Gen00062 00

GEN00062-00
Field Assembly Instruction
BULLDOZER
D375A -5
SERIAL NUMBERS
D375A-5-18553
and up
Preface
Preface
You are required to execute full inspection and maintenance before
starting the engine and assembling the workequipment. Since the work
is often carried out in dangerous places and positions by a team, hold
a safety meeting in advance and appoint a crane director, work leader,
etc. so that the all member can work safely.
When the work is carried out in an overseas country, difference in language, customs, etc. lowers safety. Accordingly, the field liaison man
and work supervisor must examine the above point and take necessary measures.
(Instruction system)
Work leader
Work supervisor
Crane director
Director
and
deputy director
Operator for assembly

Liaison man
Mechanics
Sharing of work
Interpreter
We hope that the all members will cooperate with each other and
assemble the work equipment quickly in the field, observing the safety,
quality, and delivery time.
CONTENTS
Specifications ..................................................................................................................................................... 1
Precautions for field assembly............................................................................................................................ 2
Assembly procedure, necessary equipment, and schedule ............................................................................... 3
Style for transportation ....................................................................................................................................... 4
Tools list for field assembly ................................................................................................................................ 9
Sketch of tools .................................................................................................................................................. 11
Tightening torque ............................................................................................................................................. 14
Coating materials ............................................................................................................................................. 18
A. Assembly procedure
A-1
Installation of undercarriage............................................................................................................. 22
A-2
IInstalling track shoes....................................................................................................................... 31
A-3
Charging recoil chamber and pivot chamber with oil ....................................................................... 32
A-4
Installation of blade lift cylinder ........................................................................................................ 33
A-5
Installation of tilt hose & trunnion ..................................................................................................... 34
A-6
Assembly of blade assembly............................................................................................................ 36
A-7
Checking of arm joint clearance (U blade) ....................................................................................... 39
A-8
Installation of blade .......................................................................................................................... 40
A-9
Adjusting of lift cylinder joint area..................................................................................................... 45
A-10 Checking installation of dual tilt cylinder (If equipped) ..................................................................... 46

A-11 Checking operation of dual tilt mechanism (If equipped) ................................................................. 47
A-12 Installing ripper................................................................................................................................. 48
A-13 Installation of operator's cab ............................................................................................................ 58
A-14 Installation of ROPS......................................................................................................................... 68
A-15 Check track tension.......................................................................................................................... 70
A-16 Check fuel, coolant and lubricants ................................................................................................... 72
A-17 Lubricating........................................................................................................................................ 75
A-18 Bleeding air from hydraulic cylinders ............................................................................................... 79
M. Check and maintenance procedures after completion of assembly
M-1
Check and adjustment of operator's cab.......................................................................................... 82
M-2
Measuring engine speed.................................................................................................................. 88
M-3
Adjust control logic to specification .................................................................................................. 89
M-4
Error code ........................................................................................................................................ 90
APPENDIX 1. Installation of spill guards to u-blade ........................................................................................ 97

APPENDIX 2. Procedure for installing additional lamps................................................................................ 107
Field assembly inspection report
Specifications
Specifications
Item
Unit
Operating weight
(excluding operator's weight)
kg
Blade weight
(including cylinders)
kg
Ripper weight
(including cylinders)
kg
Engine name
Rated engine output
mm
Overall height (with ROPS)
mm
Overall width
mm
U-tiltdozer
+ Giant ripper
Semi-U-tiltdozer
+ Multi-ripper
10,540
11,790
10,540
5,470
Komatsu SA6D170E-3 diesel engine

391/1,800 {525/1,800}
10,330
10,695
4,695
5,140
10,040
4,695
km/h
3.8/6.8/11.8
km/h
5.1/9.2/15.8
Fell U-tiltdozer + variable giant ripper
10,405
4,035 (4,230)
Forward
Semi-U-tiltdozer + variable multi ripper
11,790
6,720
Reverse
U-tiltdozer
+ Multi-ripper
68,500
kW/rpm {HP/rpm}
Overall length
Travel speed
(1st/2nd/3rd)
Semi-U-tiltdozer
+ Giant ripper
5,140
Precautions for field assembly
Precautions for field assembly

1. Selection of workplace
1) When selecting a workplace, consider the following items so that you can load and unload the machine.
Width
Hardness
Flatness
Access road, place for turn
2) Do not work in a place where dust, rainwater, etc. may enter the hydraulic circuit during assembling
work.
3) Do not assemble while a strong wind is blowing or it is raining.
2. Preparation and check of slings and tools
1) Check each sling and tool thoroughly. When using wood blocks, etc., check that their inside is not rotten or broken.
3. k Check of actual work

1) Apply the parking brakes of the trailer and crane truck securely and put chocks under their wheels.
2) Before starting the work lower the temperature and pressure of the engine oil, hydraulic oil, cooling
water, etc.
3) When starting the engine, make an arranged sign such as sounding of the horn and check that the
workequipment control lever and travel lever are in neutral and the fuel control dial is at the low idling
position.
4) When using the crane, balance the load.
5) Allow only the persons concerned into the workplace.
4. Before starting the work, read this manual thoroughly and keep the precautions in your mind.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example
(1))
5. The supervisor shall write down the precautions for each work process and explain them to the
workers.
6. Hold a meeting every morning to check today's work plan and safe work.
Working
hours
Number of
workers
Total
man-hours
Wrecker
Trailer must
arrive at
field before
8:00.
3rd day
Installing
blade
Connecting
hoses
Adding and
checking oil
Installing ROPS
guard
24H
24H
32H
32H
112H
3 workers
3 workers
4 workers
4 workers
Grand total
8H
Unnecessary
Washing, touching
up, painting
Test operation
and adjustment
8H
45-ton wrecker 1 unit
Installing
cab
8H
45-ton wrecker 1 unit
Installing ripper
sub-assembly
Installing tracks
Installing T/F
8:00 10:00 12:00 14:00 16:00 18:00
4th day
8H
45-ton wrecker 2 units
Assembling blade
sub-assembly
Installing under cover
Installing pivot shaft and

blade lift cylinder
Unloading trailer
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
2nd day
1st day
Assembly procedure, necessary equipment, and schedule
Assembly procedure, necessary equipment, and schedule

The F/D assembly and pivot shaft are assumed to be installed to the body beforehand.
Any change of the schedule caused by weather is not included.
Special field work shall be arranged separately.
Schedule
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)
Overall length (mm)
5,720
Overall height (mm)
3,205
Overall width (mm)
3,060
Weight (kg)
Track frame
Overall length (mm)
4,037
Overall height (mm)
1,285
Overall width (mm)
832
Weight (kg)
26,900
7,300
Work equipment
(1) Reinforced U-blade
Overall length (mm)
5,140
Overall height (mm)
2,265
Overall width (mm)
1,814
Weight (kg)
8,000
(2) Blade (semi U)
A Overall length (mm)
4,695
B Overall height (mm)
2,265
C Overall width (mm)
2,290
Weight (kg)
6,800
Straight frame
Standard
Reinforced
A Overall length (mm)
4,215
4,215
B Overall height (mm)
640
640
C Overall width (mm)
470
490
Weight (kg)
1,124
1,346
Track shoe
Shoe width
710
A (mm)
2,500
B (mm)
2,500
Weight (kg)
610
4,200
(1/2)
4,600
(1/2)
Blade lift cylinder
Overall length (mm)
2,400
Overall height (mm)
685
Overall width (mm)
305
Weight (kg)
270
Pivot shaft
Overall length (mm)
770
Overall height (mm)
495
Overall width (mm)
515
Weight (kg)
210
Overall length (mm)
1,450
Overall height (mm)
300
Overall width (mm)
Under cover
(1)
Weight (kg)
840
275
(2)
Overall length (mm)
1,450
Overall height (mm)
290
Overall width (mm)

Weight (kg)
Cab
Overall length (mm)
1,787
Overall height (mm)
1,676
Overall width (mm)
1,740
Weight (kg)
915
250
500
ROPS
Overall length (mm)
1,850
Overall height (mm)
800
Overall width (mm)
2,350
Weight (kg)
780
Mulit-ripper beam
Overall length (mm)
2,880
Overall height (mm)
1,256
Overall width (mm)
1,710
Weight (kg)
2,500
Tools list for field assembly

No.
Tool name
Specification
Q'ty
Remarks
Air compressor
7.5 kg/cm, 15 m/min
Crane truck
Capacity: 25 tons
Welder
2 For welding blade spill guard (If equipped)

2 ton
Lever block
6 ton
Wire
26 6 m
6 For body
Wire sling
20 5 m
12 2 m
25 mm wide 3 m
50 mm wide 3 m
Nylon sling
Hydraulic wrench
600 kgm
1 For master link bolt
Impact wrench
450 kgm
1 For master link bolt
320 kgm
1 KW45FG
250 kgm
1 KW40F
20 kgm
1 KW20PI
16 kgm
1 KW14PI
14 kgm
1 KW12PI
50 46 41 36
1 T 38.1
36 32 30 27
1 T 25.4
10
Sockets set
11
Extension bar
T 38.1 L300
12
Torque wrench
210 kgm
140 kgm
60 kgm
M12 P1.75
M16 P2
2 For blade center link
SD22
BC36
SA60
1 For front hook
13
14
Eyebolt
Shackle
15
Sledge hammer
10P
16
Bar
L = 1,000 mm
17
Tap
M33 P2
1 For master link
M30 P3
M24 P3
18
Jack
15 ton
2 For assembling track frame
19
Hydraulic jack
80 ton
1 For assembling body
20
Chain block
8 ton 4 m
2 For assembling blade
21
Spanner wrenches set
Width: 19 50 mm
22
Standard tools set
23
Hydraulic oil
1
50 l For pivot
SAE30-CD
100 l For hydraulic tank
SAE10W-CD
No.
Tool name
Specification
24
Grease
G2-LI
25
Lubricant
LM-P (09940-00040)
26
Adhesive
27
Detergent
28
Paint remover
29
Paint for repair
Q'ty
Remarks
10 l
1
1 For sealing cab
20 l
5
Natural yellow
Lake blue
30
Glass cleaner
31
Cloth
32
Angle meter
33
Oil pump
Manual or air type
34
Oil jack
5l
35
Waste oil receiving
36
Step
Height: 2 m
37
Stand
Front
1 For attached tool drawing
Rear
38
Sling for track fame
39
Wood block
1
Bunch
5
1 For dual tilt (If equipped)

