Armado D375A

GEN00097-05
BULLDOZER D375A -6
SERIAL NUMBERS 60001 and up
Preface
Since this machine is large in size, it is divided into some units to meet
the transportation conditions and regulations applied to the transporta-
tion route when shipped from our factory.
This manual describes how to assemble the units into the complete
machine in the field. We hope that this machine will display its quality
and you will use it safely according to the operation manual.
Many units are large in size and heavy in weight and may be handled
in a dangerous place or posture and many workers may have to work
together to sling them with cranes.
Accordingly, before starting the assembly work, the work supervisor is
required to hold a safety meeting to oblige the workers to put on pro-
tective gear and appoint a work leader and a crane work signal man
and allot roles to all the workers for safe work.
In particular, the above meeting is more important when worker of dif-
ferent languages and customs work together.
The following is a reference supervision system diagram.
(Instruction system)
Work leader
Director
Work supervisor Crane director and
deputy director
Operator for assembly

Liaison man
Mechanics Sharing of work

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

Accordingly, before installing the work equipment, inspect and main-
tain the machine thoroughly.
Note that this manual does not describe the whole specification of the
machine but describes only the basic specification.
CONTENTS
Specifications ..................................................................................................................................................... 1
Precautions for field assembly............................................................................................................................ 2
Disposal of removed parts.................................................................................................................................. 3
Assembly procedure, necessary equipment, and schedule ............................................................................... 4
Layout of kit ........................................................................................................................................................ 5
Style for transportation ....................................................................................................................................... 6
Table of tools for field assembly ....................................................................................................................... 11
Tightening torque ............................................................................................................................................. 17
Coating materials list ........................................................................................................................................ 22
Selection of wire ropes used for assembly ....................................................................................................... 25
A. Assembly procedure
A-1 Installation of chassis ....................................................................................................................... 28
A-2 Installation of undercover ................................................................................................................. 31
A-3 Installation of pivot shaft................................................................................................................... 32
A-4 Installation of undercarriage............................................................................................................. 34
A-5 Adding oil to recoil chamber and pivot chamber .............................................................................. 61
A-6.1 Installation of engine air inlet hood................................................................................................... 62
A-6.2 Installation of engine air pre-cleaner (if equipped) ........................................................................... 63
A-7 Installing direction of exhaust pipe ................................................................................................... 64
A-8 Installation of blade lift cylinder ........................................................................................................ 65
A-9 Installation of ripper ......................................................................................................................... 67
A-10 Installation of track ........................................................................................................................... 75
A-11 Assembly of blade............................................................................................................................ 77
A-12 Installation of blade .......................................................................................................................... 93
A-13 Installation of operator's cab .......................................................................................................... 102
A-14 Installation of rear monitor camera (if equipped) ........................................................................... 121
A-15 Installation of additional cab lights (if equipped) ........................................................................... 125
A-16 Installation of ROPS....................................................................................................................... 127
A-17 Installation of VHMS, ORBCOMM antenna ................................................................................... 129
A-18 Installation of revolving warning lamp to top of ROPS (if equipped) ............................................. 130
A-19 Check track tension........................................................................................................................ 133
A-20 Check fuel, coolant and lubricants ................................................................................................. 135
A-21 Bleeding air from hydraulic cylinders ............................................................................................. 137
A-22 Lubricating...................................................................................................................................... 138
A-23 Installation of fuel quick charge piping (if equipped) ...................................................................... 141
M. Check and maintenance procedures after completion of assembly
M-1 Check and adjustment of operator's cab........................................................................................ 144
M-2 Inspection of machine monitor ....................................................................................................... 151
M-3 Checking operation of dual tilt mechanism (If equipped) ............................................................... 165
M-4 Setting procedure for USER ADJUST MODE................................................................................ 166
M-5 Setting procedure for maximum cooling fan speed........................................................................ 168
M-6 Replacement of return filter (Replacement of standard filter → special flushing parts) ................. 169
M-7 Flushing of hydraulic circuit, and bleeding air from hydraulic cylinders (Part 1) ............................ 171
M-8 Replacement of return filter (Replacement of special flushing parts → standard filter) ................ 172
M-9 Bleeding air from hydraulic cylinders (Part 2) ................................................................................ 174
APPENDIX 1. Installation procedure for spill guard (Installation by welding).................................................175
APPENDIX 2. Precautions for initialization procedures for VHMS controller .................................................187
Field assembly inspection report
Specifications
Reinforced type Reinforced type
Semi U-tiltdozer Semi U-tiltdozer
Item Unit full U-tiltdozer full U-tiltdozer
+ Giant ripper + Multi-ripper
+ Giant ripper + Multi-ripper
Operating weight *1 *2 *1 *2
kg
(excluding operator's weight) 71,555 73,735 72,155 74,335
Blade weight
kg 10,965 12,465 10,965 12,465
(including cylinders and oil)
Ripper weight
kg 6,200 6,800
(including cylinders and oil)
Engine name — Komatsu SAA6D170E-5 diesel engine
Rated engine output kW/rpm {HP/rpm} 433/1,800 {588/1,800}
Overall length mm 10,485 10,845 10,195 10,555
Overall height (with ROPS) mm 4,285 (4,265)
Overall width mm 4,775 5,215 4,775 5,215
Travel speed Forward km/h 3.5/6.8/8.0/11.8
(1st/2nd/3rd(Lo)/3rd) Reverse km/h 4.6/8.9/9.7/15.8
*1: 610 mm (24 in) shoe, ROPS cab, air conditioner

*2: 710 mm (28 in) shoe, ROPS cab, air conditioner
• Semi U-tiltdozer + variable multi ripper
• Reinforced type full U-tiltdozer + variable giant ripper
1
Precautions for field assembly
1. Selection of work place
1) When selecting a work place, consider the following.
• Is the work place sufficiently wide for loading and unloading the machine? (See the kit layout draw-
ing.)
• Is the ground sufficiently hard? (The machine and crane truck must not sink into the ground.)
• Is the ground flat? (The ground surface must not be uneven or sloping.)
• Is the road to inlet/outlet of the work place sufficient for turning the trailer and crane truck?
2) Take care extremely that dirt or water will not enter the hydraulic circuit while it is assembled.
3) Avoid working outdoors while strong wind is blowing or it is raining.
4) Take measures to protect the machine from sand, dirt and rainwater while the work is stopped.
2. How to do work
The work supervisor or the work leader should not do the work while reading this manual but should read
and understand this manual thoroughly and then start the work.
In particular, write the "Precautions" for each work process in a sheet to explain or stick that sheet to the
work place so that all the workers will observe the precautions.
3. Preparation and check of protective gear, slings and tools

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

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

When the engine is started for the first time after assembled in the field, its inside must be lubricated with
engine oil. Lubricate according to “M-4 No-injection cranking of engine” in this manual.
7. This edition describes the maximum disassembly range.

Accordingly, since notes are given to each work step, follow them.
2
Disposal of removed parts
As described in "Preface", when this machine is transported, it is divided into some units such as the body,
undercarriage, cab, work equipment, etc. according to the transportation measure, regulations, etc.
Accordingly, the hydraulic pipings and hydraulic hoses to connect the units, oil inlets and outlets of the hydrau-
lic devices, and parts which must not be damaged are plugged or covered to prevent oil leakage, entry of dirt
and dust, and damage during transportation.
In addition, fixing jigs are used to prevent a trouble caused by a fall or a shake during transportation and to
facilitate loading, unloading and crane work.
The above plugs, jigs, etc. are removed when the machine is assembled and become unnecessary after com-
pletion of the machine. Since they are useful when the machine needs to be transported in future, however,
we recommend you to keep them as long as possible.
3
•
•
•
1st day 2nd day 3rd day 4th day
8:00 10:00 12:00 14:00 16:00 18:00 8:00 10:00 12:00 14:00 16:00 18:00 8:00 10:00 12:00 14:00 16:00 18:00 8:00 10:00 12:00 14:00 16:00 18:00
Schedule
Trailer must Unloading trailer
arrive at Installing pivot shaft and
field before blade lift cylinder
8:00.
Installing under cover
Assembling blade sub-assembly

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

Installing tracks
Special field work shall be arranged separately.
Installing blade
Connecting hoses
4
Installing cab
Test operation
Installing ROPS guard and adjustment
Any change of the schedule caused by weather is not included.
Washing, touching
up, painting
Wrecker 50-ton wrecker × 2 units 50-ton wrecker × 2 units 25-ton wrecker × 1 unit Unnecessary
Working
The F/D assembly and pivot shaft are assumed to be installed to the body beforehand.
8H 8H 8H 8H
hours
Number of
workers 4 workers 4 workers 3 workers 3 workers
Total
Assembly procedure, necessary equipment, and schedule
man-hours 32H 32H 24H 24H
Grand total 112H

Layout of kit
• When selection the work site, see "Before field assembly", too.
• The delivered kits (components) should be arranged as shown in the layout below after unloaded from the
trailer and truck.
• However, since the layout below is a reference image of a work site about 30 m by 30 m, decide the actual
layout according to the area and land form of the work site, considering the transportation packaging of
each kit (component) explained later.
Approx. 30 m
Blade
Right track
Left track
Ttrack
Ttrack
Approx. 30 m
Chassis
Crane
Crane
Ripper parts CAB assembly

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

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

B Overall height (mm) 3,250
C Overall width (mm) 3,060
Weight (kg) 27,000
• Tractor (Body) (At 32t resolution transportation)

Weight (kg) 28,000
• Track frame
With full
STD
roller guard
A Overall length (mm) 4,194 4,200
B Overall height (mm) 1,280 1,280
C Overall width (mm) 840 840
Weight (kg) 7,940 8,690
2 sets of the shoes are prepared for each
machine.
6
• Track shoe
Shoe wide 610 710

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

(1) Reinforced U-blade

Weight (kg) 8,250
• Semi-U blade

Stan- Rein-
Weight (kg) dard forced
6,750 7,220
7
• Work equipment Straight frame

B Overall height (mm) 640
C Overall width (mm) 490
Weight (kg) 1,350
2 sets of the shoes are prepared for
each machine.
• Work equipment Blade lift cylinder

D Overall width (mm) 1,174.3
Weight (kg) 286.5
2 sets of the shoes are prepared
for each machine.
• Pivot shaft (At 32t resolution transportation)
A Overall length (mm) 770

Weight (kg) 210
2 sets of the shoes are prepared
for each machine.
a This part may be delivered installed to the machine.
8
• Under cover
(1) Rear (At 32t resolution transportation)

Weight (kg) 320
a This part may be delivered installed to the machine.
(2) Side (At 32t resolution transportation)

Weight (kg) 220
• Cab

Weight (kg) 500
9
• ROPS

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

Weight (kg) 2,500
• Giant-ripper beam

Weight (kg) 1,710
10
Table of tools for field assembly
No. Tool name Specification Q'ty Remarks
1 Air compressor Min. 0.69 MPa – 15 m³/min 1
2 Pneumatic hose and cou- Hose length: 30 m 1 set For air compressor
pler (for pneumatic tools) Coupler must fit impact wrench
and oil feed pump.
3 Crane truck Lifting load: 50 ton 2
Lifting load: 25 ton 1
4 Welder 2 For welding blade spill guard
(If equipped)
5 Chain lever hoist Rated load 1.5 ton 1 JIS B8819 or equivalent
(Chain block) Rated load 3.2 ton 1
Rated load 6.3 ton 1
6 Wire rope sling ø 36 × 6 m 4 Specification: JIS B8817 or equivalent
ø 20 × 5 m 2
ø 12 × 2 m 4
7 Belt sling 25 mm wide × 3 m 2 Specification: JIS B8818 or equivalent
(made of synthetic fibers) 50 mm wide × 3 m 1
8 Hydraulic wrench Min 5,890 Nm {600 kgm} 1 Mainly for master link bolt
9 Hydraulic wrench socket Width across flats: 46 1 unit For master link bolt
each
10 Extension bar T 38.1 × L300 1
11 Air impact wrench See No. 41
12 Socket for impact wrench Width across flats: 19, 22, 24, 27, 1 unit Must fit impact wrench No. 41.
30, 32, 36, 41, 46, 50 each
13 Torque wrench Tightening capacity 1 Impact wrench socket may be used if it
588 Nm {60 kgm} fits.
Tightening capacity 1
1,370 Nm {140 kgm}
Tightening capacity 1
2,060 Nm {210 kgm}
14 Soket for torque wrench Width across flats: 32, 36, 41, 46 1 unit
each
15 Eyebolt M12, Using load: 220 kg 4
M16, Using load: 450 kg 2 For blade center link
16 Shackle SD22 4 Specification symbols are quoted from
BC36 2 JIS B2801
SB44(T) 2
17 Sledge hammer Double-headed: 4.5 kg (10 lbs) 1
18 Pinch bar (Lever) ø 25 × 900 mm 1 JCMAS P018 or equivalent, Note 1)
19 Thread repair tap M33 × Pitch 2 1 For master link
M30 × Pitch 3 1
M24 × Pitch 3 1
20 Jack Screw type, Using load: 15 ton 2 For assembling track frame
21 Single ended wrench Nominal width across flats (mm) 2 units For tightening hydraulic hose mouthpiece
17, 19, 22, 24, 27, 30, 32, 36, 41, each nut
46, 50
22 Lubricating oil and grease See assembly procedures A-3 —
and A-18.
23 Anti-seize compound Molybdenum disulphide grease 200 g See coating material list.
(LM-P)
24 Cleaning oil For removing preservative 40 l
25 Paint remover For removing phthalate resin 5l
coating
26 Paint for repair See coating material list 3 units
each
11
No. Tool name Specification Q'ty Remarks
27 Glass cleaner Cleaning liquid 1 For cleaning operator cab windshield
(commercially available) glass
28 Cloth Bunch 1 kg
29 Adhesive cloth tape Width × Length × Color 1 roll
50 mm × 25 mm × Not specified
30 Plastic tube (Vinyl tube) 8 mm inside diameter × 1 mm 1 For checking airtightness (internal pres-
thick × 3 m long, soft, transparent sure) of operator cab
31 Oil feed pump Manual or pneumatic 1
32 Oil mug Capacity: Approx. 5 l 1
33 Drain oil receiver 1,000 × 700 × 150 (mm) 2 units
(made of steel sheet) 700 × 400 × 150 each
300 × 300 × 100
34 Stand for high lift work 2 m high, with stair and handrail 2
35 Safety belt Waist belt type Same as
number of
workers
36 Safety glasses Same as
number of
workers
37 Stand For attached tool drawing 1 Front
(for setting machine) For attached tool drawing 1 Rear
38 Steel plate liner (for install- 1,000 × 500 (mm) 4 With lifting hook
ing support stand No. 37) 16 mm thick
39 Sling for track fame For attached tool drawing 1
40 Wood block T 350 mm × 750 mm high 4
T 350 mm × 400 mm high 4
T 100 mm × 750 mm lengh 4
41 Pneumatic impact wrench Objective bolt thread diameter 1 Note 2)
Tightening capacity
Unit: Nm {kgm}
– 200 {20.4} M10 – M14 1 Socket No. 12 must fit this impact
– 600 {61.2} M16 – M20 1 wrench.
– 1,000 {102} M22 – M24 1
– 3.000 {306} M27 – M38 1
– 6,500 {663} Min. M39 1
42 Common tools Note 3)
Note 1) Pinch bar (Lever) No. 18 is P018-1978 (Pinch bar) of JCMAS (Japan Construction Mechanization
Association) or equivalent.
You can read the information about JCMAS on the website.
Note 2) Hydraulic wrench No. 8 may be used instead of pneumatic impact wrench No. 41 having tightening
capacity of 1,000 – 6,500 Nm {102 – 663 kgm} (suitable for tightening M27 bolt or larger), as long as
the sockets are adaptable.
Note 3) This list does not contain general hand tools (box wrenches, screwdrivers, pliers, etc.) Prepare them
separately as required.
12
Sketch of jigs
Stand (Front side)
13
SYM. Part name Material Q'ty/set Mass Remarks
01 Channel SS400C 2 C100 × 65 × 6T × 747L
02 Channel SS400C 2 C125 × 65 × 6T × 970L
03 Channel SS400C 2 C125 × 65 × 6T × 378L
04 Channel SS400C 2 C100 × 100 × 5T × 400L
Note 2) Necessary for disassembly to 32-t parts for transportation.
05 Channel SS400C 2 C100 × 100 × 5T × 351L

06 Angle SS400C 2 65 × 65 × 6T × 970L
07 Angle SS400 2 65 × 65 × 6T × 200L
08 Plate SS400 2 50 × 300L
09 Plate SS400 4 9T × 150B × 500
10 Plate SS400 10 12T × 55 × 102
11 Plate SS400 2 9T × 50 × 40
12 Plate SS400 4 32T × 180 × 250
Note 1) We are not liable for any result of use of jigs manufactured according to these drawings.
Stand (Rear side)
14
SYM. Part name Material Q'ty/set Mass Remarks
01 Channel SS400C 2 C100 × 65 × 6T × 747L
02 Channel SS400C 2 C125 × 65 × 6T × 970L
03 Channel SS400C 2 C125 × 65 × 6T × 378L
04 Channel SS400C 2 C100 × 100 × 5T × 400L
05 Channel SS400C 2 C100 × 100 × 5T × 351L
06 Angle SS400C 2 65 × 65 × 6T × 970L
07 Angle SS400 2 65 × 65 × 6T × 200L
08 Plate SS400 2 50 × 300L
09 Plate SS400 4 9T × 150B × 500
10 Plate SS400 10 12T × 55 × 102
11 Plate SS400 4 32T × 180 × 250
Sling (Track frame assembly) Note) Necessary for disassembly to 32-t parts for transportation.
Sling (Track frame assembly)
It is better to choose
a chain block.
1p
i ec
e
es
ec
pi
2
Install to carrier roller.

SYM. Part name Q'ty/set Remarks
1 Frame 1
2 Master link 1 HM125
3 Shackle 1 RS10
4 Shackle 1 RB10
5 Spring R3
6 Wire rope 2 For 5 ton
7 Wire rope 1 For 3 ton
15
Sling (Pivot shaft) Note) Necessary for disassembly to 32-t parts for transportation.
16
Tightening torque
1. Tightening torque for bolts
Tightening torque for bolts is indicated in the text as shown below. Tighten each bolt to the specified
torque.
Part No. of bolt TTTTT-TTTTT

Part No. of washer EEEEE-EEEEE
Bolt specification Thread size (Diameter, pitch, length)
Tool (Socket) Applicable socket size
Tightening torque Nm {QQQ kgm}
If tightening torque for a bolt is not specified in the text, tighten it according to Table 1.
Remarks
1. The thread diameter is the nominal diameter. For example, 16 mm is expressed as M16 and 26
mm is expressed as M20.
The pitch in Table 1 is the distance that the bolt advances every turn in the axial direction (Unit:
mm).
2. The bolt length is dimension c in Fig. 1.
3. The applicable socket size is expressed as 24 mm, 30 mm, etc. Since 24 mm, 30 mm, etc. cor-
respond to dimension b in Fig. 1, an applicable socket can be selected from Table 1, too.
4. Tightening torque is expressed as QQQ – www or QQQ ± RR. If the target tightening torque
is set, expression of QQQ ± RR is applied.
Fig. 1
a : Bolt thread diameter (Nominal diameter)

b : Width across flats of bolt head
c : Bolt length
d : Threaded part of bolt
17
Table 1 Tightening torque for bolts not specified in text
Unit: Nm {kgm}
Nominal size of thread Width across flats Tightening torque

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

O-ring at this
position
Unit: Nm {kgm}
Outside diameter Tightening torque (Nm {kgm})
Width across flats
of hose
(mm) Range Target
(mm)
Approx. 6 19 34 – 54 {3.5 – 5.5} 44 {4.5}
Approx. 10 22 54 – 93 {5.5 – 9.5} 74 {7.5}
Approx. 13 27 84 – 132 {8.5 – 13.5} 103 {10.5}
Approx. 16 32 128 – 186 {13.0 – 19.0} 157 {16.0}
Approx. 20 36 177 – 245 {18.0 – 25.0} 216 {22.0}
Table 4.2 Hydraulic hose of taper seal type
Type that does

not use O-ring
at this position
Unit: Nm {kgm}
Outside diameter Tightening torque (Nm {kgm})
Width across flats
of hose
(mm) Range Target
(mm)
Approx. 6 19 34 - 63 {3.5 – 6.5} 44 {4.5}
Approx. 10 24 59 - 98 {6.0 – 10.0} 78 {8.0}
Approx. 13 27 84 - 132 {8.5 – 13.5} 103 {10.5}
Approx. 16 32 128 - 186 {13.0 – 19.0} 157 {16.0}
Approx. 20 36 177 - 245 {18.0 – 25.0} 216 {22.0}
Note: When connecting hose, take care not to twist them.
20
4. Proper socket sizes for bolts of M39 and larger (Reference)
For the proper sizes of sockets or spanners (= width across flats) for tightening hexagon bolts of M39 and
larger, see Table 5.
Table 5
Unit: mm
Thread diameter Proper sizes of sockets or spanners
M42 65
M45 70
M48 75
M52 80
M56 85
M60 90
M64 95
21
Coating materials list
(Rev. 2009.08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
• Use to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
• Use for plastic (except polyethylene, polypropyl-
20 g Polyethylene ene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene • Features: Resistance to heat and chemicals.

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

• Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
LG-8 • Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the
ThreeBond 790-129-9310 200 g Tube
weld which must be caulked, etc.
1206D
• Can be coated with paint.
22
Cate- Komatsu
gory code
LG-10 • Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
1206E • Can be coated with paint.

