Komatsu GALEO D475A-5 Bulldozer Field Assembly Manual SN 20001 and up - PDF DOWNLOAD

GEN00012-00 (Replaces SEAW005000)

Field Assembly Manual

-5 BULLDOZER SERIAL NUMBERS

D475A-5

20001 and up

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

Copyright 2004 Komatsu Printed in U.S.A. Komatsu America Corp.

December 2004

Preface You are required to execute full inspection and maintenance before starting the engine and assembling the work equipment. Since the work is often carried out in dangerous places and positions by a team, hold a safety meeting in advance and appoint a crane director, work leader, etc. so that the all member can work safely.

When the work is carried out in an overseas country, difference in language, customs, etc. lowers safety. Accordingly, the field liaison man and work supervisor must examine the above point and take necessary measures.

Instruction system Work leader Work supervisor

Crane director

Director and deputy director

Operator for assembly Liaison man Mechanics

Sharing of work

Interpreter

We hope that the all members will cooperate with each other and assemble the work equipment quickly in the field, observing the safety, quality, and delivery time.

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

1

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

3

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

4

LAYOUT OF KIT .........................................................................................................................................

5

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

6

TOOLS LIST FOR FIELD ASSEMBLY ........................................................................................................ 11 TIGHTENING TORQUE .............................................................................................................................. 18 COATING MATERIALS .............................................................................................................................. 22 A. ASSEMBLY PROCEDURE ..................................................................................................................... 25 A-1

Installation of undercarriage ................................................................................................... 26

A-2

Installation of ripper ................................................................................................................ 33

A-3

Installation of tracks ................................................................................................................. 37

A-4

Adding oil to pivot chamber ................................................................................................... 39

A-5

Installation of ripper shank ..................................................................................................... 40

A-6

Installation of blade lift cylinder ............................................................................................. 41

A-7

Installation of trunnion ............................................................................................................ 43

A-8

Assembly of blade ................................................................................................................... 44

A-9

Adjustment of arm joint (U-blade) ......................................................................................... 50

A-10 Installation of blade ................................................................................................................. 51 A-11 Installation of counterweight .................................................................................................. 53 A-12 Installation of operator’s cab .................................................................................................. 54 A-13 Installation of ROPS ................................................................................................................. 70 A-14 Adjustment of potentiometer rod ........................................................................................... 71 A-15 Procedure for adjusting blade tilt angle limit ........................................................................ 72 A-16 Method of checking auto-reset system (Superdozer) ........................................................... 81 A-17 Check track tension .................................................................................................................. 82 A-18 Check fuel, coolant and lubricants ......................................................................................... 84 A-19 Greasing of greasing point ..................................................................................................... 86 A-20 Installation of ORBCOMM antenna and wiring harness ....................................................... 89 A-21 Replacement of return filter (Replacement of standard filter with flushing filter) ............................................................. 90 A-22 Installing direction of exhaust pipe ........................................................................................ 93 A-23 Bleeding air from hydraulic cylinders .................................................................................... 94 A-24 Installing lunchbox band (if equipped) .................................................................................. 95 M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY ..................... 97 M-1

Check and adjustment of operator’s cab ............................................................................... 98

M-2

Error code ................................................................................................................................. 105

M-3

Flushing of hydraulic circuit .................................................................................................... 114

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

SPECIFICATIONS Item

Unit

Operating weight (excluding operator's weight)

kg

Blade weight (including cylinders)

kg

Ripper weight (including cylinders)

kg

Counterweight

kg

Engine model

–

Rated engine output

mm

Overall height (with ROPS)

mm mm

U-tiltdozer + Giant ripper

103,900

Superdozer

(*1)

108,000 (*2)

13,600

14,600 9,720

–

–

6,300

Komatsu SDA12V140E-1 diesel engine

kW/rpm {HP/rpm}

Overall length Overall width

Semi-U-tiltdozer + Giant ripper

641/2,000{860/2,000} 11,560

12,065

10,525

4,240 (4,600) 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 workplace 1) When selecting a workplace, consider the following items so that you can load and unload the machine.

• Width • Hardness • Flatness • Access road, place for turn 2) Do not work in a place where dust, rainwater, etc. may enter the hydraulic circuit during assembling work.

3) Do not assemble while a strong wind is blowing or it is raining.

2. Preparation and check of slings and tools 1) Check each sling and tool thoroughly. When using wood blocks, etc., check that their inside is not rotten or broken.

3. Check of actual work 1) Apply the parking brakes of the trailer and crane truck securely and put chocks under their wheels.

2) Before starting the work lower the temperature and pressure of the engine oil, hydraulic oil, cooling water, etc.

3) When starting the engine, make an arranged sign such as sounding of the horn and check that the work equipment control lever and travel lever are in neutral and the fuel control dial (or fuel control lever) is at the low idling position.

4) When using the crane, balance the load.

5) Allow only the persons concerned into the workplace.

4. Before starting the work, read this manual thoroughly and keep the precautions in your mind.

5. The supervisor shall write down the precautions for each work process and explain them to the workers.

6. Hold a meeting every morning to check today's work plan and safe work.

3

Installation of track

5

• Welding of spill guard (If equipped)

4

Greasing

Adjustment of track tension

13

14

Remarks

Crane (Hydraulic type with operator)

Welding

Assembly

• Check of cab pressurization

• Initialization of VHMS

• Flushing of hydraulic circuit

• Pm clinic

Workers

15

Check of oil level and addition of oil

12

Final assembly inspection

Adjustment of blade tilt limit rod

Adjustment of tilt limit angle

10

11

Installation of ROPS

Installation of exhaust pipe

8

9

Installation of operator’s cab

• Installation of blade

• Assembly of blade

7

6

Installation of ripper (Installation of counterweight)

4

Blade

Installation of blade lift cylinder

Installation of track frame

2

• Unloading of other parts

• Installation of chassis

• Installation of stand

• Installation of track

Unloading

Item

3

1

No.

Schedule

45ton × 1

45ton × 2

2. Starting of assembly 2. Starting of engine

1. Arrangement before work 1. Removal of stand

4 2

2nd day

4

1st day

45ton × 1

4

3rd day

45ton × 1

3

4th day

2

5th day

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.

LAYOUT OF KIT

Approx. 30 m

Accessories CAB assembly ROPS guard

Ripper parts

5

Approx. 30 m

Right straight frame Wrecker truck

Left straight frame

Right track

Chassis

Track

Track

Blade

Left track

•

When selecting the work field, see “Before assembling in field”.

The dimensions in the drawings are reference dimensions for installation in the following space (30 m x 30 m).

If a wider work field is available, the shown dimensions should be increased.

Wrecker truck

• •

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

■ Style of each KIT. • Body

A

Overall length (mm)

6,600

B

Overall height (mm)

3,515

C

Overall width (mm) Weight (kg)

3,385 43,000

• Track frame

A

Overall length (mm)

4,604

B

Overall height (mm)

1,500

C

Overall width (mm) Weight (kg)

972 11,200

• WORK EQUIPMENT (1) U-blade

A

Overall length (mm)

6,205

B

Overall height (mm)

2,615

C

Overall width (mm) Weight (kg)

6

2,170 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)

2,180

• Super blade

Weight (kg)

14,000

• Track shoe

7

Shoe width

810

A (mm)

4,500

B (mm)

1,400

Weight (kg)

6,600 (1/2)

• Straight frame

Semi-U, U

Super

A

Overall length (mm)

4,857

5,020

B

Overall height (mm)

674

682

C

Overall width (mm) Weight (kg)

638

681

1,770

1,868

• Hydraulic cylinder (1) Pitch, tilt cylinder

Semi-U, U

Super

A

Overall length (mm)

1,930

1,754

C

Overall width (mm)

351

351

Weight (kg)

504

508

(2) Blade lift cylinder

A

Overall length (mm)

B

Overall height (mm)

630

C

Overall width (mm)

435

Weight (kg)

2,900

500

(3) Ripper cylinder

A C

8

Overall length (mm)

Lift

Tilt

1,748

1,698

Overall width (mm)

304

304

Weight (kg)

389

394

• Giant ripper beam

A

Overall length (mm)

1,545

B

Overall height (mm)

1,930

Overall width (mm)

1,535

C

Weight (kg)

2,400

A

Overall length (mm)

2,300

B

Overall height (mm)

580

Overall width (mm)

1,650

• Giant ripper arm

C

Weight (kg)

1,800

• Giant ripper shank

A

Overall length (mm)

115

B

Overall height (mm)

2,800

C

Overall width (mm) Weight (kg)

9

940 1,000

• Cab

A

Overall length (mm)

1,875

B

Overall height (mm)

1,680

Overall width (mm)

1,740

C

Weight (kg)

500

• ROPS

A

Overall length (mm)

2,100

B

Overall height (mm)

1,411

C

Overall width (mm) Weight (kg)

585 918

• Counterweight

A

Overall length (mm)

1,950

B

Overall height (mm)

1,300

C1

Overall width (mm)

C2 Weight (kg)

10

1,361 1,290 6,300

TOOLS LIST FOR FIELD ASSEMBLY No.

Tool name

1

Crane truck

2

Service car

Specification

Q'ty

Capacity: 441kN {45 tons} – 15 m3/min

–

2

–

1

–

3

Air compressor

4

Welder

5

Lever block

19.6 kN {2 ton}, 58.8 kN {6 ton}

6

Wire

ø26 x 6 m

6 For body

ø36 x 5 m

1 For body

ø30 x 3 m

2 For body

7

Wire sling

0.74 MPa {7.5

kg/cm2},

Remarks 2

–

2 For welding blade spill guard (If equipped) each 1

–

ø20 x 5 m

2

–

ø12 x 2 m

4

–

25 mm wide x 3 m

2

– –

8

Nylon sling

50 mm wide x 3 m

1

9

Hydraulic wrench

5,884 Nm {600 kgm}

1 For master link bolt

10

Impact wrench

4,413 Nm {450 kgm}

1 For master link bolt

3,138 Nm {320 kgm}

1 KW45FG

2,542 Nm {250 kgm}

1 KW40F

196 Nm {20 kgm}

1 KW20PI

157 Nm {16 kgm}

1 KW14PI

137 Nm {14 kgm}

1 KW12PI

50

46

41

36

each 1 M 38.1

36

32

30

27

each 1 M 25.4

11

Sockets set

12

Extension bar

M 38.1 x L300

1

–

13

Torque wrench

2,059 Nm {210 kgm}

1

–

1,373 Nm {140 kgm}

1

–

588 Nm {60 kgm}

1

–

4

–

14

Eyebolt

M 12 x P 1.75 M 16 x P 2

2 For blade center link

15

Shackle

SD22

4

–

BC36

2

–

SA60

1 For front hook

16

Sledge hammer

10P

1

–

17

Bar

L = 1000 mm

1

–

18

Tap

M 33 x P 2

1 For master link

M 30 x P 3

1

–

M 24 x P 3

1

–

19

Jack

147 kN {15 ton}

2 For assembling track frame

20

Hydraulic jack

785 kN {80 ton}

1 For assembling body

21

Chain block

78 kN {8 ton} x 4 m

2 For assembling blade

22

Spanner wrenches set

Width: 19 – 50 mm

23

Standard tools set

24

Hydraulic oil

SAE30-CD

25

Grease

G2-LI

26

Lubricant

LM-P (09940-00040)

–

each 1

–

1

–

50 ¬ For pivot

SAE10W-CD

400 ¬ For hydraulic tank 10 ¬

–

1 For master link

27

Detergent

–

20 ¬

–

28

Paint remover

–

5

–

29

Paint for repair

Natural yellow

5

–

Black grey

5

–

30

Glass cleaner

1

–

–

11

No.

Tool name

31

Cloth

32

Angle meter

Specification

Q'ty

Bunch

Remarks 5

–

–

1 For dual tilt (If equipped)

33

Grease pump

Air type

1

–

34

Oil pump

Manual or air type

1

–

35

Oil jack

5¬

1

–

36

Waste oil receiving pan

1

–

37

Step

Height: 2 m

1

–

38

Stand

Front

1 See attached tool drawing

39

Sling for track frame

40

Wood block

–

Rear

41

Vinyl hose (Transparent)

42

Packaging tape

43

Steel plate

1 See attached tool drawing –

1 See attached tool drawing

350 mm x 750 mm

4

–

350 mm x 400 mm

4

–

100 mm x 750 mm

4

–

3,000 mm (O.D. 10 mm)

1 For measuring cab pressurization

–

1

1,000 mm x 1,700 mm x 19 t

12

–

2 For setting under stand

No. Material 01 SS400C 02 SS400C 03 SS400C 04 SS400C 05 SS400C 06 SS400C 07 SS400C 08 SS400B 09 SS400 10 SS400 11 SS400 12 SS400 13 SS400

Q‘ty 4 2 2 2 2 2 2 4 4 4 10 2 2

Remarks C150 x 75 x t9–1432 C150 x 75 x t9–925 C150 x 75 x t9–925 C150 x 75 x t9–425 C150 x 75 x t9–459 C150 x 75 x t9–378 C150 x 75 x t9–250 50-75 t25 x 180 x 250 t12 x 200 x 739.5 t12 x 60 x 128 t16 x 124 x 130 t25 x 70 x 85

Sketch of tools Note) We are not liable for any result of use of tools manufactured according to these drawings.

Chassis stand (Front side)

13

14 Only movable part

Only movable part

No. Material 01 SS400C 02 SS400C 03 SS400C 04 SS400C 05 SS400C 06 SS400C 07 SS400C 08 SS400B 09 SS400 10 SS400 11 SS400 12 SS400 13 SS400

Q‘ty 4 2 2 2 2 2 2 4 4 4 10 2 2

Remarks C150 x 75 x t9–1432 C150 x 75 x t9–829 C150 x 75 x t9–829 C150 x 75 x t9–510 C150 x 75 x t9–548 C150 x 75 x t9–453 C150 x 75 x t9–355 50-500 t25 x 180 x 250 t12 x 200 x 655 t12 x 60 x 128 t16 x 124 x 130 t25 x 70 x 85

Total weight

Material

Chassis stand (Rear side)

Sling (Track frame)

No.

Q‘ty

No.

01

SS400

Remarks

1

07

SV063 x 120 link

Remarks

Q‘ty 1

02

SS400

1

08

VG063

1

03

HM080

1

09

M33 x 100

1

04

JIS4, 6 x 24 Z to A ø 26 x 600

1

10

M33

1

05

TSL–6(170 ¬)

1

11

M30 x 120

2

06

VN063

1

Sling (Track frame) : Detail 01

2-36 drill

Do not weld

15

393.5

Sling (track frame) : Detail 02

2-36 drill

16

Dimension of shackle

Shackle for ripper shank ➞

Shackle for front hook ➞

(Unit: mm)

Shackle (Nominal value) 6 8

t

d

B

D

d1

L1

9 11

Diameter (Nominal value) M8 M10

6 8

6 8

11 14

17 21

10 12 14 16 18

10 12 14 16 18

10 12 14 16 18

17 20 24 26 29

25 32 36 40 45

13 16 18 20 22

M12 M14 M16 M18 M20

40 48 56 64 72

20 22 24 26 28

20 22 24 26 28

20 22 24 26 28

31 34 39 41 43

50 55 62 66 70

25 27 31 33 35

M24 M24 M30 M30 M33

80 88 96 104 112

30 32 34 36 38

30 32 34 36 38

30 32 34 36 38

45 48 50 54 57

75 80 85 90 95

37 39 41 43 47

M36 M36 M39 M42 M45

120 128 136 144 152

40 42 44 46 48

40 42 44 46 48

40 42 44 46 48

60 63 66 68 72

100 105 110 115 120

49 53 56 58 60

M48 M48 M48 M48 M56

160 168 176 184 192

50 55 60

50 55 60

50 55 60

75 83 90

125 138 150

62 62 72

M56 M64 M72 ✕ 6

200 220 260

70 75 80 85 90

70 75 80 85 90

70 75 80 85 90

105 112 120 128 135

178 192 206 220 232

85 92 98 104 110

M80 ✕ 6 M80 ✕ 6 M90 ✕ 6 M90 ✕ 6 M100 ✕ 6

280 300 320 340 360

17

24 32

TIGHTENING TORQUE Remove the plugging parts (flanges, heads, caps, and O-rings) of the work equipment piping and undercarriage piping, oil stopper plugs of the greasing piping, cylinder fixing jigs, and oil stopper plugs of the tap holes of the loose-supply items which were used for transportation and keep them carefully so that they can be used again for the next transportation.

