.

(5) Carefully check the area around the dashboard, in particular. fl When any water leakage is found, apply due caulking before re-checking the section if the water leakage still occurs.

(Sealed surface) Shower test for water-tighteness

Precautions

Tools required

Others

Name

146

Equipment required Q’ty

Name

Q’ty

Assembly procedure

Check and adjustment of operator’s cab (4/7)

M-1

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

3.1

Checking the current statuses (1) Check the mounted elevation of the damper rubber. (Located at 4 places per a side and check them on both L.H and R.H sides.)

Applying a packing tape strip over the contact surfaces of the damper rubber, open and close the door for 2 to 3 times. After finishing this opening and closing cycles of the door, check the contact surface of the packing tape with the operator’s cab structure.

Normal: The back surface of the packing tape comes in light contact the operator’s cab structure when the door is being closed.

Abnormal: The back surface of the packing tape does not come in contact with the operator’s cab structure when the door is being closed, or if the two sections come in a harsh contact such as peeling off the applied packing tape.

Damper rubber (14X-911-1690) Mounting screw (01023-20616)

Packing tape strip Door Shim (14X-911-1761)

(2) Check the correlation between the door latch and the striker (on both, L.H and R.H side).

Moving the door toward the closing direction, observe the engaging state between the latch and the striker.

Latch

Striker Latch

Make the observation to check the engagement from this side.

Center of the striker Center of the latch Striker

Check if the center of the striker and the center of the latch are not deviated.

147

Assembly procedure

M-1 3.2

Check and adjustment of operator’s cab (5/7)

Adjustments (1) Adjusting the elevation of the damper rubber When adjusting the elevation of the damper rubber, supplement or reduce the shims being inserted below the damper rubber to adjust the elevation of the damper rubber properly.

Damper rubber

Shims

t1.2

Door structure

The shape of the shim (14X-911-1761)

(2) Adjusting the correlation between the latch and the striker (a) Loosening the striker mounting bolts to a temporarily tightened state, open and close the door 2 to 3 times to aligh the centers of the latch and the striker. (b) Check the engaging state between the latch and the striker. (c) Tighten the striker mounting bolts back to their original tightened state. (d) Try to open and close the door to see if the door lock can be released smoothly.

When the door lock cannot be released smoothly (when the turning effort to move the knob feels too heavy), repeat the adjustment all over again. (Appropriate knob turning effort: 68.6 ± 19.6 N {7 ± 2 kg} (3) Apply grease (G2-LI) over the latch surface.

Precautions

Tools required Name

Others

When the grease adhering over the latch surface dries out, the turning effort for the knob will become heavier.

Therefore, apply grease sufficiently in order not to allow it to become dried up.

148

Equipment required Q’ty

Name

Q’ty

Assembly procedure

M-1

Check and adjustment of operator’s cab (6/7)

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

4.1

Checking the current statuses (1) Check the correlation between the open -lock latch and the striker.

(Check them on both L.H and R.H sides.)

Move the door toward the opening direction to observe the engaging state between the latch and the striker.

Check if the claw of the latch is not riding over the bent section of the striker.

Releasing lever

The status is normal if the latch is not riding over the bent section of the striker.

Shake the door back and forth.

Latch (20Y-54-36380) Bolt (01435-30820) Striker (14X-911-1921)

Make the observation through this direction

Nut (01580-11008) Washer (01643-31032)

Bracket (198-Z11-3341) (198-Z11-3351) Check and make sure that the body of the latch and the striker are not interfering.

The correlation is normal if they are not interfering.

(2) Check the mounted elevation of the stopper rubber. (At 2 places each on one side. Check them on both L.H and R.H sides.) (a) Shaking the door back and forth in open-locked state, check for rattling. (b) Check if the turning effort for the releasing lever is too heavy.

Precautions

Tools required

Others

Name

149

Equipment required Q’ty

Name

Q’ty

Assembly procedure

Check and adjustment of operatorâ&#x20AC;&#x2122;s cab (7/7)

M-1

Adjustment (1) Adjusting the correlation between the latch and the striker Loosen the striker mounting nut and adjust the position of the striker so that it does not interfere with the latch nor the overriding over the bent section occurs before tightening the nut back to its original state.

When the interference cannot be corrected by the adjustment on the striker side, loosen the latch side mounting bolts to make the adjustment from the latch side.

Latch Clearence

Striker Door structure

Striker Stopper rubber Latch Depress the door and if it moves until the clearance disappears, bring out the stopper rubber toward the depressed side.

(2) Adjusting the elevation of the stopper rubber (a) Loosen the stopper rubber fastening nut. (b) When ratting exists, bring out the stopper rubber until the clearance disappears.

However, in case the lock is hard to engage for the turning effort for the releasing lever is too heavy, bring back the stopper rubber within the range where ratting of the door does not occur. (c) Tighten the fasting nut back to the original state.

Precautions

Tools required Name

Others

4.2

150

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-2

Inspection of machine monitor (1/13)

Machine monitor There are the following 2 designs in the machine monitor, the functions of which are the same.

•

Serial No. 30001 – 30070

•

Serial No. 30071 and up

151

Assembly procedure

M-2

Inspection of machine monitor (2/13)

Check that the "machine monitor" on the front panel can be set in the "service mode" with its special function and the "failure codes" can be displayed normally in that mode.

Fig. 13 Front panel

(1) Machine monitor (2) Upper display unit â&#x20AC;˘ Gear speed is displayed on this unit in normal mode (operator mode).

(3) Lower display unit (Multi-information unit) â&#x20AC;˘ Transmission shift mode and service meter are displayed on this unit in normal mode (operator mode).

(4) Starting switch (5) Buzzer cancel switch (6) Information switch (7) Lower cover (8) Service switch

Note: The "Service mode" is used in "Initialization of VHMS controller" of the VHMS specification described later in "Attached material 2". Accordingly, understand the operating procedure thoroughly.

152

Assembly procedure

M-2

Inspection of machine monitor (3/13)

1) Setting in "Service mode" 1.1)

Remove cover (7) under the front panel so that you can operate service switch (8).

1.2)

Turn starting switch (4) "ON".

1.3)

While pressing service switch (8), turn and hold buzzer cancel switch (5) toward the [U] mark for 3 seconds, and P, N, F2, R2, etc. displayed on upper display unit (2) of machine monitor (1) changes to 1C, 55, etc. (See Fig. 2)

a If 1C, 55, etc. is displayed, the machine monitor is set in the "service mode". 1C and 55 are service mode codes among the 8 of 1C, EE, bE, Cb, Ld, 5R, dR and 55. For details of the service mode codes, see "Testing and adjusting volume" of the shop manual.

Fig. 2

Fig. 4 Upper display unit (2) Upper display unit (2)

Lower display unit (3) Lower display unit (3)

2) Display check of "Failure code" In the service mode, a trouble that occurred in the machine can be displayed by a classification code named the "Failure code" on lower display unit (3) of machine monitor (1). With this function, the operator can grasp the cause of the trouble precisely and repair the machine quickly.

The "Failure codes" are classified into the electrical system failure codes and mechanical system failure codes, which are displayed on lower display unit (3) by setting the service mode code of upper display unit (2) to "EE (Electrical system failure code display mode)" or "bE (Mechanical system failure code display mode)".

153

Assembly procedure

M-2 2.1)

Inspection of machine monitor (4/13)

Check of "Electrical system failure code display mode"

Fig. 5

-1) Set upper display unit (2) in the service 2.1.1) mode and turn information switch (6) toward the > mark or < mark to display service mode code "EE". (See Fig. 5 3) Remark:Operation of information switch (6) â&#x20AC;˘ Toward > mark: Next code â&#x20AC;˘ Toward < mark: Previous code

2.1.2) -2) After service mode code "EE" is displayed, turn buzzer cancel switch (5) to the <> mark to settle "EE".

-3) If "EE" is settled, the "failure code" of the 2.1.3) electrical system is displayed on lower display unit (3).

-4) For the contents of display on lower dis2.1.4) play unit (3), see step 2.3).

2.2)

Check of "Mechanical system failure code display mode"

Fig. 6

2.2.1) -1) Turn buzzer cancel switch (5) to the t mark to cancel the "EE" mode.

-2) Turn information switch (6) toward the > 2.2.2) mark or < mark to display service mode code "bE". (See Fig. 4) 6 -3) Turn buzzer cancel switch (5) to the U 2.2.3) mark to settle "bE".

-4) If "bE" is settled, the "failure code" of the 2.2.4) mechanical system is displayed on lower display unit (3).

2.2.5) -5) For the contents of display on lower display unit (3), see step 2.3).

154

Assembly procedure

M-2 2.3)

Inspection of machine monitor (5/13)

Contents of display on lower display unit The "failure codes" of both "EE (Electrical system failure code display mode)" and "bE (Electrical system failure code display mode" are displayed in the same format on lower display unit (3) as shown below.

2.3.1) -1) When the assembly work is completed, no past trouble is recorded and no trouble is detected currently, thus the display is as shown in Fig. 75 in both modes.

2.3.2) -2) If a trouble occurs after this machine is put in operation or if there is the record of a past trouble, the display of (EE) becomes as shown in Fig. 8 6.

Fig. 7

Fig. 8

(1): Record No. (up to 20 Nos.) (2): Failure code (Code of trouble occurring at present blinks) (3): Number of occurrence up to now (4): Elapsed time by service meter after first occurrence (5): Elapsed time by service meter after last occurrence -3) If a trouble occurs after this machine is put in 2.3.3) operation or if there is the record of a past trouble, the display of (bE) becomes as shown in Fig. 9 7.

Fig. 9

(1): Record No. (up to 15) (2): Failure code (Code being output currently is flashing) (3): Number of past occurrences (4): Time tested by service meter after first occurrence (5): Time tested by service meter after last occurrence 2.4) Failure code As described above, the "failure codes" are classified and displayed into the "electrical system failure codes" and "mechanical system failure codes". For the details of each code, see "Testing and adjusting volume" or "Troubleshooting volume of the shop manual.