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

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

LC-G pound with metallic super-fine-grain, etc.
Seizure
NEVER- — — Can • Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharger,
etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) • Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
• Use for parts under heavy load.
Molybdenum
Caution:
disulfide SYG2-400M 400 g × 10 Bellows-type
• Do not use this grease for rolling bearings like
grease SYG2-400M-A 400 g × 20 container
swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can
• Use this grease for work equipment pins only
(G2-M)
when installing them, but do not use it afterward.
SYG2-400T-A
Hyper White
Grease
SYG0-400T-A • Seizure resistance, heat resistance and water re-

G2-T, Bellows-type
(*) 400 g sistance higher than molybdenum disulfide
G0-T (*) container
SYG2-16CNT grease.
*: For cold Can
SYG0-16CNT 16 kg • Not conspicuous on machine since color is white.
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type • Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals,
high temper- SYGA-16CNB
Can and plants.
ature and SYGA-16CNBT 16 kg
under high (*)
load
• Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond — 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
• Use for oil seals of the transmission, etc.
23
Cate- Komatsu
gory code
• Feature: Urea (organic system) grease with heat
resistance and long life, can be packed into the
Grease
G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
• Use for rubber, bearing and oil seal in damper.
• Caution: Do not mix with lithium grease.
SUNSTAR • Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER 580 tainer (Effective period: four months after date of
SUPER manufacture)
417-926-3910
SUNSTAR
• Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of
For adhered window glass

PRIMER 580 tainer
manufacture)
SUPER
SUNSTAR • Use as primer for painted cab sheet metal
PAINT Glass con- surface.
Primer
22M-54-27230 20 ml
PRIMER tainer (Effective period: four months after date of
435-95 manufacture)
• Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR • Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
PRIMER tainer (Effective period: four months after date of
GP-402 manufacture)
SUNSTAR • Use "S" in high-temperature season and
PENGUINE "W" in low-temperature season as adhesive
Polyethylene
SEAL580 417-926-3910 320 ml for glass.
container
SUPER "S" (Effective period: four months after date of
Adhesive
or "W" manufacture)
Sika Japan, • Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR • Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
• Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
2505
Caulking material
SEKISUI SIL- • Use to seal front window.

Polyethylene
ICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
• Use to seal glass-to-glass joint. Translucent
TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL
manufacture)
381
24
Selection of wire ropes used for assembly
Select wire ropes to be used for assembly according to the following table.
Annex 2, Table 1 Using loads of 6 × 24 type rope slings.
Unit: kN {tf}
Number of wire ropes 1 pc. 2 pcs.
Sling angle α α = 0° α Z 90° 90° < α Z 120°

Angle to vertical line β β = 0° β Z 45° 45° < β Z 60°
Mode coefficient M 1 1.4 1
Classification of wire rope
Outer diameter of 24G 24A 24G 24A 24G 24A
wire rope (2)d (mm)
8 Max. 4.8 {0.49} Max. 5.2 {0.53} Max. 6.7 {0.68} Max. 7.2 {0.74} Max. 4.8 {0.49} Max. 5.2 {0.53}
9 Max. 6.1 {0.63} Max. 6.6 {0.67} Max. 8.5 {0.88} Max. 9.2 {0.93} Max. 6.1 {0.63} Max. 6.6 {0.67}
10 Max. 7.6 {0.77} Max. 8.2 {0.83} Max. 10 {1.0} Max. 11 {1.1} Max. 7.6 {0.77} Max. 8.2 {0.83}
25
11.2 Max. 9.5 {0.97} Max. 10 {1.0} Max. 13 {1.3} Max. 14 {1.4} Max. 9.5 {0.97} Max. 10 {1.1}
(12) Max. 10 {1.1} Max. 11 {1.2} Max. 14 {1.5} Max. 15 {1.6} Max. 10 {1.1} Max. 11 {1.2}
12.5 Max. 11 {1.2} Max. 12 {1.3} Max. 15 {1.6} Max. 16 {1.8} Max. 11 {1.2} Max. 12 {1.3}
14 Max. 14 {1.5} Max. 16 {1.6} Max. 19 {2.1} Max. 22 {2.2} Max. 14 {1.5} Max. 16 {1.6}
(24) Max. 43 {4.4} — Max. 60 {6.1} — Max. 43 {4.4} —
A. Assembly
Remarks
1. In the "drawings" in this manual, parts and places are indicated by 1, 2, 3 ---, but
indicated by (1), (2), (3) --- in the tables and texts.
Example:
(1) Plate
(2) Collar
(3) Washer
(4) Bolt
(5) Bolt
(6) Washer
2. In some places of this manual, the words of front, rear, right hand and left hand
of machine are used. Those words indicate the directions seen from the opera-
tor's seat with the sprocket at the rear as shown below, unless otherwise speci-
fied.
Front
Left hand Right hand
Operator's seat
Sprocket
Rear
27
Assembly process No.
Installation of chassis (1/3)
A-1
1) Lay the 2 sets of track shoe assembly in parallel Fig. 1

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

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

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

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

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

This work is required for disassembly to 32-t parts for Name Q'ty Name Q'ty
transportation. ø20 × 2,000 mm 2 50-ton crane 1
Wire rope sling
Support stand (front) 1
Support stand (rear) 1
Other remarks
28
A-1
3) Sling the machine with 2 cranes having at least 50 ton capacity each to unload from the trailer and
place it on the stands described above. (Fig. 4)
a Match the direction of the machine to that of the track shoe assemblies.
Fig. 4
Hang 2 wires Hang 2 wires

Φ42 x 6 mm Φ42 x 4.5 mm
Corner pad
Shackle
a Machine weight: 27,000 kg

a Lift points of machine
Front: Hang 2 wires (ø 42 mm) to the hook of the undercover by using 2 shackles and sling as
shown in (Fig. 4).
Rear: Install wires (ø 42 mm) to the upper pins for installing the rear work equipment (ripper) (1
each on the right and left sides) and sling as shown in (Fig. 4).

Name Q'ty Name Q'ty
ø42 × 6,000 mm 2 50-ton crane 2
ø42 × 4,500 mm 2
Wire rope sling
SB44(T) shackle 2
245kN(25t) Spec.
Corner pad 2
Other remarks
29
A-1
Install 1 and 2 wire rope slings to the front and rear of the machine respectively as shown in (Fig. 4) and
sling the machine with 2 truck cranes (Install the front slings to 1 truck crane and install the rear slings to
another truck crane). Unload the machine from the trailer and place it on the chassis stand installed on
the ground.
a Install the front wire rope sling to the tow hook installed to the undercover of the machine through a
proper shackle.
If the sling interferes with the machine at this time, put a rubber or felt pad between the sling and
machine to protect the machine.
a Install the rear wire rope slings to the ripper tilt cylinder mounts installed to the machine.
Install each sling to the pin installed to each of the right and left mounts.
a Place the equalizer bar installed to the machine onto the front chassis stand and place the hull frame
(main frame of the machine) onto the rear chassis stand.
At this time, check that the chassis stands are at the lateral center of the machine.
a Before loosening the sling tension, put wooden block (13) between equalizer bar (9) and machine
main frame (10) on each of the right and left sides as shown in (Fig. 5).
<Specifications of wooden block>

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

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

(10) Machine main frame
(11) Front chassis stand
(13) Wooden block
30
Installation of undercover
A-2
1) Install the 2 undercovers in the order shown in the (Fig. 1).

Undercovers 1
01010-82470 Fig. 1
Part No. of bolt (7 pieces)
176-50-11170
Part No. of spacer (7 pieces)
Length of bolt M24 × 70 mm
Part No. of bolt 01010-82450 (2)
(Hinge area)
Part No. of washer 01643-32460 (2)
(Hinge area)
(Hinge area)
Necessary socket 36 mm
883 ± 98 Nm
Tightening torque
(90 ± 10 kgm)
Undercovers 2
Part No. of bolt 01010-82470 (8 pieces)
Part No. of spacer 176-50-11170 (8 pieces)
Part No. of bolt 01010-82450 (2)
(Hinge area)
Part No. of washer
(Hinge area) 01643-32460 (2)
Length of bolt
(Hinge area) M24 × 50 mm
883 ± 98 Nm
Tightening torque
(90 ± 10 kgm)

This work is required for disassembly to 32-t parts for Name Q'ty Name Q'ty
transportation. Impact wrench 1
(– 1,000 Nm (– 102 kgm))
1) Apply adhesive (LT-2) to the bolts before tightening.
2) Parts (1) and (2) may be installed before the

machine is delivered.
Other remarks
31
Installation of pivot shaft (1/2)
A-3
Note) This work is required for disassembly to 32-t

Fig. 1
parts for transportation.
1) Slinging pivot shaft

• To sling the pivot shaft, install the sling as
shown in (Fig. 1).
• A proper length of the sling wire is about 600
mm. Dimension (A) in (Fig. 1)
• Install the sling wire to about 500 mm from the
pivot shaft end. Dimension (B) in (Fig. 1)
Part Nos. of pivot shafts
Right shaft Left shaft
Dual 195-50-42111 195-50-42111
Single 195-50-42111 195-50-42210
2) Setting position of pivot shaft

* For details of installation, see the following page. Fig. 2
• Set the pivot shaft to the machine with its
flange directed as shown in (Fig. 2).
3) Bolting to machine
• When installing the pivot shaft, tighten the
bolts lightly and evenly in the diagonal order to
press fit the spigot joint portion until the flange
face is seated.
• Use an impact wrench (– 306 kgm) and a socket
shown in the following table. (See [Fig. 3])
• While turning the torsion seal cover properly,
tighten the bolts.
Note: After tightening, be sure to check the tight-
ening torque. Fig. 3
01010-83000
Part No. of bolt
(14 pieces each on right and left)
01643-33080
Part No. of washer
Bolt specification M30 × 100 mm
Socket 46 mm
1,720 ± 196 Nm
Tightening torque
(175 ± 20 kgm)
Tilt hose
4) Installation of cork plug

After tightening the above bolts, drive the cork plugs into the screw bolt holes in which the bolts of
the pivot shaft flange will not be installed.
Part name Part No. Q’ty
2 pieces each on
Plug 07049-03038
right and left
32
Installation of pivot shaft (2/2)
A-3
Remarks 1. Torsion seal (2) is press fitted

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

(5) for work equipment hydrau-
lic system coming out of the
pivot shaft mounting seat of
the machine. (1) Pivot shaft
Pass both of these tilt hoses (2) Torsion seal
through the center hole of the (3) Torsion seal retainer
pivot shaft so that they will (4) Tilt hose
come out of the shaft end. Set one having identification color mark on
At this time, do not twist the tilt neck up.
hoses spirally inside the pivot (5) Tilt hose
shaft hole and set the one Set one having no identification color mark
having identification color on neck down.
mark up. (Fig. 4)
3. The pivot shaft may have been installed to the machine before delivery.
4. This assembly work shall be performed on the right and left sides of the machine. The
tilt hose piping on both sides are different from each other as shown below.
Installing position in
Machine specification Tilt hose type
machine
Upper 1 hose having identification blue mark
Left
Lower 1 hose having no identification color mark
Dual tiltdozer
Upper 1 hose having identification red mark
Right
Left Without tilt hose
Single tiltdozer Upper 1 hose having identification red mark
Right
33
Installation of undercarriage (1/27)
A-4
Note) This work is required for disassembly to 32-t parts for transportation.
1) Installation of track frame assembly to machine
1. 1) Before installing the track frame assembly, remove the following parts from it.
• Rear upper cover parts of track frame assembly --- (1), (2), (3), (4), (5), (46), (47) and (48) in
(Fig. 1)
• Equalizer bar side pin and cover parts --- (6), (7), (8), (9), (10), (11), (12), (13), (14), (15), (16),
(17), (18) and (19) in (Fig. 1)
• Pivot shaft end cover parts --- (21), (22), (23) and (24) in (Fig. 1)
• Parts related to torsion seal assembly at pivot shaft end --- (40), (41), (42), (43), (44) and (45) in
(Fig. 1)
• Parts related to hydraulic hose hole cover of tiltdozer --- (31), (32) and (33) in (Fig. 1)
Note 1. This section describes assembly of right and left track frame assemblies of the dual tiltdozer
specification and that of the right track frame assembly of the single tiltdozer specification.
For the left track frame assembly of the single tiltdozer, see 1.2).
2. (Fig. 1) explains the left track frame assembly, and the right track frame assembly is similar
to it.
The O-rings which must not be reused as a rule are not shown in the figure.
3. The removed parts will be installed again during or after assembly of the track frame assem-
bly. Take care not to lose them.
4. The track frame assembly is shipped with the fixing jig installed so that the track roller area
will not sag when the track frame assembly is slung. This fixing jig is unnecessary after
completion of assembly, but do not remove it at this time. For the location of this jig and the
time to remove it, see step 7) of this assembly procedure.
Fig. 1
34
A-4
1.2) The parts to be removed from the left track frame assembly of the single tiltdozer are as follows.
• Rear cover parts of track frame assembly --- (1), (2), (3), (4), (5), (67), (68) and (69) in (Fig. 2)
• Equalizer bar side pin and cover parts --- (6), (7), (8), (9), (10), (11), (12), (13), (15), (16), (17),
(18) and (19) in (Fig. 2)
• Pivot shaft end cover parts --- (64), (65) and (66) in (Fig. 2)
• Parts related to thrust washer of pivot shaft end --- (45), (61), (62) and (63) in (Fig. 2)
• Parts related to hydraulic hose hole cover of tiltdozer --- (32), (33) and (34) in (Fig. 2)
Fig. 2
35
A-4
1.3) Fit the O-ring to the O-ring (51) groove of the

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

sion seal" press fitted to the pivot shaft
installed in "Assembly procedure A-3" is free Track frame
from foreign matter and harmful material.
See (Fig. 9), too
Fig. 4
2. The inside of the track frame assembly must
be free from foreign matter.
3. Apply oil to bush and shaft.
1.4) Sling the track frame assembly with the sling jig,
wire and crane.
a For the position of the crane and slinging method,

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

assembly.
36
A-4
1.5) While aligning the pivot shaft insertion hole of

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

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

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

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

are not shown in the figure.
37
A-4
1.7) Insertion of equalizer bar side pins Side pin holes
1.7.1) Align the equalizer bar side pin holes with each
other. See (Fig. 10) Fig. 10
1.7.2) Insert each side pin. See (Fig. 11)

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

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

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

Insert bolts (18) and (19) from underside and Fig. 12
install and tighten nuts (16) and (17) from above.
See (Fig. 12)
(16), (17), (18) and (19) removed in 1.1), 1.2) UP
195-50-51510
(18) Part No. of bolt
01643-33080
(19) Part No. of washer
01803-03034
(16) Part No. of nut
01643-33080
(17) Part No. of washer
Bolt s pecification M30 × 305 mm
Socket 46 mm
Note 1. Take care not to damage the O-ring con- Take care of bolt insertion
tact faces of the pin heads. direction (See Note 2)
2. Bolts are inserted from above into the track
frame assembly unit delivered to the field to protect their threads and for the reason of
transportation.
When connecting the track frame assembly to the equalizer bar of the machine, remove
those bolts and then insert them from below.
3. The mudguards (15) in (Fig. 1) and (Fig. 2) removed simultaneously in steps 1.1) and 1.2)
will be install later in step 8). Accordingly, tighten their bolts and nuts temporarily at this
time.
38
A-4
1.7.4) Place grease cover (8) on the equalizer bar side

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

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

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

cover (8) Right 195-50-52370 (1 piece)
Part No. of O-ring (7) 07000-12020 (1 piece each on right and left) (7), (8), (9) and (10)
Part No. 01010-81665 (4 pieces each on right and left) removed in (Fig. 1) and
Bolt (9) (Fig. 2)
Specification M16 × 65 mm
Part No. of washer (10) 01643-31645 (4 pieces each on right and left)
1.7.5) Connect the grease tube (A) coming from the equalizer bar to the grease cover.
Note: The tube joint has pipe threads. Take care not to tighten it too much. The reference tightening
torque is shown below.
Tightening torque 14.7 – 34.3 Nm {1.5 – 3.5 kgm}
1.8) Place jacks or wooden blocks under the installed track frame assembly so that the assembly will
not tip over when it is lowered from the crane. (Fig. 14)
Jack
Place the jacks or wooden blocks to at least
2 places so that the track frame assembly
will be kept horizontally in each direction. Fig. 14
1.9) Lower the track frame and start the installation work of the track frame assembly on the opposite
side.
39
A-4
1.10) Install the track frame assembly on the opposite side

according to steps 1.1) – 1.8). Fig. 15
(Fig. 15), (Fig. 16) and (Fig. 17)
Bogie fixing jig
Fig. 16
Fig. 17
Note: As described in 1.1), do not remove the bogie fixing jig for preventing the track rollers from
drooping at this time.
Removal of this jig is described in 11) of this procedure. As a rule, however, remove it after
removing the machine stand installed in "Assembly procedure A-1" and placing the whole
machine, including the track frame assembly, onto the track shoe assembly spread on the
ground.
40
A-4
2) Assembly of pivot shaft end

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

40-1 Inner washer 195-50-52120 1
40-2 Outer washer 195-50-52130 1 Assembled already
40-3 Torsion seal 195-50-22181 1
41 Bolt 01010-81690 8
42 Washer 01643-51645 8
43 Bolt 01010-81645 3
44 Washer 01643-51645 3
45 Spacer 195-50-22170 1
71 O-ring 07000-15155 1
72 O-ring 07000-15250 1
73 Pivot shaft – –
74 Track frame assembly – –
75 Hydraulic hose – – See Assembly procedure
76 Hydraulic hose – – A-5
41
A-4
2.1.1) Fit the "O-ring" to the O-ring groove at the pivot shaft end. (71) in (Fig. 18)
2.1.2) Fit the spacer to the track frame assembly side of the pivot shaft end. (45) in (Fig. 18)
These parts are the parts remove in step 1.1).
2.1.3) Fit O-rings (5) to torsion seal assemblies (40-1), (40-2) and (40-3) in (Fig. 18) and install the tor-
sion seal assemblies so that they will hold the O-rings in step 2.1.1) and spacers in step 2.1.2)
and then tighten the bolts.
The torsion seal assemblies are the parts removed in step 1.1). See (Fig. 1), (40)
* Bolts to install inner washers of torsion seals. See (41)

and (42) removed in (Fig. 18)
Tool (Socket) 24 mm
Tightening torque See Table 1 “Tightening torque”
* Bolts to install outer washers of torsion seals. See (43)

and (44) removed in (Fig. 18)
Tool (Socket) 24 mm
Note 1. Keep the track frame assemblies horizontally so that no torsion load will be applied to the
torsion seals at the beginning of assembly.
2. Set the 3 bolts to install the outer washer of the torsion seal at irregular intervals as shown
in 2.1.4).
If the bolts are not installed to correct positions, the pivot shaft end cover cannot be installed
in step 4). Take care.
42
A-4
2.1.4) Outer washer mounting bolt positions of torsion seal assembly

Install outer washer mounting bolts (43) and washers (44) of the torsion seal assembly unequally
spaced as shown in (Fig. 19), seeing from the direction of arrow Z in (Fig. 18).
Fig. 19
Note 1. The other equally spaced holes (8 places) to which (43) and (44) are not installed are for
mounting bolts (22) and (23) of pivot shaft end cover (1) removed in (Fig. 1).
2. For the single tiltdozer, perform this work on the right side only. For the left side, see step
2.2).
43
A-4
2.2) Left side of single tiltdozer

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

45 Spacer 195-50-22170 1
61 Thrust washer 195-50-42260 1
62 Bolt 01010-81650 8
63 Washer 01643-31645 8
73 Pivot shaft – –
2.2.1) Fit spacer (45) to the track frame assembly side of the pivot shaft end.
2.2.2) Install thrust washer (61) with bolts (62) and washers (63).
* Thrust washer mounting bolt (62) and (63) in (Fig. 20)

Tool (Socket) 24 mm
Remark: (45), (61), (62), (63) are the parts removed in step 1.2).
44
A-4
3) Assembly of torsion seal retainer at pivot shaft base
Fig. 21

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

Tool (Socket) 24 mm
45
A-4
4) Assembly of pivot shaft end cover

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

21 Cover 195-50-22132 1
25 Union 02781-00522 2
26 O-ring 07002-12434 2 Assembled already
86 Elbow 02783-10522 2
87 O-ring 07002-12434 2
22 Bolt 01010-81695 7
23 Bolt 01010-81615 1
24 Washer 01643-31645 8
27 O-ring 02896-11015 2
75 Hydraulic hose (Upper) – 1 With identification color mark
76 Hydraulic hose (Lower) – 1 Without identification color mark
46
A-4
4.1.1) Remove oil plugs (77) and (78) in (Fig. 23) installed to the ends of 2 hydraulic hoses (75) and (76)
in (Fig. 18) coming out of the pivot shaft end.
Fig. 23

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

Left side of
machine No discernment on hose Connect to lower elbow.
Red discernment at hose end Connect to upper elbow. Apply this assembly
Right side of
to right side of single
machine No discernment on hose Connect to lower elbow. tiltdozer, too.
a For the upper and lower unions, see (Fig. 22).
47
A-4
4.1.3) While pushing the hydraulic hoses into the pivot shaft hole, put pivot shaft end cover assembly
connected to the tilt hoses in step 4.1.2) over torsion seal assembly (40) in (Fig. 18) and secure it
to the track frame assembly with the bolts. See (Fig. 22) and (Fig. 24).
M16 × 95 mm (7 pieces each)
Bolt specification
M16 × 115 mm (1 piece each)
Tool (Socket) 24 mm
Fig. 24
4.2) Left side of single tiltdozer

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

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

Tool (Socket) 24 mm
48
A-4
5) Assembly of tilt hoses from pivot shaft end cover to trunnion

Note: Perform the following before installing the trunnion.
This assembly is for the right and left sides of the dual tiltdozer and the right side of the single tilt-
dozer.
Fig. 27