350 mm 750 mm
350 mm 400 mm
100 mm 750 mm
10
11
Channel
Channel
Channel
Channel
Channel
Angle
Angle
Plate
Plate
Plate
Plate
Plate
01
02
03
04
05
06
07
08
09
10
11
12
SYM. Part name
SS400
SS400
SS400
SS400
SS400
SS400
SS400C
SS400C
SS400C
SS400C
SS400C
SS400C
Material
10
Q'ty/set
Remarks
32T 180 250
9T 50 40
12T 55 102
9T 150B 500
50 300L
65 65 6T 200L
65 65 6T 970L
C100 100 5T 351L
C100 100 5T 400L
C125 65 6T 378L
C125 65 6T 970L
C100 65 6T 747L
Mass
Sketch of tools
Sketch of tools
Note) We are not liable for any result of use of tools manufactured according to these drawings.
Stand (Front side)
12
Channel
Channel
Channel
Channel
Channel
Angle
Angle
Plate
Plate
Plate
Plate
01
02
03
04
05
06
07
08
09
10
11
SS400
SS400
SS400
SS400
SS400
SS400C
SS400C
SS400C
SS400C
SS400C
SS400C
10
SYM. Part name Material Q'ty/set
Remarks
32T 180 250
12T 55 102
9T 150B 500
50 300L
65 65 6T 200L
65 65 6T 970L
C100 100 5T 351L
C100 100 5T 400L
C125 65 6T 378L
C125 65 6T 970L
C100 65 6T 747L
Mass
Sketch of tools
Stand (Rear side)
Sketch of tools
Sling (Track frame)
1p
iec
e
pi
ec
es
Sling (Track frame)
Fitting to the carrier roller.
13
SYM. Part name
Q'ty/set
Remarks
Frame
Master link
HM125
Shackle
RS10
Shackle
RB10
Spring
R3
Tightening torque
Tightening torque
Remove the plugging parts (flanges, heads, caps, and O-rings) of the work equipment piping and undercarriage piping, oil stopper plugs of the greasing piping, cylinder fixing jigs, and oil stopper plugs of the tap holes
of the loose-supply items which were used for transportation and keep them carefully so that they can be used
again for the next transportation.
Tighten the bolts to the torque shown in the following table, unless otherwise specified.
1. Tightening torque of bolts
When tightening the bolts with an impact wrench/spanner, apply Table 1.
Tighten the bolts according to Table 1 as a rule. When this rule is applied, the tightening torque is not
shown in the drawing.
Table 1
Unit: Nm {kgm}
Nominal size of thread
pitch
a (mm)
Width across flats

b (mm)
61
Tightening torque
Target
Range
10
12
{1.2}
8.8 14.7
{0.9 1.5}
8 1.25
13
25
{2.5}
14.7 34
{1.5 3.5}
10 1.5
17
54
{5.5}
34 74
{3.5 7.5}
12 1.75
19
89
{9}
54 123
{5.5 12.5}
14 2
22
137
{14}
84 196
{8.5 20}
16 2
24
230
{23.5}
147 309
{15 31.5}
18 2.5
27
315
{32}
201 427
{20.5 43.5}
20 2.5
30
460
{47}
319 608
{32.5 62}
22 2.5
32
650
{66.5}
471 829
{48 84.5}
24 3
36
810
{82.5}
588 1030
{60 105}
27 3
41
1180
{120}
883 1470
{90 150}
30 3
46
1520
{155}
1130 1910
{115 195}
33 3
50
1960
{200}
1470 2450
{150 250}
36 3
55
2450
{250}
1860 3040
{190 310}
39 3
60
2940
{300}
2260 3630
{230 370}
14
Tightening torque
When tightening the bolts with a torque wrench, apply Table 2.

Apply Table 2 when the proper tightening torque range is particularly narrow.
Table 2
Unit: Nm {kgm}
Nominal size of thread
pitch
a (mm)
Width across flats

b (mm)
61
Tightening torque
Target
Range
10
13.2
{1.35}
11.8 14.7
{1.2 1.5}
8 1.25
13
31
{3.2}
27 34
{2.8 3.5}
10 1.5
17
66
{6.7}
59 74
{6.0 7.5}
12 1.75
19
113
{11.5}
98 123
{10.0 12.5}
14 2
22
172
{17.5}
153 190
{15.5 19.5}
16 2
24
260
{26.5}
235 285
{23.5 29.5}
18 2.5
27
360
{37.0}
320 400
{33.0 41.0}
20 2.5
30
510
{52.3}
455 565
{46.5 58.0}
22 2.5
32
688
{70.3}
610 765
{62.5 78.0}
24 3
36
883
{90.0}
785 980
{80.0 100.0}
27 3
41
1295
{132.5}
1150 1440
{118.0 147.0}
30 3
46
1720
{175.0}
1520 1910
{155.0 195.0}
33 3
50
2210
{225.0}
1960 2450
{200.0 250.0}
36 3
55
2750
{280.0}
2450 3040
{250.0 310.0}
39 3
60
3280
{335.0}
2890 3630
{295.0 370.0}
15
Tightening torque
2. Tightening torque of pipe threads

Tighten taper male pipe threads of nominal sizes of R1/8 - R1 and Rc1/8 - Rc1 and parallel female pipe
threads of nominal size of Rp1/8 - Rp1 (coated with adhesive) according to the following standard.
If tightening torque is specified particularly, however, do not apply the following standard.
2-1. If the material of male threads is SS400, FC, or SGP, apply Table 1.
Table 1
Unit: Nm {kgm}
Material of female thread
Steel
Cast iron
Light alloy
1/8
3.9 6.9
{0.4 0.7}
2.9 5.9
{0.3 0.6}
2.0 3.9
{0.2 0.4}
1/4
5.9 11.8
{0.6 1.2}
4.9 9.8
{0.5 1.0}
3.9 7.8
{0.4 0.8}
3/8
16.7 26.5
{1.7 2.7}
13.7 21.6
{1.4 2.2}
9.8 16.7
{1.0 1.7}
1/2
32.3 52.9
{3.3 5.4}
26.5 43.1
{2.7 4.4}
19.6 32.3
{2.0 3.3}
3/4
51.0 85.3
{5.2 8.7}
42.1 70.6
{4.3 7.2}
31.4 52.9
{3.2 5.4}
86.2 173.5
{8.8 17.7}
72.5 146.0
{7.4 14.9}
54.9 111.7
{5.6 11.4}
Nominal size
2-2. If the material of male threads is S43C, apply Table 2.
Table 2
Unit: Nm {kgm}
Material of female thread
Steel
Cast iron
Light alloy
1/8
16.7 29.4
{1.7 3.0}
9.8 19.6
{1.0 2.0}
6.9 14.7
{0.7 1.5}
1/4
19.6 44.1
{2.0 4.5}
16.7 37.2
{1.7 3.8}
12.7 28.4
{1.3 2.9}
3/8
44.1 93.1
{4.5 9.5}
37.2 77.4
{3.8 7.9}
27.4 58.8
{2.8 6.0}
1/2
98.0 188.2
{10.0 19.2}
83.3 157.8
{8.5 16.1}
60.8 115.6
{6.2 11.8}
3/4
170.5 316.5
{17.4 32.3}
141.1 247.0
{14.4 25.2}
105.8 186.2
{10.8 19.0}
367.5 612.5
{37.5 62.5}
309.7 514.5
{31.6 52.5}
235.2 392.0
{24.0 40.0}
Nominal size
16
Tightening torque
3. Tightening torque of hoses (with taper/face seal)

Unit: Nm {kgm}
Nominal diameter
of hose
Width across
flatse.
02
Tightening torque
Range
Target
19
35 63 {3.5 6.5}
44 {4.5}
22
54 93 {5.5 9.5}
74 {7.5}
24
59 98 {6.0 10.0}
78 {8.0}
04
27
84 132 {8.5 13.5}
103 {10.5}
05
32
128 186 {13.0 19.0}
157 {16.0}
06
36
177 245 {18.0 25.0}
216 {22.0}
(10)
41
177 245 {18.0 25.0}
216 {22.0}
(12)
46
197 294 {20.0 30.0}
245 {25.0}
(14)
55
246 343 {25.0 35.0}
294 {30.0}
03
When connecting hoses, take care not to twist them.
17
Tightening torque
Coating materials
a The recommended coating materials such as adhesives, gasket sealants, and greases used for
disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Adhesive
Category
Komatsu
code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g
(2 pcs.)
Polyethylene
container
LT-2
09940-00030
50 g
LT-3
790-129-9060 Adhesive:
(Set of
1 kg
adhesive and Hardener:
500 g
hardener)
LT-4
790-129-9040
250 g
Holtz MH
705
790-126-9120
75 g
ThreeBond
790-129-9140
1735
Gasket sealant
Aron-alpha
790-129-9130
201
Main features and applications

Used to prevent rubber gaskets, rubber cushions, and
cork plugs from coming out.
Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and
non-metal parts which require immediate and strong
adhesion.
Polyethylene Features: Resistance to heat and chemicals.

container
Used to fix and seal bolts and plugs.
Can
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container
Used mainly to stick metals, rubbers, plastics, and
woods.
2g
Quick-setting adhesive.
Polyethylene Quick-setting type.
container
(max. strength is obtained after 30 minutes)
Used mainly to stick rubbers, plastics, and metals.
Polyethylene Features: Resistance to heat and chemicals.
container
Used for fitted portions used at high temperatures.
Loctite
648-50
79A-129-9110
50 cc
LG-1
790-129-9010
200 g
Tube
Used to stick or seal gaskets and packings of power train

case, etc.
Used to seal various threaded portions, pipe joints, and

Polyethylene
flanges.
container
Used to seal tapered plugs, elbows, and nipples of
hydraulic piping.
LG-5
790-129-9080
1 kg
LG-6
790-129-9020
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant.