The major "failure codes" are listed on the following pages.

155

Assembly procedure

M-2

Inspection of machine monitor (6/13)

Error codes list (Related to machine controller)

156

Assembly procedure

M-2

Inspection of machine monitor (7/13)

157

Assembly procedure

M-2

Inspection of machine monitor (8/13)

158

Assembly procedure

M-2

Inspection of machine monitor (9/13)

159

Assembly procedure

M-2

Inspection of machine monitor (10/13)

Error codes list (Related to VHMS controller)

160

Assembly procedure

M-2

Inspection of machine monitor (11/13)

Error codes list (Related to engine controller)

161

Assembly procedure

M-2

Inspection of machine monitor (12/13)

162

Assembly procedure

M-2

Inspection of machine monitor (13/13)

163

Assembly procedure

M-3

No-injection cranking of engine (1/3)

When starting the engine for the first time, perform its no-injection cranking to lubricate it in advance according to the following procedure.

Note: Before performing this work, check the oil levels and complete inspection and maintenance of each part.

1. Use multi-information section (3) of the machine monitor, starting switch (4), buzzer cancel switch (5) and information switch (6) to set the engine in the no-injection cranking mode.

Fig. 1 Front panel (1) Machine monitor (2) Upper display unit â&#x20AC;˘ Gear speed is displayed on this unit in normal mode (operator mode).

(3) Lower display unit (Multi-information unit) â&#x20AC;˘ Transmission shift mode and service meter are displayed on this unit in normal mode (operator mode).

(4) Starting switch (5) Buzzer cancel switch (6) Information switch

164

Assembly procedure

M-3

No-injection cranking of engine (2/3)

2. Procedure 2.1 (1) Turn the starting switch "ON". The machine monitor is turned ON. 2.2 (2) Turn buzzer cancel switch ((5) in Fig. 2) to the ] position (left side) and hold it for 2 â&#x20AC;&#x201C; 3 [ seconds.

The display of multi-information section ((3) in Fig. 1) changes to OIL, FILTER MAINTENANCE MODE (Fig. 3).

After the display changes, release the switch, and it returns to the neutral position.

2.3 ] (3) Turn information switch ((6) in Fig. 2) to the [ position (left side) or [ ] position (right side) several times to change the display of the multiinformation section to USER ADJUST MODE (Fig. 4).

Reference: Each time the information switch is turned, the 4 modes of OIL, FILTER MAINTENANCE MODE, PM CLINIC MODE, FAULT CODE DISPLAY MODE and USER ADJUST MODE are selected in either order repeatedly.

2.4 (4) After the display of the multi-information section changes to USER ADJUST MODE, turn the buzzer cancel switch to the [ ] position (left side) again to settle USER ADJUST MODE. Once this mode is settled, it does not change to another mode described in step (3) even if the information switch is turned, and the multiinformation section changes to the variation selection screen in USER ADJUST MODE. Note: If the buzzer cancel switch is turned to the [ ] position (right side) by mistake, the multiinformation section returns to the state in step 2.1.

(1).

165

Assembly procedure

M-3

No-injection cranking of engine (3/3)

2.5 (5) Turn information switch again to the [ ] position (left side) or [ ] position (right side) several times to change the display of the multiinformation section to NO INJECTION (Fig. 5).

2.6 (6) Turn the buzzer cancel switch to the [ ] position (left side) to settle NO INJECTION. Reference: In step (5), each time the information switch is turned, the 7 variations of LCD BRIGHTNES, DSP BRIGHTNES, DSP CONTRAST, FAN 100% SPEED, NO INJECTION, TILT LIMIT and PRE-LUB ON are selected in either order repeatedly.

2.7 (7) In about 3 seconds after NO INJECTION is settled, the display of the lower line of the multiinformation section changes from "WAIT" to "ACTIVE" (Fig. 6) and the mode becomes effective.

2.8 (8) Under this condition, turn starting switch ((4) in Fig. 1) to the START position to rotate the starting motor and perform no-injection cranking.

Perform no-injection cranking for about 10 seconds at the normal temperature (about 20 °C), depending on the ambient temperature.

Note 1: Do not perform no-injection cranking continuously for more than 20 seconds.

Note 2: This function does not work while the engine is running. During this period, "NOT AVAILABLE" is displayed (Fig. 7) on the lower line of the multi-information section to indicate that this mode is not available.

2.9 (9) To reset this mode, turn the buzzer cancel switch to the [ ] position (right side).

The display of the multi-information section returns to the state after step 2.1 (1) where the starting switch is turned "ON".

2.10 (10) Turn the starting switch "OFF".

166

Assembly procedure

M-4

Setting procedure of user adjust mode (1/3)

When setting the cooling fan speed to about 100% of the maximum speed forcibly for measurement of the pressure inside the cab in [M-1: Check and adjustment of operator’s cab], operate the machine monitor to display USER ADJUST MODE in the multi-information section according to the following procedure.

1. Use multi-information section (3) of the machine monitor, starting switch (4), buzzer cancel switch (5) and information switch (6) to set the user adjust mode.

Fig. 1 Front panel (1) Machine monitor (2) Upper display unit • Gear speed is displayed on this unit in normal mode (operator mode).

(3) Lower display unit (Multi-information unit) • Transmission shift mode and service meter are displayed on this unit in normal mode (operator mode).

(4) Starting switch (5) Buzzer cancel switch (6) Information switch

167

Assembly procedure

M-4

Setting procedure of user adjust mode (2/3)

2. Procedure 2.1 (1) Turn the starting switch "ON". The machine monitor is turned ON. 2.2 (2) Turn buzzer cancel switch ((5) in Fig. 2) to the ] position (left side) and hold it for 2 â&#x20AC;&#x201C; 3 [ seconds.

The display of multi-information section ((3) in Fig. 1) changes to OIL, FILTER MAINTENANCE MODE (Fig. 3).

After the display changes, release the switch, and it returns to the neutral position.

2.3 ] (3) Turn information switch ((6) in Fig. 2) to the [ position (left side) or [ ] position (right side) several times to change the display of the multiinformation section to USER ADJUST MODE (Fig. 4).

Reference: Each time the information switch is turned, the 4 modes of OIL, FILTER MAINTENANCE MODE, PM CLINIC MODE, FAULT CODE DISPLAY MODE and USER ADJUST MODE are selected in either order repeatedly.

2.4 (4) After the display of the multi-information section changes to USER ADJUST MODE, turn the buzzer cancel switch to the [ ] position (left side) again to settle USER ADJUST MODE. Once this mode is settled, it does not change to another mode described in step (3) even if the information switch is turned, and the multiinformation section changes to the variation selection screen in USER ADJUST MODE. Note: If the buzzer cancel switch is turned to the [ ] position (right side) by mistake, the multiinformation section returns to the state in step 2.1.

(1).

168

Assembly procedure

M-4

Setting procedure of user adjust mode (3/3)

2.5 (5) Turn information switch again to the [ ] position (left side) or [ ] position (right side) several times to change the display of the multiinformation section to NO INJECTION (Fig. 5).

(6) Turn the buzzer cancel switch to the [ ] 2.6 position (left side) to settle NO INJECTION. Reference: In step 2.5 (5), each time the information switch is turned, the 7 variations of LCD BRIGHTNES, DSP BRIGHTNES, DSP CONTRAST, FAN 100% SPEED, NO INJECTION, TILT LIMIT and PRE-LUB ON are selected in either order repeatedly.

2.7 (7) If the engine is started under this condition, the cooling fan speed is kept controlled to about 100% of the maximum speed. ďŹ&#x201A;

(7) 2.7 is effective only in this mode. It becomes ineffective if the system is set out of this mode.

(8) To reset this mode, turn the buzzer cancel 2.8 switch to the [ ] position (right side).

The display of the multi-information section returns to the state after step 2.1 (1) where the starting switch is turned "ON".

169

Fig. 5

Assembly procedure

M-5

Replacement of return filter (Replacement of standard filter â&#x2020;&#x2019; special flushing parts) (1/2)

1. Replace the element of hydraulic oil return filter with exclusive flushing element (1), and replace valve and strainer with plate (2). a When replacing the elements, take out the element slowly so that refuses adhered to the element do not fall inside.

Also, take out refuses by hand from the case. a Confirm the installing condition of the element in accordance with "2. Installing Condition of Element". a When the atmospheric temperature is below â&#x20AC;&#x201C;15°C, do not use (2). Replace only the element and flush the circuit while running the engine at low idle.

No. 1 2

Part Name Element Plate

Part No. 208-60-71170 21T-60-13730

Q'ty 1 1

Exclusive flushing element

a Removed standard element (208-60-71123), strainer (07069-25400) and valve (208-60-71160) will be used again after flushing is finished. Accordingly, clean and keep them so that they will not be damaged.

170

Assembly procedure

M-5

Replacement of return filter (Replacement of standard filter â&#x2020;&#x2019; special flushing parts) (2/2)

2. Installing condition of element

Element

Fig. 1 Good condition

Fig. 2 Bad condition

a Do not insert the element so that it stands on the step at the bottom of the case as shown in Fig. 2.

When the filter case is filled with oil, it is difficult to check if the element is inserted correctly, so turn the element by hand after inserting it in the case. When it turns smoothly, it is considered to be inserted correctly.

171

Assembly procedure

M-6

Flushing of hydraulic circuit, and bleeding air from hydraulic cylinders (Part 1)

After the assembly work is completed, flush the hydraulic circuit and bleed air from the hydraulic cylinders. a When performing the assembly procedure M-5 to M-8, the assembly procedure A-24 "Bleeding air from hydraulic cylinders" can be neglected. However, the air bleeding mentioned in assembly procedure A-12 "Installation of blade" and A-7 "Installation of ripper" must be performed. a Never run the engine at high idle to avoid the damage to the flushing elements. a 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. a Check the oil level, and add oil to the specified level if necessary.