88 O-ring 02896-11015 2
91 Hydraulic hose 195-71-76691 1 With identification blue mark
92 Hydraulic hose 195-71-76671 2 With no identification color mark
93 Hydraulic hose 195-71-76631 1 With identification red mark
5.1) As a rule, direct the elbows toward the center of the machine. When connecting the hydraulic
hoses described below, however, adjust the elbows so that the hydraulic hoses will not interfere
with or strongly touch other parts.
5.2) Pass hydraulic hoses (91) and (92) on the left side and (92) and (93) on the right side through the
track frame as shown in (Fig. 31) and connect them to the elbows installed in step 5.1).
At this time, take care not to forget to fit O-rings (88) to the elbows.
Connect the hydraulic hoses according to the following table.
Hose discernment Connect to pivot shaft cover

Left side of Blue discernment at hose end Connect to upper
machine No discernment on hose Connect to lower
Right side of Red discernment at hose end Connect to upper
machine No discernment on hose Connect to lower
Note : When passing the hydraulic hoses through the track frame, do not twist them spirally.
49
A-4
6) Assembly of trunnion
Install trunnions (81) necessary for connection of the blade assembly and machine described in
"Assembly procedure A-12", Installation of blade assembly, to the both right and left track frames
respectively. See (Fig. 28).
Note Before installing the trunnion, remove all the paint from face A of the track frame (mating face
to the trunnion) and face B of the trunniong (mating face to the track frame) with sandpaper
etc.
Fig. 28

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

Tool (Socket) 36 mm
Note 1. This trunnion may be installed to the track frame before the machine is delivered.
2. This assembly may be performed before "Assembly procedure A-12", Installation of blade
assembly, described later.
50
A-4
6.1) Pull out the opposite ends of the hydraulic

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

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

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

The rear work equipment (ripper) and front work equipment (blade assembly) may be
operated in the installation procedure described later and these plugs stop oil from
spouting out of hydraulic hoses A and B at that time.
2. Plugs (77) removed in step 4.1.1) may be reused.
51
A-4
6.3) Install cover (31) in (Fig. 31) to the track frame to protect the elbows described in step 5.2) and the
hydraulic hoses from the elbows to inside described in step 5.1) from dirt and sand.
Fig. 31

Left side Cover 195-30-69520 1
31
Right side Cover 195-30-69530 1
32 Bolt 01010-81635 3
33 Washer 01643-31645 3
91 Hydraulic hose – –
Left side
See step 5), 5.2)
Right side

Tool (Socket) 24 mm
52
A-4
7) Assembly of front cover of pivot shaft end cover

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

32 Bolt 01010-81635 3
33 Washer 01643-31645 3
34 Cover 195-30-69511 1

Tool (Socket) 24 mm
53
A-4
8) Assembly of parts around equalizer bar side pin

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

5 O-ring 07000-42020 2
1 Cover 195-50-52360 1
L.H
2 Connector 07213-50710 1
6
1 Cover 195-50-52370 1 Assembly already
R.H
2 Connector 07213-50710 1
7 Bolt 01010-81665 8
8 Washer 01643-31645 8
9 Bolt 195-50-51510 4
10 Washer 01643-33080 4
L.H Cover 195-30-68950 1
11
R.H Cover 195-30-68960 1
12 Bolt 01010-61650 6
13 Washer 01643-31645 6
1 Cover (Big) 195-50-52310 1
2 Cover (Small) 198-50-61350 1
L.H Assembly
3 Bolt 01010-81225 2
4 Washer 01643-31232 2
15
1 Cover (Big) 195-50-52320 1
2 Cover (Small) 198-50-61350 1
R.H Assembly
3 Bolt 01010-81225 2
4 Washer 01643-31232 2
16 Nut 01803-03034 4
17 Washer 01643-33080 4
54
A-4
8.1) Remove the nuts (16) and washers (17) installed

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

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

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

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

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

Tool (Socket) 24 mm
55
A-4
9) Assembly of mudguards at rear of track frame assembly

Left Fig. 37
Install mudguards (1) at the rear of track frame assembly
removed in steps 1.1) and 1.2) and secure them with bolts
(2), (3) and washers (4). (Fig. 37), (Fig. 38)
pcs./
No. Part name Part No. Remarks
machine
1 Cover 195-30-69311 2 Common to right
and left
2 Bolt 01010-62060 2
3 Bolt 01010-62050 8
4 Washer 01643-32060 10
5 Cover 195-30-69331 1 Left
6 Cover 195-30-69341 1 Right
7 Bolt 01010-62050 8
Right Fig. 38
8 Washer 01643-32060 8
long M20 × 60 mm
Bolt specification
short M20 × 50 mm
Tool (Socket) 30 mm
10) Installation whole machine to track shoe assemblies
10.1) After installing the right and left track frame assemblies to
the machine, sling the whole machine with 2 cranes hav-
ing at least 50 ton capacity each. For the slinging proce-
dure, see “Assembly procedure A-1” Installation of
machine.
10.2) Remove the support stands and unnecessary stands such

as the jacks, wooden blocks, etc. installed in “Assembly
procedure A-1” Installation of machine.
10.3) Place the whole machine on the track shoe assemblies

spread on the ground.
10.4) Set chocks to prevent the machine from rolling over.

Name Q'ty Name Q'ty
ø42 mm × 6 m 2 50-ton crane 2
ø42 mm × 4.5 m 2
Wire rope sling
SB44(T) shackle 2
Corner pad 2
Other remarks
56
A-4
11) Removal of bogie fixing jig
Note: Perform the following work after placing the whole machine on the track shoe assemblies
spread on the ground. If it is performed before placing the machine, the track rollers will sag
more than necessity and the work following will become difficult.
Fig. 38
No. Part name Part No. Q'ty Remarks

1 Plate 195-30-68610 3 each on right and left
2 Collar 198-30-66190 3 each on right and left
Parts to be removed
3 Washer 19M-54-11770 3 each on right and left
4 Bolt 01011-62410 3 each on right and left
5 Bolt 01010-62455 3 each on right and left Parts to removed and installed to
6 Washer 01643-32460 3 each on right and left different places
9 Washer 19M-54-11770 2 each on right and left Parts to be removed
11.1) Remove parts (1) – (11) shown in (Fig. 38). (These parts are installed to 4 places each on the out-
side of the track frame assembly, thus they are installed to 8 places in total on the right and left
track frame assemblies.)
57
A-4
11.2) Tighten the specified bolts and washers into the bolt holes (marked with a) which have been
used to install the bogie fixing jig.
Bolt specification 01010-62455 (5 pieces each on right and left) Use bolts (5) and washers (6) for 6 of
Part No. of washer 01643-32460 (5 pieces each on right and left) total of 10 places.
Tool (Socket) 36 mm
Tightening torque See Table 1 "Tightening torque"
11.3) Drive cork plugs into the tap holes part (A) in (Fig. 39) from which bolts (5) of fixing jig (1) were
removed. (3 places on each side, 6 places in total)
Fig. 39

Part A Plug 07019-02430 3 each on right and left Cork plug
58
A-4
12) Removal of bogie fixing jig of machine with full roller guard (optional)
Fig. 40

* 1 Plate 195-30-69860 3 each on right and left
Parts to be removed
3 Washer 19M-54-11770 3 each on right and left
* 5 Bolt 01010-62460 3 each on right and left Parts to removed and installed
6 Washer 01643-32460 3 each on right and left to different places
9 Washer 19M-54-11770 2 each on right and left Parts to be removed
• Parts marked with * are different from those of track frame assembly of standard specification
([Fig. 38]).
12.1) Remove parts (1) – (11) shown in (Fig. 40). (These parts are installed to 4 places each on the out-
side of the track frame assembly, thus they are installed to 8 places in total on the right and left
track frame assemblies.)
59
A-4
11.2) Tighten the specified bolts and washers into the bolt holes (marked with a: 6 places in total and
marked with u: 4 places in total) which have been used to install the bogie fixing jig.
Part No. of bolt 01010-62460 (3 pieces each on right and left)
Use bolts (5) and washers
Part No. of washer 01643-32460 (3 pieces each on right and left) (6) for 6 of total of 10
places.
Part No. of bolt 01010-62455 (2 pieces each on right and left)
Part No. of washer 01643-32460 (2 pieces each on right and left)
Bolt specification M24 × 60 mm or M24 × 55 mm
Tool (Socket) 36 mm
12.3) Drive cork plugs into the tap holes part (A) in (Fig. 39) from which bolts (5) of fixing jig (1) were
removed. (3 places on each side, 6 places in total)
• When it is standard specification, same as (Fig. 39).

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

(For installation of the track shoe, see “Assembly procedure A-10”)
60
Adding oil to recoil chamber and pivot chamber
A-5
1. Adding oil to track frame pivot chamber
1) Remove soil and gravel from around the oil

filler, and then remove the plug and add oil, tak-
ing care that dirt will not enter the case.
Oil : EO30
Quantity : 18 l/each side
Oil filler
2) Pivot case oil level H = 10 – 30 mm
2. Adding oil to track frame recoil chamber
1) After adjusting the track and positioning the

idler, check the oil level and add new oil by the
necessary quantity.
2) Recoil chamber oil level H = 96 – 116 mm
61
Installation of engine air inlet hood
A-6.1
1) Remove the dust/water seal stuck to the air inlet hood mounting opening of the engine hood shown
in the figure. (Fig. 1)
2) Insert air inlet hood (1) in the air inlet mounting opening all the way. It may be installed in any direc-
tion.
3) Tighten the band bolt of air inlet hood (1) to fix.
Fig. 1
No. Part No. Name Q’ty

1 6128-11-5180 Hood 1
62
Installation of engine air pre-cleaner (if equipped)
A-6.2
1) Remove the dust/water seal stuck to the air inlet hood mounting opening of the engine hood shown
in the figure. (Fig. 2)
2) Insert duct (2) in the air discharge mounting opening all the way. It may be installed in any direction.
3) Tighten the duct band with bolt (3), washer (4) and nut (5).
4) Insert pre-cleaner (1) in duct (2) all the way. It may be installed in any direction.
5) Tighten the band bolt of pre-cleaner (1) to fix.
Fig. 2
No. Part No. Name Q’ty

1 195-01-35210 Precleaner 1
2 195-54-68880 Duct 1
3 01016-51045 Bolt 1
4 01643-31232 Washer 1
5 01580-11008 Nut 1
63
Installing direction of exhaust pipe
A-7
1) Remove the temporarily exhaust pipe installed to the machine and then remove rain cap (4).
2) Install rain cap (4) to the exhaust pipe (1) at the angle shown in (Fig. 1) and install exhaust pipe
assembly to the hood with bolts (2) and washers (3).
Fig. 1
4 6162-14-5640 1
3 01643-31232 7
2 195-54-43210 7
1 195-01-41112 1
No. Part No. Q’ty
Install the rain cap in the direction shown in (Fig. 2).
Right of machine Fig. 2
Front of machine
Left of machine
Note) Direct the rain cap toward the inside of the machine so that the exhaust gas will not blow over the
right blade lift cylinder.
64
Installation of blade lift cylinder (1/2)
A-8
1. Remove the cap and bushing of the yoke.

Fig. 1
a When removing the cap, make a match
Bushing
mark on it for reinstallation. (The cap is Cap
a part of the yoke.)
2. Installation of cylinder
Secure the cylinder with ropes for safety as shown in the Fig. 2
photo.
01010-82000
Part No. of bolt
(4 pieces on each side)
01643-32060
Part No. of washer
(4 pieces on each side)
Length of bolt 100 mm
Tightening torque 56 ± 6 kgm
Fix the cylinder at the angle shown in the Fig. 3.

• Cap mounting bolts
Note: Do not install the yoke to the position shown in
Fig. 4.
(If it is installed to this position, it is pushed out
by the grease pressure.)
3. Cylinder sling bracket Fig. 5

Remove cylinder sling bracket than install the cylinder so
that sling posture piston.
65
Installation of blade lift cylinder (2/2)
A-8
4. Installation of hoses
Install the hoses as shown in the Fig. 6 Fig. 6
so that they will not interfere with each other.

1 Hose 07099-01016 (2 pieces on each side)
2 Split flange 07371-31049 (8 pieces on each side) Reuse the installation parts.
3 Bolt 07375-21035 (16 pieces on each side) Reuse the installation parts.
4 O-ring 07000-13032 (4 pieces on each side)
5. Installation of right cylinder hose joint cover
Fig. 7

1 Cover (left) 195-61-61871 1
2 Cover (right) 195-61-61891 1
3 Sems bolt 01024-81225 4
66
Installation of ripper (1/8)
A-9
1. Installation of beam and arm assembly
a The following is the installation proce-

dure for the giant ripper. The installation
procedure for the multi-shank ripper is
basically the same as the following.
a Remove all the rust-preventive oil from

the ripper mounting pin and then coat the
pin with new grease.
a Before starting the following work,

remove the lift cylinders and tilt cylinder
which have been installed for transporta-
tion.
Lift cylinder ass’y (1 piece) : 270 kg
Tilt cylinder ass’y (1 piece) : 260 kg
1) Sling the front part with 2 chain blocks (2

t) so that slant to the right or left can be
adjusted.
Weight of beam and arm : Approx.

4.2 t
(Multi-shank ripper specification)
2) Since the pins at the mount are heavy,

do not remove them from the mount but
leave both of them inside when installing
the arm.
a Insert a bar between the pins and insert
the pins halfway

Name Q'ty Name Q'ty
2-t chain block 2
ø20 mm × 2 m 2
Wire rope sling
ø20 mm × 3 m 1
Wire rope sling
Nylon sling for 2t 2
Other remarks
67
A-9
3) Insert either arm pin halfway and then

set the pin hole on the opposite side.
After both pins are inserted halfway,
push them in to the end.
No. Part name Part No. Q'ty

1 Pin 195-78-71190 2
2 Plate 195-78-21171 2
3 Bolt 01010-62040 4
4 Washer 01643-32060 4
5 Fitting 07020-00000 2
a Installed to the machine body.
4) After inserting the pins, place wooden

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

Name Q'ty Name Q'ty
Wooden block 1
T 300 mm × 800 mm
Wooden block 1
T 300 mm × 600 mm
Other remarks
68
A-9
2. Installation of lift and tilt cylinders

1) Installation of lift cylinder (machine side)
Sling the removed lift cylinder with crane
and insert the pin (8) into the frame.
(2 places on the right and left sides)
Do not install lock plates at this stage.
a Take care not to mistake the right and
left cylinders for each other. (The direc-
tions of their pipings are different.)
8 Pin 195-78-73170 2
9 Fitting 07020-00000 2
a Beam side pin is to be installed after

starting the engine and operating the cylinder, following all piping works (refer to item 4).
2) Installation of tilt cylinder (machine side)

Sling the tilt cylinder with the crane and
install it to the frame with pin (8), lock
plate (2), bolt (3) and washer (4) (on the
right and left sides).
a Take care not to mistake the right and
left cylinders for each other. (The
directions of their pipings are differ-
ent.)
a Beam side pin is to be installed after
starting the engine and operating the
cylinder, following all piping works
(refer to item 4).

2 Plate 195-78-21171 2
3 Bolt 01010-62040 4
4 Washer 01643-32060 4
8 Pin 195-78-73170 2
9 Fitting 07020-00000 2

Name Q'ty Name Q'ty
Nylon sling for 2 t 2
Sledge hammer (5 lb) 2
Other remarks
69
A-9
3. Installation of hydraulic piping
1) Install hoses (6), (7), O-ring (8), flange

(9) and O-ring (10) of the lift cylinder.
a When mounting cylinder, do assembling
procedure “M-4 No-injection cranking of
engine” before engine start.

6 Hose 195-61-63710 2
7 Hose 195-61-63710 2
8 O-ring 07000-13032 8
9 Flange 195-63-45710 2
10 O-ring 07000-13035 2
Assemble hose (6) to fit the groove of bracket (11).

Direct the fittings of hose (7) as shown in part A and part B in the figure, and install the hose hor-
izontally in the forward and backward directions of the machine.
• Right lift cylinder
Part A
• Left lift cylinder
Part B
70
A-9
2) Install hoses (6), (7), O-ring (8), flange

(9), and O-ring (10) of the tilt cylinder.

6 Hose 195-61-63730 2
7 Hose 195-61-63740 2
8 O-ring 07000-13032 8
9 Flange 195-63-45710 2
10 O-ring 07000-13035 2
Assemble hose (6) to fit the groove of bracket (11).
• Right tilt cylinder
• Left tilt cylinder
Installed angle of inside hoses of tilt cyl-

inder
71
A-9
4. Bleeding air
Bleed air from the hydraulic circuit according to the following procedure.
1) Run the engine at low idle.
2) Extend and retract the cylinders to above 100 mm before each stroke end 4 – 5 times. (Do not
relieve the pressure at each stroke end.)
3) Then extend and retract the cylinders to each stroke end 3 – 4 times.
4) While the shank point is on the ground, check that the hydraulic oil level is normal. If the hydrau-
lic oil level is lower than the specified level, add hydraulic oil according to the Operation and
Maintenance Manual.
a Lower the blade to the ground, too, at this time.
5) When bleeding air, check that each cylinder hose moves freely and oil does not leak through any
joint
a If the hydraulic oil level is low, the work equipment pump may be damaged. Accordingly,
bleed air carefully and check the hydraulic oil level, and then add hydraulic oil if necessary.
5. Connection of tilt cylinder (on beam side)

1) Start the engine and operate the tilt cylin-
der as shown in the figure to adjust the
cylinder length.
2) Set the pin holes and connect the tilt cyl-
inder to the beam by pin (8), lock plate
(2), bolt (3) and washer (4). (2 places on
the right and left sides)
a Sling the right or left cylinder first and
position it properly, and then sling
and position the one on the opposite
side.
2 Plate 195-78-21171 2
3 Bolt 01010-62040 4
4 Washer 01643-32060 4
8 Pin 195-78-73180 2
9 Fitting 07020-00000 4
6. Connection of lift cylinder (on beam side)

1) Start the engine and operate the lift cylin-
der as shown in the figure to adjust the
cylinder length.
2) Set the pin holes and connect the lift cyl-
inder to the beam by pin (8), lock plate
(2), bolt (3) and washer (4). (2 places on
the right and left sides)
2 Plate 195-78-21171 2
3 Bolt 01010-62040 4
4 Washer 01643-32060 4
8 Pin 195-78-73180 2
9 Fitting 07020-00000 4
a Sling the cylinder and position it
properly.
72
A-9
7. Piping of pin puller cylinder

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

1 Hose 02760-00330 2
2 Plate 195-78-72571 1
3 Sems bolt 01024-81240 2
4 Yoke 144-947-2850 1
5 Pin 04205-11028 1
6 Pin 04050-13015 1
7 Cushion 07095-00314 6 Machine without ripper point light uses only four.
8 Clamp 07094-30315 6 Machine without ripper point light uses only four.
9 Sems bolt 01024-81065 3 Machine without ripper point light uses only four.
73
A-9
8. Confirm whether the ripper cylinder hose and pin puller hose do not interfere other parts by operat-
ing the ripper to raise/lower, to tilt-in/tilt-back.
If there is any interference, adjust the hose position by loosening the mouthpiece flange of hose.
(cylinder hose)
Adjust the clamp position so that pin puller hose does not interfere others or stretch too tight.
9. Installation of shank assembly (for giant ripper)
a Perform this work after installing the tracks since the

machine is required to ride over something in reverse.
1) Install a wire to the hook at the top of the shank assem-

bly, put it up through the holder, sling it with crane, and
adjust the ripper to match the shank hole with the
holder hole as shown in the right figure.
2) Insert the pin in the shank by operating the pin puller

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

1 Shank 195-79-51150 1
2 Pin 195-78-71360 1
3 Protector 195-78-71111 1
4 Pin 195-78-71360 2
10. Installation of shank assembly (for multi-shank ripper)
1) Install a wire to the hook at the top of the shank assem-

bly, pass it up through the holder, pull it up with the
crane and set the shank hole to the holder hole.
2) Insert the shank fixing pin and lock it by hitting the lock
pin with a hammer.