Tighten the bolts to the torque shown in the following table, unless otherwise specified.

1. Tightening torque of bolts When tightening the bolts with an impact wrench/spanner, apply Table 1.

Tighten the bolts according to Table 1 as a rule. When this rule is applied, the tightening torque is not shown in the drawing.

Table 1 Unit: Nm {kgm} Material

S43C, SCM435H or equivalent

Nominal size of thread (mm)

Range

Target

6

8.8 - 14.7 {0.9 - 1.5}

12 {1.2}

8

14.7 - 34 {1.5 - 3.5}

25 {2.5}

10

34 - 74 {3.5 - 7.5}

54 {5.5}

12

54 - 123 {5.5 - 12.5}

89 {9}

14

84 - 196 {8.5 - 20}

137 {14}

16

147 - 309 {15 - 31.5}

230 {23.5}

18

201 - 427 {20.5 - 43.5}

315 {32}

20

319 - 608 {32.5 - 62}

460 {47}

22

471 - 829 {48 - 84.5}

650 {66.5}

24

588 - 1030 {60 - 105}

810 {82.5}

27

883 - 1470 {90 - 150}

1180 {120}

30

1130 - 1910 {115- 195}

1520 {155}

33

1470 - 2450 {150 - 250}

1960 {200}

36

1860 - 3040 {190 - 310}

2450 {250}

39

2260 - 3630 {230 - 370}

2940 {300}

18

When tightening the bolts with a torque wrench, apply Table 2.

Apply Table 2 when the proper tightening torque range is particularly narrow.

Table 2 Unit: Nm {kgm} Material

S43C, SCM435H or equivalent

Nominal size of thread (mm) 6

11.8 - 14.7 {1.2 - 1.5}

8

27 - 34 {2.8 - 3.5}

10

59 - 74 {6 - 7.5}

12

98 - 123 {10 - 12.5}

14

157 - 196 {16 - 20}

16

245 - 309 {25 - 31.5}

18

343 - 427 {35 - 43.5}

20

490 - 608 {50 - 62}

22

662 - 829 {67.5 - 84.5}

24

824 - 1030 {84 - 105}

27

1180 - 1470 {120 - 150}

30

1520 - 1910 {155- 195}

33

1960 - 2450 {200 - 250}

36

2450 - 3040 {250 - 310}

39

2890 - 3630 {295 - 370}

19

2. Tightening torque of pipe threads Tighten taper male pipe threads of nominal sizes of R1/8 - R1 and Rc1/8 - Rc1 and parallel female pipe threads of nominal size of Rp1/8 - Rp1 (coated with adhesive) according to the following standard.

If tightening torque is specified particularly, however, do not apply the following standard.

2-1. If the material of male threads is SS400, FC, or SGP, apply Table 1.

Table 1 Unit: Nm {kgm} Material of female thread

Steel

Cast iron

Light alloy

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

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

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

Steel

Cast iron

Light alloy

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

20

3. Tightening torque of hoses (with taper/face seal)

Unit: Nm {kgm} Nominal diameter Width across of hose flatse.

Tightening torque Range

Target

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}

04

27

84 - 132 {8.5 - 13.5}

103 {10.5}

05

32

128 - 186 {13.0 - 19.0}

157 {16.0}

06

36

177 - 245 {18.0 - 25.0}

216 {22.0}

{10}

41

177 - 245 {18.0 - 25.0}

216 {22.0}

{12}

46

197 - 294 {20.0 - 30.0}

245 {25.0}

{14}

55

246 - 343 {25.0 - 35.0}

294 {30.0}

02

03

When connecting hoses, take care not to twist them.

21

COATING MATERIALS fl The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. fl 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, featuresr

LT-1A

790-129-9030

150 g

Tube

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

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.

Polyethylene container

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

LT-1B

LT-2

09940-00030

50 g

LT-3

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

Adhesive: 1 kg Hardenin g agent: 500 g

Can

LT-4

790-129-9040

250 g

Polyethylene container

• Used as sealant for machined holes.

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.

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

Adhesives

Gasket sealant

790-129-9050

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

Aron-alpha 201

790-129-9130

2g

Polyethylene container

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 sealent for gaslets and packing of power train case, etc.

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.

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

LG-5

LG-6

790-129-9070

790-129-9020

1 kg

200 g

22

Category

Komatsu code

Part No.

Q’ty

Container

Main applications, featuresr

LG-7

790-129-9070

1g

Tube

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

Three bond 1211

790-129-9090

100 g

Tube

• Used as heat-resisting sealant for repairing engine.

LM-G

09940-00051

60g

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 lubicant for linkage, bearings, etc.

Adhesives

Molybdenum disulphide lubricant

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

Various

Various

Molybdenum disulphide lubricant

STG2-400M

400 g (10 per case)

Belows type

Grease

200 g

• General purpose type Various

23

Various

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

• Used for places with heavy load

24

A. ASSEMBLY PROCEDURE

25

Assembly procedure

A-1

Installation of undercarriage (1/7)

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

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

26

Assembly procedure

A-1

Installation of undercarriage (2/7)

1-3 Unloading of chassis 1. Holding the front tow hook and ripper top pin, sling the chassis with 2 45-t wrecker trucks.

2. Use the tow bracket of the undercover to sling the front section as shown in the photo.

• Wire: 36 mm x 5 m (Safety factor: 5) • Shackle: 60 mm x 80 mm wide

Shackle Use corner pad

16t

3. Use the ripper tilt cylinder pin to sling the rear section as shown in the photo.

• Wire: 30 mm x 3 m x 2 pieces

26t

27

Assembly procedure

Installation of undercarriage (3/7)

A-1

1-4 Installation of track frame fl Preparation work 1. Removal of accessories Remove the following 10 parts (the bolts are not counted in) from the track frame as shown in the photo.

No.

Part No.

1

198-30-62140

Cover

2

198-50-61370

Cover

3

198-50-61150

Shaft

198-30-64170

Cover (L.H.)

198-30-64180

Cover (R.H.)

198-30-61310

Cover (L.H.)

4 5 6 7 8 9 10

Part name

198-30-31320

Cover (R.H.)

198-50-51390

Cover

198-30-51430

Cover (L.H.)

198-30-51440

Cover (R.H.)

198-50-31270

Spacer

198-50-51220

Cover A’ssy

195-30-31260

Cover

198-30-62150

Cover (L.H.)

198-30-62160

Cover (R.H.)

1

6

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

O-ring

3. Check of seal for damage, maintenance of shaft, and application of grease

O-ring

28

2

7

3

8

4

9

5

10

Assembly procedure

Installation of undercarriage (4/7)

A-1

4. Install the thrust plate to the end of the track frame.

5. Slinging method

fl In these photos, the track frame is slung without the Wire (24 mm in diameter, 2 m long, 2 pieces) Lever block (6 t) Lever block (3 t) Wire (24 mm in diameter, 6 m long, 1 piece)

3m

100 mm Center of gravity is at 100 mm from holding part of track frame

Holding part of track frame

Rear view

Front view

carrier rollers installed. It may be slung with the carrier rollers directed out so that the carrier rollers will not interfere with the fender, etc.

29

Assembly procedure

A-1

Installation of undercarriage (5/7)

6. Installation of track frame 1) Sling the track frame horizontally and insert it, aligning it to the pivot shaft. fl The front worker must not stand between the chassis and track frame. Standing there is dangerous.

2) After the wire touches the fender, push in the track frame with a forklift, etc. fl Apply blankets, etc. to the interfering part of the fender to protect that part.

3) Fix the shaft and track frame with the twisted seal plate (for fixing). fl If you use a long bolt as an installation guide, you can assemble easily.

30

Assembly procedure

Installation of undercarriage (6/7)

A-1

7. Insertion of equalizer bar pin 1) Adjusting with the crane, align the pin holes accurately. fl The pin must be inserted in the correct directly.

Direct its cut part in.

There is UP mark

2) Connect the grease tube.

Grease tube Mudguard for pin

3) Install the attached cover.

4) Install the pin fixing bolt. fl Insert the pin fixing bolt from below and install the nut to the upper side.

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) 320 mm 50 mm 2,574 ± 123 Nm {262.5 ± 12.5 kgm}

8. Work around pivot • Tilt hose Match the band color of each end of the hose as shown below.

Red: Head (Upper) side Blue: Bottom (Lower) side

Reference: Perform this step on only the right side of the single tiltdozer specification and on both sides of the dual tiltdozer specification and superdozer specification.

• When connecting the cover and hose, use a guide bolt.

Color band is installed for identification.

Hose torque: 156.9 ± 9.8 Nm {16 ± 1 kgm} Necessary tools: Spanner, guide bolt

• Cover mounting bolt Part No. of bolt Part No. of washer Length of bolt Necessary socket Tightening torque

Upper side: Head

01010-81695 (9 pieces on each side) 01011-81625 (1 piece on each side) 01643-31645 (10 pieces on each side) 95 mm, 125 mm 24 mm 277.0 ± 31.9 Nm {28.25 ± 3.25 kgm}

31

Lower side: Bottom

Assembly procedure

A-1

Installation of undercarriage (7/7)

• Install the inside twisted seal cover with the notch down.

• When fixing the cover, set the track frame horizontally.

9. Remove the bogie fixing plate (special jig L) and keep it for the next modification.

L

1-5 Unloading of chassis • Sling the front section and pull out the stand.

• Sling the rear section, pull out the stand, and place the chassis on the tracks.

32

A-2

Installation of ripper (1/4)

1. Preparation • Removal of paint and rust prevention oil from mounting parts

Style

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

• Arm pin lock bolt Part No. of bolt

01010-82040 (2 pieces on each side)

Part No. of washer

01643-32060 (2 pieces on each side)

Length of bolt

40 mm

Necessary socket

30 mm

Tightening torque

549 ± 59 Nm {56 ± 6 kgm}

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

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

3. Installation of lift cylinder • Lift cylinder connecting pin lock bolt

Block

Part No. of bolt

01010-82045 (2 pieces on each side)

Part No. of washer

01643-32060 (2 pieces on each side)

Length of bolt

45 mm

Necessary socket

30 mm

Tightening torque

549 ± 59 Nm {56 ± 6 kgm}

33

A-2

Installation of ripper (2/4)

4. Installation of tilt cylinder • Tilt cylinder connecting pin lock bolt Part No. of bolt

01010-82045 (2 pieces on each side)

Part No. of washer

01643-32060 (2 pieces on each side)

Length of bolt

45 mm

Necessary socket

30 mm

Tightening torque

549 ± 59 Nm {56 ± 6 kgm}

5. Installation of right and left lift hoses and tilt hoses • Direct the hoses as shown in the photo.

• Part No. of hose : 07097 – 01012 (Common to 8 hoses on right and left sides)

Straight openings

L-adapters

6. Sub beam • Assemble the right and left grease hoses and elbows before installing them to cylinder head pin. * Connect the pin after installation.

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

• Beam connecting pin lock bolt Part No. of bolt

01010-82040 (2 pieces on each side)

Part No. of washer

01643-32060 (2 pieces on each side)

Length of bolt

40 mm

Necessary socket

30 mm

Tightening torque

549 ± 59 Nm {56 ± 6 kgm}

34

A-2

Installation of ripper (3/4)

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

8. Procedure for connecting cylinder

1. Installation of lift cylinder 2. Installation of tilt cylinder 3. Check of hydraulic oil level and addition of new oil

H

• Connecting pin lock bolt on cylinder rod side Part No. of bolt

01010-82045 (2 pieces on each side)

Part No. of washer

01643-32060 (2 pieces on each side)

Length of bolt

45 mm

Necessary socket

30 mm

Tightening torque

549 ± 59 Nm {56 ± 6 kgm}

35

A-2

Installation of ripper (4/4)

9. Installation of pin puller hoses • Clamping positions of hoses 1. Between clamp on side of beam and cylinder: 990 mm 2. Between connecting part of chassis and clamp A: 1,060 mm

A

3. Between clamp A and clamp on side of beam: 1370 mm

• Method of installing centralized greasing unit on mount side • After completing assembly, check the operation and confirm that the hose is not abnormally slackened or tensed.

• Detail of pin puller hoses installation.

36

Assembly procedure

A-3

Installation of tracks (1/2)

1. Wind the front end of each track up to the idler top. fl Set the idler to the shortest position in advance.

2. Put a block to the ripper shank holder to float the sprocket from the track.

3. Sling the rear end of the track with a crane and lay it over the sprocket.

4. Wind the track around the sprocket. Slinging the end of the track with the crane, send it forward. fl The operators of the bulldozer and crane must make clear signs to each other.

5. Connect the master link on the idler.

6. Fit the mating faces of the master link and check that you can screw in the bolts lightly.

37

Assembly procedure

A-3

Installation of tracks (2/2)

7. Insert the key in the link and place the shoe, then tighten and seat the 4 bolts evenly first with an impact wrench of 196 Nm {20 kgm}. fl Apply molybdenum disulfide grease to the bolt holes of the link and thread parts of the bolts.

8. Control of bolt toque fl Retightening method 1. Tighten the bolts to torque of 980 ± 98 Nm {100 ± 10 kgm} first and check that the mating faces of the link are fitted.

2. Make match marks (at the places pointed out with the arrow).

3. Retighten the bolt by an angle of 180° ± 10°.

fl Tightening order Tighten the bolts in the order shown at right.

fl Adjust the track tension when adding grease at last.

38

Assembly procedure

A-4 •

Adding oil to pivot chamber

Pivot chamber Add engine oil through the hole of plug (1). fl Quantity of oil: 26 ¬/each side fl Oil level (B): 10 – 30 mm from oil level (2)

39

Assembly procedure

Installation of ripper shank

A-5

fl Work properly according to the condition of each field.

•

Ride over a steel block and pull in the shank from below. fl For dimension of shackle, see TOOLS LIST FOR FIELD ASSEMBLY.

•

Align the shank holes and insert the pin.

Steel block

Precautions

Necessary tools Name

Other remarks

40

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of blade lift cylinder (1/2)

A-6

1. Remove the yoke cap and bushing.

2. Installation of cylinder • Install the cylinder with the right and left tubes out down.

• Install the upper cap and bushing to the cylinder first. After tightening the bolts temporarily, install the lower cap and bushing, lifting them up.

Install the upper cap first.

Keep the lower cap removed.

• Cap mounting bolts Part No. of bolt

01010-83040 (4 pieces on each side)

Part No. of washer

01643-33080 (4 pieces on each side)

Length of bolt

140 mm

Necessary socket

46 mm

Tightening torque

1,716 ± 196 Nm {175 ± 20 kgm}

3. Installation of hoses • Install the hoses so that they will not interfere with each other as shown in the photo.

Installation angle

Hoses must be free from interference.

41

Assembly procedure

Installation of blade lift cylinder (2/2)

A-6 •

Install the upper and lower hoses correctly.

Upper hose (1): 07098-01219 (Right and left) Lower hose (2): 07098-01218 (Right and left)

•

Blade lift cylinder connecting ports Hose Cylinder

Upper hose

Lower hose

Left lift

Bottom side

Head side

Head side

Bottom side

Right lift

42

Assembly procedure

Installation of trunnion

A-7 •

Sling and install the trunnion. fl Before installing the trunnion, remove the paint from its installing surface.

• Trunnion mounting bolts Part No. of bolt

01011-83005 (12 pieces on each side)

Part No. of washer

01643-33080 (12 pieces on each side)

Length of bolt

105 mm

Necessary socket

46 mm

Tightening torque

1,716 ± 196 Nm {175 ± 20 kgm}

43

Assembly procedure

Assembly of blade (1/6)

A-8

1. Erect the blade.

• Using the crane, erect the blade. fl Since the blade is heavy, set the crane as near the blade as possible.