1. Flushing of fan circuit 1) Check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)

2) Start the engine and run it for approximately 10 minutes at low idle.

3) Then run the engine for approximately 30 minutes in 1,000 to 1,200 rpm.

4) Check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)

2. Bleeding air and flushing of cylinder with piston valve (blade lift cylinder) 1) While running the engine at low idle, extend and retract the cylinder for 5 minutes.

However, do not move the cylinder to the stroke end. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

2) Keeping the engine at low idle, retract the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to retract the cylinder to the end of its stroke. While operating the lever, hold the cylinder in this position for 3 minutes.

3. Bleeding air and flushing of cylinder without piston valve (Blade tilt cylinder, ripper lift cylinder, ripper tilt cylinder) 1) Check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)

2) While running the engine at low idle, extend and retract the cylinder for 5 minutes.

However, do not move the cylinder to the stroke end. a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstances.

172

Assembly procedure

M-7

Replacement of return filter (Replacement of special flushing parts → standard filter) (1/2)

1. After the flushing is finished for work equipment circuit, replace the exclusive flushing parts with stored original element (3), strainer (4) and valve (5). a When replacing the elements, take out the element slowly so that refuses adhered to the element do not fall inside.

Also, take out refuses by hand from the case. a When atmospheric temperature is at -15°C or lower, pay attention that the valve and the strainer are not replaced with the plate. a Keep accordance with the procedure in “2. Installing condition of element” as the element capacity will be lower if the installing condition is wrong.

No. 3 4 5

Part Name Element Strainer Valve

Part No. 208-60-71123 07069-25400 208-60-71160

Q'ty 1 1 1

Standard element

a Scrap the used flushing element. Keep accordance with the local laws for scraping. a Replaced plate is reusable, so it is recommended to store it for the next flushing work.

173

Assembly procedure

M-7

Replacement of return filter (Replacement of special flushing parts â&#x2020;&#x2019; standard filter) (2/2)

2. Installing condition of element

Element

Fig. 1 Good condition

Fig. 2 Bad condition

a Do not insert the element so that it stands on the step at the bottom of the case as shown in Fig. 2.

When the filter case is filled with oil, it is difficult to check if the element is inserted correctly, so turn the element by hand after inserting it in the case. When it turns smoothly, it is considered to be inserted correctly.

Precautions

Tools required

Others

Name

174

Equipment required Qâ&#x20AC;&#x2122;ty

Name

Qâ&#x20AC;&#x2122;ty

Assembly procedure

M-8

Bleeding air from hydraulic cylinders (Part 2)

1. Bleeding air from cylinder with piston valve (Blade lift cylinder) 1) With the engine at high idle, retract the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to retract the cylinder to the end of its stroke. While operating the lever, hold the cylinder in this position for 1 minute.

2. Bleeding air from cylinder without piston valve (Blade tilt cylinder, ripper lift cylinder, ripper tilt cylinder) 1) While running the engine at high idle, repeat this operation for 5 minutes. Then run the engine at low idle and operate the piston rod to the end of its stroke to relieve the circuit.

3. After bleeding the air, leave the engine stopped for 1 hour.

1) After leaving for 1 hour, check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)

k

Check the oil level, and add oil to the specified level if necessary.

175

APPENDIX 1.

INSTALLATION OF SPILL GUARDS 1. Introduction ......................................................................................................................................

1

2. Additional parts ................................................................................................................................

1

3. Spill guard fabrication drawings .....................................................................................................

2

3-1. For semi-U blade .......................................................................................................................

2

3-2. For full-U blade ..........................................................................................................................

6

3-3. For superdozer blade ................................................................................................................

10

4. Installation procedure ......................................................................................................................

14

DESCRIPTION 1. Introduction When installing the spill guards in field, refer to the installation procedure described in this installation procedure.

2. Additional parts Blade Semi-U

Full-U

Superdozer

Part No.

Part Name

Qâ&#x20AC;&#x2DC;ty

Weight (kg)

198-71-61710

Spill guard (center)

1

134.6

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

198-72-63920

Spill guard (left)

1

56

198-72-63930

Spill guard (right)

1

56

198-72-63810

Spill guard (center)

1

224

198-72-63820

Spill guard (left)

1

34

198-72-63830

Spill guard (right)

1

34

1

Remarks

Refer to the fabrication drawing

3. Spill guard fabrication drawings 3-1. For semi-U blade (1) Spill guard

2

3 Part Name PLATE PLATE PLATE

Sym. 01 02 03

SS400P

SS400F

SS400F

Material

10

11

2

Q‘ty

5.75

2.55

24.5

t 19

t 19 ✕ 65

t 19 ✕ 65

Weight (kg) Remarks

1. This drawing shown CO-gas welding groove dimensions and leg length for manual welding per KES 04.351 2. Flatness of surface A in drawing to be within 2.

(2) Spill guard (for semi-U, center) 198-71-61710 fabrication drawing

4

PLATE PLATE PLATE PLATE

09

11 12

PLATE

08

10

PLATE PLATE

06

PLATE

05

07

PLATE PLATE

PLATE

02 03

PLATE

01

04

Part Name

Sym.

SS400P

SS400P

SS400P

SS400P

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

Material

1

1

1

1

1

1

1

1

1

1

1

1

Q‘ty

2.30

2.80

3.95

5.10

1.35

1.45

1.75

1.90

2.15

2.30

11.9

12.6

t 19

t 19

t 19

t 19

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

Weight (kg) Remarks

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.

(3) Spill guard (for semi-U, left) 198-71-61720 fabrication drawing

5 PLATE PLATE PLATE PLATE

09 10 11 12

PLATE PLATE

07 08

PLATE PLATE

05 06

PLATE PLATE

PLATE

02 03

PLATE

01

04

Part Name

Sym.

SS400P

SS400P

SS400P

SS400P

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

Material

1

1

1

1

1

1

1

1

1

1

1

1

Q‘ty

2.30

2.80

3.95

5.10

1.35

1.45

1.75

1.90

2.15

2.30

11.9

12.6

t 19

t 19

t 19

t 19

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

Weight (kg) Remarks

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

3-2 For full-U blade (1) Spill guard

6

7 PLATE PLATE PLATE

02

04

PLATE

01

03

Part Name

Sym.

SS400F

SS400P

SS400F

SS400F

Material

4

13

12

2

Q‘ty

0.66

6.16

2.54

29.0

t 19 ✕ 65

t 19

t 19 ✕ 65

t 19 ✕ 65

Weight (kg) Remarks

1. This drawing shown CO-gas welding groove dimensions and leg length for manual welding per KES 04.351 2. Flatness of surfaces A, B, C, D and E in drawing to be within 2.

(2) Spill guard (for full-U, center) 198-72-63910 fabrication drawing

8

PLATE PLATE PLATE

13 14 15

PLATE PLATE

11 12

PLATE PLATE

09 10

PLATE PLATE

07 08

PLATE PLATE

05 06

PLATE PLATE

PLATE

02 03

PLATE

01

04

Part Name

Sym.

SS400F

SS400P

SS400P

SS400P

SS400P

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

Material

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Q‘ty

0.40

2.40

2.76

3.98

5.28

0.98

1.11

1.41

1.55

1.84

1.99

2.23

2.42

13.5

14.2

t 16 ✕ 32

t 19

t 19

t 19

t 19

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

Weight (kg) Remarks

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.

(3) Spill guard (for full-U, left) 198-72-63920 fabrication drawing

9

PLATE PLATE PLATE

13 14 15

PLATE PLATE

11 12

PLATE PLATE

09 10

PLATE PLATE

07 08

PLATE PLATE

05 06

PLATE PLATE

PLATE

02 03

PLATE

01

04

Part Name

Sym.

SS400F

SS400P

SS400P

SS400P

SS400P

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

SS400F

Material

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Q‘ty

0.40

2.40

2.76

3.98

5.28

0.98

1.11

1.41

1.55

1.84

1.99

2.23

2.42

13.5

14.2

t 16 ✕ 32

t 19

t 19

t 19

t 19

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

Weight (kg) Remarks

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 full-U, right) 198-72-63930 fabrication drawing

3-3 For superdozer blade (1) Spill guard

10

11 Part Name PLATE PLATE PLATE PLATE

Sym. 01 02 03 04

SS400P

SS400P

SS400P

SS400F

Material

7

4

1

2

Q‘ty

7.95

6.55

74.0

34.3

t 19

t 19

t9

t 19 ✕ 65

Weight (kg) Remarks

1. This drawing shown CO-gas welding groove dimensions and leg length for manual welding per KES 04.351 2. Flatness of surfaces A, B, C, D and E in drawing to be within 2.

(2) Spill guard (for superdozer, center) 198-72-63810 fabrication drawing

12 PLATE PLATE PLATE PLATE PLATE

05 06 07 08 09

PLATE PLATE

PLATE

02 03

PLATE

01

04

Part Name

Sym.

SS400F

SS400F

SS400F

SS400P

SS400F

SS400P

SS400F

SS400P

SS400F

Material

1

1

1

1

1

1

1

1

1

Q‘ty

6.50

9.35

2.35

3.20

2.05

3.05

1.75

2.05

1.65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19

t 19 ✕ 65

t 19

t 19 ✕ 65

t 19

t 19 ✕ 65

Weight (kg) Remarks

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.

(3) Spill guard (for superdozer, left) 198-72-63820 fabrication drawing

13 PLATE PLATE PLATE PLATE PLATE

05

07 08 09

PLATE

04

06

PLATE PLATE

02

PLATE

01

03

Part Name

Sym.