Used to seal flange surfaces and threaded portions.
Used to seal oil pan, final drive case, etc.
LG-7
790-129-9070
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan,
thermostat housing, etc.
ThreeBond
790-129-9090
1211
100 g
Tube
Gasket sealant used to repair engine.
ThreeBond
419-15-18131
1207B
100 g
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
18
Tightening torque
Komatsu
code
Part No.
Q'ty
Container
LM-G
09940-00051
60 g
Can
To be sed as lubricant (anti squeaking) for sliding

part.
Tube
To be used for press fit, shrink fit and preventing

scratching or seizure of thread.
To be used as lubricant for linkage and bearing
etc..
LM-P
09940-00040
200 g
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
Various
kinds
Various kinds Versatile type
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Various
kinds
Various kinds
Grease with
molybdenum
disulphide
LM-G(G2-M)
SYG2-400M
SYG2-400M-A
SYGA-16CNM
400 g x 10
400 g x 20
16 kg
Bellows type
Hyper white
grease
G2-T GO-T(*)
*: For cold
region
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A
(*)
SYG0-16CNT
(*)
400 g
16 kg
Bellows type
Can
Higher anti seizure and heat resistance than

grease with molybdenum disulphide
Body dirt is not distinctive due to white color.
Biological
grease G2-B
G2-BT(*)
*: For heat
resistance
and heavy
load
SYG2-400B
SYGA-16CNB
SYG2-400BT
(*)
SYGA-16CNBT
(*)
400 g
16 kg
Bellows type
Can
To be shortly dissolved by a bacteria in nature so

that the influence to microorganism and animals
and plants is suppressed to the minimum.
20 ml
Glass
container
To be used as primer for cab side.

(Term of validity: 4 months after manufacturing)
20 ml
Glass
container
To be used as primer for glass side.

20 ml
Glass
container
Sunstar
primer for
painting plane
580 super
Sunstar
primer for
glass 580
super
Primer
To be used for the place where the bearing

designed for normal temperature and low load
condition is used and contacts water and steam.
Sunstar
primer for
painting plane
435-95
Sunstar
primer for
glass
435-41
Sunstar
primer for
sash
GP-402
To be used for heavy load places.

Can
417-926-3910
22M-54-27230
22M-54-27240
22M-54-27250
150 ml
Steel can
20 ml
Glass
container
19
For adhesion of cab glass
Grease
Lubricant with
molybdenum disulfide
Category
To be used as primer for painting plane of cab

side.
To be used as primer for black ceramic
coated plane of glass side and polycarbonate
hard coat plane.
To be used as primer for sash (Alumite surface treatment)
Tightening torque
Komatsu
code
Part No.
Q'ty
Container
Sunstar penguin seal 580

super "S" or
"W"
417-926-3910
320 ml
Polyethylene
container
"S" and "W" are used as glass adhesive compound in high temperature (April -October)
and in low temperature (October -April )
respectively.
Sika Ltd,
Japan Sika
Flex 256HV
20Y-54-39850
310 ml
Polyethylene
container
To be used as glass adhesive compound.

Sunstar
pengiun
super 560
22M-54-27210
320 ml
ECOCART
(special container)
Sunstar
pengiun seal
No. 2505
417-926-3920
320 ml
Polyethylene
container
Sekisui silicone sealant
20Y-54-55130
333 ml
Polyethylene
container
GE Toshiba
Silicones
Tosseal 381
22M-54-27220
333 ml
Cartridge
20
For adhesion of cab glass
Coaking compound
Adhesive compound
Category
To be used as glass adhesive compound.

To be used as seal for joints of glass.
To be used for seal of front window.
To be used as seal for joints of glass.
semi-transparent white seal
A. Assembly procedure
Note) Photos of D475A-5 are used for explanation of some work
in the following assembly procedure. The basic work for
D375A-5 and D475A-5 are the same, however.
21
Assembly process No.
Installation of undercarriage (1/9)
A-1
1-1 Installation of undercovers

Install the 2 undercovers in the order
shown in the figure at right.
Part No. of bolt
01010-82470
(9 pieces on each side)
Part No. of washer
176-50-11170
Length of bolt
70 mm
Necessary socket
36 mm
Tightening torque
94.5 10.5 kgm
22
A-1
1-2 Installation of pivot shaft

1. Adjust the length of the sling wire rope
(A) to 600 mm.
2. Set the center of gravity of the shaft to
500 mm from the shaft end (B).
3. Direct the flange as shown in the photo.

4. Pass the tilt hose through the
shaft hole.
5. Tighten the bolts with 45F impact

wrench and then check the tightening
torque.
01011-83000
01643-33080
Part No. of washer
Length of bolt
100 mm
Necessary socket
46 mm
Tightening torque
175 20 kgm
Part No. of bolt
a While turning the twist seal cover,

tighten the bolts in order.
Shaft hose
23
A-1
1-3 Installation of track frame assembly
Install the track frame to the pivot.
Using a slinging fittings, sling the track frame.
Position of crane.
a Check that the torsion seal end faces are free from foreign matter and flaw.
a Check that the O-ring is fitted to the inside of the track frame.
24
A-1
Move the track frame to set it to the pivot

shaft.
25
A-1
1-4 Insertion of side pin.
Align the equalizer bar.
Install the side pin with the UP mark up.
UP
Install the greasing cover temporarily.

Bolt
: 01010-81665 (8) L = 65 mm
Washer : 01643-31645 (8)
Connect the grease tube.
NOTICE
Tighten the side pin clamp bolt first, then tighten
the cover bolts.
26
A-1
1-5 Installation of left track frame assembly

* Install the left track frame similarly to the right
one.
Remove the sling from the bogie after installing

the track to the chassis.
<How to remove bogie>

Remove the bogie removing the chassis from the stand.
(Perform this work with the track roller on the track link.)
27
A-1
1-6 Tightening of pivot shaft end bolts
Install the spacer to the pivot shaft end.

Install the outside twisted seal of the pivot shaft.
Take care of the positions of the bolts to be

installed first (3 places).
Install the pivot end cover.
Install the pivot inside retaining cover.

Bolt
: 01010-81645 (8) L = 45 mm
Washer : 01643-31645 (8)
28
A-1
1-7 Tightening of side pin bolt
Bolt
: 195-50-51510 (4)
Size M30 1.5, Length = 305 mm
Nut
: 01803-03034 (4)
Washer : 01643-33080 (8)
: Tightening torque : 1960 2450 Nm
(200 250 kgm)
a If the bolt is dragged, fix it from underside.
NOTICE
Tighten the side pin bolt first, and then tighten the greasing
cover bolts.
Install the rear upper mudguard cover of the track

frame.
29
A-1
1-8 Installation of side pin cover
Install the inside mudguard cover of the track frame.

Bolt
: 01010-61650 (6) L = 50 mm
Washer : 01643-31645 (6)
1-9 Adjustment of idler guide shim

a See the Shop Manual, Testing and adjusting.
30
A-2
Installing track shoes
1. Spread the 2 track shoe sets (for right and left

sides) in parallel to the track gauge of 2,500
mm.
a Expanded length: Approx. 12.5 m
4 1 track shoe set (610 mm wide): 4,200 kg
2. Using a crane, lift down the tractor onto the
track shoes
Take care of the front and rear ends of the
track shoes.
4 Tractor: 42.1 tons
3. Put blocks (400 mm) under the track shoe
grousers on the front side of the machine.
4. Lift up the end of the track shoes (master
links) on the rear side of the machine and
mesh them with the sprocket teeth and move
the machine slowly forward to install the track
shoes.
5. Clean the mating faces of the master links.
6. Mesh the master links and clamp them and
shoe plates with the bolts.
a Place the master link at the upper part of
idler.
a Tighten the all 4 shoe bolts with the fingers until the contact surfaces of the master link are fitted.
a If the shoe bolts are tightened forcibly
before the contact surfaces of the master
link are fitted, the threads of them and
master link may be damaged.
7. Tighten the shoe bolts for the master link in
the order shown at right.
2
Shoe bolt:
Anti-seizure agent LM-P
(Maruzen Morimax No.2 or equivalent)
Shoe bolt:
1st time : 686 69 Nm {70 7 kgm}
2nd time: Retighten by 180 10.
a Install the other side of track shoe in the

order shown above.
31
A-3
Charging recoil chamber and pivot chamber with oil
a Oil chamber of pivot shaft: 18 l/each side

(SAE30-CD)
Pivot shaft oil level (H = 10 to 25 mm)
Precautions
Necessary tools
Name
Other remarks
32
Q'ty
Necessary equipment
Name
Q'ty
Installation of blade lift cylinder
A-4
1. Remove the wire which is fixing the blade

cylinder hose.
2. Remove the cap and bushing of the yoke.
a When removing the cap, make a
match mark on it for reinstallation.
(The cap is a part on the yoke.)
Bushing
Cap
3. Installation of cylinder
Fix the cylinder at the angle shown in the photo.
Cap mounting bolts
Part No. of bolt
01010-82000
Part No. of washer
01643-32060
Length of bolt
100 mm
Necessary socket
30 mm
Tightening torque
56 6 kgm
4. Installation of hoses
Install the hoses as shown in the photo
so that they will not interfere with each other.
Part No. of hose
07125-21215
33
Installation of tilt hose & trunnion (1/2)
A-5
Installation of tilt hose.