1 Shank 195-78-71310 3
2 Pin 195-78-71360 3
3 Protector 195-78-71111 3
4 Pin 195-78-71360 6
74
Installation of track (1/2)
A-10
Note) This work is required for disassembly to 32-t parts for transportation.
1. Installation of track link Fig. 1
1-1) Wind the front end of each track up to the top
of the idler. (Fig. 1)
1-2) While rotating the sprockets forward, dis-
charge the grease from the cylinder and
retract the cylinder to the stroke end.
a Keep the grease plug open.
a Clean the master link joint.
T 300 mm × high 600 mm
1-3) Push up the machine with the ripper and dis-

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

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

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

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

check that you can screw in the bolts lightly.
(Fig. 4)
75
Installation of track (2/2)
A-10
2. Tightening of master bolts

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

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

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

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

in the figure at right. (Fig. 7)
a Adjust the track tension when supplying grease at last.
a Similarly install the track shoe on the opposite side.
76
Assembly of blade (1/16)
A-11
1. Installation of blade
Fig. 1
Stand the delivered blade vertically on the
assembly ground according to the following
procedure.
a Stand the blade means to set the back of

the blade at 90 degrees to the ground as
shown in (Fig. 1).
[1] Fix center link (A1) which is at the center

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

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

operating the main and auxiliary hoists,
stand the blade gradually as shown in Fig. 3
Auxiliary
(Fig. 3) and (Fig. 4) until it stands verti-
hoist side
cally on the object position (ground).
Main hoist
a Install the rope slings of the main side
hoist to the blade lift hydraulic cylin-
der mounting pin.
a Install the rope slings of the auxiliary
hoist to the lifting holes at both ends
of the blade top through shackles.
Weight of semi Standard Reinforced

U-blade 6.4 t 6.8 t
Weight of full U-blade 6.5 t
Fig. 4
Rope sling ø 24 mm × 5 m (4 pieces)
Shackle BC36, grade M (2 pieces)
Truck crane 25 t (1 unit)
a Use rope slings of JIS B8817 or

equivalent having the lifting capacity
of at least 4.8 ton.
a Use shackles of JI B2801 or equiva-
lent having the lifting capacity of at
least 6 ton.
77
A-11
2. Measures to prevent blade from falling

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

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

2 parts
frame brackets on both sides. (Fig. 6)
a Wooden block:
T300 mm × length 400 mm – 2 pieces Fig. 6
[3] If it is difficult to stand the blade vertically
with only the wooden blocks in steps [1]
and [2], add plates to adjust finely.
[4] After confirming that the blade stands

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

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

straight frames are installed in the cor-
rect directions. (Fig. 7) Fig. 7
a If the joint is installed in a wrong Joint
direction, rotate and install it again to
the correct direction.
[2] Remove the connecting pins installed to

the straight frame brackets on the blade.
(Fig. 8)
No. Part name Part No. Q'ty Good Wrong

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

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

(81).
a The quantity is the number of parts
necessary to 1 machine (1 blade).
78
A-11
[3] Sling the straight frame horizontally with

belt slings. (Fig. 9) Fig. 9
Belt sling
• Lifting load: Approx. 1,400 kg/piece on
each side
• Belt sling: 50 mm wide, 4 m long (2
pieces)
a If the straight frame slants to the right or

left, the joint described in [1] will not be
inserted in the bracket yoke easily. Connection
Accordingly, keep the straight frames Wooden block
horizontally.
Reference: A belt sling means a belt made of
[4] While slinging the straight frame, insert synthetic fibers used to sling heavy
the joint at its end in the bracket yoke on things. It is used to prevent damage
the blade and align the connecting pin on the products and protect the
holes. (Fig. 9) paint during sling work.
[5] Insert pin (81) removed in step [2] and fix

it to the bracket on the blade with lock
(83), bolt (84) and washer (85). (Fig. 9)
[6] Set a wooden block under the rear end

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

left sides.
[8] Sling the straight frames again and set

the right and left straight frames symmet- Fig. 11
rically about the blade and adjust the dis-
tance between both straight frames
(dimension W) to approx. 3,700 mm.
(Fig. 11)
a Clean each connecting part.
79
A-11
4. Installation of center brace

4.1 Temporary installation Fig. 12
[1] Remove the shims, bolts and washers
installed temporarily in advance to part F
(spherical seat) of the center link and
part G (spherical seat) of the straight
frame. (Fig. 12)
1 Bolt 01011-62720 8
2 Washer 01643-32780 8
3 Shim (2 mm) 195-71-61450 2
4 Shim (1 mm) 195-71-61460 4
5 Shim (0.5 mm) 195-71-61470 2
a "Q'ty" in above table indicates the

number for each spherical seat. Fig. 13
Each machine has 2 parts F and 2
parts G, 4 parts in total.
a For the "Part No." in above table, see
(Fig. 13).
a The kinds and numbers of the
removed shims are so combined that
the thickness at each place will be
4.5 mm. Accordingly, the shims
removed from part F should not be
mixed with those removed from part
G.
a When adjusting the thickness of 4.5
mm, keep each combination of A Fig. 14
and B. (Fig. 14)
[2] Install the belt sling to the center of cen-

ter brace (90). While slinging the center
brace with the crane, put the balls of the
ball joints respectively to the spherical
seat (part F) of the center link and that
(part G) of the straight frame. (Fig. 12)
90 Center brace 195-71-71120 2
a "Q'ty" in above table indicates the

number for each machine.
a Weight of center brace: Approx. 220
kg/piece
80
A-11
[3] Temporarily install the ball caps of center

brace (90) to the spherical seats of the Fig. 15
center link and straight frame (parts F
and G in (Fig. 12)) with bolts (1) and
washers (2) removed in step [1], while Ball cap
inserting shims (3), (4) and (5) removed
in step [1] in parts A. (Fig. 15) and (Fig.
16)
Tool (Socket) 41 mm
a Insert the shims so that their total
thickness is clearance + 0.5 mm
when the bolts are tightened lightly
(4 bolts are tightened evenly).
Then, tighten the bolts to the speci-
fied torque and check that the blade
moves smoothly.
a Insert the sets of shims 4.5 mm thick
in total (One 2-mm shim, Two 1-mm
shims and One 0.5-mm shim) in the
Two upper and lower places.
(Standard shim thickness: 4.5 mm)
a Tighten the bolts until the spherical Fig. 16
seat, shims and ball cap are fitted to
each other, although they are being
installed temporarily.
[4] Install the center brace on the opposite

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

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

part M (1 place) and parts N (1 place
each on the right and left sides). (Fig. 16)
a Use grease G2-LI (See the coating

material list).
[6] [Check of shim thickness] Fig. 17

Install the belt sling to either of the right
and left straight frames and move the
straight frame end up and down slowly
with the crane as shown in (Fig. 17).
(Stroke: 300 – 400 mm)
While moving up and down, check the
ball joints of the center brace for abnor-
mal sound and ensure that the ball joints
move smoothly (check the balls for inter-
nal interference).
Perform this check on both right and left
straight frames.
a If not problem is detected, go to step

4.2. If any problem is detected,
adjust the shims again (add new
shims) according to step 4.3.
81
A-11
4.2 Permanent installation

[1] If no problem is detected in step 4.1-[6],
tighten the ball cap bolts at both ends of
the center brace (1) in (Fig. 15) perma-
nently.
Tool (Socket) 41 mm
See Table 1 "Tightening
Tightening torque
torque"
a Tighten all the bolts evenly in the

diagonal order.
a After tightening to the specified
torque, check that the joint moves
smoothly.
[2] After tightening permanently, go to step

4.4.
4.3 Shim adjustment (Addition of shims) Fig. 18

[1] If any problem is detected (interference
of the ball is felt) in step 4.1-[6], remove
bolts (1) and washers (2) which are fixing
the ball caps temporarily at both ends of
the center brace and add 0.5-mm thick
shim (5) to the shim set in part A, and
then install the ball caps temporarily with
bolts (1) and washers (2) according to
step 4.1-[3]. (Fig. 18)
5 Shim (0.5 mm) 195-71-61470 2 Fig. 14
a Numbers in above fig. show the

quantity required for each spherical
seat.
a When adjusting the thickness of 4.5
mm, keep each combination of A
and B. (Fig. 14)
4.4 Adjustment of distance between tilt cylin-

der mounting pin holes Fig. 19
[1] Sling the straight frame again with the
belt sling as shown in (Fig. 19) and
adjust the distance between the mount-
ing pin holes of the tilt cylinder (or the
brace assembly on the left side in step 6
for the single tilt dozer specification)
(dimension K) to about 1,590 mm. Then,
adjust the position of the wooden block
under the straight frame so that the dis-
tance between the holes will be stabi-
lized and then remove the sling.
a Perform this adjustment on the right
and left sides.
82
A-11
5. Installation of tilt hydraulic cylinders
5.1 In case of dual tiltdozer specification

Fig. 20
[1] Install hydraulic hoses and hose protec-
tion covers to the right and left hydraulic
cylinders. (Fig. 20)

6 Hydraulic cylinder 707-01-0ZT70 2
Hydraulic hose
7 195-71-76650 2
(Overall length: 1,490 mm)
Hydraulic hose
8 195-71-75660 2
9 O-ring 07000-13022 4
10 Flange 07371-30500 8
11 Bolt 01010-80830 16
12 Washer 01643-50823 16
13 Cover 195-71-63651 2
14 Bolt 01010-82050 12
Fig. 35
15 Washer 01643-32060 12
Bolt specification Tool (Socket)

M8 13 mm
M20 30 mm
a Flange (10), bolt (11) and washer (12)

are installed to each hydraulic cylinder in
advance. (Marked )
However, do not reuse the sleeve head
(oil stop cover) installed to the hydraulic
cylinder with (10), (11) and (12) when
installing the hydraulic hoses.
a Replace O-ring (9) with new one, as a
rule.
83
A-11
[2] Remove the covers and hydraulic cylin-

der mounting pins installed to the Fig. 21
hydraulic cylinder mounting sections of
the right and left straight frames. (Fig.
21)

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

belt sling (20), with the cover side
(hydraulic hose side) down, align the
mounting pin hole on the bottom side
(clevis side) with that of the straight
frame.
Then, insert mounting pin (16) removed
in step [2] and fix it to the straight frame
with lock (17), bolt (18) and washer (19).
(Fig. 21)
• Sling weight (Weight of hydraulic cyl-

inder assembly)
RH and LH sides, approx. 300kg each

Tool (Socket) 30 mm
Tightening torque
torque"
[4] Set a wooden block between hydraulic Fig. 22

cylinder (hydraulic hose protection cover)
and straight frame so that hydraulic cylin-
der (6) will be positioned as shown in
(Fig. 22), and then loosen and remove
the sling.
a Do not connect the head side of

hydraulic cylinder (6) part R in (Fig.
22) at this time.
Connect it after installing the blade
assembly to the machine.
See “assembly procedure A-12”
84
A-11
[5] Connect the free ends of hydraulic hoses

(7) and (8) installed to hydraulic cylinder Fig. 23
(6) in step [1] to the elbows of flange (21)
installed to the straight frame. (Fig. 23)
Connect according to the letters stamped
on the flange.
Stamp Hose to be connected

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

rings (22).

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

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

cation Length : 25 mm Length : 50 mm
Tool
19 mm 30 mm
(Socket)
Tightening
See Table 1 "Tightening torque"
torque
85
A-11
5.2 In case of single tiltdozer specification
a For the single tiltdozer specification,

install the tilt hydraulic cylinder to
only the right side.
[1] Install the hydraulic hoses and hose pro-

Fig. 24
tection cover to the hydraulic cylinder.
(Fig. 24)

31 Hydraulic cylinder 707-01-0ZT80 2
Hydraulic hose
32 195-71-76731 2
Hydraulic hose
33 195-71-76660 2
34 O-ring 07000-13022 4
35 Frange 07371-30500 8
36 Bolt 01010-80830 16
37 Washer 01643-50823 16
38 Cover 195-71-63661 2
39 Bolt 01010-82050 12
40 Washer 01643-32060 12
Fig. 36

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

(37) are installed to hydraulic cylin-
der (31) in advance. (Marked )
However, do not reuse the sleeve
head (oil stop cover) installed to the
hydraulic cylinder with (35), (36) and
(37) when installing the hydraulic
hoses.
a Replace O-ring (34) with new one, as

a rule.
86
A-11
[2] Remove the covers and hydraulic cylin-

der mounting pin (41) installed to the tilt Fig. 25
hydraulic cylinder mounting section of
the right straight frame. (Fig. 25)

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

with belt sling (20), with the hydraulic
hose cover side down, align the mount-
ing pin hole on the bottom side (clevis
side) with that of the straight frame.
(Fig. 25)
• Sling weight (Weight of hydraulic cyl-

inder assembly) Fig. 26
Approx. 300 kg

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

cylinder (hydraulic hose protection cover)
and straight frame so that the hydraulic
cylinder (31) will be positioned as shown
in (Fig. 26), and then loosen and remove
the sling.
a Do not connect the head side of the

hydraulic cylinder (31) part R in (Fig.
26) at this time.
Connect it after installing the blade
assembly to the machine.
See “assembly procedure A-12”
87
A-11
[5] Connect the free ends of hydraulic hoses

(32) and (33) installed to the hydraulic Fig. 27
cylinder in step [1] to the elbows of
flange (46) installed to the straight frame.
(Fig. 27)
Connect according to the letters stamped
on the flange.
Stamp Hose to be connected

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

(47).

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

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

cation Length : 25 mm Length : 50 mm
Tool
19 mm 30 mm
(Socket)
Tightening
See Table 1 "Tightening torque"
torque
88
A-11
6. Installation of brace assembly

Fig. 28
a The brace assembly is the portion shown
in (Fig. 28) which is applied to the single
tiltdozer specification.
[1] Remove covers (51 – 54) and brace

assembly mounting pins (55 – 58) Fig. 29
installed to the brace assembly mounting
section of the left straight frame in
advance. (Fig. 29)
Bolt specification : 53, 57 M20

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

(59 – 62) installed to the brace assembly Fig. 30
mounting section of the blade in
advance. (Fig. 30)
89
A-11
[3] The brace assembly consists of the fol-

lowing parts. (Fig. 31)
Fig. 31
63 Brace 195-71-61561 1
64 Fitting 07020-00000 2
65 Seal 177-50-11170 2
66 Screw 195-71-61540 1
67 Screw 195-71-51152 1
68 Bushing 195-71-51263 1
69 Ring 04071-11160 1
70 Handle 195-71-62151 1
71 Bolt 01010-61660 2
72 Washer 01643-31645 2
[4] Supply grease (See step [9]) through fit-

ting (64) installed to brace (63) and Fig. 32
rotate brace (63) with attached lever (73)
to adjust dimension L between the holes
at both ends of brace assembly to
approximately 1,590 mm. (Fig. 32)
Reference
If brace (63) is rotated with lever (73)
while screws (66) and (67) at both ends
are fixed, dimension L increases or
decrease by 12.7 mm performance turn.
Accordingly, if only one side screw in the
both end screws is rotated by a half turn,
dimension L can be adjusted by 3.175
mm.
90
A-11
[5] While slinging brace assembly with the

belt sling, with the handle (70) up, align Fig. 33
the mounting pin hole of the brace
assembly with that of the straight frame.
(Fig. 33)
• Sling weight (Weight of brace assem-

bly)
Approx. 190 kg

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

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

in step [2] and fix it to the blade with lock
(60), bolt (61) and washer (62). (Fig. 33)

Tool (Socket) 30 mm
Tightening torque
torque"
[7] Loosen and remove the sling.
91
A-11
[8] Reinstall covers (51) – (54) removed in

step [1].
Fig. 34
Tool (Socket) 30 mm
Tightening torque
torque"
[9] Greasing
After finishing installation, supply grease
to the 5 places indicated with the arrows
in (Fig. 34) until it comes out.
Single tiltdozer 6 places indicated by arrows

Dual tiltdozer 4 places indicated by arrows
a G2-LI in "Coating material list" in this

manual is recommended as grease
for the above purpose.
92
Installation of blade (1/9)
A-12
Condition1) Before starting the following work, complete "Assembly procedure A-11".
2) Before starting the following work, set the engine so that it can run to move the machine.
1) Posture of blade assembly before installation
Fig. 1 Fig. 2
Adjust the posture of the blade assembly before installation with wooden blocks (E) and (F) as
shown in (Fig. 1) and (Fig. 2).
Dimension a Dimension b (Disconnect between sphere centers)
About 995 mm About 3,480 mm
a Dimension a in the table is set on the assumption that the machine is used on a hard ground
where the track shoe grousers will not sink. If the machine is used on a ground where the grous-
ers sink, the trunnion height decreases by the sinking distance. Accordingly, dimension a must
be lowered by the decrease of the trunnion height.
a If the center link falls, dimension b increases. To prevent this, set wooden block (F) under the
center link or arm.
a Leave wooden block (G) set to erect the blade vertically in “assembly procedure A-11" as it is.
2) Connection of blade assembly and

machine Fig. 3
2.1) Peel off the paint from the spherical

part of the trunnion and clean its sur-
face. Seat
a Apply grease [G2-LI] to the spheri-
cal part of the trunnion.
G2-LI : See [Coating materials]
2.2) Set the machine within dimension "b"

of the blade assembly and move it for-
ward so that the right and left clearances will be the same.
2.3) Move and press the machine forward until the trunnion is seated in the trunnion holder (bushing)
of the blade assembly (straight frame). (Fig. 3)
93
A-12
a If the trunnion and trunnion holder are different in height, trunnion bushing (2) in (Fig. 4) may
move when the trunnion is pressed.
If the trunnion and trunnion holder are different in height, sling the straight frame of the blade
assembly with a crane etc. and adjust their heights.
2.4) Set the trunnion parts (Fig. 4) and tighten the bolts.
a Match the chamfered portion of the nut with the round portion.
Fig. 4
Q'ty for each of

right and left
1 Blade assembly ----- ---- See “assembly procedure A-13”
2 Bushing 195-71-74250 2
3 Plate 195-71-74260 4
4 Cap 195-71-74231 1
5 Nut 195-71-11512 4 With installing direction.
6 Bolt 207-46-12141 4
7 Washer 01643-32780 4

Tool (Socket) 41 mm
2.5) Remove wooden block (E) set under the straight frame in step 1).
94
A-12
3) Connection of tiltdozer hydraulic hoses

Fig. 5
3.1) Remove the plug at the tip of the hydraulic
hose coming out from the center hole of trun-
nion (refer to item 6.4 of Assembling Proce-
dures A-6).
a Take care not to lose the "O-rings".
3.2) Remove the upper and lower locknuts from

the nipples of the flange (7) in (Fig. 5) on the
blade assembly side.
3.3) Connect the hydraulic hoses to the nipples of

the above flange. (Fig. 5)
a When connect, it certainly assembly O-ring (02896-11015) removed in step 3.1).
a Connect the hydraulic hoses according to the following table.
Hose discernment Selection of connecting nipple

Left side is blue and
Blue discernment at hose end Connect to upper nipple. right side is red.
No discernment on hose Connect to lower nipple.
a The part Nos. of the plug and nut removed from the nipple of the flange in step 2) are shown
below for reference.
Dual tiltdozer Single tiltdozer

Part name/Part No.
Q'ty Q'ty
Nut 07221-20522 2 pieces each on right and left 2 pieces on only right
Plug 07376-50522 2 pieces each on right and left 2 pieces on only right
This part is not necessary any more after the blade assembly is installed to the machine.
Keeping this part is recommended, however, since it is necessary again when the blade
assembly is removed from the machine and stored.
a When the front work equipment is the single tiltdozer, perform this work only on the right
side.
95
A-12
4) Installation of tiltdozer hydraulic hose protection cover
Install tiltdozer hydraulic hose protection cover (8) (Fig. 6) connected in step 3).
Fig. 6

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

Tool (Socket) 30 mm
a Before installing the protection cover, check the operation of the tilt cylinder in the blade adjust-
ment work described later and confirm that there is not oil leakage or another problem in the tilt
hose connection.
96
A-12
5) Connection of blade assembly and blade lift cylinders

Fig. 7
5.1) Sling the hydraulic cylinder with the belt sling and
remove the transportation sling bracket.
(Fig. 7), (Fig. 8)
Belt sling
Sling bracket
a Connect the hydraulic cylinders one by one.
5.2) Check the hydraulic oil level while the shank point is
in contact with the ground, and add new hydraulic
Fig. 8
oil according to the Operation and Maintenance
Manual if necessary. (If the hydraulic oil level is low,
the work equipment pump may be damaged.)
5.3) Start the engine and operate the blade control lever
to extend/retract the hydraulic cylinder rod and align
it with the connecting hole (joint link) of the blade
assembly. Part (A) in (Fig. 9)
a The work shall be performed by the machine

operator, crane operator, and "signalman". The
signalman must arrange the signaling method in
advance and give proper directions to both Fig. 9
operators.
5.4) Insert the connecting pin in part A. (Fig. 9)
5.5) Stop the engine.
5.6) Set the lock to the connecting pin head and bolt it to
the joint link. (Fig. 9)
198-71-61240
Connecting pin part No.
(1 piece each on right and left)
198-72-62170
Part No. of lock
(1 piece each on right and left)
01010-81635
Part No. of bolt
01643-31645
Part No. of washer
Socket 24 mm Fig. 10
5.7) Install blade cylinder holdfast (11) on the upper

side of the cylinder to fix the cylinder.
97
A-12
6) Connection of blade assembly and blade tilt hydrau-

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

the right side. For the left side, see “assembly
procedure A-11” Installation of brace assembly.