SS400F

SS400F

SS400F

SS400P

SS400F

SS400P

SS400F

SS400P

SS400F

Material

1

1

1

1

1

1

1

1

1

Q‘ty

6.50

9.35

2.35

3.20

2.05

3.05

1.75

2.05

1.65

t 19 ✕ 65

t 19 ✕ 65

t 19 ✕ 65

t 19

t 19 ✕ 65

t 19

t 19 ✕ 65

t 19

t 19 ✕ 65

Weight (kg) Remarks

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 superdozer, right) 198-72-63830 fabrication drawing

4. Installation procedure 4-1 For disassembly and assembly procedures which are not described in this manual, see the Shop Manual.

4-2 Weld the spill guard to the blade according to the drawing.

4-3 Precautions for welding 4-3-1

Remove all dirt, rust, and paint from the parts to be removed with a grinder.

4-3-2

If the parts to be welded are wet, dry them with a gas burner.

4-3-3

Do not use anti-spatter agents.

4-3-4

Use coated welding rods specified by JIS 4316 (Low-hydrogen welding rod for mild steel) or welding wires specified by JIS YGW11.

4-3-5

Before using coated welding rods, dry them at 300 - 350째C for 30 - 60 minutes.

4-3-6

Preheat the area about 50 mm from the beat to be laid at 150 - 200째C. When the ambient temperature is below 10째C, post-heat the same area, too, at 150 - 200째C.

4-3-7

Set the welding current to the lower limit of the current range specified for the diameter of the welding rod or wire.

4.3.8

When performing multi-layer welding, weave the welding rod.

4.3.9

Do not weld by letting the melted metal flow, but weld from below to above with sufficient penetration. Keep the arc length as short as possible, and take care not to make an overlap, undercut, etc.

4.3.10 Before welding the spill guard, remove all the paint (or rust) from the parts to be welded with a grinder. Then, perform tack welding, permanent welding and finishing in order.

4.3.11 Connect the ground cable to a part of the blade where paint is removed or a part where the ground cable can be connected securely electrically.

(Remark) If a painted part is welded, hydrogen in the paint will be mixed in the welded part, and that can cause cold cracking.

14

APPENDIX 2.

PRECAUTIONS FOR INITIALIZATION PROCEDURES FOR VHMS CONTROLLER 1. Initialization procedures for VHMS controller.......................................................................................... 2

1

INITIALIZATION PROCEDURES FOR VHMS CONTROLLER a

Initialization tools for VHMS controller

Symbol

Part No.

a

a

a

a

a

a

Part name

1

799-608-3211

Diskette

2

799-608-3220

Wiring harness

3

Commercially available

Notebook type personal computer (OS: Windows98/2000/ NT/Me/XP Terminal "RS232C" is with it)

Z

1.

Check of machine information, engine information and controller information a This step is a work performed on the whole machine.

Check and record the machine information, engine information, VHMS controller information and ORBCOMM terminal information.

No.

Before starting full operation after completion of local assembly or before resuming operation after storage for a long period, initialize the VHMS controller according to the following procedure.

Machine data collected with the VHMS controller are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS controller consistently. If it is not set correctly, data will not be taken into the WebCARE and data in the VHMS controller may not be utilized. Accordingly, be sure to carry out the initialization.

For the method of installing the VHMS Initialization Program to the personal computer, refer to the Operation and Maintenance Manual contained in the package of diskette Z1.

Since the service menu of the monitor panel will be used in the following procedure, read “Special functions of monitor panel” and understand the operating procedure in advance.

The initialization procedures cover both “ORBCOMM Specification” and “ORBCOMMLESS Specification”. In case of “ORBCOMMLESS” Specification”, omit the procedures necessary for “ORBCOMM Specification” only.

During the initialization work, confirm each work according to the “VHMS Initialization Work Checklist”.

2

Information to be checked

1

Machine model

2

Machine serial No.

3

Current service meter reading

4

Engine serial No.

5

Transmission serial No.

6

VHMS controller serial No.

7

ORBCOMM terminal serial No. [For ORBCOMM specification only]

a

2.

1

The VHMS controller and ORBCOMM terminal are in the VHMS controller box under the left side cover of the floor.

Connection of personal computer 1) Make sure that the starting switch is in the OFF position. k Be sure to connect and disconnect the personal computer while starting switch is in the OFF position.

2) Connect personal computer Z3 and download connectors VDW and DL1 by wiring harness Z2. a The download connectors are installed to the following places. q VDW: Inside of cab (Left rear lower part) q DL1: Rear side of chassis (Hull frame) a Connect the personal computer to the RS232C terminal.

2)

3) 4)

a a

Execute initialization of VHMS from the connector in the cab.

Use the ground download connector for only downloading.

5)

6)

3.

Select “Service mode” and “Real-time monitoring mode” in order on the monitor panel.

Input ID = 20301.

If the central part of the lower line of the multi-information display unit counts up, the VHMS controller is normal.

Check of operation and satellite capturing condition of VHMS controller a This step is a work performed in the operator's cab. a Check of satellite capturing condition is necessary o only [ORBCOMM specification].

1) Set the starting switch in the ON position.

7)

3

Judge the operation of the ORBCOMM controller by the state of the dot at the right bottom of the LED digit of the VHMS controller.

The dot at the right bottom of the LED digit of the VHMS controller can be checked in the multi-information display unit of the monitor by the following method.

1] Set the starting switch in the ON position.

2] For monitor panel specification: Referring to 10. “Real-time monitoring mode” or 11. “Dual display monitoring mode”, input ID = 20301.

At least 3 minutes after starting the VHMS, check the decimal point at the right bottom of the LED of the VHMS controller or the decimal point at the right bottom of the central part of the lower line of the multiinformation display unit.

9)

Right decimal point

Display

OFF

• Power is not supplied to ORBCOMM controller.

• Communication line to VHMS controller is abnormal.

ON

• Satellite is not captured.

• Power is supplied to ORBCOMM controller.

• Communication line to VHMS controller is normal.

Blinking

• Power is supplied to ORBCOMM controller.

• Communication line to VHMS controller is normal.

• Satellite is captured.

8)

Watch the decimal point LED on the right of the right-hand 7 segments of the VHMS controller to check that the ORBCOMM controller is capturing the satellite [ORBCOMM specification]. a Check the communication satellite capturing condition of the ORBCOMM controller on the VHMS controller side. a If the ORBCOMM controller is normal, the decimal point LED of the right-hand 7 segments flashes.

4.

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

4

Startup of VHMS initialization tool a This step is a work performed in the operator's cab (on the personal computer).

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

(Related material: Servicemate SMP623) 3) Input the 10-digit service ID in [Service ID]. a Service ID: 7826146000 4) Select [Data clear and Set up] in the [Select Function] column.

5) Press the [OK] button to go to the setup screen.

5.

Initialization of VHMS controller (Tool before Ver. 3.5.2.1) a This step is a work performed in the operator's cab (on the personal computer). a When initializing, do not change the data of service meter [SMR].

[Machine information] 1) Open the [Machine information] tab. a The [Machine information] tab is displayed first in the [Data clear and Set up] menu.

2) Check all the data.

5

3)

If information in the [Date/Time] box is not correct, change it according to the following procedures: 1] Press [Edit] button (1) on the right lower part of the [Date/Time] box to display the correction screen.

2] Correct the information and press the [OK] button.

4)

If information in the [Machine information] box is not correct, change it according to the following procedures: 1] Press the [Edit] button (2) on the right lower part of the [Machine information] box to display the correction screen.

2] Correct the information and press the [OK] button.

5)

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

[Communication Setting] [For ORBCOMM specification only] a Execute this setting after requesting for opening of the ORBCOM terminal and finishing the opening procedure.

6) Open the [Communication Setting] tab.

7) Check all the data.

8)

6

To change the setting in [SHORT FAULT HISTRY], follow the procedure below: 1] Select [SHORT FAULT HISTRY] on the screen and press [Edit] button (5) on the left lower part of the [File Transfer Setting] block to display the setting screen.

2] Change the setting and then press the [OK] button. a At initialization, select [Occurrence] at [Timing] and set the function to [ON].

9)

To change setting in [SHORT TREND ANALYSIS], follow the procedures below: 1] Select [SHORT TREND ANALYSIS] on the screen and press [Edit] button on the left lower part of the [File Transfer Setting] block to display the setting screen.

2] Change the setting and then press the [OK] button. a At initialization, input [20h] to [SMR] and set the function to [ON].

11) After checking/changing all the data in [Communication Setting], press [Apply] button to settle the setting. a If the [Apply] button is pressed, the s c r ee n fo r c he c k i n g t he s e tt in g appears. Check the setting again and press the [OK] button if the setting is correct.

10) To change the setting of [Satellite Setting], follow the procedure below.

1] Press the [Edit] button in the [Satellite Setting] block to display the setting screen.

2] Set the GCC Code to the applicable area and then press the [OK] button.

12) After checking/changing the data of [Machine Information] and [Communication Setting], press the [Exit] button at the right lower part of the screen to finish [VHMS Initialization Tool].

GCC codes and applicable areas Code 1 120

Applicable Area

Code

Applicable Area

U.S.A.

121

Malaysia

Brazil

122

Korea

Italy

130

Japan

7

6.

Initialization of VHMS controller (Ver. 3.5.2.1 or after) a This step is a work performed in the operator's cab (on the personal computer). a When initializing, do not change the data of service meter [SMR].

1) Select [VHMS Setting] and press the “Next” button.

3)

Check the machine information. If it does not need to be corrected, press the “Next” button.

a

2)

Select [Set up & All clear] and press the “Next” button.

8

If the VHMS was installed additionally, the information of [Serial No.] etc. must be input.

4) 5) 6)

Select the time zone.

Input the local time.

If the DST (Daylight Saving Time) is used now, select it and press the “Next” button. a If the DST is selected, the clock is advanced 1 hour automatically, thus the time must be corrected again.

7)

8)

The contents of the setting are displayed finally. If there is not a problem, press the “Apply” button.

9)

The system asks you if you save the data before changing the setting. If you do not need to save, select “NO”.

Set the GCC Code to the applicable area and then press the “Next” button.