• Set blocks at 4 places to prevent the blade from falling down.

Joint

Correct

Wrong

2 places on right and left side

• Pull out the straight frame mounting pins inward.

2 places on right and left side

44

Assembly procedure

A-8

Assembly of blade (2/6)

2. Installation of right and left straight frames Caution • Sling the straight frames horizontally in each direction.

Sling straight frames with 2 nylon slings.

• Set the straight frames to a low position so that you can install the tilt cylinder easily.

• Set the straight frames a little open so that you can install the arm rod easily.

• Using a chain block, pull up the center link in parallel with the back of the blade.

3. Installation of arm rod Caution • Install the center link side first and support it with a block.

• Sling the straight frames with the crane, move them in, and connect the joints.

• Tighten both sides of the arm temporarily.

45

Assembly procedure

Assembly of blade (3/6)

4. Adjustment of clearance in arm ball joint (Adjust both inside and outside similarly)

➞

➞

A-8

AB

 Standard: 5 mm

Procedure

(1) Pull the flange with the bolt and seat the joint end without inserting a shim. (Take care since the frame slips slightly at this time.)

(2) Insert shims in maximum clearance A and minimum clearance B, and then calculate the proper shim thickness by (A + B)/2 + 0.5.

(3) Tighten the bolt with an impact wrench, and then swing the frame and check the clearance visually.

Part No. of bolt

01010-83335 (8 pieces on each side)

Part No. of shim

Thickness (mm)

Part No. of washer

01643-33380 (8 pieces on each side)

198-71-31450

2

Length of bolt

135 mm

198-71-31460

1

Necessary socket

50 mm

198-71-31470

0.5

Tightening torque

2,207 ± 245 Nm {225 ± 25 kgm}

(4) Adjust the clearance on the opposite side similarly.

5. Installation of tilt cylinder Caution • Install the hoses and cover of the tilt cylinder in advance.

For superdozer, install the tube, block, hoses and cover of the tilt cylinder in advance.

• Install the tilt cylinder assembly to the straight frames. fl You may insert the pin on the rod side after starting the engine.

• Tilt cylinder connecting pin lock bolt Part No. of bolt

01010-82050 (6 pieces on each side)

Part No. of washer

01643-32060 (4 pieces on each side)

Length of bolt

50 mm

Necessary socket

30 mm

Tightening torque

549 ± 59 Nm {56 ± 6 kgm}

46

Assembly procedure

Assembly of blade (4/6)

A-8 •

Connection of cylinder hose and installation of cover

Hose

Intermediate cover

Hose

Step cover

Part No. of bolt

01010-82040 (4 pieces on each side)

Part No. of washer

01643-32060 (4 pieces on each side)

Length of bolt

40 mm

Necessary socket

30 mm

Tightening torque

549 ± 59 Nm {56 ± 6 kgm}

Step cover

Part No. of bolt

01010-82045 (6 pieces on each side)

Part No. of washer

01643-32060 (6 pieces on each side)

Length of bolt

45 mm

Necessary socket

30 mm

Tightening torque

549 ± 59 Nm {56 ± 6 kgm}

Intermediate cover

47

Part No. of bolt

01010-81225 (2 pieces on each side)

Part No. of washer

01643-31232 (2 pieces on each side)

Length of bolt

25 mm

Necessary socket

19 mm

Tightening torque

110 ± 12 Nm {11.25 ± 1.25 kgm}

Assembly procedure

A-8

Assembly of blade (5/6)

6. Move the center link and match the straight frames to the width of the trunnion center. fl If you sling the straight frames with the crane, you can move it easily.

3980

7. Match the straight frames trunnion to the height of the chassis trunnion center. fl Sling the frame with the crane and adjust its height.

980

48

Assembly procedure

A-8

Assembly of blade (6/6)

• Adjustment of length of single tiltdozer brace 1) Raise the blade a little.

2) Tilting to the right and left in the operator’s seat, rotate the brace.

3) Adjust the length of the brace so that the tilting distances on both sides will be the same.

Rotate with this lever.

Distance between pins

49

Assembly procedure

Adjustment of arm joint (U-blade)

A-9 Check of clearance in arm ball joint Adjustment of shim

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

Shim (1) Bolt (2)

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

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

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

50

Assembly procedure

Installation of blade (1/2)

A-10 Caution

• Checking the inside clearance between the track and straight frame on the right and left sides, move the chassis forward until it touches the trunnion.

• When connecting the tilt hose, check the marks (red and blue). q

Red

Head side

Upper side

w

Blue

Bottom side

Lower side

q w

• Pass the bolts through the cap and install wires to them.

• Cap mounting bolts Part No. of bolt

198-61-11250 (4 pieces on each side)

Part No. of washer

01643-33380 (4 pieces on each side)

Length of bolt

305 mm

Necessary socket

50 mm

Tightening torque

2,207 ± 245 Nm {225 ± 25 kgm}

• Hose cover mounting bolts Part No. of bolt

01010-82050 (6 pieces on each side)

Part No. of washer

01643-32060 (6 pieces on each side)

Length of bolt

50 mm

Necessary socket

30 mm

Tightening torque

549 ± 59 Nm {56 ± 6 kgm}

51

Assembly procedure

Installation of blade (2/2)

A-10

• Sling the blade cylinder with the crane and remove the hanging bracket for shipping.

Nylon sling Hanging bracket

• Connect the cylinders one by one.

• While extending the cylinder, connect the rod. fl The person in charge of making signs shall make signs to the operators of the crane and bulldozer properly to prevent a mistake in operation.

fl The joint link is installed on the blade side.

• Joint connecting pin lock bolt Part No. of bolt

01010-81635 (4 pieces on each side)

Part No. of washer

01643-31645 (4 pieces on each side)

Length of bolt

35 mm

Necessary socket

24 mm

Tightening torque

277 ± 32 Nm {28.25 ± 3.25 kgm}

• After installing the cylinders to the blade, install the right and left tilt control rods. fl Standard length of rod : 425 mm Adjustment rod Potentiometer

fl Detail of adjusting rod installation

To blade cylinder yoke

52

No.

Part No.

Q'ty

1

01010-81055

2

2

01643-31032

2

3

04250-81056

2

4

195-33-11220

2

5

01582-11008

2

6

04248-31037

2

Assembly procedure

Installation of counterweight

A-11

(1) Sling the counterweight assembly and set it to the mounting part.

(2) Insert the mounting pin and lock it. fl Tightening torque of bolt: 549 ± 59 Nm {56 ± 6 kgm}

Precautions

Necessary tools Name

Other remarks

53

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installation of operator’s cab (1/16)

A-12

fl Remove the power supply wiring harness for the cab (Refer Fig. 10) and install it again after assembling the cab.

1. Installation of open lock striker Install right and left open lock striker mounting brackets (1) and (2) with bolts (3) and washers (4) as shown in Fig. 1. fl 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 L-plate Install indoor L-plate (10) and outdoor L-plate (11) temporarily with bolts (12) and washers (13) as shown in Fig. 2. (3 pieces on each side) Before installing the cab, loosen bolts (12).

Fig. 1

Fig. 2

Precautions

No.

Part No.

Q'ty

1

198-Z11-3341

1

2

198-Z11-3351

1

3

01010-D1230

10

4

01643-71232

10

5

14X-911-1921

2

6

01580-11008

8

7

01643-31032

8

8

09453-00002

2

9

01580-01210

2

10

198-Z11-3571

1

11

198-Z11-3581

1

12

01010-D1230

12

13

01643-71232

12

Necessary tools Name

Other remarks

54

Necessary equipment Q’ty

Name

Q’ty

A-12

Installation of operator’s cab (2/16)

3. Installation of seals to dashboard bracket (1) Apply the sealant to the joints of the dashboard bracket and floor as shown in Photo 1.

Photo 1

Apply sealant (packed separately).

(2) Fit seal (14) to the guide plate of the dashboard bracket and apply liquid sealant (55) as shown in Photo 2.

Photo 2

Apply sealant (packed separately).

(3) Apply grease (G2-LI) to the outside of the seal (14) (cab and sealing face) as shown in Photo 3.

Photo 3 (14) Apply grease

Remark: Before lowering the cab, apply grease so that the cab will slip well and the seal will not be moved or deformed.

55

A-12

Installation of operator’s cab (3/16)

4. Installation of seals of operator’s cab mating faces (1) Sling the operator’s cab assembly. fl Sling the operator’s cab to stick the seal to its mating faces.

4 Operator’s cab assembly: 455 kg (2) Remove dirt, oil, and grease from the seal sticking faces.

(3) Remove the release paper from seals (15), (16), and (17), and then stick the seals, referring to Fig. 4 on the next page.

Fig. 3

Precautions

No.

Part No.

Q'ty

14

198-Z11-3540

1

15

14X-911-5911

5

16

198-Z11-7420

2

17

198-Z11-7430

2

Necessary tools

Since the seals are longer than the necessary length, cut them properly when sticking.

Name

Other remarks

56

Necessary equipment Q’ty

Name

Q’ty

A-12

Installation of operator’s cab (4/16)

Stick seals so that it will project about 10 mm.

Apply sealant to clearance.

Front Apply sealant before assembling cab.

(On both sides)

(For how to stick (16) and (17), see photos 1 and 2 on page 5/15)

Overlap here.

Apply sealant to clearance.

(See Photo 3 on page 5/15)

Spacer plate (t2.3) Do not place sealing sponge over spacer plate.

Sealing sponge

Fig. 4 How to stick seals (View from bottom of operator’s cab)

57

A-12

Installation of operator’s cab (5/16)

Photo 1

Photo 2

Apply sealant to clearance.

Photo 3

Apply sealant to clearance.

Precautions

Necessary tools Name

Other remarks

58

Necessary equipment Q’ty

Name

Q’ty

A-12

Installation of operator’s cab (6/16)

5. Installation of operator’s cab (1) Lower the operator’s cab assembly slowly onto the floor frame. fl Lower the operator’s cab carefully since the reaction force of the sealing sponge is large. fl Take care not to move or damage the seals. fl Check that the seal of the air conditioner duct on the cab side is fitted tightly to the air conditioner duct on the dashboard side. fl Lower the operator’s cab carefully since the clearance between the air conditioner duct on the cab side and monitor is narrow.

(2) Tighten bolts (18) and (20) and washers (19) temporarily. (See Fig. 10) fl Note that the bolt length and washer at the door are different.

(3) Check that there is not clearance in the joint (a) of the seal and floor frame.

(4) As a result of check step (3) above, if there is clearance, reinstall the operator’s cab. If the clearance is narrow, however, seal it with sealant (55).

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

Lower cab in direction of arrow.

Flange Cab body

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

Dashboard bracket

Fig. 5 No.

Part No.

Q'ty

18

01010-81275

15

19

124-54-26540

21

20

01010-81245

6

55

198-Z11-3960

1

Lower cab in direction of arrow.

59

A-12

Installation of operator’s cab (7/16)

(5) 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.

(6) 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.

(7) Permanently tighten bolts (18) and (20) which were tightened temporarily in step (2) above .

(8) Permanently tighten mounting bolts (12) of Lplates (10) and (11) which were installed temporarily in step (2) above.

Air conditioner duct on cab side

Clearance Clearance Monitor

Dashboard

Fig. 6 Air conditioner duct on cab side

Monitor Face C

Seal

Face C Dashboard assembly Air conditioner duct on dashboard side

Fig. 7 Air conditioner duct on cab side

Monitor

Dashboard

Duct mounting screw

Fig. 8 Precautions

Necessary tools Name

Other remarks

60

Necessary equipment Q’ty

Name

Q’ty

A-12

Installation of operator’s cab (8/16)

(9) Install plates (21) with bolts (25) and washers (26). (2 pieces on each side) (10) Install right and left foot rests (24) and (25) with bolts (26) and washers (27). (2 pieces on each side) (11) Install pedal caps (28) to the foot rests.

Fig. 9

Precautions

No.

Part No.

21

198-Z11-2961

2

22

01010-D1230

4

23

01643-71232

4

24

14X-911-5711

1

25

14X-911-5721

1

26

01010-D1230

4

27

01643-71232

4

28

203-43-56450

2

Necessary tools Name

Other remarks

61

Q'ty

Necessary equipment Q’ty

Name

Q’ty

A-12

Installation of operator’s cab (9/16)

(12) Referring to Fig. 10, bind the windshield washer hoses, windshield washer connector, and cab power supply wiring harnesses with strings. Pass them through holes (A) and (B), and then connect the wiring harnesses on the chassis side from the decorative cover above the left fender.

Marks fl at 15 places

Marks ª at 6 places

Floor frame assembly

Windshield washer hoses Red Blue Black –

............. Right door ............. Left door ............. Rear window ............. Front window

Part under door

Wiring harness From floor

From cab

4-pole connector ............................ Windshield washer Red (Nominal JIS size: 5) ............... Power supply Yellow (Nominal JIS size: 0.85) ..... Backup power supply (For radio)

Fig. 10 View X (sean from rear)

fl After connecting the hoses and connectors, fit the grommet on the wiring harness side securely.

62

A-12

Installation of operator’s cab (10/16)

6. Installation of left parking brake lever knob (1) Before installing the panel, remove the lever knob.

(2) After installing the panel, apply adhesive (LT2) to the thread part of the knob, and then install the knob to the lever.

Panel

Knob (Lever) Fig. 11

63

A-12

Installation of operator’s cab (11/16)

7. Installation of bellows bracket (1) Pull and remove bellows (1) and bellows bracket (2) of blade lever as shown in the photo.

(2) Similarly, remove beldwwwlows (3) and bellows bracket (4) of ripper lever.

(3) Install cover (33).

(4) Install the bellows bracket to fixing spring (5).

•

Installing condition of cover (33)

Correct

Wrong

Fig. 16

Precautions

Necessary tools Name

Other remarks

64

Necessary equipment Q’ty

Name

Q’ty

A-12

Installation of operator’s cab (12/16)

8. Installation of interior parts (1) Install floor covers (29), (30), and (31) with screws (34) (14 pieces).

(2) Install covers (32), (33), and (34) with button (37). (16 places) (3) Install cup holder (40) with screws (41) to plate (36). Then, install ashtray (38) and cigarette lighter (39) to plate (36) with screws (41) and washers (42).

(4) Install grille (44).

(5) Install rubber chutes (45) and (46). fl When installing plate (35), connect the ground wire of the cigarette lighter with the mounting screw of part (A) (shown on the next page).

When connecting, remove the paint from the screw fixing part of the cab to secure grounding.

Fig. 12

Fig. 13 Precautions

Part No.

Q'ty

29

198-Z11-6170

1

30

198-Z11-6190

1

31

198-Z11-6150

1

32

198-54-61511

1

33

198-54-61531

1

34

01024-D0820

14

35

198-54-61521

1

36

198-Z11-6160

1

37

23D-950-4450

16

38

20Y-06-21751

1

39

20Y-06-2347

1

40

17A-Z11-3180

1

41

01245-00616

4

42

01643-70623

4

43

01370-40408

2

44

201-979-7820

2

45

198-Z11-6230

1

46

198-Z11-6240

1

Necessary tools Name

1. Install plate (36) on cover (32) as shown in the photo.

2. Install cover (32) first, and then install plate (36).

Match the mounting holes of cover (32) before installing plate (36). After plate (36) is installed, the position of cover (32) cannot be adjusted.

3. If the band to fix the optional lunch box is selected, see also A-24.

No.

Other remarks

65

Necessary equipment Q’ty

Name

Q’ty

A-12

Installation of operator’s cab (13/16)

Correct installation

Wrong installation

Plate (36) is installed under cover (32).