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

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

cylinder has been connected to the straight Fig. 12
frame already. See “assembly procedure A-11"
Raise one end of this hydraulic cylinder with the
belt sling and remove the wooden block placed
under it. (Fig. 12)
6.3) With the hydraulic cylinder raised, start the

engine and operate the blade control lever to
extend/retract the hydraulic cylinder rod and
align its pin hole (P) with the pine hole (Q) of the
blade. (Fig. 12)
a The work shall be performed by the machine

operator, crane operator, and "signalman". The
signalman must arrange the signaling method in
advance and give proper directions to both
operators.
98
A-12
6.4) After aligning the pin holes, stop the engine and
insert pin (12) removed in step 6.1) and fix it to Fig. 13
the blade with lock (13), bolt (14) and washer
(15). (Fig. 13)
a Perform the work from step 6.2) to step 6.4) on

the right and left sides.
However, perform on only the right side for the
single tiltdozer.
a For the tightening torque of bolt (14), see "Tight-

ening torque", Table 1 in this manual.
6.5) Loosen and remove the slings of the hydraulic

cylinder.
6.6) Start the engine again and operate the blade

control lever to raise the whole blade assembly.
Then, remove all the wooden blocks placed
under the blade.
6.7) Lower the blade to the ground and stop the

engine.
7) Confirmation of operation of blade assembly
7.1) Check of hydraulic oil level and supply of new oil
[1] Check the hydraulic oil level again and supply new oil, if necessary.
a Confirm the oil level after lowering the ripper shank and blade to the ground and set the back of
the blade perpendicular to the ground.
a About the kind of used fluids refer to “Assembly procedure A-20” Check on the amount of lubri-
cants and coolant.
a If the hydraulic oil level is low, the work equipment pump may be damaged.
7.2) Check of each part for interference
[1] Move the blade slowly and check that each part does not make interference or abnormal sound.
If abnormal sounds seem to come from the ball joints at both ends of the center brace, see step
7.5).
[2] Confirm that the blade does not interfere with the machine (radiator guard) when it is tilted to the
maximum (or dual-tilted to the maximum for the dual tiltdozer) at the maximum lifting height.
[3] Confirm that there is sufficient clearances between the straight frames of the blade assembly
and the tracks of the undercarriage when the blade is tilted to the maximum (or dual-tilted to the
maximum for the dual tiltdozer).
99
A-12
7.3) Confirmation of operation of single tiltdozer

[1] Confirm that the blade is "raised" and "low- Fig. 14
ered" according to the operation of the
blade control lever. (Fig. 14) Raise
[2] Confirm that the blade is "right-tilted" and
"left-tilted" according to the operation of
the blade control lever. (Fig. 15)
[3] Inspect according to the "Field assembly
inspection check sheet" attached to the
Lower
end of this manual.
a If the lateral balance or the clearance
between blade assembly and machine
needs to be adjusted and the brace
assembly length must be adjusted con-
sequently as a result of the check, Fig. 15
return to “assembly procedure A-11”
Assembly of blade, 6. Installation of
brace assembly, and readjust those Right tilt
items.
The above items can be adjusted with
the adjustment handle attached to the
brace, the direction of the handrail may
change. Accordingly, do not apply this
method. Left tilt
If brace (63) is rotated with lever (73) to
adjust dimension L, the direction of
handle (70) changes. According, do
not apply this method.
7.4) Confirmation of operation of dual tiltdozer

[1] In addition to [1] and [2] of the single tilt-
dozer specification, ensure that the blade Fig. 16
is "pitched back" and "pitched forward" Reverse pitch
according to the operation of the blade
control lever. (Fig. 16)
[2] Furthermore, confirm that the blade is "left- Forward pitch
dual-tilted" and "right-dual-tilted" according
to the operation of the blade control lever.
[3] Inspect according to the "Field assembly
inspection check sheet" attached to the
end of this manual.
7.5) Readjustment of ball joint shims at both

ends of center brace
When the blade is tilted to the right or left, if abnormal sound comes from either of the ball joints
at both ends of the center brace, remove the ball cap of the ball joint which produces the abnor-
mal sound and add the thinnest shim (0.5 mm) according to “assembly procedure A-11” Assem-
bly of blade, step 4, and tilt the blade again to check.
100
A-12
7.6) Bleeding air

Bleed air from the hydraulic circuit according to the following procedure.
1) Run the engine at low idle
2) Extend and retract the cylinders to above 100 mm before each stroke end 4 – 5 times. (Do not
relieve the pressure at each stroke end.)
3) Extend and retract the cylinders to each stroke end 3 – 4 times.
4) While the shank point is on the ground, check that the hydraulic oil level is normal. If the hydrau-
lic oil level is lower than the specified level, add hydraulic oil according to the Operation and
Maintenance Manual.
a Lower the blade to the ground, too, at this time.
5) When bleeding air, check that each cylinder hose moves freely and oil does not leak through any
joint
a If the hydraulic oil level is low, the work equipment pump may be damaged. Accordingly,
bleed air carefully and check the hydraulic oil level, and then add hydraulic oil if necessary.
101
Installation of operator’s cab (1/19)
A-13
1) Installation of open lock striker

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

plate)
Temporarily tighten the bracket (11) (L-shaped plate
for outdoor use) to the position shown in [Fig. 2] by
using sems bolts (12) (3 pieces on each side).
Loosen the sems bolts (12) before installation the
cab.
Fig. 2
Q'ty for each of

right and left
1 Bracket (L.H) 198-Z11-3341 1 Left
2 Bracket (R.H) 198-Z11-3351 1 Right
3 Sems bolt 01024-D1230 10
5 Striker 14X-911-1921 2
6 Nut 01580-11008 8
7 Washer 01643-31032 8
8 Stopper 09453-00002 2
9 Nut 01580-01210 2
11 Bracket 198-Z11-7980 1
12 Sems bolt 01024-D1230 3
102
A-13
3) Installation of rubber seals (13) to dashboard bracket

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

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

seal (13) will slip well against each other
and rubber seal (13) will not be shifted or
deformed when the cab is installed.
Remark 2: For the ease of assembly, remove both of

right and left covers (A) before installing the
cab and reinstall them after installing the
cab.
Apply G2-LI

13 Rubber seal 198-Z11-3540 1 Sponge rubber
55 Paste seal 198-Z11-3960 1
103
A-13
4) Installation of rubber seals to mating face of operator cab bottom
4.1) Weight of operator cab assembly: Approx. 500 kg
4.2) Remove dirt, oil and grease from the rubber seal sticking faces of operator cab bottom.
4.3) Peel off the release paper of rubber seals (14), (15) and (16) and stick those seals, referring to
(Fig. 7) on the next page.
Remark : Since the rubber seals are made a little longer than required, cut them properly when stick-
ing.
Fig. 6

14 Rubber seal 14X-911-5911 3
15 Rubber seal 198-Z11-7420 2
16-1 Rubber seal 198-Z11-7410 1
16-2 Rubber seal 198-Z11-7430 1
104
A-13
Fig. 7 How to stick seals (View from bottom of operator’s cab)
Remark : For the base seal shown in the figure, see the next page.
105
A-13
Fig. 8 Fig. 9
Apply paste seal (55)

to clearance
16
Fig. 10
Fig. 11
Apply paste seal (55) The seal may cover on the mounting
to clearance hole. In such case, cut it off accord-
ingly.

55 Paste seal 198-Z11-3960 1
106
A-13
5) Installation of rubber seals to mating face of front window duct bottom of operator's cab
5.1) Remove dirt, oil, and grease from the rubber seal sticking faces of the front window duct bottom
of the operator's cab.
5.2) Peel off the release paper of rubber seals (17) and (18) and stick those seals according to the
figure below (Fig.11-1).
Front window duct on

inside of operator's cab
Stick the seal to the under surface

of the front window duct, matching
it to the hole of the under surface.
Under surface of front window duct
Fig.11-1

17 Rubber seal 198-Z11-6350 1
18 Rubber seal 198-Z11-6360 1
107
A-13
6) Installation of operator cab (hereinafter referred to as Fig. 12

cab)
After installing cab,
6.1) Lower the operator's cab assembly slowly onto the check that there is not
floor frame. clearance at each cor-
ner.
a Since the clearance between the air conditioner
duct on the cab side and the machine monitor
(instrument panel) is narrow, lower the cab care-
fully, taking care not to hit it.
a Since the rubber seal has high reaction force, take

care that the cab will not swing or move laterally.
Lower cab in direction
a Take care that the rubber seal will not be moved or of arrow.
damaged.
a Eliminate the clearance between the rubber seal

of the air conditioner duct on the cab side and the
air conditioner duct on the dashboard side.
Fig. 13
Remark: For the machine monitor, see "assembly pro-
cedure M-2".
6.2) Tighten bolts (17) and (19) and washers (18) tem-
porarily. See (Fig. 15)
a The bolts at the cab door inlet have different After installing cab,
length. Take care. check that there is not
clearance at each cor-
ner.
Lower cab in direction

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

part (a) of the rubber seal and floor frame. (Fig. 14) Fig. 14
a If there is a clearance as a result of the confirma-

tion, sling the cab again and repeat the procedure
from step 5.1).
If the clearance is very narrow, however, fill it with
paste seal (55).
108
A-13
6.4) After installing the cab on the floor, temporarily assemble the L-shaped plate for indoor use (11)
by using sems bolts (12) (in order to prevent damage to the wiring on dashboard).
Fig. 15

11 Bracket 198-Z11-3571 1
12 Sems bolt 01024-D1230 9
17 Bolt 01010-81275 15
18 Washer 124-54-26540 21
19 Bolt 01010-81245 6
55 Paste seal 198-Z11-3960 1
109
A-13
6.5) Check that the clearance between the air condi-

tioner duct on the cab side and monitor is even
on the right and left sides.
At the same time, check that the air conditioner
duct seal on the cab side is fitted to faces C on
the right and left sides of the air conditioner duct
on the dashboard side and it is not moved to the
right or left.
6.6) 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.
6.7) Permanently tighten bolts (17) and (19) which

were tightened temporarily in step 5.2) above .
6.8) Permanently tighten mounting bolts (12) of

Lplates (11) which were installed temporarily in
step 5.4 above.
11
View Z
* If the machine is equipped with the rear camera, the camera wiring must be connected to the
multi-monitor.
See A-14 "Installation of rear monitor camera".
110
A-13
6.9) Install plates (20) with bolts (21) and washers (22). (2 pieces on each side)
6.10) Install right and left foot rests (23) and (24) with bolts (25) and washers (26).
6.11) Install pedal caps (27) to the foot rests.
Fig. 19

20 Plate 198-Z11-2961 2
21 Sems bolt 01024-D1230 4
23 Foot rest (left) 14X-911-5711 1
24 Foot rest (right) 14X-911-5721 1
25 Sems bolt 01024-D1230 4
27 Pedal cap 203-43-56450 2
111
A-13
6.12) Installation of defroster ducts for right and left doors

Install left and right defroster ducts (56) and (57) with sems (58).
Fig. 31

56 Duct (L.H.) 198-911-9511 1
57 Duct (R.H.) 198-911-9521 1
58 Sems bolt 01024-D1230 4
112
A-13
6.13) The bundle of window washer tubes and the

power supply wiring harness for cab (A) in Fig. 20
(Fig. 20) come out of the bottom of the cab left
side pillar (pillar at the left door hinge) into the
cab. Take them out of the cab through the hole
on the floor frame (B) in (Fig. 20).
6.14) Fit the grommet of the rubber boot protecting

above bundle (A) to hole (B) and connect the
boot to the cab and floor frame. (Fig. 21)
6.15) Connect bundle of the window washer tubes

and power supply wiring harness for cab (A)
pulled out in step 5.13) to the window washer
tubes and power supply wiring harness for cab
installed to the machine in advance at a place
out of hole (B) indicated with X-> in (Fig. 20).
(Fig. 22), (Fig. 23)
a The window washer tubes and power sup-

ply wiring harness for cab have connector
No. indicating rings at their ends as shown
in (Fig. 22).
Connect the tubes having the same color
marks and the connectors having the
same Nos. together respectively.
Fig. 21
113
A-13
Identification color marks

Fig. 22
Red - - - - For right door
Blue - - - - For left door
Black - - - For rear window
— ----- For front window
Window washer tubes
Connectors No.
Wiring harness connectors
Connector No. indicating ring
CN-SX8 Fig. 23
Washer wiring ground 01024-81020
CN-19
Connection of washer wiring and cab wiring Washer wiring (from fender)
CN-12VS Cab wiring and washer hose

Connection of cab wiring and floor wiring
Floor wiring (from floor)

CN-21
CN-20
30
Unused clip
31
Wind tape onto excessive cable and fix to

outside of wiring with band.
Cab wiring (from cab) 29

Washer hose (from cab)

29 Clip 04435-51910 1 Fix cab wiring and washer wiring simultaneously.
30 Clip 04434-51812 1
31 Sems bolt 01024-81020 2 Tighten 04434-51910 and 04434-51812 together.
114
A-13
7) Installing the internal decorative parts and accessories
Fig. 24

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

49 Cover 195-54-68282 1
50 Screw 01245-00616 4
51 Washer 01643-70623 4
52 Btracket (left) 198-Z11-3850 1
53 Btracket (right) 198-Z11-3860 1
Installed already
54 Screw 01245-00616 2
55 Washer 01643-70623 2
8.1) Install cover (49) to the rear side of the box of the front duct containing the machine monitor
(instrument panel) with screws (50) and washers (51).
a Install the cover to the brackets (52) and (53) which are already installed to the bottom of the
duct with screws (54) and washers (55). (Fig. 26)
116
A-13
9) Installation of rear view mirror (optional)
Fig. 27

1 Mirror 14X-911-6140 1
2 Bracket 198-Z11-3670 1
3 Sems bolt 01024-D0845 2
9.1) Install rear view mirror (1) to bracket (2)
9.2) Install bracket (2) to the front duct top of the operator cab.
a The rear view mirror is an optional part, which is not installed to the operator cab of the standard
specification.
a Each operator cab to be equipped with the rear view mirror is delivered with the rear view mirror
installed, as a rule.
Accordingly, this work is required only when the rear view mirror is delivered uninstalled.
117
A-13
10) Installation of floor mats
10.1) Install the floor mats (57), (58).
Fig. 28 a Floor mat (56) is

installed together with
the operator seat to
the floor frame when
delivered.

56 Mat 195-54-68981 1 Installed already
57 Mat 195-54-68971 1
58 Mat 195-54-68891 1
a If the floor mats may be stained during the following work, floor mats (57) and (58) should be
installed just before completion of the assembly of the machine.
118
A-13
10.2) Hold the right and left ends of floor mat (57) with plates (59) and (60) installed to the bottom of
the operator cab doorway. See (Fig. 29)
Fig. 29

59 Plate 198-Z11-7590 2
60 Bolt 01024-D0650 6
119
A-13
11) Change of installed angle of radio antenna
Fig. 30
11.1) Loosen the wing bolt at the center of rotation of the radio antenna, rotate the antenna from posi-
tion (T) indicate with the broken line to position (P) indicated with the solid line, and stand it verti-
cally.
Tighten the wing bolt again to fix the antenna.
a Loosen and tighten the wing bolt with the hand.
a The radio antenna is set to position (T) indicated with the broken line for packing when the
operator cab is transported from the factory to the field.
12) Installation of the guard for cab windshield glass

Install the cover (61) to the lower part of cab wind-
shield glass by using sems bolts (62).

61 Cover 198-Z11-7991 1
62 Sems bolt 01024-D1230 2
120
Installation of rear monitor camera
A-14 (if equipped) (1/4)
1. Camera sub-assembly
(1) Install camera (1) to bracket (2) by using

bolts (3).
* Match the center of bolt (3) with the sev-
enth line from the top in the scale stuck to
bracket (2).
2. Camera bracket sub-assembly
(1) Install bracket (9) to camera bracket (7) by

using bolts (10).
(2) Insert cushion (12) into bracket (11) and

install them to bracket (9) by using bolts
(13).
(3) Install camera (1) to plate (11) by using

bolts (4), (5), and (6).
(4) Put grommet (14) over the camera wiring.
(5) Install grommet (15) to bracket (7).
* For details of each part, see (4/4).
121
3. Installation of camera sub-assembly
(1) Install sub-assembled camera bracket (7)

to the cab by using bolts (8).
* Keep the radio antenna erected.
(2) Pass camera wiring (A) installed to the rear

of the cab through grommet (15) fitted to
camera bracket (7) and connect it to cam-
era wiring (B).
(3) Fix the connectors of camera wirings (A)

and (B) by using cushion (16) and clamps
(17) and (18).
(4) Fix camera wiring (B) to camera bracket (7)

by using clamps (19) and (20).
(5) Fix camera wiring (A) to camera bracket (7)

by using clamps (21) and (22).
4. Connection of camera wiring to multi-monitor
(1) Remove monitor panel cover (C) before

installing the cab.
(2) After installing the cab, connect the camera

wiring to the connector on the right side of
the multi-monitor.
(3) Install the monitor panel cover.
* Install the monitor panel cover in order to

make that the clearance between the
monitor panel and the panel cover hole is
even.
122
5. Check of camera direction

(1) After assembling the machine, change
the multi-monitor screen to the camera
screen.
(2) Ensure that a part of the rear cover is
displayed at the bottom of the camera
screen.
When the screen is wrong, adjust the
camera direction.
* The above camera view range is a
proper range. Adjust it according to the
customer's request.
6. Installation of camera cover

(1) Install cover (23) to bracket (9) by using
bolts (24).
123

1 Camera 7835-33-1100 1 Packed in 7835-33-1001
2 Bracket 7835-33-1201 1 Packed in 7835-33-1001
3 Bolt 7835-33-1310 2 Packed in 7835-33-1001
4 Bolt 7835-33-1320 4 Packed in 7835-33-1001
5 Washer 7835-33-1330 4 Packed in 7835-33-1001
6 Washer 7835-33-1340 4
7 Bracket 195-06-55491 1
8 Sems bolt 01024-D1225 4
9 Bracket 20Y-06-41661 1
10 Sems bolt 01024-D1025 2
11 Bracket 20Y-06-41670 1
12 Cushion 20Y-810-1240 4
13 Sems bolt 01024-D0835 4
14 Grommet 201-54-13210 1
15 Grommet 205-977-7310 1
16 Cushion 07095-00317 1
17 Clamp 04434-53211 1
18 Sems bolt 01024-D1020 1
19 Clamp 04434-50610 1
20 Sems bolt 01024-D1020 1
21 Clamp 04434-51010 3
22 Sems bolt 01024-D1020 3
23 Cover 20Y-06-41681 1
24 Sems bolt 01024-D1020 2
124
Installation of additional cab lights
For machine without camera
1. Installation of additional lights to cab

top
(1) Install brackets (1), (2), (3), and (4)

to the top and rear of the cab by
using bolts (5).
(2) Install wiring (6) by using clamps

(7), (8), and bolts (9).
(3) Remove the cap at the rear of the

cab, take out the internal wiring
connectors (No. CN-1, 25) through
the hole, connect them, and return
them into the cab.
Put wiring grommet (A) to the hole.
(4) Tighten clip (10) together with the

clamp to fix the connector (CN-P4).
(5) Install lamps (11) to the brackets

and connect the connectors (CN-
AL3, AL4, AL5 and AL6).
* Adjust the light angles as neces-

sary.

1 Bracket 198-Z11-7830 1 For left
2 Bracket 198-Z11-7840 1 For right
3 Bracket 198-Z11-5490 2 For rear
4 Bracket 207-92-51270 1 For right rear
5 Sems bolt 01024-D1225 8
6 Wiring harness 195-Z11-7350 1
7 Clamp 04434-51412 7
8 Clamp 04434-51012 4
9 Sems bolt 01024-81220 9
10 Clip 08193-21012 1
11 Work lamp 17A-06-17931 4 Halogen
Work lamp 21T-06-33980 4 HID
125
Installation of additional cab lights
For machine with camera
1. Installation of additional lights to cab

top
(1) Install brackets (1) and (2) to the

top and rear of the cab by using
bolts (5).
(2) Tighten bracket (4) together with

the camera bracket.
(3) Install wiring (6) by using clamps

(7), (8), and bolts (9).
(4) Remove the cap at the rear of the

cab, take out the internal wiring
connectors (No. CN-1, 25) through
the hole, connect them, and return
them into the cab.
Put wiring grommet (A) to the hole.
(5) Tighten clip (10) together with the

clamp to fix the connector (CN-P4).
(6) Install lamps (11) to the brackets

and connect the connectors (CN-
AL3, AL4, AL5 and AL6).
* Adjust the light angles as neces-

sary.

1 Bracket 198-Z11-7830 1 For left
2 Bracket 198-Z11-7840 1 For right
4 Bracket 207-92-51270 1 For right rear
5 Sems bolt 01024-D1225 4
6 Wiring harness 195-Z11-7350 1
7 Clamp 04434-51412 6
8 Clamp 04434-51012 4
9 Sems bolt 01024-81220 9
10 Clip 08193-21012 1
11 Work lamp 17A-06-17931 4 Halogen
Work lamp 21T-06-33980 4 HID
126
Installation of ROPS (1/2)
A-16
1. Installation of roof to ROPS

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

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

Name Q'ty Name Q'ty
Torque wrench (60 kgm) 1 25-ton crane 1
M24 socket 1
ø12 mm × 2 m 2
Wire rope sling
Other remarks
127
Installation of ROPS (2/2)
A-16
2. Sling the ROPS with the crane and set it to

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

{155 – 195 kgm}
4 3

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

Enter the tightening torque (measured) of the mounting Name Q'ty Name Q'ty
bolts in the Record column on page 8/8 of "Field Torque wrench 1
assembly check sheet" at the end of this manual. (210 kgm)
46-mm socket 1
ø12 mm × 2 m 2
Wire rope sling
Other remarks
128
Installation of VHMS, ORBCOMM antenna
A-17
Fig. 1

1 Antenna 8A13-10-2100 1
2 Bracket 195-54-73450 1
3 Bolt 01024-81016 2
4 Clamp 04434-51408 4
5 Bolt 01024-80816 4
1) Install antenna installation bracket (2) to the hood of the ROPS guard.
2) Install the antenna cable from the ORBCOMM terminal installed to the machine to the ROPS guard
with clamps (4) and then install its end to the antenna installation bracket (2).
a When installing the antenna cable end to the antenna installation bracket, apply adhesive (LT-2)
to the female threads of the nut and male threads of the cable end, and then tighten the nut. Do
not stick the adhesive to the core or internal material of the antenna cable.
a Adjust the route of the antenna cable so that the antenna cable will not interfere with the hood
(particularly part A) or legs of the ROPS by changing the directions of the clamps (4) properly.
3) Install antenna (1) to the antenna cable end.
VHMS: Abbreviation for Vehicle Health Monitoring System
129
Installation of revolving warning lamp to top of ROPS
1. Revolving warning lamp sub-assembly

(1) Remove connector (B) of lamp (1).
(2) Install grommet (4) to bracket (2), pass the wir-
ing of lamp (1) through the hole of grommet (4),
and install lamp (1) with nuts (A) attached to
lamp (1).
(3) Reinstall connector (B) that was removed from
lamp (1).
(4) Fix connector (B) of lamp (1) to bracket (2) by
using the clip.
2. Installation of revolving warning lamp to top of ROPS

For machine without additional lamp
(1) Connect connector (CN-P3) of wiring (5) to
connector (B) of lamp (1). Machine without additional
lamp
(2) Install lamp (1) to the top of the ROPS by
using bolts (3).
(3) Remove the cap at the rear of the cab, take
out the internal wiring connector (CN-25)
through the hole, connect it, and return it
into the cab.
Fit grommet (C) of wiring (5) to the hole.
(4) Install bracket (8) to the rear of the cab by
using bolt (9).
For the machine with the rear view camera,
tighten bracket (8) by using the mounting
bolts of the camera bracket.
(5) Install wiring (5) by using clamps (6), (10),
and (7).
For the machine with the rear view camera,
tighten clamp (10) and the camera wiring
clamp together.
Machine without additional lamp and with
rear view camera
(10)To be tight-
ened together
(8) To be tight-
ened together
Camera bracket
For details of each part, see (3/3).
130
For machine with additional lamp

Machine with additional
lamp
connector (B) of lamp (1).
(2) Install lamp (1) to the top of the ROPS by

using bolts (3).

connector (CN-P4) of the additional lamp wir-
ing on the top of the cab.
(4) Install wiring (5) by using clamps (6) and (7).
Machine with additional lamp and

rear view camera
For details of each part, see (3/3).
131
3. Installation of revolving warning lamp switch
(1) Remove the switch panel at the right top

inside the cab.
(2) Remove the blind cover of the switch

panel and install switch (11).
(3) Connect connector (CN-26) of switch

(11) to wiring connector (CN-26) in the
cab. Switch panel
Blind cover
(4) Install the switch panel.