Hoses on bottom
side are marked
(with color bands)
for distinction
Colors of machine body hoses

Bottom
Head
Right
Red
No color band
Left
Blue
Yellow
Upper: Bottom
Lower: Head
Hose tighting torque : 117.6 161.7 Nm

{12.0 16.5 kgm}
Installation of trunnion
Installing bolt : 01010-62475 (10 pieces on each side)
Washer :
01643-32460 (10 pieces on each side)
34
A-5
Installation of tilt hose & trunnion (2/2)
Greasing before installing the cover.
35
Assembly of blade assembly (1/3)
A-6
To prevent from falling down

a Place cribbing blocks underneath
Adjust height of trunnion

H = 853 mm (from ground)
W = 3484 mm
Precautions
Necessary tools
Name
Other remarks
36
Q'ty
Necessary equipment
Name
Q'ty
A-6
Installation of frame
Installation of blade tilt cylinder
Precautions
Take care when connecting the hoses.
Necessary tools
Name
Other remarks
37
Q'ty
Necessary equipment
Name
Q'ty
A-6
Remove the paint from the ball joint and

clean the ball joint.
Installation of arm joint
Precautions
Necessary tools
Name
Other remarks
38
Q'ty
Necessary equipment
Name
Q'ty
Checking of arm joint clearance (U blade)
A-7
Check of clearance in arm ball joint

Shim adjustment
1. Remove shim (1) and tighten bolts (2) to eliminate the ball joint play.
2. Measure clearance [A] and remove bolts (2).
3. Install shim (1) having thickness of [A+0.5] mm to [A+1.0] mm.
4. Confirm the ball joint can move smoothly after tightening bolts (2).
Precautions
Necessary tools
Name
Other remarks
39
Q'ty
Necessary equipment
Name
Q'ty
Installation of blade (1/5)
A-8
Center brace
Straight frame part
Blade tilt cylinder part
Precautions
Necessary tools
Name
Other remarks
40
Q'ty
Necessary equipment
Name
Q'ty
A-8
Connect of tilt hose
Trunnion part
Precautions
Necessary tools
Name
Other remarks
41
Q'ty
Necessary equipment
Name
Q'ty
A-8
Installing hose
Precautions
Necessary tools
Name
Other remarks
42
Q'ty
Necessary equipment
Name
Q'ty
A-8
Blade lift cylinder part
Precautions
Necessary tools
Name
Other remarks
43
Q'ty
Necessary equipment
Name
Q'ty
A-8
Check of clearance in blade cylinder cap

Adjustment of blade cylinder cap shim
Set the standard shim thickness of the blade
cylinder cap to 4 mm.
Reduce the shim thickness according to the
wear of the cap and cylinder mounting ball.
Proper clearance: Max. 1 mm
Adjusting blade (Single tiltdozer)

When installing the blade, adjust distance l
between the joints to 1,554 mm.
Method of adjusting brace

Start the engine and tilt both sides in the inching mode to swing the blade vertically and
revolve the brace handle, and you can adjust
the brace easily.
When shortening the brace, place it on a
block and revolve the brace handle, and you
can adjust the brace easily.
REMARK
As the blade is tilted by the above operation,
the handle becomes heavy gradually. If the
handle becomes too heavy, return the tilted
blade to the horizontal position and revolve
the handle again by the above method.
Precautions
Necessary tools
Name
Set the work equipment in a safe position, stop

the engine, and apply the safety lock lever
securely.
When servicing while the engine is running, one
person shall sit on the operator's seat and
another person shall service the machine, conforming safety with each other.
Other remarks
44
Q'ty
Necessary equipment
Name
Q'ty
Adjusting of lift cylinder joint area
A-9
Check the movement by moving blade raise/

lower and RH/LH tilt and pitch back/pitch dumping after adjustment.
If some noise is coming from above ball joint
area, Re-adjust above.
Precautions
Necessary tools
Name
Other remarks
45
Q'ty
Necessary equipment
Name
Q'ty
A-10
Checking installation of dual tilt cylinder (If equipped)
If the machine is a dual tilt dozer, check that the tilt cylinders on both sides are installed normally.
Both tilt cylinders are different from each other in the sectional shapes of the parts shown below.
Left tilt cylinder: Octagonal section
Right tilt cylinder: Circular section
Precautions
Necessary tools
Name
Other remarks
46
Q'ty
Necessary equipment
Name
Q'ty
A-11
Checking operation of dual tilt mechanism (If equipped)
<Dual tilt operation>

(C) + (B): Left dual tilt (While selector switch (C)
is in the DUAL position, move the knob in direction (B).)
(C) + (A): Right dual tilt (While selector switch (C)
is in the DUAL position, move the knob in direction (A).)
If the blade is tilted while knob switch (C) is
in the DUAL position, it is tilted more than by
the normal tilting operation.
The dual tilt operation is applicable while the
blade is raised, hold, or lowered, regardless
of its position.
<Pitch operation>
(D) + (B) Reverse pitch: Reduce the cutting edge
angle (Pressing button (D) and move the knob in
direction (B).)
(D) + (A) Reverse pitch: Increase the cutting
edge angle (Pressing button (D) and move the
knob in direction (A).)
The pitch circuit is given priority. If the pitch
button is pressed while the blade is being
tilted, the blade is pitched.
47
Installing ripper (1/10)
A-12
The giant ripper is used as an example in the following explanation. The multi-shank ripper is
installed similarly to the giant ripper, however,
1. Placing
Place stands. Lift up and set the beam and arm assembly on those stands.
Beam and arm assembly : 3,660 kg (Giant ripper)
: 4,170 kg (Multi ripper)
2. Removing lift cylinder
Remove the installed lift cylinders. (Pull out the head pins on both sides.)
Lift cylinder assembly: 345 kg
Precautions
Necessary tools
Name
Clean and grease each pin before installing.

After pulling out each lift cylinder pin, install it to
the beam temporarily.
Other remarks
48
Q'ty
Necessary equipment
Name
Q'ty
A-12
3. Installing beam and arm assembly

Connect the beam and arm assembly to the machine body frame with pins (1), lock plates (2), bolts
(3), and washer (4).
a Set the beam and arm assembly to the machine body frame roughly by moving the machine forward and in reverse, then adjust the pins and holes finely by lifting up the arm with the crane.
Precautions
07020-00000
01643-32060
01010-52040
195-78-21171
195-78-71190
No.
Part No.
Qty
Necessary tools
Name
Pins (1) are installed to the body frame.
4 plates (2) are installed to the body and the
other 4 are installed to the ripper beam (for the
cylinders).
8 bolts and washers (3) and (4) are installed to
the body frame and the other 8 are installed to
the ripper beam (for the cylinders).
If the ripper can be installed to the machine,
Other remarks
grease fittings (5) are installed to the pin.
49
Q'ty
Necessary equipment
Name
Q'ty
A-12
4. Installing lift cylinders (Machine body side)

Lift up the lift cylinders removed in step 2 with the crane and install them to the frame with pins (8),
lock plates (2), bolts (3), and washer (4) (on each side).
a Take care not to mistake both lift cylinders for each other (Their piping directions are different).
Precautions
Necessary tools
Name
Other remarks
50
01643-32060
01010-52040
195-78-21171
195-78-71170
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-12
5. Installing piping
Install lift cylinder hoses (6) and O-ring (7).
Precautions
Necessary tools
Name
Other remarks
51
01643-51032
32
07372-21035
32
07371-31049
16
07000-13032
07124-01010
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-12
6. Installing lift cylinders (Beam side)

(1) Remove pins (9), lock plates (2), bolts (3) and washers (4) installed to the beam temporarily.
(2) Start the engine and set the lift cylinder to the beam mounting part as shown in the following figure. (2 places on right and left sides)
a Apply pressure to the cylinders while they are lifted up with the crane.
(3) Stop the engine and connect the lift cylinders to the beams with pins (9), lock plates (2), bolts (3),
and washers (4) (on each side).
Precautions
Necessary tools
Name
Pins (9) are installed to the ripper beams.
Other remarks
52
01643-32060
01010-52040
195-78-21171
195-78-71120
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-12
7. Installing tilt cylinders (Machine body side)

Lift up the tilt cylinders with the crane and install them to the frame with pins (8), lock plates (2), bolts
(3), and washer (4) (on each side).
a Take care not to mistake both tilt cylinders for each other (Their piping directions are different).
Precautions
Necessary tools
Name
Other remarks
53
01643-32060
01010-52040
195-78-21171
195-78-71170
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-12
8. Installing piping
Install tilt cylinder hoses (6) and O-ring (7).
Note) As the parts marked with *, use plugs of cylinder piping.
Precautions
Necessary tools
Name
Other remarks
54
01643-51032
32
07372-21035
32
07371-31049
16
07000-13032
07124-01010
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-12
9. Installing tilt cylinders (Beam side)

(1) Run the engine and apply pressure to the tilt cylinders to adjust their length as shown below.
(2) Stop the engine and connect the tilt cylinders to the beams with pins (9), lock plates (2), bolts (3),
and washers (4) (on each side).
a Apply pressure to the cylinders while they are lifted up with the crane.
Precautions
Necessary tools
Name
Other remarks
55
01643-32060
01010-52040
195-78-21171
195-78-71120
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-12
10. Bleeding air

Bleed air from the hydraulic circuit according to the following procedure.
(1) Run the engine at low idling.
(2) Move each cylinder to about 100 mm before each stroke end 4 - 5 times. (Do not relieve the oil
at each stroke end.)
(3) Move each cylinder to each stroke end 3 - 4 times.
(4) Lower the shank point to the ground and check that the hydraulic oil level is proper. If the oil level
is low, add new oil according to the operation manual.
a At this time, lower the blade to the ground, too.
(5) When bleeding air, check that each cylinder hose moves freely and oil does not leak through
each joint.
11. Installing piping to pin puller cylinder
Connect the hoses for the pin puller cylinder as shown below.
a For the hose clamps, see the details of each part.
a Run the engine and operate the ripper (extend and retract the lifting, tilting, and pin puller cylinders) and check that each hose does not receive excessive forces.
Hose: 49 19.6 Nm {5 2 kgm}
Precautions
Necessary tools
Name
Other remarks
56
Q'ty
Necessary equipment
Name
Q'ty
A-12
12. Installing shank assembly

(1) As shown in the figure at right, install
wires to the hook at the top of the shank
assembly and pass them through the
holder. Lift up the shank with a crane and
match its hole to the hole of the holder.
(2) Insert the pin in the shank by operating
the pin puller cylinder.
a Do not move the holder and shank simultaneously.
Precautions
Necessary tools
Name
Other remarks
57
Q'ty
Necessary equipment
Name
Q'ty
Installation of operators cab (1/10)
A-13
1. Installing the open lock striker