Precautions

Necessary tools Name

Other remarks

66

Necessary equipment Q’ty

Name

Q’ty

A-12

Installation of operator’s cab (14/16)

(6) Install sensor (52) to cover (51), and then install them with screws (53) and washers 54. (4 pieces) (7) Install plates (47) and (48) with screws (49) and washers (50). (8 pieces) (8) Install cab door plate (56). (On both sides).

(9) After installing cab door plate (56), apply liquid sealant (55) all around the plate. (On both sides) Before opening and closing the door, wait until the sealant dries up.

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

CN-SLS Cut band and connect.

Fig. 14 Precautions

No.

Part No.

Q'ty

47

198-Z11-2941

1

48

198-Z11-2951

1

49

01245-00616

8

50

01643-70623

8

51

198-Z11-6280

1

52

20Y-979-6161

1

53

01245-00616

4

54

01643-70623

4

55

198-Z11-3960

1

56

198-Z11-6410

2

65

01010-D0645

6

66

01643-70623

6

Necessary tools Name

Other remarks

67

Necessary equipment Q’ty

Name

Q’ty

A-12

Installation of operator’s cab (15/16)

(9) Install cushion (57) and install mat (58) on it.

(10) Install mat (59).

(11) Install plate (56). (On both sides)

Fig. 15

Precautions

Necessary tools Name

Other remarks

68

Necessary equipment Q’ty

Name

Q’ty

A-12

Installation of operator’s cab (16/16)

9. Change of antenna mounting angle When delivered, the antenna is directed down for packing and transportation of the operator’s cab (Fig. 17). After mounting the operator’s cab, set the antenna at the correct angle (Fig. 18).

Antenna (198-Z11-4610) Left window

Directed down when delivered Rear window

Fig. 17 • Loosen the wing bolt at part (b) near the antenna mounting part and direct the antenna up. Then, tighten the wing bolt.

Antenna

b

Left window

Rear window

Fig. 18

Precautions

Necessary tools Name

Other remarks

69

Necessary equipment Q’ty

Name

Q’ty

A-13 •

Installation of ROPS

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

4 ROPS: 918 kg

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

fl Set stamp F on the front side.

Precautions

No.

Part No.

1

01011-83310

16

2

01643-33380

16

Necessary tools Name Q’ty Torque wrench 1 (2,059 Nm {210 kgm}) Socket 50 mm 1 (38.1 )

Other remarks

70

Q'ty

Necessary equipment Name

Q’ty

Assembly procedure

Adjustment of potentiometer rod

A-14 Length of rod : 425 mm

Reference: See the A-15 PROCEDURE FOR ADJUSTING BLADE TILT ANGLE LIMIT.

Precautions

Necessary tools Name

Other remarks

71

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15

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.

1-2 Run the engine at low idling and set the blade in the following standard position.

1) Set the tilt angle to 0°.

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

3) Lower the blade to the ground.

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

Tilt switch

Dual tilt

Precautions

Necessary tools Name

Other remarks

72

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15

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 1) Hold buzzer cancel switch (3) in the position for 2.5 seconds, and the maintenance mode is displayed. Then, set the buzzer cancel switch to information switch (2), and the adjustment mode is selected.

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

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

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

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

Precautions

Necessary tools Name

Other remarks

73

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15

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

1-5 Raise the blade tip to about 1 m above the ground.

1-6 Tilt the blade to the left with the blade control lever and set the left tilt angle to 12°. (User adjustment mode) fl Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase too much. fl 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. fl When the saving operation is finished, the buzzer sounds.

Tilt switch

Single tilt Dual tilt

Precautions

Necessary tools Name

Other remarks

74

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15

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

Necessary tools Name

Other remarks

75

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15

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°. fl Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase too much. fl Adjust the tilt angle accurately with angle gauge.

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

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

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

Precautions

Necessary tools Name

Other remarks

76

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15

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.

2-2 Run the engine at low idling and set the blade in the following standard position.

1) Set the tilt angle to 0°.

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

3) Lower the blade to the ground.

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

• Mounting dimension “a”: 425 mm

Precautions

Necessary tools Name

Other remarks

77

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15

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

2-4 Mode and operation 1) Hold buzzer cancel switch (3) in the position for 2.5 seconds, and the maintenance mode is displayed. Then, set the buzzer cancel switch to information switch (2), and the adjustment mode is selected.

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

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

4) Set the buzzer cancel switch in the select 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.

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

2-5 Operate the blade according to the following procedure so that it can be tilted.

1) Raise the blade tip to 200 – 300 mm above the ground.

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

Precautions

Necessary tools Name

Other remarks

78

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15

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 2-5 and tilt it 7° to the left. Under this condition, press the pitch-dump button (upper button), and the buzzer sounds and the left limit position is saved. fl Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase too much. fl Adjust the tilt angle accurately with angle gauge.

2-8 Tilt the work equipment 7° to the right. Under this condition, press the pitch-dump button (upper button), and the buzzer sounds and the right limit position is saved. fl Since the tilt limiting function does not work, operate slowly so that the tilt angle will not increase too much. fl Adjust the tilt angle accurately with angle gauge.

Precautions

1000mm

Necessary tools Name

Other remarks

79

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-15

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

2-9 The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( ) to leave the adjustment mode, and then lower the work equipment to the ground and stop the engine.

2-10 Start the engine again and tilt the blade to the right and left and check that the blade stops tilting to the right and left in the following range automatically, regardless of its height.

• Automatic tilt stopping angle: 7 ± 1°

Precautions

Necessary tools Name

Other remarks

80

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Method of checking auto-reset system (Superdozer)

A-16

System to return the blade to the digging position automatically Pitch dump

1.

2.

3.

4.

5.

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.

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

Necessary tools Name

Other remarks

81

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Check track tension (1/2)

A-17

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

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

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

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

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

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

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

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

5. Tighten plug (4).

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

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

Precautions

Necessary tools

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.

Name

Other remarks

82

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Check track tension (2/2)

A-17

INSPECTION Stop the machine on level ground (stop with the transmission in FORWARD without applying the brake).

Then place a straight bar on the track shoes between the carrier roller and the idler as shown in the figure, and measure the clearance is 20 to 30 mm, the tension is standard.

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

Precautions

Necessary tools Name

Other remarks

83

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-18

Checking oil/coolant levels (1/2)

Fuel and oil Choose fuel and oil as shown in the following table, depending on the atmospheric temperature.

The rated capacity is the total quantity of oil in each device and its piping. The refill capacity is the quantity of oil replaced for inspection or maintenance.

When starting the engine at a temperature below 0°C, be sure to use SAE10W, SAE10W-30, or SAE15W-40, even if the temperature rises to about 10°C during the daytime.

Even if single-grade oil is mixed in multi-grade oil (SAE10W-30, SAE15W-40), no problem occurs.

Add the single-grade oil matched to the atmospheric temperature shown in the following table, however.

Use city water as coolant.

Coolant The coolant is a mixture of Komatsu genuine Super Coolant (AF-NAC) and water, so it does not need to be changed as long as the atmospheric temperature does not lower below –10°C. If the atmospheric temperature lowers below –10°C, adjust the ratio of Super Coolant to water.

84

Assembly procedure

Checking oil/coolant levels (2/2)

A-18

Check the lowest atmospheric temperature in the past and decide the ratio of antifreeze to water according to the following mixing ratio table. Actually, set the mixing ratio for a temperature about 10°C below the recorded lowest atmospheric temperature.

Min. atmospheric temperature (°C)

–10

–15

–20

–25

–30

Antifreeze

73.5

88

100.5

113

122.5

Water

171.5

157

144.5

132

122.5

Quantity (¬)

 WARNING Since antifreeze is flammable, take care of fire.

Use city water as the coolant.

Control the mixing ratio with an antifreeze densitometer.  WARNING When removing the drain plug, take care that the coolant will not splash over you.

Precautions

Necessary tools Name

If the oil/coolant is insufficient, add new oil/coolant.

Other remarks

85

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

A-19

Greasing of greasing point (1/3)

1. Blade

Center ball joint

Center link pin

Left ball joint

Right ball joint

2. Blade lift cylinder support yoke

Cap upper side

86

Cap lower side

Assembly procedure

A-19

Greasing of greasing point (2/3)

3. Blade lift cylinder support shaft

Support shaft LH and RH

4. Ripper

Cylinder foot LH and RH

LH & RH

LH & RH

LH & RH

Arm foot LH and RH

87

Assembly procedure

A-19

Greasing of greasing point (3/3)

5. Equalizer bar side pin

Equalizer bar side pin LH and RH

6. Equalizer bar both end.

Pivot shaft lubrication plug LH and RH Track adjustment plug LH and RH

88

Assembly procedure

Installation of ORBCOMM antenna and wiring harness

A-20

1. Remove left cover (6) (above the left fender).

2. Install the wiring harness and antenna (3) as shown in the following figure.

3. Install left cover (6).

Precautions

No.

Part No.

Q'ty

1

01024-81220

5

2

04434-50612

5

3

8A13-10-2100

1

4

21N-54-38450

1

5

01024-81225

1

Necessary tools Name

Other remarks

89

Necessary equipment Q’ty

Name

Q’ty

A-21

Replacement of return filter (Replacement of standard filter with flushing filter) (1/3)

Replace the hydraulic oil return filter element with flushing element (1) and plate (2). fl When replacing the element, lift it up slowly so that the dirt sticking to it will not drop in the tank.

Remove the dirt remaining in the case with your hand.

Replace the relief valve with this plate only when flushing the piping.

Replacement

Valve

Strainer

Flushing element Absolute filtration rating 6µ

Hydraulic tank (Note 1) When the atmospheric temperature is below –15°C, install the valve and strainer (without installing oil stopper plate (2)) and flush the piping with the engine speed at low idling.

(Note 2) For the flushing procedure, see “Testing and maintenance procedure after completing assembly M-3”.

Precautions

No.

Part No.

1

208-60-71170

1

2

21T-60-13730

1

Necessary tools Name

Keep removed standard element (208-60-71120)-1, strainer (07069-25400)-1, and valve (208-60-71160)-1 carefully, since they will be used again after flushing is finished.

Other remarks

90

Q'ty

Necessary equipment Q’ty

Name

Q’ty

A-21

Replacement of return filter (Replacement of standard filter with flushing filter) (2/3)

Return removed hydraulic oil return filter element (1), strainer (2), and valve (3). fl When replacing the element, lift it up slowly so that the dirt sticking to it will not drop in the tank.

Remove the dirt remaining in the case with your hand.

Valve

Replacement

Strainer

Standard element

Hydraulic tank

Precautions

Necessary tools Name

• Before performing the work in this section, perform A-23: Bleeding air from hydraulic cylinder and M-3: Flushing in order.

Other remarks

91

Necessary equipment Q’ty

Name

Q’ty

A-21

Replacement of return filter (Replacement of standard filter with flushing filter) (3/3)

Installing condition of element

Element

Fig. 1 Good condition

Fig. 2 Bad condition

fl Do not install the element with its bottom on the elevated part of the case bottom as shown in Fig. 2. In particular, if the filter case is filled with oil, it is difficult to see if the element is installed normally. In this case, turn the element with your hand. If you can turn it smoothly, it is installed normally.

Precautions

Necessary tools Name

After finishing flushing, discard the removed flushing element.

Keep the removed plate, however, since it will be used again.

Other remarks

92

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installing direction of exhaust pipe

A-22

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

Right of chassis

Left of chassis

Front of chassis

Precautions

No.

Part No.

Q'ty

1

6162-13-5611

2

2

01010-81025

4

3

01643-51032

4

Necessary tools Name

Other remarks

93

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Bleeding air from hydraulic cylinders

A-23

fl After disassembling for transpotation, changing the oil in the hydraulic tank, or removing the hydraulic cylinders or work equipment piping, bleed the air from the hydraulic circuit as follows.

1. Blade lift cylinder (with piston valve) 1) Start the engine and run at low idling for approx. 5 minutes.

2) With the engine at low idling, extend and retract the cylinder four or five times without operating it to the end of its stroke. fl Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstance.

3) Keeping the engine at low idling, extend the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of stroke. Hold it in this position for 3 minutes.

4) With the engine at high idling, extend the cylinder to a point approx. 100 mm before the end of the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of its stroke. Hold it in this position for 1 minute.

2. Blade tilt cylinder (without piston valve) 1) Start the engine and run at low idling for approx. 5 minutes.

2) With the engine at low idling, raise and lower the blade four or five times without operating the cylinder to the end of its stroke. fl Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any circumstance.

3) Repeat this operation with the engine at full throttle, then run the engine at low idling and operate the piston rod to the end of its stroke to relieve the circuit.

 If from the beginning the engine is run at full throttle; or the cylinders are operated to the end of their stroke, the piston packing may be damaged, so never operate in this way.

 Check the oil level, and add oil to the specified level if necessary.

Precautions

Necessary tools Name

Other remarks

94

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installing lunchbox band (if equipped) (1/2)

A-24

Note) When performing the following procedure, refer to A-12 Installing operator's cab (12/15), too.

1. After installing plate (1) to the operator's cab, pass the band through the rear U-hook as shown below.

2. Install cover (3).

Slide and position cover (3) to the rear U-hook as shown in the figure of part P, and then fix it.

P

Precautions

No.

Part No.

Q'ty

1

198-Z11-6170

1

2

198-911-7350

2

3

198-54-61511

1

Necessary tools Name

Other remarks

95

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

Installing lunchbox band (if equipped) (2/2)

A-24

3. Referring to A-12 Installing operator's cab (12/15), install the lining and rubber plate.

4. Install the band as shown below.

After installing cover (3), pass band through front and side U-hooks.

Lining Front Rubber plate

Precautions

Necessary tools Name

Other remarks

96

Necessary equipment Q’ty

Name

Q’ty

M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY

97

M-1

Check and adjustment of operator’s cab (1/7)

1. Measuring pressure in cab (1) Measure the pressure in the cab. fl Criterion: Measured value ≥ 98.1 Pa {10 mmH2O} fl Testing condition : Run the engine at full throttle and set the engine fan to 100%. : Set the blower to the high (Hi). 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.

98

Blower at high (Hi)

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

10 mm or more

(a) Prepare a transparent vinyl hose (of an outer diameter of 10 mm and 3,000 mm long). (b) Pour water into the hose bore for about a half of the hose length. (c) Remove the sliding windshield lock lever located on the side panel of the 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. (d) Seal the gap occurring between the lock-lever hose and the outer periphery-of the hose. (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)

Remove lock lever and insert vinyl hose.

Fix vinyl hose to top end of back seat

Vinyl hose

99

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

Necessary tools Name

Other remarks

100

Necessary equipment Q’ty

Name

Q’ty

M-1

Check and adjustment of operator’s cab (4/7)

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.

101

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

Necessary tools Name

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.

Other remarks

102

Necessary equipment Q’ty

Name

Q’ty

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

Necessary tools Name

Other remarks

103

Necessary equipment Q’ty

Name

Q’ty

M-1 4.2

Check and adjustment of operator’s cab (7/7)

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

Necessary tools Name

Other remarks

104

Necessary equipment Q’ty

Name

Q’ty

Assembly procedure

M-2

Error code (1/9)

1. Turn starting switch (2) ON. 2. Operate service switch (3) and buzzer cancel switch (4) to select the service mode. fl While holding the service switch in the ON position, hold the buzzer cancel switch in the [ ] position for 2.5 seconds. fl When the system is set in the service mode, [1C] is displayed in gear speed display unit (1).

3. Display of electrical and mechanical failure codes 1) Select EE (electrical system failure code display mode) with information switch (5) and execute with buzzer cancel switch (4).

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

• [ • [ • [

]: Increase the mode No. ]: Decrease the mode No. ]: Execute the mode.

105

Assembly procedure

Error code (2/9)

M-2 •

Electrical system failure coad display mode

•

Mechanical system failure coad display mode

106

Assembly procedure

M-2

Error code (3/9)

•

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

•

Display when any code is recorded If there is any past or current failure code recorded, the panel displays as shown at right.