GCC codes and applicable areas

Code 1 120

Applicable Area

Code

Applicable Area

U.S.A.

121

Malaysia

Brazil

122

Korea

Italy

130

Japan

10) After finishing the work of changing the contents of initialization, press the “OK” button to finish the program.

9

7.

Procedures for executing Quick Pm a The Quick Pm means the Pm Clinic executed with the manual snap shot function of the monitor panel. a Data in 7 minutes 30 seconds are saved in the VHMS controller. k Stop the machine on a flat place.

2] 3]

Set the buzzer cancel switch in the [U] position.

“READY” is displayed and the system is ready to start. a On the lower line, 15 pieces of “-” are displayed.

1) 2)

Start the engine.

Set the monitor panel to display the service menu. a For the operating method, see “Special functions of monitor panel”.

3) Selection and execution of mode.

1] Select “Snap shot mode” on the mode selection screen. a If the mode is selected, code (55) is displayed in gear speed display unit (1) and the title is displayed in multi-information unit (2).

Serial numbers: 30001 – 30070 4]

Serial numbers: 30071 and up

10

Set the buzzer cancel switch in the [U] position, and the snap shot operation starts. a After the snap shot operation starts, the elapsed time is displayed on the upper line. a On the lower line, 1 “ ” is added every 30 seconds. While multiple “ ” are displayed, the one at the right end blinks. a To interrupt the snap shot operation, set the buzzer cancel switch in the [t] position.

5]

After starting the snap shot operation, operate the machine according to Table 1. a Check that the engine coolant temperature and torque converter oil temperature are in the operating range. a After 10 “ ” are displayed (After 5 minutes), “#” is added up to 5. a “ ”: The data sampling interval is 10 seconds. a “#”: The data sampling interval is 1 second.

11

Time (sec)

Finish

Start

No.

Table 1 Operations of machine to be executed while snap shot is operated Operation of machine State of machine

1

0:00 0:25 25

2

0:25 0:50 25

3

0:50 1:40 50

4

1:40 2:30 50 Deceleration slow

5

2:30 3:00 30

6

Transmission

Fuel SteerWork equipment control ing dial

Decelerator pedal

Brake pedal

Parking brake

N

LH

N

LOW

HI

Released Released

N

RH

N

LOW

HI

Released Released

N

N

N

HI

HI

Released Released

N

N

N

HI

LOW

Released Released

High-pressure relief & high idle

N

N

HI

HI

Released Released

3:00 3:30 30

High-pressure relief & low idle

N

N

Right tilt (or pitch back in case of dual tilt model)

LOW

HI

Released Released

7

3:30 4:00 30

Port relief & high idle

N

N

8

4:00 4:30 30

Port relief & low idle

N

9

4:30 5:10 40

Torque converter stall & low idle

Torque converter 10 5:10 6:00 50 stall (F3) & high idle (Note 1) 11 6:00 6:30 30

Low idle High idle

High idle

Torque converter 12 6:30 7:10 40 stall + High-pressure relief 13 7:10 7:30 20

High idleo Low idle (Note 2)

HI

HI

Released Released

N

Left tilt (or pitch dump in case of dual tilt model)

LOW

HI

Released Released

NoF1oF2oF 3oNoR1oR2 oR3oN

N

N

LOW

HI

ON

Released

NoF3 (Shift to F3, then run engine at full throttle)

N

N

HI

LOWo Shift to F3, then HI

ON

Released

N

N

N

HI

HI

NoF3 (Shift to F3, then run engine at high idle)

N

Left tilt (or pitch dump in case of dual tilt model)

HI

LOWo Shift to F3, then HI

ON

Released

N

N

N

HIo LOW

HI

Released

ON

Released Released

(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.

(Note 2): Keep running the engine at low idle until the oil temperature is lowered to the normal level. a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine speed to high idle. a After stalling the torque converter, watch the power train oil temperature gauge and take care not to overheat the power train oil.

(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the engine at high idle to lower the oil temperature.)

12

6]

The screen shown below appears 7 minutes 30 seconds after the snap shot is started, and then the initial screen appears 5 seconds after. (End of snap shot)

q q

q

q q q q q

q

q

Important The data of the Quick Pm is recorded only once. If the Quick Pm is executed again, the current data are overwritten. Accordingly, be sure to save the data in the personal computer after executing the Quick Pm, referring to â&#x20AC;&#x153;8. Downloading of set dataâ&#x20AC;?.

7] a 8] a

q q

q q

Using the analysis tool, read the data of the Quick Pm. For the usage of the analysis tool, see the operation manual.

Open the data of the Quick Pm and translate them into a graph.

Set the time to the X-axis and set the following items to the Y-axis. q Engine Speed q Fuel Inject

q q

q

q

13

Blowby Press Exhaust Temp RB (Exhaust temperature of right bank: 1, 2, 3, 4, 5, 6) Exhaust Temp LB (Exhaust temperature of left bank: 1, 2, 3, 4, 5, 6) Engine Oil Press Engine Oil Temp Eng Coolant Temp Ambient Temp Demand Eng Speed (Engine speed demanded by controller) T/C Oil Temp (Torque converter oil temperature) T/M Main Press (Transmission main relief pressure) T/M Output Speed (Transmission output speed) Shift Position ( Tr a n s m i s s i o n , t r a v e l , g e a r speed) S/T Clutch Pos. (Steering clutch position) S/T Brake Pos. (Steering brake position) Hydr Oil Temp (Hydraulic oil temperature) Pump 1 Press (Work equipment pump 1 oil pressure) Pump 2 Press (Work equipment pump 2 oil pressure) Body Pitch Angle (Pitch angle)

9]

Check “Click position graphic value display”.

14

10] Click a point in the graph, and the value of each measurement item at that point on the X-axis is displayed under the graph.

(Example of displayed graph: This is different from the actual graph.)

15

11] Enter the above value in the Pm Clinic Inspection Sheet. a The relationship between the data necessary for the Pm Clinic and the measurement conditions is as follows.

Engine at high idle

Q

Q

Q

Deceleration slow

Q

High-pressure relief & engine at full throttle

Q

Q

Q

Q

Q

Q Q

High-pressure relief & engine at slow Port relief & engine at full throttle

Q

Q Q

Port relief & engine at slow Q

Torque converter stall & engine at slow Torque converter stall (F3) & engine at full throttle

Work equipment pump (FR)

3rd clutch fill switch

2nd clutch fill switch

1st clutch fill switch

Rear clutch fill switch

Steering right brake fill switch

Q

Steering left brake fill switch

Q

Steering right clutch fill switch

Q

Steering left clutch fill switch

Engine at low idle

Front clutch fill switch

Transmission main relief pressure

Exhaust temperature

Blow-by pressure

Engine speed

State of machine

Engine oil pressure

Measurement items

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Engine at full throttle Torque converter stall & high-pressure relief

Q

Engine at high idle o Engine at low idle

a

The stall speed measured with Snapshot is not the exact value. If measuring the stall speed exactly, set stall mode "0530" and measure it.

16

8.

Downloading of set data 1) Connect personal computer Z3 and download connectors VDW in the cab or ground download connector DL1 by wiring harness Z2.

2)

3) a

Download connector VDW in the cab is installed to the left rear lower part of the operator's seat.

4)

When using download connector VDW in the cab, set the starting switch in the ON position.

When using ground download connector DL1, turn switch (2) ON. a The green LED lights up.

Operate the icon of [VHMS Technical Analysis Tool] on the personal computer to start the VHMS technical analysis tool.

a a a

Ground download connector DL1 is installed in frame (1) at the rear of the machine.

17

Input [User Name] and [Password].

For the operation procedures, see the Operation and Maintenance Manual for VHMS Technical Analysis Tool.

5)

9.

Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. a For the operation procedures, see the Operation and Maintenance Manual for VHMS Technical Analysis Tool. a Make sure that downloading has completed before proceeding to the next step.

10. Disconnection of Personal Computer 1) Make sure that the starting switch is in the OFF position. k Be sure to turn off the starting switch before connecting or disconnecting the personal computer.

2) Finish the OS of the personal computer and then turn the personal computer OFF.

Check of downloaded data a This step is a work performed in the operator's cab (on the personal computer).

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

2)

After checking the set data, terminate [VHMS Technical Analysis Tool].

18

3)

If the data was downloaded in the cab, disconnect wiring harness Z2 from download connector VDW.

4)

If the data was downloaded on the ground, turn switch (2) OFF and disconnect wiring harness Z2 from download connector DL1.

11. Communication to Komatsu After completing steps 1 to 9 successfully, send the â&#x20AC;&#x153;VHMS/WebCARE setting notification formâ&#x20AC;? to VHMS/WebCARE Support Center of Komatsu, Tokyo. a Since Komatsu has to set the receiving side of the satellite communication, be sure to inform Komatsu of the completion of the setting. a Send the VHMS data by Notes (LAN) or E-mail (WAN).

Komatsu VHMS/WebCARE Support Center

2-3-6, Akasaka Minato-ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan) FAX: 03-5561-4766 (Domestic user) E-mail: webcare@komatsu.co.jp

19

(Objective model: D475A-5E0 Bulldozer)

20

(Objective model: D475A-5E0 Bulldozer)

21

To: VHMS / WebCARE Support Center FAX : 81-3-5561-4766

SEKN5051-1 Attached Sheet

VHMS / WebCARE Basis Information Sheet For Machine Registration into WebCARE

Please describe clearly.

<<DB information>>

Distributor name / Branch

/

Person in charge e-mail address DB code(GCPS code) <<Customer information>>

Customer name / Site name

/

<<Machine information>>

Model - type Serial No. Engine Serial No.

/

(Enter both of two engines if mounted.)

Transmission Serial No. Unit No. Date of Orbcomm activation For initial download data check

Result (Note 1) The new machine delivery or Retro - Fit

Reason for VHMS setting *Check the reason on the right. *For replacement,enter the serial No.of the replaced component below each column (Note).