Install the open lock striker mounting bracket (1) or
(2) at the position designated in Fig. 1 below using
bolts and washers (3) or (4). (Use 5 units each of
the bolts and washers on one side.)
a The striker (5), nut (6) washer (7) stopper rubber (8), and nut (9) are already installed to the
bracket before shipment from the factory.
2. Installing the L-shaped operator's cab mounting

plate
L-shaped operator's cab mounting plates (13) and
(14) are installed to the cab temporarily. Before
installing the cab, loosen bolts (15).
Precautions
Necessary tools
Name
Other remarks
58
16
01643-71232
12
15
01010-D1230
12
14
198-Z11-3581
13
198-Z11-3571
01580-11210
09453-00002
01643-31032
01580-11008
14X-911-1921
01643-71232
10
01010-D1230
10
198-Z11-3351
198-Z11-3341
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-13
3. Applying the seal around the air conditioner

box
(1) Apply the seal (17) around the air conditioner box engaging it into the guide plate
of the air conditioner box.
(2) Apply grease (G2-Li) over the outside
surface of the seal.
a The sealing surface which will come
in contact with the operator's cab
structure.
4. Applying the seal over the mating surfaces of

the operator's cab assembly
(1) Hoist the operator's cab to apply seal to
the mating surfaces of the operator's cab
assembly.
a Applying the seal over the mating surfaces of the operator's cab
Weight : 420 kg
(2) Before applying the seal remove dust and
grease stains if any from the mating surface of the operator's cab assembly.
(3) Remove the release liner paper from the
seal (18) to apply over the sections designated in Fig. 5 on the succeeding page.
Precautions
Necessary tools
Name
Since the seal has an excess length, cut the

exceeding portion.
Other remarks
59
18
14X-911-5911
17
198-Z11-3540
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-13
Fig. 5 Schematic diagram designating the sections to apply the seal on.
(Bottom view of the operators cab assembly)
60
A-13
5. Installing the operator's cab assembly

(1) Carefully lower the operator's cab assembly to its position on the floor frame.
a Since the seal sponge will exhibit
substantial reaction force, lower the
operator's cab assembly slowly and
carefully.
a Pay great attention not to dislocate or
damage the seal.
a Make sure the seal covering the operator's cab side air conditioner duct is
in close contact with the dashboard
side air conditioner duct and free from
causing any gap.
a Lower the operator's cab assembly
slowly and carefully since the clearance between the operator's cab side
air conditioner duct and the monitor is
very narrow.
(2) Temporarily tighten the bolts (19), (21)
and washers (20), (22).
a Since the bolt length and the washer
type are different for ones to be used
in the entrance door section, be sure
to use the right parts in each place.
(3) Check and make sure there is no gap
between the seal sponge and air conditioner bracket and cab.
(4) Check and make sure there is no gap
between the seal sponge and the floor
frame (in the section (a)).
(5) After making the checks according to the
above Paragraphs (3) and (4), if any gaps
are found, redo the installation work of
the operator's cab. However, if the gaps
are negligible, apply the sealant (56) to
pad and seal the gap.
56
Precautions
Necessary tools
Name
Other remarks
61
198-Z11-3960
22
01643-11232
21
01010-81245
20
124-54-26540
15
19
01010-81275
15
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-13
(6) Check and make sure the clearance

occurring between the operator's cab
assembly side air conditioner duct and
the upper edge of the monitor is even on
the left-hand and right-hand sides. Similarly, check and make sure the seals of
the air conditioner duct seal at the operator's cab side are fitted both faces C of
the air conditioner duct at the dashboard
side without lateral deviation.
(7) When the clearance occurring between
the operator's cab assembly side air conditioner duct and the upper edge of the
monitor has been found uneven, loosen
the air conditioner duct mounting screws
to adjust the clearance even on the lefthand and right-hand sides. When the air
conditioner duct at the operator's cab
side is deviated laterally, adjust it similarly
to the above.
(8) Make final tightening of bolts (19) and
(21) that have been temporarily tightened
according to the above Paragraph (2).
(9) Make final tightening of mounting bolt
(15) for L-shaped plates (13) and (14)
that have been temporarily installed
according to the above Paragraph (2).
Precautions
Necessary tools
Name
Other remarks
62
Q'ty
Necessary equipment
Name
Q'ty
A-13
(10) Fasten the plate (23) by the bolts and

washers (24) and (25). (Use 2 units
each of the bolts and washers on one
side.)
(11) Install the defroster damper assembly
(26) or (27) using the bolts (28) and
washers (29). (Use 2 units each of the
bolts and washers on one side.)
(12) Install the foot-rest (30) or (31) using the
bolts and washers (32) and (33). (Use 2
units each of the bolts and washers on
one side.)
(13) Install the pedal cap (34) onto the footrest.
Precautions
Necessary tools
Name
Other remarks
63
34
203-43-56450
33
01643-71232
32
01010-D1230
31
14X-911-5721
30
14X-911-5711
29
01643-71232
28
01010-D1230
27
198-911-9520
26
198-911-9510
25
01643-71232
24
01010-D1230
23
198-Z11-2961
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-13
(14) Referring to Fig. 11 below, bind the window washer hoses with strings, etc. and connect the
window washer harness connectors through holes (A) and (B) to the mating connectors of the
power circuit harness in the operator's cab.
Fig. 11
a After finishing connections of the hoses and connectors designated above, securely engage
the harness side grommet.
64
A-13
6. Installing the internal decorative parts and

accessories
(1) Install the handle (38) to the floor edge
covers (35), (36) and (37).
a When installing the optional lunch box
fixing band, use screw (51) to connect grounding of cigarette lighter
(46) at part (C).
(2) Install the bracket (39) to the floor frame
using bolts (40). (Use 2 bolts.)
(3) Install the floor edge covers to each of
which the handle was installed according
to the above Paragraph (1) to their positions using the screws and washers (41)
and (42). (Use a total of 13 units each.)
(4) Install the box (43) using the screws and
washers (47) and (48).
a Use 2 units each of the screws and
washers.
a The ashtray (44), socket assembly
(45) and the cigarette lighter (46) are
already installed to the box before its
shipment from the factory.
Precautions
Necessary tools
Name
When installing the box, connect the ground wire of

the cigarette lighter by using the screw fitted at part
(c). For secure grounding, remove the paint from
the screw fitting part of the cab.
Other remarks
65
48
01643-70823
47
01245-00820
46
08913-02400
45
198-Z11-2640
44
20G-54-13420
43
198-Z11-2612
42
01643-70823
13
41
01245-00820
13
40
01435-30825
39
198-Z11-3990
38
198-Z11-2850
37
198-Z11-2892
36
198-Z11-2882
35
198-Z11-2872
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-13
(5) Install the cover (49) or (50) using the

screws and washers (51) and (52).
(Use 4 units each of the screws and
washers on one side.)
(6) Install the cover (53) using the screws
and washers (54) and (55).
(Use 4 units each of the screws and
washers.)
(7) Install the floor mats (57), (58) and (59).
Precautions
Necessary tools
Name
Other remarks
66
59
195-54-68640
58
17A-54-12411
57
195-54-78550
55
01643-70623
54
01245-00616
53
195-54-68281
52
01643-70623
51
01245-00616
50
198-Z11-2951
49
198-Z11-2941
No.
Part No.
Qty
Q'ty
Necessary equipment
Name
Q'ty
A-13
7. Changing the antenna mounting direction

Since the antenna is positioned downward for
packaging and transportation purposes of the
operator's cab assembly when shipped from
the factory (Fig. 14), correct the direction of
the antenna to the normal state (Fig. 15) after
finishing the installation work of the operator's
cab onto the chassis.
Fig. 14
Loosen the set scerws for the antenna

base (b) to turn and position the antenna
upward.
When the antenna is positioned upward
properly, tighten the set screws.
Fig. 15
Precautions
Necessary tools
Name
Other remarks
67
Q'ty
Necessary equipment
Name
Q'ty
Installation of ROPS (1/2)
A-14
Installation of roof to ROPS

4
Roof: 170 kg
ROPS guard: 500 kg
Mounting bolt (3): 245 309 Nm

{25 31.5 kgm}
Precautions
Necessary tools
Name
Torque wrench (60 kgm)
Other remarks
68
01643-31645
20
01010-81640
20
No.
Part No.
Qty
Q'ty
1
Necessary equipment
Name
Q'ty
Installation of ROPS (2/2)
A-14
Sling the ROPS with the crane and set it to

the installing position.
4
ROPS: 766 kg
Mounting bolt (1) : 1,716 196.1 Nm

{175 20 kgm}
: 1,716 196.1 Nm
{1,264 144 ft. lb}
Precautions
Necessary tools
Name
Torque wrench
(210 kgm)
46 mm socket
(38.1T)
Other remarks
69
01011-83010
12
No.
Part No.
Qty
Q'ty
1
1
Necessary equipment
Name
Q'ty
Check track tension (1/2)
A-15
Adjusting
When increasing tension
1. First remove the bolts (1) and then remove the cover (2).
2. Pump in grease through the grease fitting
(3) with a grease pump.
3. To check that the correct tension has
been achieved, move the machine backwards and forwards.
4. Check the track tension again, and if the
tension is not correct, adjust it again.
5. Continue to pump in grease until S becomes 600 mm.
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.
When loosening tension

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

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 procedure given here, please contact your Komatsu distributor.
When removing cover (2), be careful not to let any dirt
get inside.
There is a safety label stuck to the back of cover (2). Other remarks
Be careful not to damage the safety label.
70
Q'ty
Necessary equipment
Name
Q'ty
Check track tension (2/2)
A-15
Inspection
Stop the machine on level ground (stop with
the transmission in FORWARD without applying the brake). Then place a straight bar on
the track shoes between the carrier roller and
the idler as shown in the figure, and measure
the clearance between the bar and the
grouser at the midpoint. If the clearance is 20
to 30 mm, the tension is standard. If the track
tension is not at the standard value, adjust it
in the following manner.
Precautions
Necessary tools
Name
Other remarks
71
Q'ty
Necessary equipment
Name
Q'ty
Check fuel, coolant and lubricants (1/3)
A-16
Precautions
Necessary tools
Name
Other remarks
72
Q'ty
Necessary equipment
Name
Q'ty
A-16
Specified
amount
Refill
capacity
Engine
oil pan
Power train oil pan