(1): Record No. (Max. 20 Nos.) (2): Failure code (Current failure code flashes) (3): Number of occurrences up to now (4): Elapsed time indicated by service meter after first occurrence (5): Elapsed time indicated by service meter after last occurrence

107

Assembly procedure

Error code (4/9)

M-2 Failure code

Failure

Trouble

Caution Caution Controller Action code lamp buzzer

1500L0

Double failure of transmission

* See separate list (LO)

TM

CALL

E03

ⓦ

ⓦ

15SAL1

Forward clutch oil pressure

* See separate list (L1)

TM

CALL

E03

ⓦ

ⓦ

15SALH

Forward clutch oil pressure

* See separate list (LH)

TM

CALL

E03

ⓦ

ⓦ

15SBL1

Reverse clutch oil pressure

* See separate list (L1)

TM

CALL

E03

ⓦ

ⓦ

15SBLH

Reverse clutch oil pressure

* See separate list (LH)

TM

CALL

E03

ⓦ

ⓦ

15SEL1

1st clutch oil pressure

* See separate list (L1)

TM

CALL

E03

ⓦ

ⓦ

15SELH

1st clutch oil pressure

* See separate list (LH)

TM

CALL

E03

ⓦ

ⓦ

15SFL1

2nd clutch oil pressure

* See separate list (L1)

TM

CALL

E03

ⓦ

ⓦ

15SFLH

2nd clutch oil pressure

* See separate list (LH)

TM

CALL

E03

ⓦ

ⓦ

15SGL1

3rd clutch oil pressure

* See separate list (L1)

TM

CALL

E03

ⓦ

ⓦ

15SGLH

3rd clutch oil pressure

* See separate list (LH)

TM

CALL

E03

ⓦ

ⓦ

1800MW

Power train clutch slip

Slip (MV)

TM

E02

ⓦ

ⓦ

2201L1

Right clutch oil pressure

* See separate list (L1)

ST

CALL

E04

ⓦ

ⓦ

2201LH

Right clutch oil pressure

* See separate list (LH)

ST

CALL

E04

ⓦ

ⓦ

2202L1

Left clutch oil pressure

* See separate list (L1)

ST

CALL

E04

ⓦ

ⓦ

2202LH

Left clutch oil pressure

* See separate list (LH)

ST

CALL

E04

ⓦ

ⓦ

2300NR

Brake thermal load

Abnormal heating (NR)

ST

2301L1

Right brake oil pressure

* See separate list (L1)

ST

CALL

E04

ⓦ

ⓦ

2301LH

Right brake oil pressure

* See separate list (LH)

ST

CALL

E04

ⓦ

ⓦ

2301NR

Right steering brake thermal load

Abnormal heating (NR)

ST

2302L1

Left brake oil pressure

* See separate list (L1)

ST

CALL

E04

ⓦ

ⓦ

2302LH

Left brake oil pressure

* See separate list (LH)

ST

CALL

E04

ⓦ

ⓦ

2302NR

Left steering brake thermal load

Abnormal heating (NR)

ST

E00

A000N1

Engine speed sensor abnormality

Over run (N1)

VHMS

E00

A70XLK

Governor servo system right abnormality

* See separate list (LK)

ENG

CALL

E04

ⓦ

ⓦ

A70YLK

Governor servo system left abnormality

* See separate list (LK)

ENG

CALL

E04

ⓦ

ⓦ

AA1ANX

Air cleaner clogging

Clogging (NX)

AB00MA

Battery charge abnormality

E00

E00

Machine

E00

Malfunction (MA)

Machine

E00

B@BAZG Engine oil pressure lowering

Lowering of oil pressure (ZC)

Machine

E00

B@BAZK Engine oil level lowering

Lowering of level (ZK)

Machine

E00

B@BCNS Coolant overheating

Overheating (NS)

Machine

E00

B@BCZK Coolant water level lowering

Lowering of level (ZK)

Machine

E00

B@CENS Power train overheating

Overheating (NS)

Machine

E00

B@HANS Hydraulic oil overheating

Overheating (NS)

Machine

E00

B@HAZK Hydraulic oil level lowering

Lowering of level (ZK)

Machine

E00

D110KA

BR relay holding

Disconnection (KA)

ST

E00

D110KB

BR relay holding

Short circuit (KB)

ST

E00

D130KA

N safety relay

Disconnection (KA)

TM

E02

ⓦ

ⓦ

D130KB

N safety relay

Short circuit (KB)

TM

E02

ⓦ

ⓦ

D161KA

Backup alarm relay

Disconnection (KA)

TM

E01

D161KB

Backup alarm relay

Short circuit (KB)

TM

E01

D182KZ

Preheating relay

Lowering of level (ZK)

ST

E01

D1D0KA

Governor cut relay right disconnection Disconnection (KA)

ENG

E01

D1D0KB

Governor cut relay right short circuit

Short circuit (KB)

ENG

E01

D1D1KA

Governor cut relay left disconnection

Disconnection (KA)

ENG

E01

108

Assembly procedure

Error code (5/9)

M-2 Failure code

Failure

Trouble

Controller Action code Caution Caution lamp buzzer

D1D1KB

Governor cut relay left short circuit

Short circuit (KB)

ENG

E01

D5ZFKA

N-signal 1

Disconnection (KA)

TM

E01

D5ZFKB

N-signal 1

Short circuit (KB)

TM

E01

D5ZFL4

N-signal abnormality

* See separate list (L4)

ENG

E01

D5ZGKA

N-signal 2

Disconnection (KA)

TM

E01

D5ZGKB

N-signal 2

Short circuit (KB)

TM

E01

D5ZKKX

Chassis throttle signal abnormality

Out of input signal range (KX)

D5ZRKA

Snap shot signal disconnection

Disconnection (KA)

ST

E00

D5ZRKB

Snap shot signal short circuit

Short circuit (KB)

ST

E00

DAFRKR

RTCDB abnormality

Defective communication (Objective component abnormality) (KR)

MON

CALL

DAQ0KK

Source voltage abnormality

Lowering of source voltage (input) (KK)

TM

CALL

DAQ0KT

Saved value abnormality

Internal defect of controller (KT)

TM

DAQ5KK

Potentiometer power supply abnormality

Lowering of source voltage (input) (KK)

TM

DAQ6KK

Sensor power supply abnormality

Lowering of source voltage (input) (KK)

TM

DAQ9KQ

“Model selection 1, 2, 3”

Disagreement of model selection signals (KQ)

TM

CALL

DAQRKR

RTCDB abnormality

Defective communication (Objective component abnormality) (KR)

TM

CALL

DAQSKR

Network abnormality

Defective communication (Objective component abnormality) (KR)

TM

DB30KK

Source voltage abnormality

Lowering of source voltage (input) (KK)

ST

DB30KT

Saved value abnormality

Internal defect of controller (KT)

ST

DB35KK

Potentiometer power supply abnormality

Lowering of source voltage (input) (KK)

ST

CALL

DB36KK

Sensor power supply abnormality

Lowering of source voltage (input) KK)

ST

DB39KQ

“Model selection 1, 2, 3”

Disagreement of model selection signals (KQ)

DB3RKR

RTCDB abnormality

DB3SKR

ⓦ

ⓦ

E03

ⓦ

ⓦ

E04

ⓦ

ⓦ

ⓦ

ⓦ

E04

ⓦ

ⓦ

E03

ⓦ

ⓦ

ⓦ

ⓦ

E03

ⓦ

ⓦ

CALL

E03

ⓦ

ⓦ

ST

CALL

E04

ⓦ

ⓦ

Defective communication (Objective component abnormality) (KR)

ST

CALL

E03

ⓦ

ⓦ

Network abnormality

Defective communication (Objective component abnormality) (KR)

ST

DB40KK

Source voltage abnormality

Lowering of source voltage (input) (KK)

ENG

CALL

E04

ⓦ

ⓦ

DB41KK

Switch power supply abnormality

Lowering of source voltage (input) (KK)

ENG

CALL

E03

ⓦ

ⓦ

DB42KK

Lowering of source voltage (input) Solenoid power supply 1 abnormality (KK)

ENG

CALL

E04

ⓦ

ⓦ

DB43KK

Backup power supply abnormality

Lowering of source voltage (input) (KK)

ENG

CALL

E03

ⓦ

ⓦ

DB44KK

Lowering of source voltage (input) Solenoid power supply 2 abnormality (KK)

ENG

CALL

E04

ⓦ

ⓦ

DB45KP

Rack sensor power supply abnormality Lowering of output voltage (KP)

ENG

CALL

E03

ⓦ

ⓦ

DB49KM

Connector wrong connection

Mistake in operation or setting (KM)

ENG

CALL

E04

ⓦ

ⓦ

Model selection abnormality

Disagreement of model selection signals (KQ)

ENG

E02

ⓦ

ⓦ

DB49KQ

109

ENG

CALL

E03

E01 CALL

E03 E01

E01 CALL

E04 E01

E01

Assembly procedure

Error code (6/9)

M-2 Failure code

Failure

Trouble

Controller Action code Caution Caution lamp buzzer

DBB0KK

VHMS supply constant voltage abnor- Lowering of power source voltage VHMS mality (KK)

DBB0KQ

VHMS contoroller abnormality

Disagreement of model selection signals (KQ)

VHMS

E00

DBB3KK

VHMS contoroller battery direct power Lowering of battery direct source source voltage (KK)

VHMS

E00

DBB5KP

5V power source for sensor abnormality Lowering of output voltage (KP)

VHMS

E00

DBB6KP

24V power source for sensor abnormality Lowering of output voltage (KP)

VHMS

E00

DBB7KP

12V power source for sensor abnormality Lowering of output voltage (KP)

VHMS

E00

DBBQKR

VHMS KOM-NET network abnormality Defective communication (KR)

VHMS

E00

DD12KA

Shift-up SW

Disconnection (KA)

TM

E02

ⓦ

ⓦ

DD12KB

Shift-up SW

Short circuit (KB)

TM

E02

ⓦ

ⓦ

DD13KA

Shift-down SW

Disconnection (KA)

TM

E02

ⓦ

ⓦ

DD13KB

Shift-down SW

Short circuit (KB)

TM

E02

ⓦ

ⓦ

DD14KA

Travel lock SW

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DD14KB

Travel lock SW

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

DDB9KA

Reverse SW

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DDB9KB

Reverse SW

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

DDK3KA

Forward SW

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DDK3KB

Forward SW

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

DDK5KA

Shift SW

Disconnection (KA)

TM

E02

ⓦ

ⓦ

DDK5KB

Shift SW

Short circuit (KB)

TM

E02

ⓦ

ⓦ

DDN2LD

PPC tilt right oil pressure SW

* See separate list (LD)

TM

E02

ⓦ

ⓦ

DDN3LD

PPC tilt left oil pressure SW

* See separate list (LD)

TM

E02

ⓦ

ⓦ

DDN7KA

Pitch SW

Disconnection (KA)

TM

E02

ⓦ

ⓦ

DDN7KB

Pitch SW

Short circuit (KB)

TM

E02

ⓦ

ⓦ

DDN9KA

Dual tilt SW

Disconnection (KA)

TM

E01

DDN9KB

Dual tilt SW

Short circuit (KB)

TM

E01

DDNALD

PPC lift raise full oil pressure SW

* See separate list (LD)

TM

E00

DDNBLD

PPC ripper raise oil pressure SW

* See separate list (LD)

TM

E00

DDNCLD

PPC ripper lower oil pressure SW

* See separate list (LD)

TM

E00

DDNDLD

PPC ripper tilt oil pressure SW

* See separate list (LD)

TM

E00

DDNELD

PPC ripper tilt back oil pressure SW

* See separate list (LD)

TM

E00

DDNFLD

PPC lift lower full oil pressure SW

* See separate list (LD)

TM

DDQ2KA

Travel lock SW

Disconnection (KA)

ST

CALL

E03

ⓦ

ⓦ

DDQ2KB

Travel lock SW

Short circuit (KB)

ST

CALL

E03

ⓦ

ⓦ

DDQ2L4

“Travel lock inconsistency 1, 2”

* See separate list (L4)

ST

CALL

E03

ⓦ

ⓦ

DDT5KA

Neutral SW

Disconnection (KA)

TM

CALL

E04

ⓦ

ⓦ

DDT5KB

Neutral SW

Short circuit (KB)

TM

CALL

E04

ⓦ

ⓦ

DDT5KQ

Lever specification selection error

Disagreement of model selection signals (KQ)

TM

CALL

E04

ⓦ

ⓦ

DGE1KB

Engine oil temperature sensor

Short circuit (KB)

VHMS

E00

DGE1KY

Engine oil temperature sensor

Disconnection (KY)

VHMS

E00

DGE2KX

Water temperature sensor abnormality Out of input signal range (KX)

ENG

E02

DGE3KA

Water temperature sensor abnormality Disconnection (KA) (Low temperature side)

ST

E01

DGE5KB

Atmospheric temperature sensor

VHMS

E00

Short circuit (KB)

110

E00

E00

Assembly procedure

Error code (7/9)

M-2 Failure code

Failure

Trouble Out of input signal range (KX)

Controller Action code Caution Caution lamp buzzer

DGS1KX

Hydraulic oil temperature sensor

TM

E00

DGT5KA

Left bank exhaust temperature sensor Disconnection (KA)

VHMS

E00

DGT5KB

Left bank exhaust temperature sensor Short circuit (KB)

VHMS

E00

DGT6KA

Right bank exhaust temperature sensor Disconnection (KA)

VHMS

E00

DGT6KB

Right bank exhaust temperature sensor Short circuit (KB)

VHMS

E00

DH22KA

Hydraulic oil pressure 1 (F) sensor

Disconnection (KA)

TM

E00

DH22KB

Hydraulic oil pressure 1 (F) sensor

Short circuit (KB)

TM

E00

DH23KA

Hydraulic oil pressure 2 (R) sensor

Disconnection (KA)

TM

E00

DH23KB

Hydraulic oil pressure 2 (R) sensor

Short circuit (KB)

TM

E00

DHE4KA

Engine oil pressure sensor

Disconnection (KA)

ST

E02

ⓦ

ⓦ

DHE4KB

Engine oil pressure sensor

Short circuit (KB)

ST

E02

ⓦ

ⓦ

DHE5KB

Blow-by pressure sensor

Disconnection (KB)

VHMS

E00

DHE5KY

Blow-by pressure sensor

Short circuit with power supply line VHMS (KY)

E00

DHT3KX

Transmission oil pressure sensor

Out of input signal range (KX)

VHMS

E00

DK01KA

Left yoke angle sensor

Disconnection (KA)

TM

E02

ⓦ

ⓦ

DK01KB

Left yoke angle sensor

Short circuit (KB)

TM

E02

ⓦ

ⓦ

DK03KA

Right yoke angle sensor

Disconnection (KA)

TM

E02

ⓦ

ⓦ

DK03KB

Right yoke angle sensor

Short circuit (KB)

TM

E02

ⓦ

ⓦ

DK10KX

Fuel control dial abnormality

Out of input signal range (KX)

ENG

CALL

E03

ⓦ

ⓦ

DK12KX

Deceleration potentiometer abnormality Out of input signal range (KX)

ENG

CALL

E03

ⓦ

ⓦ

DK30KA

Swing potentiometer 1 disconnection

Disconnection (KA)

ST

CALL

E03

ⓦ

ⓦ

DK30KB

Swing potentiometer 1 short circuit

Short circuit (KB)

ST

CALL

E03

ⓦ

ⓦ

DK30KX

Swing system 2 system

Out of input signal range (KX)

ST

CALL

E04

ⓦ

ⓦ

DK30KZ

Steering potentiometer abnormality

Disconnection or short circuit (KZ)

ST

CALL

E04

ⓦ

ⓦ

DK30L8

Swing potentiometer shifting

* See separate list (L8)

ST

CALL

E03

ⓦ

ⓦ

DK31KA

Swing potentiometer 2 disconnection

Disconnection (KA)

ST

CALL

E03

ⓦ

ⓦ

DK31KB

Swing potentiometer 2 short circuit

Short circuit (KB)

ST

CALL

E03

ⓦ

ⓦ

DK40KA

Brake potentiometer

Disconnection (KA)