(Note 1) Replace the VHMS controller.

(Note 2 or 3) Replace the component. (engine or transmission)

Setting date

(mm:dd:yyyy)

(

:

:

)

Setting time (Checked by watch)

(HH :MM: SS)

(

:

:

)

Person in charge of setting Service Meter Reading (Note1) New VHMS controller serial number.

(Note2) New engine serial number.

Enter both of two engines if mounted.

(Note3) New transmission serial number.

GCC code(If Orbcomm is equipped)

No.1 Engine

(

)

No.2 Engine

(

)

Time difference (GMT)

(Time Zone offset

Summer time (Daylight Savings Time) Did you initialize VHMS as described in the shop manual ?

ON

/

: 00) OFF

YES

***Important*** *After entering the VHMS/WebCARE Basis Information Form,fax or email it to the following location with the initial download data.

VHMS / WebCARE support center (Product Support Div. Komatsu LTD.) TEL : 81-3-5561-2765 *** FAX : 81-3-5561-4766 *** EMAIL : webcare@komatsu.co.jp

22

U-dozer or Semi U-dozer specification 1/7

Report No.

FIELD ASSEMBLY INSPECTION REPORT (For Full U-dozer or Semi U-dozer)

After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.

Model-Type

Machine Serial No.

User Unit No.

Engine Model

D475A-5E0 Service Meter Reading (Hr):

Engine Serial No.

SAA12V140E-3 Date of Inspection

Inspector's name:

Location of Machine at Inspection:

Distributor's Name:

Specification

Customer's name: (Country)

Address:

Blade

U

Semi U.

Ripper or counterweight

VGR

Shoe width

910 mm

Cab

With cab, Without cab

VMR

(Dual

Single)

CW (

810 mm

Ton) 710 mm

Enter specification of optional/local Others (Optional/Local procurement part) procurement part, if there is any Delivery Report No. attached:

Inspector's comments:

KOMATSU USE ONLY: Sheet Receiving Date:

By:

Remark:

Check sheets filling instruction: 1. Use following indexes for entry of judgement Normal

Correction made on abnormal point

Abnormal

Not applied

2. Enter actually measured values in parenthese, [

].

Note: Criteria are based on the standards when the machine is shipped out of the factory

U-dozer or Semi U-dozer specification 2/7

COOLANT AND OIL LEVEL

Category

Inspection Item

Inspection

Criteria

Main radiator coolant level

Above the bottom Radiator surface Strainer

Reserve tank coolant level

Low – Full

Engine oil level

EO15W40-DH

(H+L)/2 – (H+20)

Engine : Stopped

Power train oil level

TO30

L – (H+20)

Engine : Low idle (After 3 to 5 minutes)

Damper case oil level

TO30

(H+L)/2 – (H+10)

Engine : Stopped

Hydraulic tank oil level • Between H – L

TO10

Center to upper level of sight gauge

Pitch back on the ground.

Ripper point on the ground.

Engine : stopped

Final drive oil level

GO85W-140

H – (H–20)

See operation manual.

Engine : stopped

(H+10) – (H+30) from shaft end

See operation manual.

a=100 ± 10

See operation manual.

Oil level

Pivot shaft oil level

LH RH LH

TO30 EO30-CD RH LH

Recoil spring oil level

TO30 EO30-CD RH

Battery electrolyte level Check battery

Between L and H UPPER LEVEL LOWER LEVEL

Must be no adhesion of grease, loosened terminal, or crack

Window washer tank water level

Full

Fuel tank

Full (1670 l)

Draining of fuel tank

Drain fuel tank (Drain water, foreign matter, etc.)

Horn

Must be of no beat sound or sound deterioration.

Backup alarm (Starting engine)

Backup alarm must sound when the PCCS lever is at the back position.

Must be of no beat sound or sound deterioration.

Monitor display

Monitor must be turned on with buzzer sound, then go off after 3 seconds. After that all gauge lamps must come on.

No error code indicated in the service meter.

INSPECTION

Operation of service meter (Engine: Low idle)

Before engine start, meter must not operate when the key switch turned on.

Charge lamp (Engine: Low idle)

Must not light up when all lamps are turned on.

Lamp ON (Head lamp, tail lamp and work lamp)

Must light up when turned on.

Preheating switch (Auto preheating when at ON position)

(Manual preheating when turned to left)

Preheating lamp (green) must light up

Corrosion resistor valve

Must be fully open.

Heater hose valve

Winter: Open valve fully (Close valve fully in summer)

Controller error code indication (make sure that error does not recur)

Clear error code after confirming it.

Flushing (Before starting engine, replace standard filter with flushing filter.

After flushing, replace flushing filter with standard filter.)

Execute flushing

Air bleeding of the hydraulic cylinder

Perform air bleeding of the hydraulic cylinder

After flushing, replace flushing filter with standard filter

Measurement of cab pressurization

Max. 0.10 kPa {10 mm Aq.} (If pressure is below standard value, adjust it, referring to M-1, pages 4/7 – 7/7.)

Confirmation of VHMS controller initialization

Must be done.

U-dozer or Semi U-dozer specification 3/7 Category

Inspection Item

Inspection

Parking lever

Criteria The engine must not be started when the parking lever is free.

The machine must not be moved when the parking lever is locked.

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

Must be of no pinching or abnormal sound.

Notch must not be released.

Must be of no pinching or abnormal sound.

Must return to the N position smoothly.

FUNCTION / OPERATION

Play: Max. 5 mm

N, F1, F2, F3, R1, R2 and R3 are indicated.

Check of the gear speed indication on the monitor panel.

• Must be able to be shifted to any position with the engine at low idle and the brake turned on.

Must be no indication error.

Check of front/rear adjustment of the travel lever box • 10-level position adjustment • Check of the box lock (up/down)

Must be adjustable.

Must not move after locking.

Free Lock

Case

Case

Must work smoothly.

• Full stroke: 60 to 88 mm

Check of the brake pedal operation Check of the deceleration pedal operation • Set the fuel dial to high idle position.

• Check the deceleration RPM

Must work smoothly.

High idle: 2,000 ± 50 rpm Low idle: 900 ± 50 rpm

Check of the fuel dial operation

Must move smoothly.

Check of tilt direction

SINGLE

RH tilt

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

RH tilt

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

LH tilt

LH tilt

Check of dual tilt and pitch direction Check of tilt direction

Pitch back Pitch dump LH dual tilt RH dual tilt

DUAL

LH tilt RH tilt

LH tilt RH tilt

Check of tilting restriction adjustment • Measure tilting angle at the top of the cutting edge LH tilt when the tilting limit switch is turned on.

RH tilt

Blade must move backward. D + B Blade must move forward. D + A

Blade must move to left (both cylinders move) a + B

Blade must move to right (both cylinders move) a + A Blade must move to left (LH cylinder retracted) B + b

Blade must move to right (LH cylinder lengthened) A + b

Note: See manual of tilting restriction.

12 ± 1° 12 ± 1°

U-dozer or Semi U-dozer specification 4/7 Category

Inspection Item

Inspection

Criteria

Check of the clearance between frame and track (Difference of LH and RH)

Difference of LH and RH is max. 30 mm (Measure on flat ground) Move blade up and down and stop 100 mm above ground, and then measure.

Check of the work equipment lock lever lock function

No actuator must work when the work equipment lock lever is at ON position (Lever can move but work equipment must not move)

WORK EQUIPMENT

Must be of no hydraulic drift (Engine: Low idle) Check of the blade lever floating Check of the blade lever floating notch release Check of the quick drop valve operation • Quick dropping of the blade from top position.

At the engine full, set the blade lever at down position. When the lever is set at the N position after the blade drops by 1000 mm, it must stop.

Main relief valve function (Engine: Low idle)

Must be bridged with the blade and the ripper (Chassis)

Check of the accumulator function (blade, ripper)

Must function immediately after the engine stops then drop from the top to the ground.

Blade cylinder oil leakage • Leakage from U-packing, damaged rod, quick drop valve, tube, flange or dust seal

UNDERCARRIAGE

Tilt cylinder/pitch cylinder oil leakage • Leakage from U-packing, damaged rod, tube, flange or dust seal

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

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

CAB

Engine stops at floating, then notch must be released.

LH

Must be none.

RH

LH

Must be none.

RH

LH RH

LH

• Tense a string or a bar between the first carrier roller and the idler 20 – 30 mm to measure distance between the string (bar) and the grouser.

20 – 30 mm (Difference between LH and RH : Max. 20 mm) • Target is 30 mm when new.

RH

Flanges must be free from contact with links at all times.

LH

Must be none.

RH

Beat noise inside the cab, beat noise of the outer cover

Must be none.

Opening/closing and locking effect of the cab doors.

Must work smoothly to securely lock the doors by door-locking or key-locking.

Cab door-open lock release lever

Lever must operate smoothly and unlock securely.

(Unlock: Door is pushed out of stopper rubber section.)

Opening/closing and locking effect of the left/right side slide glass

Must work smoothly to securely lock.

Lighting of the room lamp

Must come on/go off by turning the switch on/off.

Operation of the window wiper and the window washer

Must be on/off by turning the switch on/off.

Wiper: Must operate smoothly (without beat noise)

Operation of the radio and cassette system (Volume, tuning, AM/FM switching, cassette)

Must operate correctly

Operation of the cigar lighter Ash tray installation

Must be red-heated.

Must be installed.

Operation of the air conditioner

Cold and warm air must be able to be switched by monitor operation.

Air flow amount must be able to be adjusted

Air flow amount must be able to be adjusted (Hi, Mid or Lo) • Louver must be smoothly switched

Air comes out from each blowout port.