(incl. transmission,
torque converter and
bevel gear cases)
Damper
case
Final drive
case
(each)
Hydraulic
system
Fuel
tank
Cooling
system
liter
68
275
2.1
65
270
1050
165
US gal
17.97
72.66
0.55
17.17
71.33
277.41
43.59
liter
55.5
150
2.1
65
120
US gal
14.66
39.63
0.55
17.17
31.70
Notice
Always use diesel oil for fuel.
To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine
mounted on this machine uses an electronically controlled high-pressure fuel injection device.
This device requires high precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durability may drop markedly.
Note 1: HTHS (High-Temperature High-Shear Viscosity 150 C), specified by ASTM D4741 must be
equal to or higher than 3.5 mPa-S. Komatsu EOS0W30 and EOS5W40 are the most suitable
oils.
Note 2: Powertrain oil has different properties from engine oil. Be sure to use the recommended oils.
Note 3: Hyper grease (G2-T, G2-TE) has a high performance.
When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings, the use of G2-T or G2-TE is recommended.
Note 4: Supercoolant (AF-NAC)
1) Coolant has the important function of anticorrosion as well as antifreeze.
Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential.
Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AFNAC has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for
2 years or 400 hours.
Komatsu Supercoolant AF-NAC is strongly recommended wherever available.
2) For details of the ratio when diluting super coolant with water, see CLEAN INSIDE OF COOLING
SYSTEM (A-16 (3/3)).
Supercoolant AF-NAC may be supplied in premix. In this case, always top off with premix solution
(never dilute with water).
3) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30% and 68 %.
Precautions
Necessary tools
Name
Other remarks
73
Q'ty
Necessary equipment
Name
Q'ty
A-16
Recommended brands, recommended quality for products other than Komatsu

genuine oil
When using commercially available oils other than Komatsu genuine oil, consult your Komatsu distributor.
Precautions
Necessary tools
Name
Other remarks
74
Q'ty
Necessary equipment
Name
Q'ty
Lubricating (1/4)
A-17
1. Blade lift cylinder support yoke (4 places)
2. Blade lift cylinder support shaft (2 places)
3. Blade arm ball joint (3 places)

4. Brace screw (2 places)
5. Equalizer bar side shaft (2 places)
Precautions
Necessary tools
Name
Other remarks
75
Q'ty
Necessary equipment
Name
Q'ty
Lubricating (2/4)
A-17
6. Equalizer bar center shaft (1 place)
7. Engine tension pulley (1 place)
8. Engine fan pulley (1 place)

a Do not use molybdenum disulfide grease.
Precautions
Necessary tools
Name
Other remarks
76
Q'ty
Necessary equipment
Name
Q'ty
Lubricating (3/4)
A-17
9. Universal joint (2 places)
a Do not use molybdenum disulfide grease.
Remove inspection cover (3) of the undercover on the rear bottom of the chassis as follows.
1) Remove 2 bolts (1) at the front of the
machine.
2) Support the cover with your elbow while

gradually removing 2 bolts (2) at the rear
of the machine.
3) Lower the cover gradually to open it.
Precautions
Necessary tools
Name
The undercover is heavy (Approx. 50 kg). Never try to

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.
Other remarks
77
Q'ty
Necessary equipment
Name
Q'ty
A-17
Lubricating (4/4)
10. Decelerator pedal shaft (1 place)
11. Brake pedal (1 place)

12. Brake rod lever (1 place)
13. Steering, forward-reverse, gearshift lever

rotating link (4 places)
78
Bleeding air from hydraulic cylinders
A-18
a After disassembling for transportation, changing the oil in the hydraulic tank, or removing the hydraulic cylinders or work equipment piping, bleed the air from the hydraulic circuit as follows.
1. Blade lift cylinder (with piston valve)
1) Start the engine and run at low 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 circuit under any circumstances.
3) Keeping the engine at low idling, extend the cylinder to a point approx. 100 mm before the end of
the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of its
stroke. Hold it in this position for 3 minutes.
4) With the engine at high idling, extend the cylinder to a point approx. 100 mm before the end of
the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of its
stroke. Hold it in this position for 1 minute.
2. Blade tilt cylinder (without piston valve)
1) Start the engine and run at low idling for approx. 5 minutes.
2) With the engine at low idling, raise and lower the blade four or five times without operating the
cylinder to the end of its stroke.
a Operate the piston rod to approx. 100 mm form the end of the stroke; do not relieve the circuit under any circumstances.
3) Repeat this operation with the engine at full throttle, then run the engine at low idling and operate
the piston rod to the end of its stroke to relieve the circuit.
k If from the beginning the engine is run at full throttle, or the cylinders are operated to the end of
their stroke, the piston packing may be damaged, so never operate in this way.
k Check the oil level, and add oil to the specified level if necessary.
Precautions
Necessary tools
Name
Other remarks
79
Q'ty
Necessary equipment
Name
Q'ty
M. Check and maintenance procedures

after completion of assembly
81
Check and adjustment of operator's cab (1/6)
M-1
1. Inspecting the coating

(1) Check and make sure the bolt heads loosened
and re-tightened for the disassembly, and reassembly work are properly coated without peeling
off.
(2) Check and make sure the coating being provided
over the sealed section between the floor frame
and the tank and the coating over the borders
between the covers and the chassis structures
are not dislocated.
a When coating at any place is found peeling off or
not too neat, apply touch-up painting to remedy
the coating failures.
2. Pressurizing tests
(1) Measure the internal pressure of the operator's
cab.
a Determination criteria : Measurement
value X6 mmH2O
a Test conditions
: Engine at full throttle
a Blower
: HI
a Inside/Outside air changeover lever
: Outside-air position
a When the above criterion is not being satisfied,
check if the blind plug is inserted to the prescribed position of the control box or if any place
else is not airtight.
(2) Outlined below is a simplified method for the internal pressure measurement of the operator's
cab:
a) Prepare a transparent vinyl hose (of an outer diameter of 10 mm and 3,000 mm long).
b) Pour water into the hose bore for about a half of the hose length.
c) Remove the sliding windshield lock lever located on the side panel of the operator's cab to
insert one end of the vinyl hose before fastening an adjacent part of the hose to the top end
of the back seat using packing tape.
d) Seal the gap occurring between the lock-lever hose and the outer periphery of the hose.
e) Match the water levels of the beginning part and the ending part of the water column inside
the transparent vinyl hose at the outside of the operator's cab.
f) Start the engine and run it at full speed to read the difference between the two water levels.
Precautions
Necessary tools
Name
Other remarks
82
Q'ty
Necessary equipment
Name
Q'ty
M-1
3. 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".
(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.
Precautions
Necessary tools
Name
Other remarks
83
Q'ty
Necessary equipment
Name
Q'ty
M-1
4. 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.
4.1 Checking the current statuses
(1) Check the mounted elevation of the damper rubber. (Located at 4 places per a side and check
them on both L.H and R.H sides.)
Applying a packing tape strip over the contact surfaces of the damper rubber, open and close the
door for 2 to 3 times. After finishing this opening and closing cycles of the door, check the contact
surface of the packing tape with the operator's cab structure.
Normal:
The back surface of the packing tape comes in light contact the operator's cab structure when the door is being closed.
Abnormal: The back surface of the packing tape does not come in contact with the operator's
cab structure when the door is being closed, or if the two sections come in a harsh
contact such as peeling off the applied packing tape.
(2) Check the correlation between the door latch and the striker (on both L.H and R.H side).
Moving the door toward the closing direction, observe the engaging state between the latch and
the striker.
Precautions
Necessary tools
Name
Other remarks
84
Q'ty
Necessary equipment
Name
Q'ty
M-1
4.2 Adjustments
(1) Adjusting the elevation of the damper rubber
When adjusting the elevation of the damper rubber, supplement or reduce the shims being
inserted below the damper rubber to adjust the elevation of the damper rubber properly.
(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.
Precautions
Necessary tools
Name
When the grease adhering over the latch surface dries

out, the turning effort for the knob will become heavier.
Therefore, apply grease sufficiently in order not to allow
it to become dried up.
Other remarks
85
Q'ty
Necessary equipment
Name
Q'ty
M-1
5. Checking the open-locked state of the door

Check the correlation between the operator's cab structure and the door when the door is in openlocked state. When anything is found abnormal, make due adjustment to correct it.
5.1 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. 23
(2) Check the mounted elevation of the stopper rubber. (At 2 places each on one side. Check them
on both L.H and R.H sides.)
(a) Shaking the door back and forth in open-locked state, check for rattling.
(b) Check if the turning effort for the releasing lever is too heavy.
Precautions
Necessary tools
Name
Other remarks
86
Q'ty
Necessary equipment
Name
Q'ty
M-1
5.2 Adjustments
(1) Adjusting the correlation between the latch and the striker
Loosen the striker mounting nut and adjust the position of the striker so that it does not interfere
with the latch nor the overriding over the bent section occurs before tightening the nut back to its
original state.
When the interference cannot be corrected by the adjustment on the striker side, loosen the
latch side mounting bolts to make the adjustment form the latch side.
(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.
Precautions
Necessary tools
Name
Other remarks
87
Q'ty
Necessary equipment
Name
Q'ty
M-2
Measuring engine speed
a Measure the engine speed using the monitoring mode of the monitor panel.
For an overall explanation of the monitoring
mode, see MONITOR PANEL DISPLAY AND
SPECIAL FUNCTIONS in Shop Manual.
1. Measuring low-idling and high-idling speed
1) Turn the starting switch ON.
2) Turn service switch (1) ON, and economy
mode switch (2) OFF, and [--] is displayed
in display (3) of the monitor panel.
a The service switch is installed inside
the cover.
3) Hold buzzer cancel switch (4) for at least
7 seconds at the ON position and [99] is
displayed on the display (3) at the top of
the panel.
a [99] is the code for measuring engine
speed (all speed range).
4) Start the engine, and measure the speed
with the number displayed on display (5)
at the bottom of the panel when the following conditions are set.
a The engine speed is shown in units of
1 rpm on the display at the bottom of
the panel.
1] Measuring low idling speed:
Set the PCCS lever and work equipment levers to the neutral position and
set the fuel control dial to the low idling
position.
2] Measuring low idling speed:
Set the PCCS lever and work equipment levers to the neutral position and
set the fuel control dial to the high
idling position.
5) After completing the measurement, turn
service switch (1) OFF switch the panel to
the normal mode.
88
Adjust control logic to specification
M-3
a The machine model is set when the machine

is shipped. If the machine specification is
changed or the controller is replaced after
shipment, set the machine model again
according to the following procedure.
1. Turn key "ON".
2. Turn service switch (1) "ON".
Display (3) shows "--"
3. Turn buzzer cancel switch (4) counterclockwise for 7 seconds.
Display (3) shows "99".
4. Set economy mode switch (2) to "1" (On the
monitor panel)
Display (3) shows "AF"
5. Press "Reverse slow mode" switch (6), until
Display (3) changes to "5C"
6. Click the auto shift down switch (7) repeatedly until display (5) shows specification code
as shown below.
7. Turn buzzer cancel switch (4) and hold for
longer than 1 second. The buzzer sound will
indicate that the procedure is correct.
8. Turn service switch (1) in "OFF" and key
"OFF"
Specification code
Machine specification
body 00
NON-SSC & SINGLE TILT
body 01
SSC & SINGLE TILT
body 10
NON-SSC & DUAL TILT
body 11
SSC & DUAL TILT
89
Error code (1/6)
M-4
1. Turn key "ON"
2. Service switch (1) "ON", Display (3) shows "--"
3. Turn buzzer cancel switch (4 counterclockwise for 7 seconds.
Display (3) shows "99"
4. Set economy mode switch (2) to "2"
5. If display (3) shows "--",
System has no failure.
Then turn service switch "OFF" and Key
"OFF"
6. Display section (3) displays the past faults by
the fault Nos. in the order of occurrence time
and display section (5) displays the error
codes corresponding to the fault Nos.
7. Press "Reverse" slow mode switch (6). If there
are other failures, number showed on display
(3) will increase and display (5) showed next.
Display (5) shows next error code.
Repeat the procedure until display shows
"01" again.
8. Check cause of failure by error code list on
shop manual.
After assembling the machine, memorized
history of failure must be cleared by buzzer
cancel switch (4). If cleared, display (3) will
show "--".
9. Turn service switch (1) "OFF" and Key "OFF"
90
Error code (2/6)
M-4
Table of service codes