1 Lamp 14X-890-1160 1
2 Bracket 154-06-31310 1
3 Sems bolt 01024-81020 3
4 Grommet 08037-01008 1 For right rear
5 Wire harness 195-06-43490 1 Other than machine with additional lamp
195-06-43480 1 For machine with additional lamp
6 Clamp 04434-51412 4 Use only 2 pieces for machine with additional lamp
7 Sems bolt 01024-81220 4 Use only 2 pieces for machine with additional lamp
8 Bracket 207-62-51270 1 Unnecessary to machine with additional lamp
9 Sems bolt 01024-81225 1 Unnecessary to machine with cameral and additional lamp
10 Clamp 04434-51412 1 Only machine with camera
11 Switch 22U-06-22310 1
132
Check track tension (1/2)
A-19
Adjusting
• When increasing tension Fig. 1
1. First remove the bolts (1) and then re-
move the cover (2). (Fig. 1)
2. Pump in grease through the grease fit-
ting (3) with a grease pump. (Fig. 3)
3. To check that the correct tension has
been achieved, move the machine back-
wards and forwards.
4. Check the track tension again, and if the
tension is not correct, adjust it again.
5. Continue to pump in grease until S Fig. 2

becomes 720mm (28.4 in).
If the tension is still loose, the pin and
bushing are excessively worn, so they
must be either turned or replaced.
Please contact your Komatsu distributor.
(Fig.2)
• When loosening tension

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

• There is danger of plug (4) flying out under the high Name Q'ty Name Q'ty
internal pressure of the grease. Never loosen plug (4)
more than 1 turn.
Never loosen any part other than plug (4). Never put
your face in the mounting direction of plug (4).
If the track tension cannot be loosened with the proce-
dure given here, please contact your Komatsu distrib-
utor.
• When removing cover (2), be careful not to let any dirt
get inside.
• There is a safety label stuck to the back of cover (2). Other remarks
Be careful not to damage the safety label.
133
Check track tension (2/2)
A-19
Inspection
Stop the machine on level ground (stop with Fig. 4
the transmission in FORWARD without
applying the brake). Then place a straight
bar on the track shoes between the carrier
roller and the idler as shown in the figure,
and measure the clearance between the bar
and the grouser at the midpoint. If the clear-
ance is 20 to 30 mm (0.79 to 1.18 in), the
tension is standard. If the track tension is not
at the standard value, adjust it in the follow-
ing manner. (Fig. 4)

Name Q'ty Name Q'ty
Other remarks
134
Check fuel, coolant and lubricants (1/2)
A-20
Check the amount of lubricant and coolant in every device.

When refill is required, perform it reference to [Fig.1] and [Table 1].
Fig. 1 Using temperature range of oil, grease, fuel and coolant
• ASTM : American Society of Testing and Material
135
Check fuel, coolant and lubricants (2/2)
A-20
Table 1 Specified capacity and refill capacity of each part

Hydraulic Cooling
Final drive
Engine oil Damper Power system system
case Fuel tank
pan case train case (With blade, (including
(each)
without ripper) sub-tank)
Specified Liters 87 2.1 275 61 280 120 1,200
capacity US gal 22.99 0.55 72.66 16.12 73.98 31.70 317.04
Refill Liters 86 2.1 150 61 130 – –
capacity US gal 22.72 0.55 39.63 16.12 34.34 – –
Oil and coolant addition condition
• Use Komatsu genuine oil and grease.
• When adding oil, do not mix oils of different types. When changing the type of oil, replace the oil
of the specified capacity (all the oil). (The oil remaining in the piping etc. may be mixed with the
new oil.)
• When the machine is delivered, the oil, fuel and coolant shown in (Table 2) are filled, unless oth-
erwise specified.
Table 2
Item Type
Engine oil pan Engine oil 15W40DH-1 (Komatsu genuine)
Power train case
Final drive case Power train oil TO30 (Komatsu genuine)
Damper case
Hydraulic tank Power train oil TO10 (Komatsu genuine)
Fuel tank JIS No. 1, JIS No. 2, JIS No. 3 in winter (Oct. – Mar.)
Radiator Supercoolant AF-NAC (Concentration: Min. 30%) (Komatsu genuine)
136
Bleeding air from hydraulic cylinders
A-21
a After disassembling for transportation, changing the oil in the hydraulic tank, or removing the hydrau-
lic cylinders or work equipment piping, bleed the air from the hydraulic circuit as follows.
1. Blade lift cylinder (with piston valve)

1) Start the engine and run at low idling for approx. 5 minutes.
2) With the engine at low idling, extend and retract the cylinder four or five times without operating
it to the end of its stroke.
a Operate the piston rod to approx. 100 mm form the end of the stroke; do not releive the cir-
cuit under any circumstances.
3) Keeping the engine at low idling, retract the cylinder to a point approx. 100 mm before the end of
the stroke, then use fine control (at least 10 seconds) to retract the cylinder to the end of its
stroke. While operating the lever, hold it in this position for 3 minutes.
4) With the engine at high idling, retract the cylinder to a point approx. 100 mm before the end of
the stroke, then use fine control (at least 10 seconds) to retract the cylinder to the end of its
stroke. While operating the lever, hold it in this position for 1 minute.
2. Blade tilt cylinder (without piston valve)

1) Start the engine and run at low idling for approx. 5 minutes.
2) With the engine at low idling, raise and lower the blade four or five times without operating the
cylinder to the end of its stroke.
a Operate the piston rod to approx. 100 mm form the end of the stroke; do not relieve the cir-
cuit under any circumstances.
3) Repeat this operation with the engine at full throttle, then run the engine at low idling and operate
the piston rod to the end of its stroke to relieve the circuit.
k If from the beginning the engine is run at full throttle, or the cylinders are operated to the end of
their stroke, the piston packing may be damaged, so never operate in this way.
k Check the oil level, and add oil to the specified level if necessary.

Name Q'ty Name Q'ty
Other remarks
137
Lubricating (1/3)
A-22
1. Blade lift cylinder support yoke (4 places)

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

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

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

About the kind of used fluids refer to “Assembly Name Q'ty Name Q'ty
procedure A-20” Check on the amount of lubricants and
coolant.
For other related matters, confirm them by Operation
Manual.
Other remarks
138
Lubricating (2/3)
A-22
11. Equalizer bar side shaft (1 place) (Fig. 4)

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

(1 place) (Fig. 5)

Name Q'ty Name Q'ty
Other remarks
139
Lubricating (3/3)
A-22
13. Universal joint (2 places) (Fig. 6)

Fig. 6
a Do not use molybdenum disulfide
grease.
Remove inspection cover (3) of the under-
cover on the rear bottom of the chassis as
follows.
1) Remove 2 bolts (1) at the front of the

machine. (Fig. 7)
2) Support the cover with your elbow

while gradually removing 2 bolts (2) Fig. 7
at the rear of the machine. (Fig. 7),
(Fig. 8)
3) Lower the cover gradually to open it.
14. Steering/directional/gear shift lever rotation

Fig. 8
link (4 places)

The undercover is heavy (Approx. 50 kg). Never try to Name Q'ty Name Q'ty
open or close the cover when directly beneath it. When
removing bolts (2), carry out the work from the rear of
the cover so that you can easily get out of the way.
Take measures to prevent the engine from being started
by mistake.
(Pull out the key, etc.)
Other remarks
140
Installation of fuel quick charge piping (if equipped)
A-23
(1) Remove the blind plug from the left top of the fuel tank and connect the hose. (Fig. 1)
(2) Remove the left ripper pin lock plate and install the brackets and tubes. (Fig. 1)
(3) Connect the hoses to the tubes. (Fig. 1)
(4) Fix the hoses to the fuel tank with the clamps. (Fig. 1)
(5) Tighten the U-bolts permanently so that the tubes will be set in the specified directions. (Fig. 2)
Fig. 1
To be reused.
To be replaced with
ripper pin lock plate.
Take care of angle.
Apply LG-5 to
threaded part.
Tightening torque
196.1 Nm {20 kgm}
Fig. 2
To be reused.

1 Flange 07371-32076 4
2 Sems bolt 07375-21240 8
3 Clip 07283-36163 2
4 Seat 07283-56170 2
5 Washer 01643-31032 4
6 Nut 01597-01009 4
Fix coupler chain. 7 Plate 195-04-42680 1
A 8 Tube 195-04-42670 1
A 9 Receiver 198-04-66170 1
10 Hose 195-04-42660 1
Actual angle: 30°C 11 O-ring 07000-12060 2
12 Clamp 42C-16-11510 2
13 Cusion 07095-02062 1
A (8), (9) is assembled already. 14 Bolt 01011-81210 2
15 Washer 01643-31232 2
16 Bolt 01010-62040 2
17 Washer 01643-32060 2
18 Screw 01023-10610 1
141
M. Check and maintenance procedures
after completion of assembly
143
Check and adjustment of operator's cab (1/7)
M-1
1. Measuring pressure in cab
(1) Measure the pressure in the cab.
• Criterion : Measured value X 78.5 Pa {8 mmH2O}

• Testing condition : Run the engine at full throttle and set the engine fan to 100%.
: Max. cooling fan speed.
: Set the blower to the high (Hi).
a Set the maximum cooling fan speed with the mode adjustment function of the service menu of
the machine monitor.
For the setting procedure for the maximum cooling fan speed with the adjustment mode, see
assembly procedure "M-5".
a Operate the blower according to the following procedure.
Fig. 1
1) Select the fresh air mode with the RECIRC/FRESH air selector switch (2). (Fig. 1)
2) Depress fan switch (1) to set the blower to the high (Hi). (Fig. 1)
a If the standard pressure is not obtained, check the seals around the dashboard and the seals of
the fitting faces of the cab and floor for an opening. (Run water over outside to see if it enters the
cab.) If there is an opening, fill it with liquid seal.
144
M-1
(2) Outlined below is a simplified method for

the internal pressure measurement of Fig. 2
the operator’s cab:
a) Prepare a transparent vinyl hose (of
an outer diameter of 10 mm and Lock lever
3,000 mm long). mount hole
b) Pour water into the hose bore for
about a half of the hose length.
c) Remove the sliding windshield lock
lever located on the side panel of the
operator’s cab to insert one end of
the vinyl hose before fastening an
adjacent part of the hose to the top
end of the back seat using packing Fig. 3
8 mm or more
tape. (Fig. 5)
d) Seal the gap occurring between the
lock-lever hose and the outer periph-
ery-of the hose.
e) Match the water levels of the begin-
Inside the
ning part and the ending part of the operator's cab Outside
water cloumn inside the transparent (Atmospheric pressure)
vinyl hose at the outside of the oper-
ator’s cab.
f) Start the engine and run it at full
speed to read the difference between
the two water levels. (Fig. 3)
Remove lock lever and insert vinyl hose. Fig. 5
a Before measuring the internal pressure,
ensure that the grommets shown in Fig.
4 are fitted securely.
Fig. 4
Fix vinyl hose to top end of back seat Fig. 6
• Fig. 4 is the same as Fig. 21 in "Assembly

procedure A-11".
Vinyl hose
145
M-1
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 5 gal. (about 19 l)/min. through a water hose.
(3) Pour water to the area around the hatched section in Fig. 18 for about 10 minutes. When doing
this, it is not necessary to use pressurized water.
(4) Pour water horizontally to the sealed surface according to the "Cross-section A-A". (Fig. 7)
(5) Carefully check the area around the dashboard, in particular.
a When any water leakage is found, apply due caulking before re-checking the section if the water
leakage still occurs.
Fig. 7

Name Q'ty Name Q'ty
Other remarks
146
M-1
3. Checking the door lock

Check the correlation between the operator's cab structure and the door when the door is opened
and closed. When anything is found abnormal, make due adjustment to correct it.
3-1 Checking the current statuses
(1) Check the mounted elevation of the damper rubber. (Located at 4 places per a side and check
them on both L.H and R.H sides.)
Applying a packing tape strip over the contact surfaces of the damper rubber, open and close the
door for 2 to 3 times. After finishing this opening and closing cycles of the door, check the contact
surface of the packing tape with the operator's cab structure. (Fig. 8)
Normal: The back surface of the packing tape comes in light contact the operator's cab struc-
ture when the door is being closed.
Abnormal: The back surface of the packing tape does not come in contact with the operator's
cab structure when the door is being closed, or if the two sections come in a harsh
contact such as peeling off the applied packing tape.
Fig. 8
(2) Check the correlation between the door latch and the striker (on both L.H and R.H side). (Fig. 9)
Moving the door toward the closing direction, observe the engaging state between the latch and
the striker.
Fig. 9

Name Q'ty Name Q'ty
Other remarks
147
M-1
3-2 Adjustments
(1) Adjusting the elevation of the damper rubber (Fig. 10)
When adjusting the elevation of the damper rubber, supplement or reduce the shims being
inserted below the damper rubber to adjust the elevation of the damper rubber properly.
Fig. 10
(2) Adjusting the correlation between the latch and the striker
(a) Loosening the striker mounting bolts to a temporarily tightened state, open and close the
door 2 to 3 times to align the centers of the latch and the striker.
(b) Check the engaging state between the latch and the striker.
(c) Tighten the striker mounting bolts back to their original tightened state.
(d) Try to open and close the door to see if the door lock can be released smoothly. When the
door lock cannot be released smoothly (when the turning effort to move the knob feels too
heavy), repeat the adjustment all over again.
a Appropriate knob turning effort: 68.6 ± 19.6 N {7 ± 2 kgf}
(3) Apply grease (G2-LI) over the latch surface.

When the grease adhering over the latch surface dries Name Q'ty Name Q'ty
out, the turning effort for the knob will become heavier.
Therefore, apply grease sufficiently in order not to allow
it to become dried up.
Other remarks
148
M-1
4. Checking the open-locked state of the door (Fig. 11)

Check the correlation between the operator's cab structure and the door when the door is in open-
locked state. When anything is found abnormal, make due adjustment to correct it.
4-1 Checking the current statuses
(1) Check the correlation between the open-lock latch and the striker. (Check them on both L.H and
R.H sides.)
Move the door toward the opening direction to observe the engaging state between the latch and
the striker. (Fig. 11)
Fig. 11
(2) Check the mounted elevation of the stopper rubber. (At 2 places each on one side. Check them
on both L.H and R.H sides.)
(a) Shaking the door back and forth in open-locked state, check for rattling.
(b) Check if the turning effort for the releasing lever is too heavy.

Name Q'ty Name Q'ty
Other remarks
149
M-1
4-2 Adjustments
(1) Adjusting the correlation between the latch and the striker (Fig. 12)
Loosen the striker mounting nut and adjust the position of the striker so that it does not interfere
with the latch nor the overriding over the bent section occurs before tightening the nut back to its
original state.
When the interference cannot be corrected by the adjustment on the striker side, loosen the
latch side mounting bolts to make the adjustment form the latch side.
Fig. 12
(2) Adjusting the elevation of the stopper rubber

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

Name Q'ty Name Q'ty
Other remarks
150
Inspection of machine monitor (1/14)
M-2
Check that the "machine monitor" on the front panel can be set in the "service menu" with its special
function and the "failure codes" can be displayed normally in that mode.
Front panel
(1) Machine monitor
Fig. 1
(2) Front lamp, working lamp switch
(3) Rear lamp switch
(4) Additional heater switch (if equipped)
(5) Starting switch
(6) Monitor switches portion
(7) Air conditioner panel or heater panel
a The "Service menu" is used in "Initialization of VHMS controller" of the VHMS specification
described later in "Attached material 2". Accordingly, understand the operating procedure thor-
oughly.
151
M-2
1. Service menu
To change the operator mode to the service menu, perform the following operation.
This operation is always required when you use the service menu.
1) Check of display of screen and operation of switches

While the ordinary screen is displayed, perform the following operation with the numeral input
switches.
• Operation of switches (While pressing [4], perform the operation in order):
[4] + [1] o [2] o [3]
a This operation of the switches is accepted only while the ordinary screen is displayed.
Fig. 2
2. Display check of "Failure code"

In the service menu, a trouble that occurred in the machine can be displayed by a classification code
named the "Failure code" on lower display unit (3) of machine monitor (1). With this function, the
operator can grasp the cause of the trouble precisely and repair the machine quickly.
The "Failure codes" are classified into the electrical system failure codes and mechanical system
failure codes, which are displayed on lower display unit (3) by setting the service menu code of
upper display unit (2) to "EE (Electrical system failure code display mode)" or "bE (Mechanical sys-
tem failure code display mode)".
152
M-2
3. Abnormality Record" (Mechanical system

"Abnormality Record")
The machine monitor classifies and records
the abnormality which occurred in the past or
which are occurring at present into the
mechanical system abnormality, electrical
system abnormality, and air conditioner
abnormality or heater abnormality.
To check the mechanical system "Abnormal-
ity Record", perform the following proce-
dures.
3.1) Selecting menu

Fig. 3
Select "02 Abnormality Record" on the
"Service Menu" screen.
Fig. 4
3.2) Selecting sub menu
After the "Abnormality Record" screen
is displayed, select "01 Mechanical
Systems" with the function switches or
numeral input switches.
• [F3]:Move to lower record
• [F4]:Move to upper record
• [F5]:Return to service menu screen
• [F6]:Confirm selection
a You may enter a 2-digit code with
the numeral input switches to select
the record of that code and confirm
it with [F6].
153
M-2
3.3) Information displayed on "Abnormality

Fig. 5
Record" screen
On the "Mechanical Systems" screen,
the following information is displayed.
(a): Occurrence order of abnormality
from latest one/Total number of
records
(b): Failure code
(c): Contents of trouble
(d): Number of occurrence time
(e): Service meter reading at first
occurrence
(f): Service meter reach at last occur-
rence
• [F1]: Move to next page (screen) (if
displayed)
• [F2]: Move to previous page
(screen) (if displayed)
• [F5]: Return to "Abnormality
Record" screen
a If no "Abnormality Record" is re-
corded, "No Abnormality Record"
is displayed.
a If the number of occurrence time is
1 (first occurrence), the service
meter reading at the first occur-
rence and that at the last occur-
rence are the same.
a If [E] is displayed on the left of a
failure code, the abnormality is still
occurring or resetting of it has not
been confirmed.
a For all the failure codes that the
machine monitor can record, see
the failure codes table in "Abnor-
mality Record (Electrical system
Abnormality Record)".
3.4) Deleting "Abnormality Record"
The contents of the mechanical system
"Abnormality Record" cannot be
deleted.
Fig. 6
4. "Abnormality Record" (Electrical system
"Abnormality Record")
The machine monitor classifies and
records the abnormality which occurred in
the past or which are occurring at present
into the mechanical system abnormality,
electrical system abnormality, and air con-
ditioner abnormality or heater abnormality.
To check the electrical system "Abnormal-
ity Record", perform the following proce-
dures.
4.1) Selecting menu

Select "02 Abnormality Record" on the
"Service Menu" screen.
154
M-2
4.2) Selecting sub menu

Fig. 7
After the "Abnormality Record" screen
is displayed, select "02 Electrical Sys-
tems" with the function switches or
numeral input switches.
• [F3]: Move to lower record
• [F4]: Move to upper record
• [F5]: Return to service menu screen
• [F6]: Confirm selection
a You may enter a 2-digit code with
the numeral input switches to
select the record of that code and
confirm it with [F6].
4.3) Information displayed on "Abnormality

Fig. 8
Record" screen
On the "Electrical Systems" screen, the
following information is displayed.
(a): Occurrence order of abnormality
from latest one/Total number of
records
(b): Failure code
(c): Contents of trouble
(d): Number of occurrence time
(e): Service meter reading at first
occurrence
(f): Service meter reach at last occur-
rence
• [F1]: Move to next page (screen) (if
displayed)
• [F2]: Move to previous page (screen)
(if displayed)
• [F3]: Move to lower record
• [F4]: Move to upper record
• [F5]: Return to "Abnormality Record"
screen
a If no "Abnormality Record" is re-
corded, "No Abnormality Record"
is displayed.
a If the number of occurrence time is
1 (first occurrence), the service
meter reading at the first occur-
rence and that at the last occur-
rence are the same.
failure code, the abnormality is still
occurring or resetting of it has not
been confirmed.
a For all the failure codes that the
machine monitor can record, see
the failure codes table.
155
M-2
4.4) Deleting "Abnormality Record"