U-dozer or Semi U-dozer specification 5/7 Category

Inspection Item

Inspection

BLADE

LUBRICATION

Portions to be lubricated

Criteria Q'ty

• Equalizer bar side pin shaft

2

• Equalizer bar center pin shaft

1

• Blade lift cylinder support shaft and yoke

6

• Blade center pin

1

• Blade oblique arm ball joint

3

• Brace screw (Single tiltdozer)

2

Interference and twist of blade lift cylinder hoses (Check through operation range) Check of ripper direction

Example: U blade

When blade is tilted up, down and to right and left, hoses must not interfere or twist. a Raise

c Lower A Tilt in

B Tilt out

Ripper lift cylinder oil leakage • U-packing, damaged rod, tube, flange, dust seal loosing

RIPPER

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

LH

Must be none

RH

LH

Must be of no contact.

RH

Interference and twist of hoses during ripper operation (Ripper lift and tilt hoses, pin-puller hoses) (Check through operation range)

When ripper is raised, lowered and tilted in and out, hoses must not interfere or twist.

Creak of the ripper link pin

Must be of no creak.

Check of the pin puller switch direction A: Pin out B: Pin in

Must be the same as the pin puller cylinder operation direction

Check of the pin puller cylinder hose clamp position (Entire operation area must be checked)

Must be of no contact Must be of no excess hose tension.

Pin puller cylinder oil leakage • Leakage from U-packing, damaged rod, tube or flange

Must be none LH

Check of ripper lubricated hose installation (Add grease)

RH

Must be no contact or no excess bend.

Grease must not leak

Portions to be lubricated

Q'ty

• Ripper lift cylinder head

8

2

• Ripper lift cylinder bottom

6

2

• Ripper tilt cylinder head

7

2

• Ripper tilt cylinder bottom

5

2

• Ripper arm pin (front)

9

2

• Ripper arm pin (rear)

0

2

Must be lubricated (right and left)

U-dozer or Semi U-dozer specification 6/7 <Precautions for measurement> Measure each performance value after each oil temperature has increased.

(Reference) Engine coolant temperature: Within operating range

Power train oil temperature: 75 – 85°C

Hydraulic oil temperature: 45 – 55°C

Engine speed

Engine

Category

Item

Condition

Engine speed

Run engine at low idle (low speed).

Run engine at high idle (engine high). *2 Set decelarator at low speed.

Stall torque converter. *1

Unit

Standard

rpm rpm rpm rpm

600 – 700 2100 – 2200 850 – 950 1640 – 1740

Result

*1: Measure stall speed 1 segment before red range of torque converter oil temperature gauge.

Measure with ID "0530" in adjustment mode of monitor. *2: Measure high idle speed with adjustment mode ID "0007" of monitor.

Power train oil pressure Transmission

Category

Item

Condition

Main relief pressure *3 Run engine at low speed and set transmission in N. Run engine at full throttle and set transmission in N.

Unit

Standard

MPa {kg/cm2} MPa {kg/cm2}

2.35 – 2.89 {24.0 – 29.5} 2.65 – 2.98 {27.0 – 30.4}

Result

*3: Measure main relief pressure with monitoring mode ID "43000" of monitor.

Work equipment oil pressure *4 • Single tilt specification Work equipment oil pressure

Category

Item

Condition

High pressure relief pressure

Port relief pressure

Control circuit basic pressure

Unit

Standard

Run engine at low speed and set transmission in N.

MPa {kg/cm2}

26.0 – 28.8 {266 – 294}

Run engine at full throttle and set transmission in N.

MPa {kg/cm2}

26.0 – 28.8 {266 – 294}

Run engine at low speed and set transmission in N.

MPa {kg/cm2}

21.6 – 24.4 {221 – 249}

Run engine at full throttle and set transmission in N.

MPa {kg/cm2}

23.1 – 25.9 {236 – 264}

Lever neutral

Run engine at full throttle and set transmission in N.

MPa {kg/cm2}

3.92 – 4.51 {40 – 46}

Unit

Standard

Pitch back

Run engine at low speed and set transmission in N.

MPa {kg/cm2}

26.0 – 28.8 {266 – 294}

Run engine at full throttle and set transmission in N.

MPa {kg/cm2}

26.0 – 28.8 {266 – 294}

Run engine at low speed and set transmission in N.

MPa {kg/cm2}

19.7 – 22.5 {201 – 229}

Run engine at full throttle and set transmission in N.

MPa {kg/cm2}

23.1 – 25.9 {236 – 264}

Run engine at full throttle and set transmission in N.

MPa {kg/cm2}

3.92 – 4.51 {40 – 46}

Blade right tilt

Blade left tilt

Result F pump R pump F pump R pump F pump R pump F pump R pump F pump R pump

• Dual tilt specification Work equipment oil pressure

Category

Item

Condition

High pressure relief pressure

Port relief pressure

Control circuit basic pressure

Pitch dump

Lever neutral

Result F pump R pump F pump R pump F pump R pump F pump R pump F pump R pump

*4: Measure work equipment relief pressure of F pump with monitoring mode ID "70700" of monitor.

Measure work equipment relief pressure of R pump with monitoring mode ID "70702" of monitor.

Work equipment speed Category

Item Blade lift

Ripper tilt

Condition

Unit

Standard

RAISE

Run engine at full throttle and set transmission in N.

sec

4.5 – 5.5

LOWER

Run engine at full throttle and set transmission in N.

sec

1.5 – 2.1

Tilt IN

Run engine at full throttle and set transmission in N.

sec

4.7 – 5.7

Tilt BACK

Run engine at full throttle and set transmission in N.

sec

2.8 – 3.8

Unit

Standard

Result

Hydraulic drift of work equipment Category

Item

Condition

Blade lift

Engine stopped, Cutting edge height: 500 – 800 mm. mm/min

Max. 50/5

Ripper lilt

Engine stopped, Ripper point height: 300 – 600 mm. mm/min

Max. 30/5

Result

U-dozer or Semi U-dozer specification 7/7 Check sheet for tightening torque for bolts of ROPS Sketch

Record

1. Tightening torque of ROPS From right to left of machine rear A – H From right to left of machine front I – P (rear 8 + front 8, total 16) Position

Location

Record

Standard tightening torque

A

Machine backward

B C D E F G H I

Machine forward

J K L M N O P

1960 – 2450 Nm {200 – 250 kgm}

Superdozer specification 1/7

Report No.

FIELD ASSEMBLY INSPECTION REPORT (For Superdozer)

After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.

Model-Type

Machine Serial No.

User Unit No.

Engine Model

D475ASD-5E0 Service Meter Reading (Hr):

Engine Serial No.

SAA12V140E-3 Date of Inspection

Inspector's name:

Location of Machine at Inspection:

Distributor's Name:

Specification

Customer's name: (Country)

Address:

Blade

Super

Ripper or counterweight

VGR

Shoe width

910 mm

Cab

With cab, Without cab

CW (

Ton)

810 mm

Enter specification of optional/local Others (Optional/Local procurement part) procurement part, if there is any Delivery Report No. attached:

Inspector's comments:

KOMATSU USE ONLY: Sheet Receiving Date:

By:

Remark:

Check sheets filling instruction: 1. Use following indexes for entry of judgement Normal

Correction made on abnormal point

Abnormal

Not applied

2. Enter actually measured values in parenthese, [

].

Note: Criteria are based on the standards when the machine is shipped out of the factory

Superdozer specification 2/7

COOLANT AND OIL LEVEL

Category

Inspection Item

Inspection

Criteria

Main radiator coolant level

Above the bottom Radiator surface Strainer

Reserve tank coolant level

Low – Full

Engine oil level

EO15W40-DH

(H+L)/2 – (H+15)

Engine : Stopped

Power train oil level

TO30

L – (H+20)

Engine : Low idle (After 3 to 5 minutes)

Damper case oil level

TO30

(H+L)/2 – (H+10)

Engine : Stopped

Hydraulic tank oil level • Between H – L

TO10

Center to upper level of sight gauge

Pitch back on the ground.

Ripper point on the ground.

Engine : stopped

Final drive oil level

GO85W-140

H – (H–20)

See operation manual.

Engine : stopped

(H+10) – (H+30) from shaft end

See operation manual.

a=100 ± 10

See operation manual.

Oil level

Pivot shaft oil level

LH RH LH

TO30 EO30-CD RH LH

Recoil spring oil level

TO30 EO30-CD RH

Battery electrolyte level Check battery

Between L and H UPPER LEVEL LOWER LEVEL

Must be no adhesion of grease, loosened terminal, or crack

Window washer tank water level

Full

Fuel tank

Full (1670 l)

Draining of fuel tank

Drain fuel tank (Drain water, foreign matter, etc.)

Horn

Must be of no beat sound or sound deterioration.

Backup alarm (Starting engine)

Backup alarm must sound when the PCCS lever is at the back position.

Must be of no beat sound or sound deterioration.

Monitor display

Monitor must be turned on with buzzer sound, then go off after 3 seconds. After that all gauge lamps must come on.

No error code indicated in the service meter.

INSPECTION

Operation of service meter (Engine: Low idle)

Before engine start, meter must not operate when the key switch turned on.

Charge lamp (Engine: Low idle)

Must not light up when all lamps are turned on.

Lamp ON (Head lamp, tail lamp and work lamp)

Must light up when turned on.

Preheating switch (Auto preheating when at ON position)

(Manual preheating when turned to left)

Preheating lamp (green) must light up

Corrosion resistor valve

Must be fully open.

Heater hose valve

Winter: Open valve fully (Close valve fully in summer)

Controller error code indication (make sure that error does not recur)

Clear error code after confirming it.

Flushing (Before starting engine, replace standard filter with flushing filter.

After flushing, replace flushing filter with standard filter.)

Execute flushing

Air bleeding of the hydraulic cylinder

Perform air bleeding of the hydraulic cylinder

After flushing, replace flushing filter with standard filter

Measurement of cab pressurization

Max. 0.10 kPa {10 mm Aq.} (If pressure is below standard value, adjust it, referring to M-1, pages 4/7 – 7/7.)