Service
code
Controller
Nature of abnormality
User
code
Warning
lamp
Alarm
buzzer
S/T
CALL03
MON
CALL03
E0105 Abnormality in network system (steering system)
S/T
CALL03
E0111
Abnormality in steering controller power source system
S/T
CALL
E0112
Abnormality in transmission controller power source system
T/M
CALL
E0120 Short circuit in warning lamp system
MON
CALL03
E0121 Short circuit in alarm buzzer system
MON
CALL03
E0142 Abnormality in transmission controller 5V power source system
T/M
CALL03
E0143 Abnormality in steering controller 5V power source system
S/T
CALL03
E0145 Abnormality in steering controller 24V power source system
S/T
CALL03
E0146 Abnormality in transmission controller 24V power source system
T/M
E01
E0151 Abnormality in steering controller specification selection
S/T
CALL
E0152 Abnormality in network system (steering controller)
S/T
CALL03
E0160 Abnormality in transmission controller ROM
T/M
E01
E0161 Abnormality in steering controller ROM
S/T
E02
E0164 Abnormality in network system (transmission controller)
T/M
CALL03
E0176 Disconnection in battery relay system
S/T
E0177 Short circuit in battery relay system
S/T
E0178 Disconnection in neutral safety relay system
T/M
E02
E0179 Short circuit in neutral safety relay system
T/M
E02
E0101 Abnormality in network system (steering system)

E0104 Abnormality in network system (monitor panel system)
Abnormality in torque converter oil temperature
MON
E0212 Short circuit in torque converter lock-up solenoid system
E0211
T/M
E01
E0213 Disconnection in torque converter lock-up solenoid system
T/M
E01
E0221 Disconnection, short circuit in tilt angle sensor system
T/M
E01
E0225 Slippage of power train clutch
T/M
E02
E0230 Simultaneous abnormality in directional potentiometer system (1)
T/M
CALL
T/M
CALL
T/M
CALL
E0233 Disconnection, short circuit in directional potentiometer 1 system
T/M
CALL03
E0234 Disconnection, short circuit in directional potentiometer 2 system
T/M
CALL03
E0235 Divergence of directional potentiometer system signal
T/M
CALL03
E0236 Disconnection, short circuit in shift up switch system
T/M
E02
E0237 Disconnection, short circuit in shift down switch system
T/M
E02
E0238 Disconnection, short circuit in parking lever switch system
T/M
CALL03
E0239 Mismatch in parking lever switch system signals
T/M
CALL03
E0250 Disconnection in transmission FORWARD clutch ECMV system
T/M
CALL03
E0251 Short circuit in transmission FORWARD clutch ECMV system
T/M
CALL03
E0252 Disconnection in transmission REVERSE clutch ECMV system
T/M
CALL03
91
Error code (3/6)
M-4
Service
code
Controller
User
code
Warning
lamp
Alarm
buzzer
E0253 Short circuit in transmission FORWARD clutch ECMV system
T/M
CALL03
E0254 Disconnection in transmission 1st clutch ECMV system
T/M
CALL03
E0255 Short circuit in transmission 1st clutch ECMV system
T/M
CALL03
E0256 Disconnection in transmission 2nd clutch ECMV system
T/M
CALL03
E0257 Short circuit in transmission 2nd clutch ECMV system
T/M
CALL03
E0258 Disconnection in transmission 3rd clutch ECMV system
T/M
CALL03
E0259 Short circuit in transmission 3rd clutch ECMV system
T/M
CALL03
E0260 Defective engagement of transmission FORWARD clutch
T/M
CALL03
E0261 Defective disengagement of transmission FORWARD clutch
T/M
CALL03
E0262 Defective engagement of transmission REVERSE clutch
T/M
CALL03
E0263 Defective disengagement of transmission REVERSE clutch
T/M
CALL03
E0264 Defective engagement of transmission 1st clutch
T/M
CALL03
E0265 Defective disengagement of transmission 1st clutch
T/M
CALL03
E0266 Defective engagement of transmission 2nd clutch
T/M
CALL03
E0267 Defective disengagement of transmission 2nd clutch
T/M
CALL03
E0268 Defective engagement of transmission 3rd clutch
T/M
CALL03
E0269 Defective disengagement of transmission 3rd clutch
T/M
CALL03
E0270 Multiple failure in transmission clutch
T/M
CALL03
E0271 Multiple failure in transmission clutch
T/M
CALL
E0306 Short circuit in blade tilt right oil pressure switch system
T/M
E02
E0307 Short circuit in blade tilt left oil pressure switch system
T/M
E02
E0308 Short circuit in ripper RAISE oil pressure switch system
S/T
E0309 Short circuit in ripper LOWER oil pressure switch system
S/T
E0310 Short circuit in ripper TILT IN oil pressure switch system
S/T
E0311
T/M
E02
E0312 Disconnection, short circuit in blade tilt switch system
T/M
E01
E0321 Disconnection in blade dual tilt selection solenoid system
T/M
E01
E0322 Short circuit in blade dual tilt selection solenoid system
T/M
E01
E0323 Disconnection in blade pitch selection solenoid system
T/M
E02
E0324 Short circuit in blade pitch selection solenoid system
T/M
E02
E0364 Disconnection in front pump oil pressure sensor system
T/M
E0365 Short circuit in front pump oil pressure sensor system
T/M
E0366 Disconnection in center pump oil pressure sensor system
T/M
E0367 Short circuit in center pump oil pressure sensor system
T/M
E0405 Disconnection, short circuit in fuel control dial system
ENG
CALL03
E0486 Abnormality in transmission controller model selection
T/M
CALL
E0501 Disconnection, short circuit in acceleration sensor system
S/M
E01
E0610 Disconnection in backup alarm relay system
T/M
E01
Disconnection, short circuit in blade pitch switch system
92
Error code (4/6)
M-4
Service
code
E0611
Short circuit in back-up alarm relay system
Controller
User
code
T/M
E01
Warning
lamp
Alarm
buzzer
E0660 Disconnection in ACC signal drive relay system
S/T
E0661 Short circuit in ACC signal drive relay system
S/T
E0721 Disconnection, short circuit in tilt angle sensor system
S/T
CALL03
E0730 Simultaneous abnormality in steering potentiometer system (1)
S/T
CALL
S/T
CALL
S/T
CALL
E0733 Disconnection, short circuit in steering potentiometer 1 system
S/T
CALL03
E0734 Disconnection, short circuit in steering potentiometer 2 system
S/T
CALL03
E0735 Divergence in steering potentiometer system signal
S/T
CALL03
E0736 Disconnection, short circuit brake potentiometer system
S/T
CALL03
E0750 Disconnection in right steering clutch ECMV system
S/T
CALL03
E0751 Short circuit in right steering clutch ECMV system
S/T
CALL03
E0752 Disconnection in left steering clutch ECMV system
S/T
CALL03
E0753 Short circuit in left steering clutch ECMV system
S/T
CALL03
E0754 Disconnection in right steering brake ECMV system
S/T
CALL
E0755 Short circuit in right steering brake ECMV system
S/T
CALL
E0756 Disconnection in left steering brake ECMV system
S/T
CALL
E0757 Short circuit in left steering brake ECMV system
S/T
CALL
E0760 Defective engagement of right steering clutch
S/T
CALL
E0761 Defective disengagement of right steering clutch
S/T
CALL
E0762 Defective engagement of left steering clutch
S/T
CALL
E0763 Defective disengagement of left steering clutch
S/T
CALL
E0764 Defective engagement of right steering brake
S/T
CALL
E0765 Defective disengagement of right steering brake
S/T
CALL
E0766 Defective engagement of left steering brake
S/T
CALL
E0767 Defective disengagement of left steering brake
S/T
CALL
E0779 Disconnection in sudden stop prevention solenoid system
S/T
CALL
E0780 Short circuit in sudden stop prevention solenoid system
S/T
CALL
E0781 Disconnection, short circuit parking lever switch system
S/T
CALL03
E0782 Mismatch of parking lever switich system signals
S/T
CALL03
E0930 Disconnection in engine speed sensor systems
S/T
E01
E0931 Disconnection in engine speed sensor system
T/M
E01
E0932 Disconnection in transmission speed sensor system
S/T
E01
E0933 Disconnection in transmission speed sensor system
T/M
E01
E1939 Abnormality in J1939 communication system
S/T
E01
ENG
CALL
E1999 (Spare code)