ST

CALL

E03

ⓦ

ⓦ

DK40KB

Brake potentiometer

Short circuit (KB)

ST

CALL

E03

ⓦ

ⓦ

DK55KX

Forward-Reverse system 2 system

Out of input signal range (KX)

TM

CALL

E04

ⓦ

ⓦ

DK55KZ

Forward-Reverse potentiometer abnorDisconnection or short circuit (KZ) mality

TM

CALL

E04

ⓦ

ⓦ

DK55L8

Forward-Reverse potentiometer shifting and OK& potentiometer shifting when * See separate list (L8) key is turned ON

TM

CALL

E03

ⓦ

ⓦ

DK56KA

Forward-Reverse potentiometer 1 disDisconnection (KA) connection

TM

CALL

E03

ⓦ

ⓦ

DK56KB

Forward-Reverse potentiometer 1 short Short circuit (KB) circuit

TM

CALL

E03

ⓦ

ⓦ

DK57KA

Forward-Reverse potentiometer 2 disDisconnection (KA) connection

TM

CALL

E03

ⓦ

ⓦ

DK57KB

Forward-Reverse potentiometer 2 short Short circuit (KB) circuit

TM

CALL

E03

ⓦ

ⓦ

DK60KA

Acceleration sensor

Disconnection (KA)

ST

E01

DK60KB

Acceleration sensor

Short circuit (KB)

ST

E01

111

Assembly procedure

Error code (8/9)

M-2 Failure code

Failure

Trouble

Caution Caution Controller Action code lamp buzzer

DKF0KX

Fuel injection pump rack sensor

Out of input signal range (KX)

VHMS

DKF1KX

Rack sensor right abnormality

Out of input signal range (KX)

ENG

CALL

E03

ⓦ

ⓦ

DKF2KX

Rack sensor left abnormality

Out of input signal range (KX)

ENG

CALL

E03

ⓦ

ⓦ

DKH1KA

Pitch angle sensor

Disconnection (KA)

ST

CALL

E03

ⓦ

ⓦ

DKH1KB

Pitch angle sensor

Short circuit (KB)

ST

CALL

E03

ⓦ

ⓦ

DLE1KA

Engine speed sensor

Disconnection (KA)

ST

DLE4LC

Engine speed sensor A abnormality

* See separate list (LC)

ENG

CALL

E03

ⓦ

ⓦ

DLE5LC

Engine speed sensor B abnormality

* See separate list (LC)

ENG

CALL

E03

ⓦ

ⓦ

DLF1KA

Transmission speed sensor

Disconnection (KA)

DLT3KA

Transmission output shaft speed sensor Disconnection (KA)

DV00KB

Caution buzzer

Short circuit (KB)

E01

ⓦ

–

DW55KA

Pitch back solenoid

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DW55KB

Pitch back solenoid

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

DW56KA

Pitch dump solenoid

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DW56KB

Pitch dump solenoid

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

DW57KA

Left tilt limit solenoid

Disconnection (KA)

TM

E02

ⓦ

ⓦ

DW57KB

Left tilt limit solenoid

Short circuit (KB)

TM

E02

ⓦ

ⓦ

DW58KA

Right tilt limit solenoid

Disconnection (KA)

TM

E02

ⓦ

ⓦ

DW58KB

Right tilt limit solenoid

Short circuit (KB)

TM

E02

ⓦ

ⓦ

DW59KA

Dual tilt selection solenoid

Disconnection (KA)

TM

E01

DW59KB

Dual tilt selection solenoid

Short circuit (KB)

TM

E01

DW5AKA Pitch selection solenoid

Disconnection (KA)

TM

E02

ⓦ

ⓦ

DW5AKB Pitch selection solenoid

Short circuit (KB)

TM

E02

ⓦ

ⓦ

DW5DKA Pitch selection solenoid

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DW5DKB Pitch selection solenoid

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

DW7BKA Fan reverse solenoid

Disconnection (KA)

TM

E01

DW7BKB Fan reverse solenoid

Short circuit (KB)

TM

E01

DWJ0KA

Pump merge-divider solenoid

Disconnection (KA)

ST

CALL

E03

ⓦ

ⓦ

DWJ0KB

Pump merge-divider solenoid

Short circuit (KB)

ST

CALL

E03

ⓦ

ⓦ

DWN3KA Sudden stop prevention solenoid

Disconnection (KA)

ST

CALL

E04

ⓦ

ⓦ

DWN3KB Sudden stop prevention solenoid

Short circuit (KB)

ST

CALL

E04

ⓦ

ⓦ

DWN5KA Fan control solenoid 1

Disconnection (KA)

TM

E01

DWN5KB Fan control solenoid 1

Short circuit (KB)

TM

E01

DWNCKA Fan control solenoid 2

Disconnection (KA)

TM

E01

DWNCKB Fan control solenoid 2

Short circuit (KB)

TM

E01

DXE0KA

LS set selector solenoid (LSV)

Disconnection (KA)

TM

E02

ⓦ

ⓦ

DXE0KB

LS set selector solenoid (LSV)

Short circuit (KB)

TM

E02

ⓦ

ⓦ

DXH1KA

Lockup solenoid

Disconnection (KA)

TM

E01

DXH1KB

Lockup solenoid

Short circuit (KB)

TM

E01

DXH4KA

1st clutch ECMV

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DXH4KB

1st clutch ECMV

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

DXH5KA

2nd clutch ECMV

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DXH5KB

2nd clutch ECMV

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

DXH6KA

3rd clutch ECMV

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DXH6KB

3rd clutch ECMV

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

112

E00

E01

TM

E01

TM

E01

MON

Assembly procedure

Error code (9/9)

M-2 Failure code

Failure

Trouble

Caution Caution Controller Action code lamp buzzer

DXH7KA

Reverse clutch ECMV

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DXH7KB

Reverse clutch ECMV

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

DXH8KA

Forward clutch ECMV

Disconnection (KA)

TM

CALL

E03

ⓦ

ⓦ

DXH8KB

Forward clutch ECMV

Short circuit (KB)

TM

CALL

E03

ⓦ

ⓦ

DXH9KA

Right clutch ECMV

Disconnection (KA)

ST

CALL

E03

ⓦ

ⓦ

DXH9KB

Right clutch ECMV

Short circuit (KB)

ST

CALL

E03

ⓦ

ⓦ

DXHAKA Left clutch ECMV

Disconnection (KA)

ST

CALL

E03

ⓦ

ⓦ

DXHAKB

Left clutch ECMV

Short circuit (KB)

ST

CALL

E03

ⓦ

ⓦ

DXHBKA

Right brake ECMV

Disconnection (KA)

ST

CALL

E04

ⓦ

ⓦ

DXHBKB

Right brake ECMV

Short circuit (KB)

ST

CALL

E04

ⓦ

ⓦ

DXHCKA

Left brake ECMV

Disconnection (KA)

ST

CALL

E04

ⓦ

ⓦ

DXHCKB

Left brake ECMV

Short circuit (KB)

ST

CALL

E04

ⓦ

ⓦ

DXHDKA Governor solenoid right disconnection Disconnection (KA)

ENG

CALL

E04

ⓦ

ⓦ

DXHDKB

Governor solenoid right short circuit

Short circuit (KB)

ENG

CALL

E04

ⓦ

ⓦ

DXHEKA

Governor solenoid left disconnection

Disconnection (KA)

ENG

CALL

E04

ⓦ

ⓦ

DXHEKB

Governor solenoid left short circuit

Short circuit (KB)

ENG

CALL

E04

ⓦ

ⓦ

DXHFKA

Pre-stroke solenoid left disconnection Disconnection (KA)

ENG

CALL

E03

ⓦ

ⓦ

DXHFKB

Pre-stroke solenoid left short circuit

ENG

CALL

E03

ⓦ

ⓦ

DXHGKA Pre-stroke solenoid left disconnection Disconnection (KA)

ENG

CALL

E03

ⓦ

ⓦ

DXHGKB Pre-stroke solenoid left short circuit

Short circuit (KB)

ENG

CALL

E03

ⓦ

ⓦ

F@BBZL

Over pressure (ZL)

Blow-by pressure sensor abnormality

Short circuit (KB)

VHMS

E00

Left bank exhaust temperature sensor F@BYNR (2) abnormality Abnormal heating (NR)

VHMS

E00

Left bank exhaust temperature sensor F@BYNS (1) abnormality Overheating (NS)

VHMS

E00

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

VHMS

E00

Right bank exhaust temperature sensor F@BZNS (1) abnormality Overheating (NS)

VHMS

E00

113

Assembly procedure

Flushing of hydraulic circuit

M-3

After finishing assembly, flush the hydraulic circuit.

(1) Run the engine at low idling with the lever in neutral for 30 minutes.

(2) Run the engine at medium speed with the lever in neutral for 30 minutes.

(3) Run the engine at about 1,700 rpm and operate the levers (Hold the lever for 1 minute - 1minute 30 seconds in each operation). Repeat the following operation pattern 4 times.

Raise blade ➞

➞

Lower blade ➞

Raise ripper ➞

Tilt blade to left ➞

Lower ripper

➞

Precautions

Tilt ripper in ➞

Necessary tools Name

Note • When the atmospheric temperature is below –15°C, install the valve and strainer (without installing oil stopper plate and flush the piping with the engine speed at low idling.

• Flushing is performed to separate dirt from the hydraulic oil. Install the flushing element (See A-21 (1/3)) and perform the work in this section to separate the dirt.

Tilt blade to right

Other remarks

114

Tilt ripper back

Necessary equipment Q’ty

Name

Q’ty

APPENDIX 1.

INSTALLATION OF SPILL GUARDS

DESCRIPTION 1. Introduction When installing the spill guards in field, refer to the installation procedure described in this installation procedure.

2. Additional parts Blade Semi-U

Full-U

Superdozer

Part No.

Part Name

Q‘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

05

08

PLATE

PLATE

PLATE

03 04

PLATE

PLATE

02

06

PLATE

01

07

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 Part Name PLATE PLATE PLATE PLATE

Sym. 01 02 03 04

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

04

PLATE PLATE PLATE

13 14 15

PLATE PLATE

PLATE 11

PLATE

09 10

12

PLATE PLATE

07 08

PLATE

PLATE

03

PLATE

PLATE

02

05

PLATE

01

06

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

04

PLATE PLATE PLATE

13 14 15

PLATE PLATE

PLATE 11

PLATE

09 10

12

PLATE PLATE

07 08

PLATE

PLATE

03

PLATE

PLATE

02

05

PLATE

01

06

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 Part Name PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE

Sym. 01 02 03 04 05 06 07 08 09

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 Part Name PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE PLATE

Sym. 01 02 03 04 05 06 07 08 09

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 - 350°C for 30 - 60 minutes.

4-3-6

Preheat the area about 50 mm from the beat to be laid at 150 - 200°C. When the ambient temperature is below 10°C, post-heat the same area, too, at 150 - 200°C.

4-3-7

Set the welding current to the lower limit of the current range specified for the diameter of the welding rod or wire.

4.3.8

When performing multi-layer welding, weave the welding rod.

4.3.9

Do not weld by letting the melted metal flow, but weld from below to above with sufficient penetration. Keep the arc length as short as possible, and take care not to make an overlap, undercut, etc.

4.3.10 Before welding the spill guard, remove all the paint (or rust) from the parts to be welded with a grinder. Then, perform tack welding, permanent welding and finishing in order.

4.3.11 Connect the ground cable to a part of the blade where paint is removed or a part where the ground cable can be connected securely electrically.

(Remark) If a painted part is welded, hydrogen in the paint will be mixed in the welded part, and that can cause cold cracking.

14

APPENDIX 2.

PRECAUTIONS FOR INITIALIZATION PROCEDURES FOR VHMS CONTROLLER

1

PRECAUTIONS FOR INITIALIZATION OF VHMS CONTROLLER AND ORBCOMM TERMINAL (OPTIONAL) When a machine equipped with VHMS controller is delivered to a customer,

Delivery of machine equipped with VHMS controller

Step 1) Notify the machine information for registration in WebCARE. Application for registration in WebCARE If you have not registered an ID for reading WebCARE, Application for registration of WebCARE user Step 2) When installing an ORBCOMM communication terminal optionally, notify the terminal information.

Request for opening ORBCOMM (optional) terminal Step 3) Initialize the VHMS controller.

Step 4) Initialize the ORBCOMM communication terminal.

Step 5) Send the check sheet after initialization.

Check sheet for VHMS controller initialization Check sheet for ORBCOMM initialization Step 6) Send the first downloaded data by E-mail.

2

1. Registration of WebCARE machine information • •

Fill the attached "Application for registration in WebCARE" and send it to VHMS/WebCARE Global Support Center.

The model name, serial No., customer information, etc. will be registered in the WebCARE server of the support center.

a If you have not obtained an ID and a password for reading WebCARE, fill the attached "Application for registration of WebCARE user" and send it to VHMS/WebCARE Global Support Center.

After you are registered, your ID and password will be sent you.

Komatsu’s distributor

Application for registration in WebCARE

Application

Komatsu VHMS/WebCARE Support center

Server Registration Model Serial No. User etc.

3

2. Application for opening ORBCOMM terminal (Optional) • • • •

If the ORBCOMM is installed optionally, an application for opening a communication terminal is necessary.

The "Request for opening ORBCOMM terminal" and "terminal part No. seal" (which is the same as one stuck to the terminal) are packed together with the terminal or the machine.

Stick the seal to the request and fill it, and then send it to KOMTRAX Service Hot Line.

After a contract is made with ORBCOMM Co., Ltd., the date of opening the terminal will be notified.

IMPORTANT:

It takes 1 – 2 weeks to make a contract with ORBCOMM Co., Ltd. after the application is received. Keep the antenna removed and do not set the terminal until the date of opening the terminal is notified.

Komatsu’s distributor

ORBCOMM terminal Komatsu Solution Division

Seal having serial No. of controller

Request for opening ORBCOMM terminal Komatsu KOMTRAX Service Hot Line

Making of contract with ORBCOMM Co., Ltd.

1 to 2 weeks

4

•

Set the ORBCOMM terminal after the date of opening the terminal.

Case 1: Procedure for operating the machine before opening the terminal Step 1) Initialize only the VHMS controller.

VHMS controller

Remove the antenna and fit the cap to the connector.

Never set the communication system before making contract with ORBCOMM.

Step 2) After receiving notification of date of opening the terminal (After that date), set ORBCOMM.

ORBCOMM terminal

Connection of antenna

Case 2:Procedure for operating the machine after opening the terminal Initialize of both VHMS controller and ORBCOMM simultaneously.

VHMS controller

5

ORBCOMM terminal

3. Preparation of tools and items to be executed after initialization (IMPORTANT) a A cable to connect a personal computer and the VHMS controller is necessary for setting VHMS/ORBCOMM. Purchase and prepare it. a A setting program to be installed to the personal computer is also necessary. (This program is contained in the VHMS analysis tool software.) Purchase the VHMS analysis tool software.

Service kit Components • Analysis tool CD & FD • Cable 1) 2) 3) 4)

799-608-3101 799-608-3211 799-608-3220

The initialization procedures of VHMS controller are entered in the Shop Manual for each model.

Initialize the VHMS controller according the Shop Manual or the field assembly manual.

Fax the check sheet filled when the VHMS controller is initialized.

When performing step 3) above, send the first setting downloaded data to VHMS/WebCARE Global Support Center by E-mail.

Komatsu VHMS/WebCARE Support Center 2-3-6, Akasaka Minato-ku Tokyo, Japan FAX: 81-3-5561-4766 (from outside of Japan) webcare@komatsu.co.jp

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PLACE TO STORE DOWNLOADED DATA 1. Open the "VHMS_DATA" icon in drive C (or the drive specified when the software was installed).

2. Open the icon of the applicable model. Next, open the icon of the serial No., and then open the icon of the date and time of downloading.

Example: D475

Example: Serial No.20002

Example: Sept. 4, 2003

Caution: All of the files downloaded today are stored in the icons.