Confirmation of VHMS controller initialization

Must be done.

Superdozer specification 3/7 Category

Inspection Item

Inspection

Parking lever

Criteria The engine must not be started when the parking lever is free.

The machine must not be moved when the parking lever is locked.

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

Must be of no pinching or abnormal sound.

Notch must not be released.

Must be of no pinching or abnormal sound.

Must return to the N position smoothly.

Play: Max. 5 mm

N, F1, F2, F3, R1, R2 and R3 are indicated.

Check of the gear speed indication on the monitor panel.

• Must be able to be shifted to any position with the engine at low idle and the brake turned on.

Must be no indication error.

Check of front/rear adjustment of the travel lever box • 10-level position adjustment • Check of the box lock (up/down)

Must be adjustable.

Must not move after locking.

Free

FUNCTION / OPERATION

Lock

Case

Case

Must work smoothly.

• Full stroke: 60 to 88 mm

Check of the brake pedal operation Check of the deceleration pedal operation • Set the fuel dial to high idle position.

• Check the deceleration RPM

Must work smoothly.

High idle: 2,000 ± 50 rpm Low idle: 900 ± 50 rpm

Check of the fuel dial operation

Must move smoothly.

Check of pitch direction Pitch backward Pitch dump Pitch forward

Pitch back

Pitch dump

Blade must move to forward smoothly.

Pitch back

Blade must move to backward smoothly.

LH tilt

Blade must move to left

RH tilt

Blade must move to right

Check of tilt direction RH tilt RH tilt LH tilt

LH tilt

Check of tilting restriction adjustment • Measure tilting angle at the top of the cutting edge LH tilt when the tilting limit switch is turned on.

RH tilt

Note: See manual of tilting restriction.

Check of auto pitch back operation • After pitch dumping, move backward with the speed gear at R1, then turn the pitch back switch on.

52 ± 3° Blade should be horizontal after pitch back to the stroke end, and pitch dumping is performed to return to the digging posture.

7 ± 1° 7 ± 1°

Superdozer specification 4/7 Category

Inspection Item

Inspection

Criteria

Check of the clearance between frame and track (Difference of LH and RH)

Difference of LH and RH is max. 30 mm (Measure on flat ground) Move blade up and down and stop 100 mm above ground, and then measure.

Check of the work equipment lock lever lock function

No actuator must work when the work equipment lock lever is at ON position (Lever can move but work equipment must not move)

WORK EQUIPMENT

Must be of no hydraulic drift (Engine: Low idle) Check of the blade lever floating Check of the blade lever floating notch release Check of the quick drop valve operation • Quick dropping of the blade from top position.

At the engine full, set the blade lever at down position. When the lever is set at the N position after the blade drops by 1000 mm, it must stop.

Main relief valve function (Engine: Low idle)

Must be bridged with the blade and the ripper (Chassis)

Check of the accumulator function (blade, ripper)

Must function immediately after the engine stops then drop from the top to the ground.

Blade cylinder oil leakage • Leakage from U-packing, damaged rod, quick drop valve, tube, flange or dust seal

UNDERCARRIAGE

Tilt cylinder/pitch cylinder oil leakage • Leakage from U-packing, damaged rod, tube, flange or dust seal

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

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

CAB

Engine stops at floating, then notch must be released.

LH

Must be none.

RH

LH

Must be none.

RH

LH RH

LH

• Tense a string or a bar between the first carrier roller and the idler 20 – 30 mm to measure distance between the string (bar) and the grouser.

20 – 30 mm (Difference between LH and RH : Max. 20 mm) • Target is 30 mm when new.

RH

Flanges must be free from contact with links at all times.

LH

Must be none.

RH

Beat noise inside the cab, beat noise of the outer cover

Must be none.

Opening/closing and locking effect of the cab doors.

Must work smoothly to securely lock the doors by door-locking or key-locking.

Cab door-open lock release lever

Must work smoothly to securely lock.

Opening/closing and locking effect of the left/right side slide glass

Must work smoothly to securely lock.

Lighting of the room lamp

Must come on/go off by turning the switch on/off.

Operation of the window wiper and the window washer

Must be on/off by turning the switch on/off.

Wiper: Must operate smoothly (without beat noise)

Operation of the radio and cassette system (Volume, tuning, AM/FM switching, cassette)

Must operate correctly

Operation of the cigar lighter Ash tray installation

Must be red-heated.

Must be installed.

Operation of the air conditioner

Cold and warm air must be able to be switched by monitor operation.

Air flow amount must be able to be adjusted

Air flow amount must be able to be adjusted (Hi, Mid or Lo) • Louver must be smoothly switched

Air comes out from each blowout port.

Superdozer specification 5/7 Category

Inspection Item

Inspection

BLADE

LUBRICATION

Portions to be lubricated

Criteria Q'ty

• Equalizer bar side pin shaft

2

• Equalizer bar center pin shaft

1

• Blade lift cylinder support shaft and yoke

6

• Blade center pin

1

• Blade oblique arm ball joint

3

Interference and twist of blade lift cylinder hoses (Check through operation range) Check of ripper direction

Example: Super blade

When blade is tilted up, down and to right and left, hoses must not interfere or twist. a Raise

c Lower A Tilt in

B Tilt out

Ripper lift cylinder oil leakage • U-packing, damaged rod, tube, flange, dust seal loosing

RIPPER

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

LH

Must be none

RH

LH

Must be of no contact.

RH

Interference and twist of hoses during ripper operation (Ripper lift and tilt hoses, pin-puller hoses) (Check through operation range)

When ripper is raised, lowered and tilted in and out, hoses must not interfere or twist.

Creak of the ripper link pin

Must be of no creak.

Check of the pin puller switch direction A: Pin out B: Pin in

Must be the same as the pin puller cylinder operation direction

Check of the pin puller cylinder hose clamp position (Entire operation area must be checked)

Must be of no contact Must be of no excess hose tension.

Pin puller cylinder oil leakage • Leakage from U-packing, damaged rod, tube or flange

Must be none LH

Check of ripper lubricated hose installation (Add grease)

RH

Must be no contact or no excess bend.

Grease must not leak

Portions to be lubricated

Q'ty

• Ripper lift cylinder head

8

2

• Ripper lift cylinder bottom

6

2

• Ripper tilt cylinder head

7

2

• Ripper tilt cylinder bottom

5

2

• Ripper arm pin (front)

9

2

• Ripper arm pin (rear)

0

2

Must be lubricated (right and left)

Superdozer specification 6/7 <Precautions for measurement> Measure each performance value after each oil temperature has increased.

(Reference) Engine coolant temperature: Within operating range

Power train oil temperature: 75 – 85°C

Hydraulic oil temperature: 45 – 55°C

Engine speed

Engine

Category

Item

Condition

Engine speed

Run engine at low idle (low speed).

Run engine at high idle (engine high). *2 Set decelarator at low speed.

Stall torque converter. *1

Unit

Standard

rpm rpm rpm rpm

600 – 700 2100 – 2200 850 – 950 1640 – 1740

Result

*1: Measure stall speed 1 segment before red range of torque converter oil temperature gauge.

Measure with ID "0530" in adjustment mode of monitor. *2: Measure high idle speed with adjustment mode ID "0007" of monitor.

Power train oil pressure Transmission

Category

Item Main relief pressure *3

Condition

Unit

Standard

Run engine at low speed and set transmission in N.

MPa {kg/cm2} MPa {kg/cm2}

2.35 – 2.89 {24.0 – 29.5} 2.65 – 2.98 {27.0 – 30.4}

Unit

Standard

Run engine at full throttle and set transmission in N.

Result

*3: Measure main relief pressure with monitoring mode ID "43000" of monitor.

Work equipment oil pressure *4 • Superdozer specification Work equipment oil pressure

Category

Item

Condition

High pressure relief pressure

Port relief pressure

Control circuit basic pressure

Pitch back

Pitch dump

Lever neutral

Run engine at low speed and set transmission in N.

MPa {kg/cm2}

26.0 – 28.8 {266 – 294}

Run engine at full throttle and set transmission in N.

MPa {kg/cm2}

26.0 – 28.8 {266 – 294}

Run engine at low speed and set transmission in N.

MPa {kg/cm2}

19.7 – 22.5 {201 – 229}

Run engine at full throttle and set transmission in N.

MPa {kg/cm2}

23.1 – 25.9 {236 – 264}

Run engine at full throttle and set transmission in N.

MPa {kg/cm2}

3.92 – 4.51 {40 – 46}

Result F pump R pump F pump R pump F pump R pump F pump R pump F pump R pump

*4: Measure work equipment relief pressure of F pump with monitoring mode ID "70700" of monitor.

Measure work equipment relief pressure of R pump with monitoring mode ID "70702" of monitor.

Work equipment speed Category

Item Blade lift

Superdozer specification

Ripper tilt

Condition

Unit

Standard

RAISE

Run engine at full throttle and set transmission in N.

sec

4.6 – 5.6

LOWER

Run engine at full throttle and set transmission in N.

sec

1.4 – 2.0

Tilt IN

Run engine at full throttle and set transmission in N.

sec

4.7 – 5.7

Tilt BACK

Run engine at full throttle and set transmission in N.

sec

2.8 – 3.8

Result

Hydraulic drift of work equipment Category

Unit

Standard

Blade lift

Item

Engine stopped, Cutting edge height: 500 – 800 mm.

Condition

mm/min

Max. 50/5

Ripper lilt

Engine stopped, Ripper point height: 300 – 600 mm.

mm/min

Max. 30/5

Result

Superdozer specification 7/7 Check sheet for tightening torque for bolts of ROPS Sketch

Record

1. Tightening torque of ROPS From right to left of machine rear A – H From right to left of machine front I – P (rear 8 + front 8, total 16) Position

Location

Record

Standard tightening torque

A

Machine backward

B C D E F G H I

Machine forward

J K L M N O P

1960 – 2450 Nm {200 – 250 kgm}