Fig. 9
4.4-1) While the "Electrical Systems"
screen is displayed, perform the fol-
lowing operation with the numeral
input switches.
• Operation of switches (While
pressing [4], perform the opera-
tion in order): [4] + [1] o [2] o [3]
a Operate the switches similarly to
the procedure for changing the
ordinary display to the service
menu.
4.4-2) Check that the screen is set in the

delete mode, and then delete the
items one by one or together with the
function switches.
a If the screen is set in the delete
mode, [CLEAR] graphic mark is Fig. 10
indicated at [F2].
• [F2]: Delete all items
• [F3]: Move to lower item
• [F4]: Move to upper item
• [F5]: Return to "Abnormality
Record" screen
• [F6]: Delete selected item
a To delete items one by one:
Select the item to be deleted with
[F3] or [F4] and press [F6].
a To delete all items together:
Press [F2], and all the items are
deleted, regardless of selection
of the items.
failure code, the deleting opera-
tion is accepted but the informa-
tion is not deleted.
4.4-3) After the "Electrical Sys. Error Reset" Fig. 11

screen is displayed, operate the
function switches.
• [F5]: Return to "Electrical Sys.
Error Reset" screen
(Delete mode)
• [F6]: Execute deletion
a The following figure shows the
screen displayed when the items
are deleted one by one (which is
a little different from the screen
displayed when all the items are
deleted together).
156
M-2
4.5) If the screen to notify completion of

deletion is displayed and then the
Fig. 12
"Electrical Sys. Error Reset" (delete
mode) screen is displayed, the deletion
of the "Abnormality Record" is com-
pleted.
a After a while, the screen returns to
the "Electrical Sys. Error Reset"
screen.
5. Failure code
As described above, the "failure codes“ are
classified and displayed into the "electrical
system failure codes" and "mechanical sys-
tem failure codes". For the details of each
code, see "Testing and adjusting volume" or
"Troubleshooting volume of the shop man-
ual.
The major "failure codes" are listed on the

following pages.
157
M-2
158
M-2
159
M-2
160
M-2
161
M-2
162
M-2
163
M-2
164
Checking operation of dual tilt mechanism (If equipped)
M-3
<Dual tilt operation> (Fig. 1)

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

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

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

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

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

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

ton is pressed while the blade is being tilted, the
blade is pitched.
Fig. 4
165
Setting procedure for USER ADJUST MODE (1/2)
M-4
Display of No Injection
If the engine is operated after long storage of the machine, it may be worn or damaged because of insuf-
ficient lubrication with oil. To prevent this, the function to lubricate the engine before starting it by crank-
ing it without injecting fuel is installed.
Set the No Injection while the engine is stopped.
1. Selecting menu Fig. 1

Select "10 No Injection" on the "Service
Menu" screen.
2. Displaying check screen

If the "No Injection" screen is displayed, the Fig. 2
machine monitor asks the operator if no-
injection cranking should be performed.
Answer with the function switch.
• [F5]: Do not perform (Return to Service
menu screen)
• [F6]: Perform
a While the screen is changing to the fol-
lowing screen, the screen of "Communi-
cation between controllers is being
checked" is displayed.
3. Starting no-injection cranking

If no-injection cranking (Fuel injection in no Fig. 3
cylinders) becomes effective, that is dis-
played on the screen. Under this condition,
crank the engine with the starting motor.
a While the screen is changing to the fol-
lowing screen, the screen of "Setting is
being prepared" is displayed.
a Limit the cranking time to 20 seconds to
protect the starting motor.
166
Setting procedure for USER ADJUST MODE (2/2)
M-4
4. Finishing no-injection cranking

After completing the no-injection cranking Fig. 4
operation, press [F6], and finish of no-injec-
tion cranking is displayed and the screen
returns to the "Service Menu" screen auto-
matically.
5. Prohibiting no-injection cranking

Fig. 5
If the operator tries to perform the no-injec-
tion cranking while the engine is running, the
message that the engine is running is dis-
played and the no-injection cranking is not
set effective.
This function can be selected even while the
engine is running. If the no-injection crank-
ing is performed, however, the message of
"Engine is running" is displayed on the
screen.
167
Setting procedure for maximum cooling fan speed
M-5
During measurement of the cab internal pressure

in "M-1: Check and adjustment of operator's cab",
the cooling fan speed can be set forcibly to the
maximum which is the measurement condition
with the adjustment mode of the service menu of
the machine monitor.
For changing the service menu, see [M-2 Inspec-

tion of machine monitor].
1. Step
1.1 Turn the starting switch to the ON posi-

tion and display the machine monitor
screen.
1.2 Select "07 Adjustment" on the service Adjustment

menu screen.
Please input ID
1.3 Input adjustment ID "1005" and confirm

it.
1.4 The monitor screen changes to adjust-

ment ID "1005".
Adjustment
1.5 Start the engine and run at high idle

under this condition, and the cooling fan
speed is kept at the maximum.
The fan speed is displayed in the "FAN
SPEED" section of the screen, and the
Adjustment
engine speed in the "ENGINE SPEED"
section.
1210
1900
1.6 This mode can be reset by pressing
function switch "F5" or turning the start-
ing switch to the OFF position.
Note: Do not touch any function switch other

Dthan F5. If you do, the fan speed set-
ting may change.
168
Replacement of return filter
M-6 (Replacement of standard filter → special flushing parts) (1/2)
1. Replace the element of hydraulic oil return filter with exclusive flushing element (1), and replace valve and strainer
with plate (2).
a When replacing the elements, take out the element slowly so that refuses adhered to the element do not fall in-
side. Also, take out refuses by hand from the case.
a Confirm the installing condition of the element in accordance with "2. Installing Condition of Element".
a When the atmospheric temperature is below –15°C, do not use (2). Replace only the element and flush the circuit
while running the engine at low idle.
No. Part Name Part No. Q'ty

1 Element 208-60-71170 1
Exclusive flushing element
2 Plate 21T-60-13730 1
a Removed standard element (208-60-71123), strainer (07069-25400) and valve (208-60-71160) will be used
again after flushing is finished. Accordingly, clean and keep them so that they will not be damaged.
169
M-6 (Replacement of standard filter → special flushing parts) (2/2)
2. Installing condition of element
Element
Fig. 1 Good condition Fig. 2 Bad condition
a Do not insert the element so that it stands on the step at the bottom of the case as shown in Fig. 2.
When the filter case is filled with oil, it is difficult to check if the element is inserted correctly, so turn the element
by hand after inserting it in the case. When it turns smoothly, it is considered to be inserted correctly.
170
Flushing of hydraulic circuit, and bleeding air from
M-7 hydraulic cylinders (Part 1)
After the assembly work is completed, flush the hydraulic circuit and bleed air from the hydraulic cylinders.
a When performing the assembly process No. M-6 to M-9, the assembly process No. A-21 "Bleeding air from
hydraulic cylinders" can be neglected. However, the air bleeding mentioned in assembly process No. A-12
"Installation of blade" and A-9 "Installation of ripper" must be performed.
a Never run the engine at high idle to avoid the damage to the flushing elements.
a If from the beginning the engine is run at full throttle, or the cylinders are operated to the end of their stroke, the
piston packing may be damaged, so never operate in this way.
a Check the oil level, and add oil to the specified level if necessary.
1. Flushing of fan circuit
1) Check the oil level in the hydraulic tank.

(Check that the oil level is between "L" and "H" of
the sight gauge. If it is not between "L" and "H",
add oil.)
2) Start the engine and run it for approximately 10

minutes at low idle.
3) Then run the engine for approximately 30 minutes
in 1,000 to 1,200 rpm.
(Check that the oil level is between "L" and "H" of
the sight gauge. If it is not between "L" and "H",
add oil.)
2. Bleeding air and flushing of cylinder with piston valve (blade lift cylinder)
1) While running the engine at low idle, extend and retract the cylinder for 5 minutes.
However, do not move the cylinder to the stroke end.
a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any
circumstances.
2) Keeping the engine at low idle, retract the cylinder to a point approx. 100 mm before the end of the stroke,
then use fine control (at least 10 seconds) to retract the cylinder to the end of its stroke. While operating the
lever, hold the cylinder in this position for 3 minutes.
3. Bleeding air and flushing of cylinder without piston valve (Blade tilt cylinder, ripper lift cylinder, ripper tilt cylinder)

(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)
2) While running the engine at low idle, extend and retract the cylinder for 5 minutes.
However, do not move the cylinder to the stroke end.
a Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the circuit under any
circumstances.
171
M-8 (Replacement of special flushing parts → standard filter) (1/2)
1. After the flushing is finished for work equipment circuit, replace the exclusive flushing parts with stored original
element (3), strainer (4) and valve (5).
a When replacing the elements, take out the element slowly so that refuses adhered to the element do not fall
inside. Also, take out refuses by hand from the case.
a When atmospheric temperature is at -15°C or lower, pay attention that the valve and the strainer are not re-
placed with the plate.
a Keep accordance with the procedure in “2. Installing condition of element” as the element capacity will be low-
er if the installing condition is wrong.
No. Part Name Part No. Q'ty

3 Element 208-60-71123 1
4 Strainer 07069-25400 1 Standard element
5 Valve 208-60-71160 1
a Scrap the used flushing element. Keep accordance with the local laws for scraping.
a Replaced plate is reusable, so it is recommended to store it for the next flushing work.
172
M-8 (Replacement of special flushing parts → standard filter) (2/2)
2. Installing condition of element
Element
Fig. 1 Good condition Fig. 2 Bad condition
a Do not insert the element so that it stands on the step at the bottom of the case as shown in Fig. 2.
When the filter case is filled with oil, it is difficult to check if the element is inserted correctly, so turn the element
by hand after inserting it in the case. When it turns smoothly, it is considered to be inserted correctly.

Name Q'ty Name Q'ty
Others
173
M-9
Bleeding air from hydraulic cylinders (Part 2)
1. Bleeding air from cylinder with piston valve (Blade lift cylinder)
1) With the engine at high idle, retract the cylinder to a point approx. 100 mm before the end of the stroke, then
use fine control (at least 10 seconds) to retract the cylinder to the end of its stroke. While operating the lever,
hold the cylinder in this position for 1 minute.
2. Bleeding air from cylinder without piston valve (Blade tilt cylinder, ripper lift cylinder, ripper tilt cylinder)
1) While running the engine at high idle, repeat this operation for 5 minutes. Then run the engine at low idle and
operate the piston rod to the end of its stroke to relieve the circuit.
3. After bleeding the air, leave the engine stopped for 1 hour.
1) After leaving for 1 hour, check the oil level in the hydraulic tank.
(Check that the oil level is between "L" and "H" of the sight gauge. If it is not between "L" and "H", add oil.)
k Check the oil level, and add oil to the specified level if necessary.
174
APPENDIX 1.
Installation procedure for spill guard

(Installation by welding)
1. Spill guard fabrication drawings...................................................................... 176

1-1. For semi U-blade ........................................................................................ 176
1-2 For U-dozer ................................................................................................ 179
1-3 Semi U-blade, U-blade (plate) .................................................................... 182
2. Installation (Welding) of spill guard................................................................. 183
3. Spill guard installation (welding) procedure................................................... 184
3-1. For semi U-dozer........................................................................................ 184
3-2. For U-dozer ................................................................................................ 185
a Weld the spill guard to the blade according to the following procedure.
175
1-1. For semi U-blade
1. Spill guard fabrication drawings
176
(1) Spill guard (middle): 195-71-77611 fabrication drawing
1. This dwg shown co2-gas arc welding groove

Dimensions and leg length.
2. Welding quality to conform to kes 04.343
3. Flatness of surface (A) made of 9 portion in drawing to be within 2.
05 195-71-77611-05 Plate
SS400F 2 1.68 65 × t12
04 195-71-77611-04 Plate
SS400P 9 3.15 t12
03 195-71-77611-03 Plate
SS400F 1 13.84 65 × t12
SS400F
02 195-71-77611-02 Plate or 1 8.96 65 × t12
SS400P
01 195-71-77611-01 Plate SS400P 1 47.10 t9
Index SYM. Part name Material Q'ty/set Mass Remarks
(2) Spill guard (Left): 195-71-77621 fabrication drawing
177
(3) Spill guard (Right): 195-71-77631 fabrication drawing
178
1-2 For U-blade
(1) Spill guard (middle): 195-72-75611 fabrication drawing
179
(2) Spill guard (Left): 195-72-75621 fabrication drawing
180
(3) Spill guard (Right): 195-72-75631 fabrication drawing
181
1-3 Semi U-blade, U-blade (plate)
For semi U-blade, U-blade (2 pcs./machine) 195-71-77690
182
2. Installation (Welding) of spill guard
(1) After making the spill guard, weld it to the blade according to "3. Installation drawing for spill guard" shown
below.
(2) Precautions for welding

(a) Remove all matter harmful to welding such as dirt, rust, and paint from the parts to be welded.
(b) If the parts to be welded are wet, dry them with a gas burner.
(c) Do not use anti-spatter agents.
(d) Use coated welding rods specified by JIS 4316 (Low-hydrogen welding rod for mild steel) or welding
wires specified by JIS YGW11.
(e) Before using coated welding rods, dry them at 300 – 350 °C for 30 – 60 minutes.
(f) Preheat the area about 50 mm from the bead to be laid at 150 - 200 °C. When the ambient tempera-
ture is below 10 °C, post-heat the same area at 150 – 200 °C, too.
(g) Set the welding current to the lower limit of the current range specified for the diameter of the welding
rod or wire.
(h) When performing multi-layer welding, weave the welding rod.
(i) Do not weld by letting the melted metal flow, but weld from below to above with sufficient penetration.
Keep the arc as short as possible and take care not to make an overlap, undercut, etc.
(j) Before welding the spill guards, remove all the paint from the parts to be welded with a grinder (See
note marked with a below). Then, perform tack welding, permanent welding and finishing in order.
a If the painted surface is welded, the base metal cracks easily.
(k) Connect the ground cable to a part from which the paint has been removed or a part at which the cable
can be grounded securely (blade unit).
(I) When welding the spill guard with the blade assembly installed to the machine (body), cover the rods of
the blade lift cylinder and blade tilt cylinder to protect them from welding spatters.
183
3. Spill guard installation (welding) procedure
3-1. For semi U-dozer
As shown in Fig., weld spill guards (1), (2) and (3) to the semi U-blade.
184
3-2. For U-dozer
As shown in Fig., weld spill guards (1), (2) and (3) to the U-blade.
185
APPENDIX 2.
PRECAUTIONS FOR INITIALIZATION PROCEDURES

FOR VHMS CONTROLLER
187
Initialization procedures for VHMS 1. Check of machine information, engine
controller 1 information and controller information
a This step is a work performed on the
a Initialization tools for VHMS controller whole machine.
Symbol Part No. Part name Check and record the machine information,
engine information, VHMS controller informa-
1 799-608-3211 Diskette tion and ORBCOMM terminal information.
2 799-608-3220 Wiring harness
No. Information to be checked
Z Notebook type personal com-
1 Machine model
Commercially puter (OS: Windows98/2000/
3
available NT/Me/XP/VISTA* Terminal 2 Machine serial No.
"RS232C" is with it)
3 Current service meter reading
* VHMS setup tool Ver3.06.00.03 or newer VHMS 4 Engine serial No.
analysis tool Ver3.05.00.00 or newer
5 Transmission serial No.
a Before starting full operation after completion
of local assembly or before resuming operation 6 VHMS controller serial No.
after storage for a long period, initialize the ORBCOMM terminal serial No.
7
VHMS controller according to the following [For ORBCOMM specification only]
procedure.
a Machine data collected with the VHMS control- a VHMS controller (1) is in the control box
ler are stored and managed in WebCARE on the left side of the floor and ORB-
database. To process the data smoothly on the COMM terminal (2) is in the control box on
WebCARE, it is necessary to set the VHMS the right side of the floor.
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 uti-
lized. Accordingly, be sure to carry out the ini-
tialization.
a For the method of installing the VHMS Initial-
ization Program to the personal computer,
refer to the Operation and Maintenance Man-
ual contained in the package of diskette Z1.
a Since the service menu of the monitor panel
will be used in the following procedure, read
"Special functions of monitor panel" and under-
stand the operating procedure in advance.
a The initialization procedures cover both "ORB-
COMM Specification" and "ORBCOMMLESS
Specification". In case of "ORBCOMMLESS”
Specification", omit the procedures necessary
for "ORBCOMM Specification" only.
a During the initialization work, confirm each
work according to the "VHMS Initialization
Work Checklist".
188
2. Connection of personal computer
1) Make sure that the starting switch is in the
OFF position.
k Be sure to connect and disconnect
the personal computer while start-
ing switch is in the OFF position.
2) Connect personal computer Z3 and down-
load connectors (VDW) and (DL1) by wir-
ing harness Z2.
a The download connectors are installed
to the following places.
q (VDW): Inside of cab (Left rear
lower part)
q (DL1): Left rear side of machine
3. Check of operation and satellite capturing
(Side of backup lamp)
condition of VHMS controller
a Connect the personal computer to the
a This step is a work performed in the oper-
RS232C terminal.
ator's cab.
a Check of satellite capturing condition is
necessary o only [ORBCOMM specifica-
tion].
1) Set the starting switch in the ON position.
2) Switch the monitor panel to Service Menu
and select "Monitoring".
3) Input ID = 99003.
MAN
Monitoring
99003 Orbcomm Communication Status
Orbcomm Con. Power ON Satellite Condition On
Date Transmission OFF
a Execute initialization of VHMS from

the connector in the cab.
a Use the ground download connector
for only downloading.
Monitoring Hold
4) 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.
189
5) The dot at the right bottom of the LED digit 4. When checking satellite capturing condi-
of the VHMS controller can be checked in tion with VHMS controller
the multi-information display unit of the 1) Watch the 7-segment LED of the VHMS
monitor by the following method. controller to check that the controller is
1] Set the starting switch in the ON posi- operating normally.
tion.
2] Switch the monitor panel to Service
Menu and select "Monitoring".
MAN
Monitoring
20300 VHMS LED Monitor 0 2.
OFF
Monitoring Hold
2) Watch the decimal point LED on the right
of the right-hand 7 segments of the VHMS
controller to check that the ORBCOMM
6) At a time 3 minutes or more after start of controller is capturing the satellite [ORB-
VHMS, confirm either by the LED (light- COMM specification].
emitting-diode) display of decimal point on a Check the communication satellite
the lower right of VHMS controller or by capturing condition of the ORBCOMM
the display of decimal point on the lower controller on the VHMS controller
right of the monitor panel. side.
MAN
a If the ORBCOMM controller is nor-
Monitoring mal, the decimal point LED of the
20300 VHMS LED Monitor 0 2.
right-hand 7 segments flashes.
OFF
Check with indication of

decimal point
Monitoring Hold
Right decimal
Display
point
• Power is not supplied to ORB-
COMM controller.
OFF
• Communication line to VHMS
controller is abnormal.
• Satellite is not captured.
• Power is supplied to ORB-
ON COMM controller.
• Communication line to VHMS
controller is normal.
• Power is supplied to ORB-
COMM controller.
Blinking • Communication line to VHMS
controller is normal.
• Satellite is captured.
190
5. Startup of VHMS initialization tool 6. Initialization of VHMS controller (Tool
a This step is a work performed in the oper- before Ver. 3.5.2.1)
ator's cab (on the personal computer). a This step is a work performed in the oper-
1) Turn on the personal computer and start ator's cab (on the personal computer).
the OS. a When initializing, do not change the data
2) Click the icon of [VHMS Initialization Tool] of service meter [SMR].
on the personal computer screen to start [Machine information]
the VHMS initialization tool. 1) Open the [Machine information] tab.
a The [Machine information] tab is dis-
Important played first in the [Data clear and Set
a The setting screen varies with the up] menu.
version No. of the VHMS setting tool. 2) Check all the data.
a When using a tool before Ver. 3.5.2.1
(CD-ROM), set the VHMS in step 5.
a When using an updated tool (Ver.
3.5.2.1 or after), set the VHMS in step
6.
a It is recommended to download the
latest VHMS setting tool from the
WebCARE and update your tool.
(Related material: Servicemate SMP-
623)
3) Input the 10-digit service ID in [Service
ID].
a Service ID: 7826147000
4) Select [Data clear and Set up] in the
[Select Function] column.
5) Press the [OK] button to go to the setup
screen. 3) If information in the [Date/Time] box is not
correct, change it according to the follow-
ing procedures:
1] Press [Edit] button (1) on the right
lower part of the [Date/Time] box to
display the correction screen.
2] Correct the information and press the
[OK] button.
191
4) If information in the [Machine information] [Communication Setting] [For ORBCOMM spec-
box is not correct, change it according to ification only]
the following procedures: a Execute this setting after requesting for open-
1] Press the [Edit] button (2) on the right ing of the ORBCOM terminal and finishing the
lower part of the [Machine informa- opening procedure.
tion] box to display the correction 6) Open the [Communication Setting] tab.
screen. 7) Check all the data.
2] Correct the information and press the
[OK] button.
5) After checking/changing all the data in

[Machine information], press [Apply] but-
ton (3) to settle the setting.
a Press the [Apply] button (3), and the
screen for checking the setting will 8) To change the setting in [SHORT FAULT
appear. Check the setting again and HISTORY], follow the procedure below:
press the [OK] button if the setting is 1] Select [SHORT FAULT HISTORY] on
correct. the screen and press [Edit] button (5)
a In case of the ORBCOMM Specifica- on the left lower part of the [File
tion, execute [Communication Set- Transfer Setting] block to display the
ting] first and then settle the setting. setting screen.
2] Change the setting and then press
the [OK] button.
a At initialization, select [Occur-
rence] at [Timing] and set the
function to [ON].
192
9) To change setting in [SHORT TREND 11) After checking/changing all the data in
ANALYSIS], follow the procedures below: [Communication Setting], press [Apply]
1] Select [SHORT TREND ANALYSIS] button to settle the setting.
on the screen and press [Edit] button a If the [Apply] button is pressed, the
on the left lower part of the [File s c r ee n f o r c he c k i ng th e s et ti n g
Transfer Setting] block to display the appears. Check the setting again and
setting screen. press the [OK] button if the setting is
2] Change the setting and then press correct.
the [OK] button.
a At initialization, input [20h] to
[SMR] and set the function to
[ON].
10) To change the setting of [Satellite Setting], 12) After checking/changing the data of
follow the procedure below. [Machine Information] and [Communica-
1] Press the [Edit] button in the [Satellite tion Setting], press the [Exit] button at the
Setting] block to display the setting right lower part of the screen to finish
screen. [VHMS Initialization Tool].
2] Set the GCC Code to the applicable
area and then press the [OK] button.
GCC codes and applicable areas

Applicable Applicable
Code Code
Area Area
1 U.S.A. 122 Korea
120 Italy 1 Brazil
120 Malaysia 130 Japan
193
7. Initialization of VHMS controller (Ver. 3.5.2.1 3) Check the machine information. If it does
or after) not need to be corrected, press the "Next"
a This step is a work performed in the oper- button.
ator's cab (on the personal computer).
a When initializing, do not change the data
of service meter [SMR].
1) Select [VHMS Setting] and press the
"Next" button.
a If the VHMS was installed addition-

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

"Next" button.
194
4) Select the time zone. 8) The contents of the setting are displayed
5) Input the local time. finally. If there is not a problem, press the
6) If the DST (Daylight Saving Time) is used "Apply" button.
now, select it and press the "Next" button.
9) The system asks you if you save the data

7) Set the GCC Code to the applicable area before changing the setting. If you do not
and then press the "Next" button. need to save, select "NO".
GCC codes and applicable areas

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

contents of initialization, press the "OK"
button to finish the program.
195
8. Procedures for executing Quick Pm q Color of the bar is yellow for the
a The Quick Pm means the Pm Clinic exe- first 5 minutes and red thereafter.
cuted with the manual snap shot function
of the monitor panel. Snapshot
a Data in 7 minutes 30 seconds are saved in
the VHMS controller.
k Stop the machine on a flat place.
Engine Speed Hyd Oil Temp.
OFF
k Check that the engine coolant tempera-

0 r/min 1 ℃
ture and torque converter oil tempera- Executing 5:23

ture are within the operating range.
1) Start the engine.