The icon of the largest number has the latest file.

3. After finishing initialization and downloading the data, send all the files in this icon by E-mail.

7

METHOD OF INSTALLING VHMS SETTING TOOL 1. Insert the CD-ROM in the CD drive, and installation of the analysis tool is started automatically. Perform the shown procedures, and the analysis tool icon is made on the desktop.

Now, installation of the analysis (including download and FTP) tool is completed.

2. Insert the CD-ROM again, and installation of the analysis tool is started automatically again. When the following screen is displayed, click "Cancel" and interrupt the operation by clicking "Exit Setup".

8

3. Select the drive of the CD-ROM by "My computer" (or "Explorer") and click "Open". a Do not double-click.

4. Select and open the "Setting Tool" icon.

5. Click "Set up.EXE".

6. Installation of the setting tool is started automatically and the icon is made on the desktop. Now, installation of the setting tool is completed.

9

INITIALIZATION PROCEDURES FOR VHMS CONTROLLER a Initialization tools for VHMS controller Symbol 1 W 2

Part No.

a The VHMS controller and ORBCOMM terminal are in the VHMS controller box under the left side cover of the floor.

Part name

799-608-3101

Service kit

799-608-3211

• Diskette

799-608-3220

• Wiring harness

Commercially available

Notebook type personal computer (OS: Windows98/2000/ NT/Me/XP)

a Before starting 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. a 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 s et 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.

Be sure to perform the initialization. a For method of installation for the VHMS Initialization Program to a personal computer, refer to the Operation and Maintenance Manual contained in the W1 service kit package. a The initialization procedures cover both "ORBCOMM Specification" and "ORBCOMMLESS Specification". In case of "ORBCOMMLESS" Specification", omit the procedures necessary for "ORBCOMM Specification" only. a During the initialization work, make necessary confirmations for each work according to the "VHMS Initialization Work Checklist".

2. Connection of personal computer 1) Make sure the starting switch is turned to the OFF position. k Be sure to connect and disconnect the personal computer while the starting switch is turned to the OFF position.

2) Connect the personal computer W2 and the download connectors DL1 and VDW with wiring harness [1] of service kit W1. a The download connectors are installed to the following places.

• VDW: Inside of cab (Left rear lower part) • DL1: Rear side of chassis (Hull frame) a Connect the personal computer to the RS232C terminal.

1. Check of machine information, engine information, and controller information a This step applied to works on the whole machine.

Check and record the machine information, engine information, VHMS controller information, and ORBCOMM terminal information.

Information to be checked No. Information

Remarks

1

Machine model

2

Machine serial No.

5 digits

3

Engine serial No.

6 digits

4

Transmission serial No.

6 digits

5

VHMS controller serial No.

5 digits

6

ORBCOMM terminal serial No. 11 digits [For only ORBCOMM specification]

10

4. Startup of VHMS initialization tool 1) Switch on the personal computer and start the OS. 2) Click the icon of [VHMS Initialization Tool] on the personal computer screen to start the VHMS initialization tool.

3) Input the 10-digit service ID in [Service ID]. a Service ID: 7826113000 4) Select [Data clear and Set up] in the [Select Function] column.

5) Press the [OK] button to shift to the setup screen.

3. Performance check of VHMS controller 1) Set the starting switch to the ON position.

2) Select "Service mode" and "Real-time monitoring mode" in order on the monitor panel.

3) Input ID = 20300.

4) If the central part of the lower line of the multi-information display unit counts up, the VHMS controller is normal.

11

5. Performance check of ORBCOMM terminal [For only ORBCOMM specification] 1) 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.

2) 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. i) Set the starting switch to the ON position. ii) For monitor panel specification: Referring to 10 "Real-time monitoring mode" or 11 "Dual display monitoring mode" above, input ID = 20300.

Decimal point at right bottom

Indication

OFF

Power is not applied to ORBCOMM controller.

ON

Satellite is not captured.

Quick flashing

ORBCOMM controller does not have transmission data.Satellite is captured.

Slow flashing

ORBCOMM controller has transmission data.Satellite is captured.

6. Initialization of VHMS controller [Machine information] 1) Open the [Machine information] tab. a The [Machine information] tab is displayed first in the [Data clear and Set up] menu.

2) Check all the data.

3) 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 multi-information display unit.

3) When information in the [Date/Time] box is not correct, change it according to the following procedures: i) Click on [Edit] (1) located in the right lower part of the [Date/Time] box to display the correction screen. ii) Correct the information, then click [OK].

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4) When information in the [Machine information] box is not correct, change it according to the following procedures: i) Click on [Edit] (2) located in the right lower part of the [Machine information] box to display the correction screen. ii) Correct the information, then click [OK].

[For ORBCOMM specification only] a Set the ORBCOMM terminal after the date of opening the terminal.

1) Open the VHMS Setting Tool according to the procedure for "Start of VHMS initialization tool".

2) Open the [Communication Setting] tab.

5) After checking and changing all the data in [Machine information], click on the [Apply] (3) to apply the settings. a Click [Apply] (3), the screen for checking the settings will appear. Recheck the settings and click [OK] when all the settings are correct. a In case of the ORBCOMM Specification, execute [Communication Setting] and settle it.

3) To change setting in [SHORT FAULT HISTRY], follow the procedure below: i) Select [SHORT FAULT HISTRY] on the screen and click [Edit] (5) located in the left lower part of the [File Transfer Setting] block to display the setting screen. ii) Change the settings, then click [OK]. a At initialization, select [Occurrence] at [Timing] screen, and set the function to [ON].

6) After checking/changing the data of [Machine Information], click [Exit] (4) to finish [VHMS Initialization Tool].

4) To change setting in [SHORT TREND ANALYSIS], follow the procedures below: i) Select [SHORT TREND ANALYSIS] on the screen and click [Edit] (5) located in the left lower part of the [File Transfer Setting] block to display the setting screen. ii) Change the settings, then click [OK].

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a At initialization, select [20h] at [SMR] screen, and set the function to [ON].

5) To change the setting of [Satellite Setting], follow the procedure below: (Important) i) Click [Edit] (6) in the [Satellite Setting] block to display the setting screen. ii) Bring GCC Code to the applicable area, then click [OK].

[Exit] 7) After checking/changing the data of [Communication Setting], click [Exit] (8) to finish [VHMS Initialization Tool].

GCC Code and Application Area Code

Applicable Area

1

U.S.A.

120

Italy

121

Malaysia

122

Korea

123

Brazil

130

Japan

6) After checking and changing all data in the [Communication Setting], click [Apply] (7) to apply the settings. a Click [Apply] (3), the screen for checking the settings will appear. Recheck the settings and click [OK] when all the settings are correct.

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PROCEDURES FOR EXECUTING QUICK PM a The Quick Pm means the Pm Clinic executed with the snap shot function of the monitor panel. k Stop the machine on a flat place.

1. Start the engine.

2. Set the monitor panel to display the service menu. a For the operating method, see "Special functions of monitor panel".

3. Mode selection and excution 1) Select "Snap shot mode" on the mode selection screen. a If the mode is selected, code (55) is displayed in gear speed display unit (1) and the title is displayed in multi-information unit (2).

2) Set the buzzer cancel switch in the [U] position.

3) "READY" is displayed as shown in the figure and the system is ready to start.

4) If the buzzer cancel switch is set in the [U] position, the snap shot function starts. a After the snap shot function is started, the elapsed time is displayed. a On the lower line, 1 " " is added every 30 seconds. While multiple " " are displayed, the one at the right end flashes. a To interrupt the snap shot function, set the buzzer cancel switch in the [t] position.

15

Time (sec)

Finish

Start

No.

5) After starting the snap shot function, operate the machine according to Table 1. a Check that the engine coolant and torque converter oil temperatures are in operating range. a After 10 " " are displayed (After 5 minutes), "#" is added up to 5.

• " ": The data sampling interval is 10 seconds.

• "#": The data sampling interval is 1 second.

1

0:00 0:30 30

2

0:30 1:00 30

3

1:00 2:00 60

4 5

Operation of machine State of machine

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

2:00 3:00 60 Deceleration slow

N

N

N

HI

LOW

Released Released

3:00 3:30 30

High-pressure relief & high idling

N

N

HI

HI

Released Released

6

3:30 4:00 30

High-pressure relief & low idling

N

N

Right tilt (or pitch back in case of dual tilt model)

LOW

HI

Released Released

7

4:00 4:30 30

Port relief & high idling

N

N

8

4:30 5:00 30

Port relief & low idling

N

9

5:00 5:30 30

Torque converter stall & low idling

10 5:30 6:00 30

Low idling High idling

HI

HI

Released Released

N

Left tilt (or pitch dump in case of dual tilt model)

LOW

HI

Released Released

NoF1oF2oF3o NoR1oR2oR3 oN

N

N

LOW

HI

ON

Released

Torque converter stall (F3) & high idling (Note 1)

NoF3 (Shift to F3, then run engine at full throttle)

N

N

HI

LOWo Shift to F3, then HI

ON

Released

11 6:00 6:30 30

High idling

N

N

N

HI

HI

12 6:30 7:00 30

Torque converter stall + High-pressure relief

NoF3 (Shift to F3, then run engine at high idling)

N

Left tilt (or pitch dump in case of dual tilt model)

HI

LOWo Shift to F3, then HI

ON

Released

13 7:00 7:30 30

High idlingo Low idling (Note 2)

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 idling until the oil temperature is lowered to the normal level. a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine speed to high idling. a After stalling the torque converter, watch the power train oil temperature gauge and take care not to overheat the power train oil.

(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the engine at high idling to lower the oil temperature.)

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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)

8) Open the data of the Quick Pm and translate them into a graph. a Set the time to the X-axis and set the following items to the Y-axis.

• Engine Speed • Fuel Inject • 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 (Transmission, travel, gear 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)

Important The data of the Quick Pm is recorded on 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. 7) Using the analysis tool, read the data of the Quick Pm. a For the usage of the analysis tool, see the operation manual.

17

9) Check "Click position graphic value display".

18

10) Click a point in the graph, and the value of each measurement item at that point on the X-axis is displayed under the graph.

(Example of displayed graph: This is different from the actual graph.)

19

11) Enter the above value in the Pm Clinic Inspection Sheet. a The relationship between the data necessary for the Pm Clinic and the measurement conditions is as follows.

Engine at high idling

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

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Q

Engine at full throttle Torque converter stall & high-pressure relief

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 idling

Front clutch fill switch

Transmission main relief pressure

Exhaust temperature

Blow-by pressure

Engine speed

State of machine

Engine oil pressure

Measurement items

Q

Engine at high idling o Engine at low idling

20

4. Downloading of Set Data 1) Turn the starting switch to the ON position.

2) Click the icon of [VHMS Technical Analysis Tool] on the personal computer to start the VHMS analysis tool.

5. Check of Downloaded Data a This step applies to works in the cab (on the personal computer).

1) Check the set data with [View] function. a For the operation procedures, refer to the Operation and Maintenance Manual for VHMS Technological Analysis Tool. a Make sure that the [MFA0] code at the time of snapshot is displayed in [Fault History]. a Make sure that the SNAPSHOT data has been recorded.

a Input [User Name] and [Password]. a For the operation procedures, refer to the Operation and Maintenance Manual for VHMS Technological Analysis Tool.

2) After having checked the set data, terminate [VHMS Technical Analysis Tool].

6. Disconnection of Personal Computer 1) Make sure the starting switch is turned to the OFF position. k Be sure to turn off the starting switch before connecting or disconnecting the personal computer.

2) Terminate the OS of the personal computer and switch off the personal computer.

3) Disconnect the wiring harness [1] of the service kit W1 from the download connectors VDW and DL1.

3) Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. a For the operation procedures, refer to the Operation and Maintenance Manual for VHMS Technological Analysis Tool. a Make sure that the downloading has completed before proceeding to the next step.

21

7. Communication to Komatsu After having completed Steps 1 to 15 successfully, please send the check sheet and the VHMS data to VHMS/WebCARE Support Center of Komatsu, Tokyo. a Since Komatsu has to arrange the setting for satellite communication on the receiving side, please be sure to inform Komatsu of the completion of the setting. a Fax the check sheet to Komatsu. a Send the VHMS data by Notes (LAN) or Email (WAN).

Contact VHMS/WebCARE Support Center by Telephone: 81-3-5561-2765 FAX: 81-3-5561-4766 E-mail: webcare@komatsu.co.jp

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23

24

25

26

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U-dozer specification 1/5 Report No.

FIELD ASSEMBLY INSPECTION REPORT (For Full U-dozer or Semi U-dozer) After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.

Model-Type

Machine Serial No.

User Unit No.

Engine Model

D475A-5 Service Meter Reading

Engine Serial No.

SDA12V140 Date of Inspection

Specification

Location of Machine at Inspection

Distributor’s Name

Blade

U

Semi U

(Dual

Ripper or counterweight

VGR.

VMR.

CW (

Shoe width

910 mm

810 mm

Single) )

710 mm

Others Customer’s name

Address

Signature :

Delivery Report No. attached

Date :

Inspector’s Comments

Inspector’s Name Title

KOMATSU USE ONLY

:

C. Sheet Receiving Date

:

By

:

Remark :

Signature :

Check sheets filling instruction : 1. Use following indexes for entry of judgement ✓ .......... Normal ✕ .......... Abnormal

2. Enter actually measured values in parenthese, [

✕ .......... Correction made on abnormal point ........... Not applied

].

Note : (1) Criteria are based on the standards when the machine is shipped out of the factory

q Distributor copy

Printed in Japan

U-dozer specification 3/5 Category

Inspection Item

Inspection

Main radiator coolant level

Criteria Above the bottom surface

Main radiator Sub-radiator Strainer

Sub radiator coolant level

Full

Reserve tank coolant level

(H+L)/2 to (H+10)

Engine oil level

(H+L)/2 to (H+15)

Engine : Stopped

Power train oil level

L to (H+20)

Engine : Low idling

Damper case oil level

(H+L)/2 to (H+10)

Strainer

COOLANT AND OIL LEVEL

(After 3 to 5 minutes)

Refer to Operation & Maintenance Manual

Hydraulic tank oil level • Between H - L Final draive oil level

LH

Center to upper level Pitch back on the ground. of sight gauge Ripper point on the ground.

Engine : stopped H to (H–20)

RH Oil level

Pivot shaft oil level

LH

Engine : Stopped

See operation manual.

Engine : stopped

(H+10) to (H+30) from shaft end

See operation manual.

a=100 ± 10

See operation manual.

RH Recoil spring oil level

LH RH

Battery electrolyte level Check battery

Between L and H

Window washer tank water level

INSPECTION

Must be no adhesion of grease, loosened terminal, or crack

UPPER LEVEL LOWER LEVEL

LH

Full

Fuel tank

Full (1670 ¬)

Horn

Must be of no beat sound or sound deterioration.

Backup alarm (Starting engine)

Backup alarm must sound when the transmission lever is at the back position.

Monitor display

Monitor must be turned on with buzzer sound, then go off after 3 seconds. After that all gauge lamps must come on.

Operation of service meter (Engine: Low idling)

No error code indicated in the service meter.

Before engine start, meter must not operate when the key switch turned on.

Charge lamp (Engine: Low ilding)

Must not light up when all lamps are turned on.

Lamp ON (Head lamp, tail lamp and work lamp)

Must light up when turned on.

Preheating switch

Preheating lamp (green) must light up

(Auto preheating when at ON position) (Manual preheating when turned to left)

Main corrosion resistor cock

Must be fully open.

Sub corrosion resistor cock

Must be fully open.

Heater hose cock

Must be fully open.

Controller error code indication (make sure that error does not recur)

Clear error code after confirming it.

Air bleeding of the hydraulic cylinder

Perform air bleeding of the hydraulic cylinder

Measurement of cab pressurization

Max. 0.10 kPa {10 mm Aq.} (If pressure is below standard value, adjust it, referring to M-1, pages 4/7 - 7/7.)