2) Set the monitor panel to display the ser-
vice menu.
a For the operating method, see "Spe-
cial functions of monitor panel".
3) Selection and execution of mode.
1] Select "Snap shot" on the mode
selection screen.
Snapshot
Engine Speed OFF Hyd Oil Temp.
0 r/min 1 ℃
0:00
2] "START" is displayed and the system

is set in the waiting state.
3] When selecting "START", snapshots
will start.
a After the snap shot operation
starts, the elapsed time is dis-
played on the upper line.
a To stop the snapshots during the
execution, select " ".
Snapshot
Engine Speed OFF Hyd Oil Temp.
0 r/min 1 ℃
Executing 0:30
196
Table 1 Operations of machine to be executed while snap shot is operated
Operation of machine
Time (sec)
Finish
Start
Fuel
No.
State of machine Steer- Decelera- Brake Parking

Transmission Work equipment control
ing tor pedal pedal brake
dial
1 0:00 1:00 60 N LH N LOW HI Released Released
Low idle
2 1:00 2:00 60 N RH N LOW HI Released Released
3 2:00 3:00 60 High idle N N N HI HI Released Released
4 3:00 4:00 60 Deceleration slow N N N HI LOW Released Released
5 4:00 4:30 30 Relief & high idle N N HI HI Released Released
Ripper lift
6 4:30 5:00 30 Relief & low idle N N LOW HI Released Released
NoF1oF2oF
Torque converter
7 5:00 5:30 30 3oNoR1oR2 N N LOW HI ON Released
stall & low idle
oR3oN
NoF3 (Shift to
Torque converter LOWo
F3, then run
8 5:30 6:00 30 stall (F3) & high N N HI Shift to F3, ON Released
engine at full
idle (Note 1) then HI
throttle)
9 6:00 6:30 30 High idle N N N HI HI Released Released
NoF3 (Shift to
LOWo
Torque converter F3, then run
10 6:30 7:00 30 N Ripper lift HI Shift to F3, ON Released
stall + Relief engine at high
then HI
idle)
High idleo HIo
11 7:00 7:30 30 N N N HI Released ON
Low idle (Note 2) LOW
(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.
(Note 2): Keep running the engine at low idle until the oil temperature is lowered to the normal level.
a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine
speed to high idle.
a After stalling the torque converter, watch the power train oil temperature gauge and take care not to
overheat the power train oil.
(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature
gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the
engine at high idle to lower the oil temperature.)
197
4] The screen shown below appears 7 q Exhaust Temp FB (Exhaust tem-
minutes 30 seconds after the snap perature of front bank: 1, 2, 3)
shot is started, and then the initial q Exhaust Temp RB (Exhaust tem-
screen appears 5 seconds after. (End perature of rear bank: 1, 2, 3,)
of snap shot) q Boost press
q Engine Oil Press
Snapshot
q Engine Oil Temp
q Eng Coolant Temp
Engine Speed Hyd Oil Temp. q Ambient Temp
OFF
q Demand Eng Speed
0 r/min 1 ℃
(Engine speed demanded by
Finish 7:30 controller)
q T/C Oil Temp
(Torque converter oil tempera-
ture)
q T/M Main Press
(Transmission main relief pres-
sure)
Important q T/M Output Speed
The data of the Quick Pm is recorded only (Transmission output speed)
once. If the Quick Pm is executed again, q Shift Position
the current data are overwritten. Accord- ( Tr a n s m i s s i o n , t r a v e l , g e a r
ingly, be sure to save the data in the per- speed)
sonal computer after executing the Quick q S/T Clutch Pos.
Pm, referring to "8. Downloading of set (Steering clutch position)
data". q S/T Brake Pos. (Steering brake
position)
5] Using the analysis tool, read the data q Hydr Oil Temp
of the Quick Pm. (Hydraulic oil temperature)
a For the usage of the analysis tool, q Pump 1 Press
see the operation manual. (Work equipment pump 1 oil
6] Open the data of the Quick Pm and pressure)
translate them into a graph. q Body Pitch Angle (Pitch angle)
a Set the time to the X-axis and set the q Fan Speed
following items to the Y-axis.
q Engine Speed
q Fuel Inject
q Blowby Press
198
7] Click a point in the graph, and the value of each test item at that point on the X-axis is dis-
played under the graph.
(Example of displayed graph: This is different from the actual graph.)
199
8] Enter the above value in the Pm Clinic Inspection Sheet.
a The relationship between the data necessary for the Pm Clinic and the test conditions is as fol-
lows.
Test items
Transmission main pressure
Work equipment pump (FR)

Steering clutch position
Steering brake position

Exhaust temperature
Engine oil pressure
Blow-by pressure
State of machine
Engine speed
Shift position
Engine at low idle Q Q Q Q Q
Engine at high idle Q Q Q
Deceleration slow Q
Relief & engine at high idle Q Q
Relief & engine at low idle Q
Torque converter stall & engine at slow idle Q Q Q
Torque converter stall (F3) & engine high idle Q Q Q
Engine at high idle
Torque converter stall & relief Q
Engine at high idle o Engine at low idle Q
qShift position qSteering brake position

Test value Measuring method Test value Measuring method
-1 R1 and lock up OFF 11 Left clutch ON and right clutch ON
-2 R2 and lock up OFF 10 Left clutch ON and right clutch OFF
-3 R3 and lock up OFF 1 Left clutch OFF and right clutch ON
1 R1 and lock up OFF 0 Left clutch OFF and right clutch OFF
2 R2 and lock up OFF
3 R3 and lock up OFF
0 N
-11 R1 and lock up ON
11 R1 and lock up ON
qSteering clutch position

Test value Measuring method
11 Left clutch ON and right clutch ON
10 Left clutch ON and right clutch OFF
1 Left clutch OFF and right clutch ON
0 Left clutch OFF and right clutch OFF
200
9. Downloading of set data 2) When using download connector (VDW)
1) Connect personal computer Z3 and down- in the cab, set the starting switch in the
load connectors (VDW) in the cab or ON position.
ground download connector (DL1) by wir- 3) When using ground download connector
ing harness Z2. (DL1), turn switch (3) ON.
a The green LED lights up.
4) Operate the icon of [VHMS Technical
Analysis Tool] on the personal computer to
start the VHMS technical analysis tool.
a Download connector (VDW) in the

a Input [User Name] and [Password].
cab is installed to the left rear lower
a For the operation procedures, see the
part of the operator's seat.
Operation and Maintenance Manual
for VHMS Technical Analysis Tool.
a The ground download connector (DL1) 5) Use the [Download] function to download
is installed to the side of the left the data recorded in the VHMS controller
backup lamp on the rear frame of the to the personal computer.
machine. a For the operation procedures, see the
Operation and Maintenance Manual
for VHMS Technical Analysis Tool.
a Make sure that downloading has
completed before proceeding to the
next step.
201
10. Check of downloaded data 3) If the data was downloaded in the cab,
a This step is a work performed in the oper- disconnect wiring harness Z2 from down-
ator's cab (on the personal computer). load connector (VDW).
1) Check the set data with the [View] func-
tion.
a For the operation procedures, refer to
the Operation and Maintenance Man-
ual for VHMS Technical Analysis Tool.
a Make sure that the [MFA0] code at
the time when the snapshot was
operated is displayed in [Fault His-
tory].
a Make sure that the snap shot data is
recorded.
4) If the data was downloaded on the

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

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

1) Make sure that the starting switch is in the
OFF position.
k Be sure to turn off the starting
switch before connecting or dis-
connecting the personal computer.
2) Finish the OS of the personal computer
and then turn the personal computer OFF. 12. Communication to Komatsu
After completing steps 1 to 9 successfully,
send the "VHMS/WebCARE setting notification
form" to VHMS/WebCARE Support Center of
Komatsu, Tokyo.
a Since Komatsu has to set the receiving
side of the satellite communication, be
sure to inform Komatsu of the completion
of the setting.
a Send the VHMS data by Notes (LAN) or
E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: [email protected]
202
(Objective model: D375A-6 Bulldozer)
203
(Objective model: D375A-6 Bulldozer)
204
205
1/8
Report No.
Field assembly inspection report

After completion of assembling a machine, make inspections according to these check sheets for assuring machine performance and quality.
Model-Type Machine Serial No. User Unit No. Engine Model Engine Serial No.
D375A-6 SAA6D170E-5
Service Meter Reading Date of Inspection

Specification
Blade U Semi U (Dual Single)

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

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

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

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

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

Fuel tank Full
Horn Must be of no beat sound or sound deterioration.
Backup alarm Backup alarm must sound when the T/M lever is at
(Starting engine) the back position.
Monitor display When starting switch is turned ON, caution lamp,
warning lamp and alarm buzzer are turned ON simul-
taneously for 2 seconds.
No error code indicated in the service meter.
Operation of service meter
Inspection
Before engine start, meter must not operate when the

(Engine: Low idling)
key switch turned on.
Charge lamp (Engine: Low idling) Must not light up when all electrical equipment are
turned on.
Lamp ON (Heated lamp, tail lamp and work lamp) Must light up when turned on.
Heater hose cock. Must be fully open.
Controller error code indication (make sure that error does not Clear error code after confirming it.
recur)
Air bleeding of the hydraulic cylinder Perform air bleeding of the hydraulic cylinder.
See assembly procedure A-21 "Bleeding air from
hydraulic cylinders."
3/8
Cate- Inspec-
gory tion
Check of auto shift-down function (When stalled) Auto shift-down function must not work when stalled.
Effect of parking brake lever When parking brake lever is in FREE position, engine
Free Lock must not start.
Travel and gear shifting must be prohibited when
locked.
Free Confirmation of "Lock" indication of the monitor panel
Lock
Operability of travel lever Must be free from hitch and abnormal sound.
• Gear shifting operation Must not come off notch.
• Travel direction change operation Must be free from hitch and abnormal sound.
• Steering operation Must return smoothly.
(To each direction) Max. 10 mm
Play when lever is
in “N” position.
Check of the gear speed indication on the monitor panel. N, F1, F2, F3L, F3, R1, R2, R3L and R3 are all indi-
• Must be able to be shifted to any position with the engine at cated.
low idling and the brake turned on. Must be of no indication error.
Check of longitudinal adjustment Must be adjustable.
of steering lever box Free Must not move after locking.
Function/ operation
• Adjustment of steps Lock Case

• Check of lock lever of box
(Upper and lower)
Case
Case Knob
Check of the deceleration pedal operation Must work smoothly.

• Set the fuel dial to high idle position. Must be contained play at high idle.
• Check the deceleration RPM 850 – 950 rpm
Check of the fuel dial operation Must move smoothly.
Check of tilting directions Blade must move to left.
Blade must move to right.
Right tilt
Left tilt
Operation of isolator Switch must work properly.

• Check of operation of engine emergency stop switch
Check of dual tilt and pitch direction
Check of tilt direction
Pitch back Blade must move backward. (D) + (B)
Pitch dump Blade must move forward. (D) + (A)
LH dual tilt Blade must move to left (both cylinders move) (E) + (B)
Dual
RH dual tilt Blade must move to right (both cylinders move) (E) + (A)
LH tilt Blade must move to left (right cylinder moves) (B) + (F)
RH tilt Blade must move to right (left cylinder moves) (A) + (F)
4/8
Cate- Inspec-
gory tion
Clearance between straight frame and track Difference between right and left must be 30 mm or
Left mm
less (when measured on flat ground).
Move the blade up and down and stop it at 100 mm
Right mm above ground, then measure.
Check of the safety lever lock function No actuator must work when the safety lock lever is at
ON position.
Free In addition, engine is required not to start when the
Lock lever is free. (The lever may move, but the work equip-
ment never moves.)
Confirmation of "Lock" indication of the monitor panel
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.
Work equipment
Check of the quick drop valve operation At the engine full, set the blade lever at down position.
• Quick dropping of the blade from top position. When the lever is set at the N position after the blade
drops by 1000 mm, it must stop.
Main relief valve function (Engine: Low idling) Must be bridged with the blade and the ripper (Chassis)
Check of the accumulator function (blade, ripper) Must function immediately after the engine stops then
drop from the top to the ground.
Blade cylinder OL Must be none.
• Leakage from U-packing, damaged rod, quick drop LH
valve, tube, flange or dust seal
RH
Tilt cylinder/pitch cylinder OL Must be none.
• Leakage from U-packing, damaged rod, quick drop LH
valve, tube, flange or dust seal
RH
End bit, cutting edge mounting bolt Must be tightened.
Blade and bit stopper contact Must be contacted
1. End bit (partial contact is acceptable)
2. Stopper
Track tension adjustment Tense a string or a bar between the first

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

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

• Leakage from idler, carrier roller, bogie, pivot shaft, LH
adjustment cylinder, and lubricated track (plug, seal)
RH
Beat noise inside the cabin, beat noise of the outer cover Must be none.
Space between S/T lever and the cabin at forward travel + left Must be 40 mm or more.
steering with the S/T lever at the front position.
Opening/closing and locking effect of the cabin doors. Must work smoothly to securely lock the doors by
door-locking or key-locking.
Cabin door-open lock release lever Lever must operate smoothly and unlock securely.
(Unlock: Door is pushed out of stopper rubber section.)
Opening/closing and locking effect of the left/right side slide Must work smoothly to securely lock.
glass
Lighting of the room lamp Must come on/go off by turning the switch on/off.
Operation of the window wiper and the window washer Must be on/off by turning the switch on/off.
Cabin
Wiper: Must operate smoothly (without beat noise)

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

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

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

• Leakage from U-packing, damaged rod, tube of flange
Portions to be lubricated Q’ty Must be lubricated (right and left)

• Ripper lift cylinder head (8)
• Ripper lift cylinder bottom (6) 2
• Ripper tilt cylinder head (7) 2
• Ripper tilt cylinder bottom (5)
• Ripper arm pin (front) (9) 2
• Ripper arm pin (rear) (10) 2
2
2
6/8
Refer to the “Testing and adjusting” on Shop manual for the measurement
<Precautions for measurement>

Measure each performance value after each oil temperature has increased.
(Reference) Engine coolant temperature: Within operating range
Power train oil temperature: 75 – 85 °C
Hydraulic oil temperature: 45 – 55 °C
Engine speed
Cate- Measure-
Item Condition Unit Standard ment Criteria
gory value
Engine speed Run engine at low idling (low speed). rpm 700 – 800
* Measure stall
speed 1 segment Run engine at high idling (at full throttle). rpm 1850 – 1900
before red range of
torque converter oil Set decelarator at low speed. rpm 850 – 950
temperature gauge
Stall torque converter. (Service mode: 0530) rpm 1480 – 1580
Engine
Stall torque converter and work equipment relief. rpm 1450 – 1550
(Service mode: 0530)
Engine speed while hydraulic pump is in relief rpm 1850 – 1900

(blade tilt relief)
Manual E mode Run engine at full throttle and set transmission in N. rpm 1350 – 1450
Hydraulic pressure
Cate- Measure-
gory value
Inlet pressure Run engine at full throttle and set trans- Mpa 0.69 – 1.05
mission in N.
{kg/cm²} 7.0 – 10.7
Run engine at low speed and set trans- Mpa 0.03 – 0.25
Torque convertor
mission in N.
{kg/cm²} 0.3 – 2.5
Outlet pressure Run engine at full throttle and set trans- Mpa 0.44 – 0.70
mission in N.
{kg/cm²} 4.5 – 7.0
Run engine at low speed and set trans- Mpa 0.03 – 0.20
mission in N.
{kg/cm²} 0.3 – 2.0
Hydraulic pressure
Cate- Measure-
gory value
Work equipment Run engine at low speed and set trans- Mpa 27.5 – 29.4
Work equipment
pump mission in N.
Oil pressure
(Relief pressure) {kg/cm²} 280 – 300

Blade tilt relief
Run engine at full throttle and set trans- Mpa 27.5 – 29.4
mission in N.
{kg/cm²} 280 – 300
7/8
Work equipment speed
Cate- Measure-
gory value
Blade lift RAISE Run engine at full throttle. sec 3.7 – 4.7
Semi U
Blade lift RAISE Run engine at full throttle. sec 3.7 – 4.7
Full U
Single tilt LEFT tilt Run engine at full throttle. sec 2.5 – 3.5
Semi U • Full U
RIGHT tilt Run engine at full throttle. sec 2.5 – 3.5
Single tilt (Dual tilt specification) LEFT tilt Run engine at full throttle. sec 2.5 – 3.5
Full U • Semi U
Dual tilt LEFT tilt Run engine at full throttle. sec 2.5 – 3.5
Dual tilt Pitch DUMP Run engine at full throttle. sec 2.5 – 3.5
Ripper tilt Tilt IN Run engine at full throttle. sec 4.5 – 5.5
Tilt BACK Run engine at full throttle. sec 2.8 – 3.8
Hydraulic drift of work equipment
Cate- Measure-
gory value
Blade lift Cutting edge height: 500 – 800 mm. mm/min Max. 65/5
Ripper lift Ripper point height: 300 – 600 mm. mm/min Max. 25/5
8/8
Tightening torque record/check sheet for ROPS mounting bolts
ROPS
Mounting bolt
Sketch
(Front)
Nameplate side is rear.
a, b, c
Front right Mounting bolt (Rear)
Rear right
g, h, i
d, e, f
Front left
Rear left
Bolt position symbols j, k, l
Mounting bolt specification : M30 × 110 mm ---- 12 pieces

Specified tightening torque : 1,520 – 1,910 Nm {155 – 195 kgm}
Record of measured values : Symbolize the bolt positions as [a, b, c], [d, e, f], [g, h, i]
and [j, k, l] from the right to the left.
Record
Bolt position
(Unit: )
a
Recording column
Rear right b
c
d
Rear left e
f
g
Front right h
i
j
Front left k
l
GEN00097-05

Armado D375A

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GEN00097-05

Operator for assembly

Mechanics Sharing of work

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

*1: 610 mm (24 in) shoe, ROPS cab, air conditioner

• Semi U-tiltdozer + variable multi ripper

• Reinforced type full U-tiltdozer + variable giant ripper

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

4. k Check during actual work

6. Precautions for starting engine

7. This edition describes the maximum disassembly range.

Assembling blade sub-assembly

Adding and checking oil

Installing ripper sub-assembly

man-hours 32H 32H 24H 24H

Grand total 112H

Ripper parts CAB assembly

t Style of each KIT.

A Overall length (mm) 5,848

• Tractor (Body) (At 32t resolution transportation)

A Overall length (mm) 5,848

Shoe wide 610 710

• Work equipment Blade

A Overall length (mm) 5,125

A Overall length (mm) 4,775

A Overall length (mm) 4,300

• Work equipment Blade lift cylinder

A Overall length (mm) 2,575

• Pivot shaft (At 32t resolution transportation)

A Overall length (mm) 770

a This part may be delivered installed to the machine.

A Overall length (mm) 1,450

a This part may be delivered installed to the machine.

(2) Side (At 32t resolution transportation)

A Overall length (mm) 1,450

A Overall length (mm) 1,787

A Overall length (mm) 2,055

* ROPS is an abbreviation for Rollover Protective Structure.

A Overall length (mm) 2,880

A Overall length (mm) 1,397

Stand (Front side)

05 Channel SS400C 2 C100 × 100 × 5T × 351L

Sling (Track frame assembly)

Install to carrier roller.

Part No. of bolt TTTTT-TTTTT

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

a : Bolt thread diameter (Nominal diameter)

Nominal size of thread Width across flats Tightening torque

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

Table 4.1 Hydraulic hose of face seal type

Type that uses

Table 4.2 Hydraulic hose of taper seal type

Type that does

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

Thread diameter Proper sizes of sockets or spanners

• Use to prevent rubber gaskets, rubber cushions,

Polyethylene • Features: Resistance to heat and chemicals.

• Use to seal oil pan, final drive case, etc.

1206E • Can be coated with paint.

portions, shrinkage-fitted portions, and threaded