Confirmation of VHMS controller initialization

Must be done.

q Distributor copy

U-dozer specification 5/5 Category

Inspection Item

Inspection

Parking lever

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

The engine must not be started when the parking lever is free.

FUNCTION / OPERATION

Operability of the travel lever • Gear change

Must be of no pinching or abnormal sound.

Notch must not be released.

• Forward-reverse

Must be of no pinching or abnormal sound.

Must return to the N position smoothly.

• Steering (right/left) Play of the lever at “N” position

Max. 10 mm

Check of the gear speed indication on the monitor panel.

N, F1, F2, F3, R1, R2 and R3 are indicated.

• Must be able to be shifted to any position with the engine at low idling and the brake turned on.

Must be no indication error.

Check of front/rear adjustment of the travel lever box • 10-level position adjustment

Must be adjustable.

• Check of the box lock (up/down)

Must not move after locking.

Free Case

Lock

Case

Check of the deceleration pedal operation

Must work smoothly.

• Set the fuel dial to high idle position.

Play of pedal A required at high idle position.

• Check the deceleration RPM

900 ± 50 rpm

Check of the fuel dial operation

Must move smoothly.

Check of tilt direction RH tilt LH tilt

RH tilt

Blade must move to left Blade must move to right

LH tilt

DUAL

Check of dual tilt and pitch direction Check of tilt direction

Pitch back

Blade must move backward. D + B

Pitch dump

Blade must move forward. D + A

LH dual tilt

Blade must move to left (both cylinders move) a + B

RH dual tilt

Blade must move to right (both cylinders move) a + A

LH tilt

Blade must move to left (right cylinder moves) B + b

RH tilt

Blade must move to right (left cylinder moves) A + b

Check of tilting restriction adjustment • Measure tilting angle at the top of the cutting edge when the tilting limit switch is turned on.

q Distributor copy

Note: See manual of tilting restriction.

LH tilt

12 ± 1°

RH tilt

12 ± 1°

U-dozer specification 7/5 Category

Inspection Item

WORK EQUIPMENT

Check of the clearance between frame and track

Inspection LH RH

Move Blade up and down and stop 100 mm above ground, and then measure.

Check of the safety lever lock function

No actuator must work when the safety lock lever is at ON position (Lever can move but work equipment must not move)

Check of the blade lever floating

Must be of no hydraulic drift (Engine: Low idling)

Check of the blade lever floating notch release

Engine stops at floating, then notch must be released.

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 ilding)

Must be bridged with the blade and the ripper (Chassis)

Check of the accumulator function (blade, ripper)

Must function immediately after the engine stops then drop from the top to the ground.

Blade cylinder oil leakage

Must be none.

• Leakage from U-packing, damaged rod, quick drop valve, tube, flange or dust seal

LH RH

Tilt cylinder/pitch cylinder oil leakage • Leakage from U-packing, damaged rod, tube, flange or dust seal

Must be none.

LH RH

Track tension adjustment

UNDERCARRIAGE

Criteria Difference of LH and RH is max. 30 mm (Measure on flat ground)

• With the gear at F1 and the engine at low idling, 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.

LH RH

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.

LH

Flanges must be free from contact with links at all times.

RH

Undercarriage oil leakage • Leakage from idler, carrier roller, bogie, pivot shaft, adjustment cylinder, and lubricated track (plug, seal)

• Tense a string or a bar between the first carrier roller and the idler to measure distance between the 20 – 30 mm string (bar) and the grouser.

(Difference between LH and RH : Max. 20 mm) • Target is 30 mm when new.

20 – 30 mm

Must be none.

LH RH

Beat noise inside the cabin, beat noise of the outer cover

Must be none.

Opening/closing and locking effect of the cabin doors.

Must work smoothly to securely lock the doors by door-locking or key-locking.

Cabin door-open lock release lever

Must work smoothly to securely lock

Opening/closing and locking effect of the left/right side slide glass

Must work smoothly to securely lock.

Lighting of the room lamp

Must come on/go off by turning the switch on/off.

Operation of the window wiper and the window washer

Must be on/off by turning the switch on/off.

Operation of the radio and cassette system

Must operate correctly

CABIN

Wiper: Must operate smoothly (without beat noise) (Volume, tuning, AM/FM switching, cassette) Operation of the cigar lighter

Must be red-heated.

Ash tray installation

Must be installed.

Power supply of 12 V

Power of 12 V must be supplied.

• Check by connecting the radio unit Operation of the air conditioner

Cold and warm air must be able to be switched by monitor operation.

Air flow amount must be able to be adjusted

Air flow amount must be able to be adjusted (Hi, Mid or Lo) • Louver must be smoothly switched

q Distributor copy

Air comes out from each blowout port.

U-dozer specification 9/5 Category

Inspection Item

Inspection

LUBRICATION

Portions to be lubricated

Criteria Q’ty

• Equalizer bar side pin shaft

Example: U blade

2

• Equalizer bar center pin shaft

1

• Blade lift cylinder support shaft and yoke

6

• Blade center pin

1

• Blade oblique arm ball joint

3

• Brace screw

2

Check of ripper direction a Raise c Lower A Tilt in B Tilt out

Ripper lift cylinder oil leakage

Must be none

• U-packing, damaged rod, tube, flange, dust seal loosing

LH RH

Ripper tilt cylinder oil leakage

Must be of no contact.

• U-packing, damaged rod, tube, flange, dust seal loosing

LH RH

Contact with the hose at ripper operation

Must be of no contact.

RIPPER

• Entire operation area must be chedked Creak of the ripper link pin

Must be of no creak.

Check of the pin puller switch direction

Must be the same as the pin puller cylinder operation direction

A: Pin out B: Pin in

Check of the pin puller cylinder hose clamp position

Must be of no contact

(Entire operation area must be checked)

Must be of no excess hose tension.

Pin puller cylinder oil leakage

Must be none

• Leakage from U-packing, damaged rod, tube or flange Check of ripper lubricated hose installation

LH

Must be no contact or no excess bend.

RH Portions to be lubricated

Q’ty

• Ripper lift cylinder head

i

2

• Ripper lift cylinder bottom

y

2

• Ripper tilt cylinder head

u

2

• Ripper tilt cylinder bottom

t

2

• Ripper arm pin (front)

o

2

• Ripper arm pin (rear)

!0

2

q Distributor copy

Must be lubricated (right and left)

Superdozer specification 1/5 Report No.

FIELD ASSEMBLY INSPECTION REPORT After completion of a machine, make inspections according to these check sheets for assuring machine performance nad quality.

Model-Type

Machine Serial No.

User Unit No.

Engine Model

D475A-5 Service Meter Reading

Engine Serial No.

SDA12V140 Date of Inspection

Specification

Location of Machine at Inspection

Distributor’s Name

Blade

Super.

Ripper or counterweight

VGR.

VMR.

Shoe width

910 mm

810 mm

CW (

)

Others Customer’s name

Address

Signature :

Delivery Report No. attached

Date :

Inspector’s Comments

Inspector’s Name Title

KOMATSU USE ONLY

:

C. Sheet Receiving Date

:

By

:

Remark :

Signature :

Check sheets filling instruction : 1. Use following indexes for entry of judgement ✓ .......... Normal ✕ .......... Abnormal

2. Enter actually measured values in parenthese, [

✕ .......... Correction made on abnormal point ........... Not applied

].

Note : (1) Criteria are based on the standards when the machine is shipped out of the factory

q Distributor copy

Printed in Japan

Superdozer specification 3/5 Category

Inspection Item

Inspection

Main radiator coolant level

Criteria Above the bottom surface

Main radiator Sub-radiator Strainer

Sub radiator coolant level

Full

Reserve tank coolant level

(H+L)/2 to (H+10)

Engine oil level

(H+L)/2 to (H+15)

Engine : Stopped

Power train oil level

L to (H+20)

Engine : Low idling

Damper case oil level

(H+L)/2 to (H+10)

Strainer

(After 3 to 5 minutes)

Refer to Operation & Maintenance Manual

COOLANT AND OIL LEVEL

Hydraulic tank oil level • Between H - L Final draive oil level

LH

Center to upper level Pitch back on the ground. of sight gauge Ripper point on the ground.

Engine : stopped H to (H–20)

RH Oil level

Pivot shaft oil level

LH

Engine : Stopped

See operation manual.

Engine : stopped

(H+10) to (H+30) from shaft end

See operation manual.

a=100 ± 10

See operation manual.

RH Recoil spring oil level

LH RH

Battery electrolyte level Check battery

Between L and H

Window washer tank water level

INSPECTION

Must be no adhesion of grease, loosened terminal, or crack

UPPER LEVEL LOWER LEVEL

LH

Full

Fuel tank

Full (1670 ¬)

Horn

Must be of no beat sound or sound deterioration.

Backup alarm (Starting engine)

Backup alarm must sound when the transmission lever is at the back position.

Monitor display

Monitor must be turned on with buzzer sound, then go off after 3 seconds. After that all gauge lamps must come on.

Operation of service meter (Engine: Low idling)

No error code indicated in the service meter.

Before engine start, meter must not operate when the key switch turned on.

Charge lamp (Engine: Low ilding)

Must not light up when all lamps are turned on.

Lamp ON (Head lamp, tail lamp and work lamp)

Must light up when turned on.

Preheating switch

Preheating lamp (green) must light up

(Auto preheating when at ON position) (Manual preheating when turned to left)

Main corrosion resistor cock

Must be fully open.

Sub corrosion resistor cock

Must be fully open.

Heater hose cock

Must be fully open.

Controller error code indication (make sure that error does not recur)

Clear error code after confirming it.

Air bleeding of the hydraulic cylinder

Perform air bleeding of the hydraulic cylinder

Measurement of cab pressurization

Max. 0.10 kPa {10 mm Aq.} (If pressure is below standard value, adjust it, referring to M-1, pages 4/7 - 7/7.)

Confirmation of VHMS controller initialization

Must be done.

q Distributor copy

Superdozer specification 5/5 Category

Inspection Item

Inspection

Parking lever

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

The engine must not be started when the parking lever is free.

Operability of the travel lever • Gear change

Must be of no pinching or abnormal sound.

Notch must not be released.

• Forward-reverse

Must be of no pinching or abnormal sound.

Must return to the N position smoothly.

• Steering (right/left) Play of the lever at “N” position

Max. 10 mm

Check of the gear speed indication on the monitor panel.

N, F1, F2, F3, R1, R2 and R3 are indicated.

• Must be able to be shifted to any position with the engine at low idling and the brake turned on.

Must be no indication error.

Check of front/rear adjustment of the travel lever box • 10-level position adjustment

Must be adjustable.

• Check of the box lock (up/down)

Must not move after locking.

Free

FUNCTION / OPERATION

Lock

Case

Case

Check of the deceleration pedal operation

Must work smoothly.

• Set the fuel dial to high idle position.

Play of pedal A required at high idle position.

• Check the deceleration RPM

900 ± 50 rpm

Check of the fuel dial operation

Must move smoothly.

Pitch backward

Check of pitch direction Pitch dump Pitch back

Blade must move backward smoothly.

Pitch forward

Blade must move forward smoothly.

Check of tilt direction RH tilt LH tilt

RH tilt

Blade must move to left Blade must move to right

LH tilt

Check of tilting restriction adjustment • Measure tilting angle at the top of the cutting edge when the tilting limit switch is turned on.

Note: See manual of tilting restriction.

LH tilt

7 ± 1°

RH tilt

7 ± 1°

Check of auto pitch back operation

52 ± 3°

• After pitch dumping, move backward with the speed gear at R1, then turn the pitch back switch on.

Blade should be horizontal after pitch back to the stroke end, and pitch dumping is performed to return to the digging posture.

q Distributor copy

Superdozer specification 7/5 Category

Inspection Item

WORK EQUIPMENT

Check of the clearance between frame and track

Inspection LH RH

Move Blade up and down and stop 100 mm above ground, and then measure.

Check of the safety lever lock function

No actuator must work when the safety lock lever is at ON position (Lever can move but work equipment must not move)

Check of the blade lever floating

Must be of no hydraulic drift (Engine: Low idling)

Check of the blade lever floating notch release

Engine stops at floating, then notch must be released.

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 ilding)

Must be bridged with the blade and the ripper (Chassis)

Check of the accumulator function (blade, ripper)

Must function immediately after the engine stops then drop from the top to the ground.

Blade cylinder oil leakage

Must be none.

• Leakage from U-packing, damaged rod, quick drop valve, tube, flange or dust seal

LH RH

Tilt cylinder/pitch cylinder oil leakage • Leakage from U-packing, damaged rod, tube, flange or dust seal

Must be none.

LH RH

Track tension adjustment

UNDERCARRIAGE

Criteria Difference of LH and RH is max. 30 mm (Measure on flat ground)

• With the gear at F1 and the engine at low idling, 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.

LH RH

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.

LH

Flanges must be free from contact with links at all times.

RH

Undercarriage oil leakage • Leakage from idler, carrier roller, bogie, pivot shaft, adjustment cylinder, and lubricated track (plug, seal)

• Tense a string or a bar between the first carrier roller and the idler to measure distance between the 20 – 30 mm string (bar) and the grouser.

(Difference between LH and RH : Max. 20 mm) • Target is 30 mm when new.

20 – 30 mm

Must be none.

LH RH

Beat noise inside the cabin, beat noise of the outer cover

Must be none.

Opening/closing and locking effect of the cabin doors.

Must work smoothly to securely lock the doors by door-locking or key-locking.

Cabin door-open lock release lever

Must work smoothly to securely lock

Opening/closing and locking effect of the left/right side slide glass

Must work smoothly to securely lock.

Lighting of the room lamp

Must come on/go off by turning the switch on/off.

Operation of the window wiper and the window washer

Must be on/off by turning the switch on/off.

Operation of the radio and cassette system

Must operate correctly

CABIN

Wiper: Must operate smoothly (without beat noise) (Volume, tuning, AM/FM switching, cassette) Operation of the cigar lighter

Must be red-heated.

Ash tray installation

Must be installed.

Power supply of 12 V

Power of 12 V must be supplied.

• Check by connecting the radio unit Operation of the air conditioner

Cold and warm air must be able to be switched by monitor operation.

Air flow amount must be able to be adjusted

Air flow amount must be able to be adjusted (Hi, Mid or Lo) • Louver must be smoothly switched

q Distributor copy

Air comes out from each blowout port.

Superdozer specification 9/5 Category

Inspection Item

Inspection

LUBRICATION

Portions to be lubricated

Criteria Q’ty

• Equalizer bar side pin shaft

Example: U blade

2

• Equalizer bar center pin shaft

1

• Blade lift cylinder support shaft and yoke

6

• Blade center pin

1

• Blade oblique arm ball joint

3

• Brace screw

2

Check of ripper direction a Raise c Lower A Tilt in B Tilt out

Ripper lift cylinder oil leakage

Must be none

• U-packing, damaged rod, tube, flange, dust seal loosing

LH RH

Ripper tilt cylinder oil leakage

Must be of no contact.

• U-packing, damaged rod, tube, flange, dust seal loosing

LH RH

Contact with the hose at ripper operation

Must be of no contact.

RIPPER

• Entire operation area must be chedked Creak of the ripper link pin

Must be of no creak.

Check of the pin puller switch direction

Must be the same as the pin puller cylinder operation direction

A: Pin out B: Pin in

Check of the pin puller cylinder hose clamp position

Must be of no contact

(Entire operation area must be checked)

Must be of no excess hose tension.

Pin puller cylinder oil leakage

Must be none

• Leakage from U-packing, damaged rod, tube or flange Check of ripper lubricated hose installation

LH

Must be no contact or no excess bend.

RH Portions to be lubricated

Q’ty

• Ripper lift cylinder head

i

2

• Ripper lift cylinder bottom

y

2

• Ripper tilt cylinder head

u

2

• Ripper tilt cylinder bottom

t

2

• Ripper arm pin (front)

o

2

• Ripper arm pin (rear)

!0

2

q Distributor copy

Must be lubricated (right and left)