EC111 Abnormality in engine controller memory
93
Error code (5/6)
M-4
Service
code
Controller
User
code
Warning
lamp
Alarm
buzzer
EC112 Abnormality in timing rail actuator
ENG
CALL
EC113 Abnormality in timing rail actuator system current
ENG
CALL03
EC115 Abnormality in engine speed sensor 2 system
ENG
CALL
EC116 Abnormality in timing rail pressure sensor system high level
ENG
CALL
EC117 Abnormality in timing rail pressure sensor system low level
ENG
CALL
EC118 Abnormality in fuel pump pressure sensor system high level
ENG
CALL03
EC119 Abnormality in fuel pump pressure sensor system low level
ENG
CALL03
EC121 Abnormality in engine speed sensor 1 system
ENG
CALL03
EC122 Abnormality in boost pressure sensor system high level
ENG
E01
EC123 Abnormality in boost pressure sensor system low level
ENG
E01
EC131 Abnormality in throttle sensor system high level
ENG
CALL
EC132 Abnormality in throttle sensor system low level
ENG
CALL
EC133 Abnormality in remote throttle sensor system high level
ENG
CALL
EC134 Abnormality in remote throttle sensor system low level
ENG
CALL
EC135 Abnormality in engine oil pressure sensor system high level
ENG
CALL03
EC141 Abnormality in engine oil pressure sensor system low level
ENG
CALL03
EC143 Abnormal drop in engine oil pressure
ENG
EC144 Abnormality in water temperature sensor system high level
ENG
CALL03
EC145 Abnormality in water temperature sensor system low level
ENG
CALL03
EC151 Abnormal rise in water temperature
ENG
EC153 Abnormality in intake air temperature sensor system high level
ENG
CALL03
EC154 Abnormality in intake air temperature sensor system low level
ENG
CALL03
EC221 Abnormality in atmospheric pressure sensor system high level
ENG
CALL03
EC222 Abnormality in atmospheric pressure sensor system low level
ENG
CALL03
EC234 Abnormal overspeed
ENG
EC254 Abnormality in fuel shut-off valve system voltage
ENG
E01
EC259 Abnormality in fuel shut-off valve
ENG
CALL
EC261 Rise in fuel temperature
ENG
EC263 Abnormality in fuel temperature sensor system high level
ENG
CALL03
EC265 Abnormality in fuel temperature sensor system low level
ENG
CALL03
EC316 Abnormality in fuel pump actuator system current
ENG
CALL03
EC318 Abnormality in fuel pump actuator
ENG
CALL03
EC346 Abnormal engine controller power down
ENG
CALL03
EC384 Abnormality in preheater control system
ENG
CALL03
EC423 In-range abnormality in timing rail pressure sensor system
ENG
CALL03
EC441 Abnormality in battery voltage system low level
ENG
E01
94
Error code (6/6)
M-4
Service
code
Controller
User
code
Warning
lamp
Alarm
buzzer
EC442 Abnormality in battery voltage system high level
ENG
E01
EC451 Abnormality in fuel rail pressure sensor system high level
ENG
CALL
EC452 Abnormality in fuel rail pressure sensor system low level
ENG
CALL
EC455 Abnormality in fuel rail actuator system current
ENG
CALL
EC467 Abnormality in timing rail actuator control
ENG
CALL03
EC468 Abnormality in fuel rail actuator control
ENG
CALL03
EC514 Abnormality in fuel rail actuator
ENG
CALL
EC554 In-range abnormality in fuel rail pressure sensor system
ENG
CALL03
a Letter at head of service code

E : Code for problem detected at present
P : Code for problem not detected at present
a The controller in the Controller column indicates the controller or monitor panel responsible for the
system check for the applicable code.
MON : Monitor panel
ENG : Engine controller
T/M : Transmission controller
S/T : Steering controller
95
APPENDIX 1.
INSTALLATION OF SPILL GUARDS TO U-BLADE
DESCRIPTION
1. Introduction
When installing the spill guards to the semi U-blade or to the U-blade in field, refer
to the installation procedure described in this installation procedure.
97
(1) Spill guard (middle): 195-71-72211 fabrication drawing
98
04
03
02
01
Plate
Plate
Plate
Plate
SS400F
SS400P
SS400F
SS400F
10
9
1
1
This dwg shown co2-gas arc welding groove

Dimensions and leg length.
Welding quality to conform to kes 04.343
Flatness of surface (A) in drawing to be within 2
1.75 65 t12
3.65
t12
14.00 65 t12
6.85 32 t12
Mass
Remarks
(kg)
2.
3.
1.
1.
Spill guard fabrication drawings
1-1. For semi U-blade
99
(2) Spill guard (L.H.): 195-71-72221 fabrication drawing
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
SS400F
SS400F
SS400F
SS400F
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
1
1
1
1
1
1
1
1
1
1
0.80
1.08
1.36
1.46
1.18
1.82
2.40
3.05
6.45
2.90
Mass
(kg)
10
09
08
07
06
05
04
03
02
01
Remarks
65 t12
65 t12
65 t12
65 t12
t12
t12
t12
t12
65 t12
32 t12
1. This dwg shown co2-gas arc welding groove

2. Welding quality to conform to kes 04.343
3. Flatness of surface A, B, C, D in drawing to be within 2
100
(3) Spill guard (R.H.): 195-71-72231 fabrication drawing
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
SS400F
SS400F
SS400F
SS400F
SS400F
SS400P
SS400P
SS400P
SS400F
SS400F
1
1
1
1
1
1
1
1
1
1
0.80
1.08
1.36
1.64
1.18
1.82
2.40
3.05
6.45
2.90
Mass
(kg)
10
09
08
07
06
05
04
03
02
01
Remarks
65 t12
65 t12
65 t12
65 t12
t12
t12
t12
t12
65 t12
32 t12

3. Flatness of surface A, B, C, D in drawing to be
within 2
(1) Spill guard (middle): 195-72-72211 fabrication drawing
101
05
04
03
02
01
Plate
Plate
Plate
Plate
Plate
SS400F
SS400P
SS400P
SS400F
SS400F
10
2
9
1
1
This dwg shown co2-gas arc welding groove

dimensions and leg length.
Welding quality to conform to kes 04.343
Flatness of surface a in drawing to be within 2
1.75 65 t12
3.70
t12
3.65
t12
14.90 65 t12
7.14 32 t12
Mass
Remarks
(kg)
2.
3.
1.
1-2 For U-dozer
102
(2) Spill guard (L.H.): 195-72-72221 fabrication drawing
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
2
1
1
1
1
1
1
1
1
1
1
1
0.23
1.15
1.20
1.25
1.35
1.45
2.10
2.10
2.35
2.90
7.15
7.35
Mass
(kg)
12
11
10
09
08
07
06
05
04
03
02
01
Remarks
32 t9
65 t12
65 t12
65 t12
65 t12
65 t12
t12
t12
t12
t12
65 t12
65 t12

3. Flatness of surface A, B, C, D, E in drawing to
be within 2
103
(3) Spill guard (R.H.): 195-72-72231 fabrication drawing
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
SS400F
SS400F
SS400F
SS400F
SS400F
SS400F
SS400P
SS400P
SS400P
SS400P
SS400F
SS400F
1
1
1
1
1
1
1
1
1
1
1
1
0.23
1.15
1.20
1.25
1.35
1.45
2.10
2.10
2.35
2.90
7.15
7.35
Mass
(kg)
12
11
10
09
08
07
06
05
04
03
02
01
Remarks
32 t9
65 t12
65 t12
65 t12
65 t12
65 t12
t12
t12
t12
t12
65 t12
65 t12

3. Flatness of surface A, B, C, D, E in drawing to be
within 2
2.
Installation procedure
(1) As shown in Fig., weld spill guards to the blade.

(2) Precautions in the welding operation.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
(j)
(k)
When sand, mud, rust or paint exists in area of the base metal, remove it with a grinder.
When areas of the base metal are wet with the moisture, dry the areas up with a gas burner.
In the welding operation, NON-SPATTER must not be used.
In the arc welding with the covered electrode, use the low-hydrogen type JIS D4316 welding electrode
(for the mild steel) and if using welding wire equivalent to JIS YGW11.
When using the covered electrode previously dry it at 300 to 350 C for 30 to 60 minutes.
In the welding operation, perform the preheating at 150 to 200 C in the area covering 50 mm from the
bead. When the ambient temperature is lower than 10 C, the post-heating must also be preformed at
150 to 200 C.
The applicable current (amperage) for the welding operation must be at the lower limit within the
amperage specified according to the dia. of the welding electrode.
The multi-layer welding operation must be performed by a weaving method.
The welding must not be performed by a flowing method but the thorough penetration of the weld metal
must be ensured by manipulating he electrode from the lower to the upper areas. Further, the arc
length must be kept as short as possible, taking care to avoid the overlaps, undercuts, etc.
In the welding of spill guards to the blade, first remove the paint (or the rust) from the portions where
the spill guards are to be welded, the proceed to the tack-welding, regular welding and finishing operations of the spill guards in this order.
Install the grounding cable between a bare part of the blade and a part which can be grounded
securely.
Remarks; If a painted part is welded, hydrogen in the paint will be mixed in the welded part, and that can
cause cold cracking.
104
3.
Spill guard installation procedure
3-1. For semi U-dozer

As shown in Fig., weld spill guards (1), (2) and (3) to the semi U-blade.
105
3-2. For U-dozer

As shown in Fig., weld spill guards (1), (2) and (3) to the U-blade.
106
APPENDIX 2.
PROCEDURE FOR INSTALLING ADDITIONAL LAMPS
1. Contents of modification
1-1 Arrangement drawing of all lamps of machine
1-2 Lamps that can be added to machine of each specification
1-3 Procedure for modification of each section
2. Electric circuit diagram
3. Introduction of lamps
108
108
109
112
113
a Install an additional lamp according to the following procedure, if necessary.

a How many lamps can be added depends on the total electric energy used by the machine and the
generation capacity of the alternator.
If too many lamps are installed, the battery goes flat easily. Since the battery capacity lowers particularly when the temperature is low, the engine may have a trouble in starting. Take care.
107
1. Contents of modification
1-1 Arrangement drawing of all lamps of machine
Place
Use on machine
(1), (2)
(5), (6)
Head lamp
Front working
lamp
(7), (8)
(9)
(10) (13)
(14), (15)
Rear lamp
Ripper lamp
Additional
head lamp
Additional
rear lamp
Factory standard
----
----
----
OP
----
----
Additional lamp
----
----
----
----
1-2 Lamps that can be added to machine of each specification

Type
A
B
C
D
Place
Use on machine
Without rotary lamp
Without additional heater
Without rotary lamp
(10)
(11)
(12)
(13)
(14)
(15)
----
----
----
----
----
----
With additional heater

With rotary lamp
Without additional heater
With rotary lamp
With additional heater
Note) It is recommended that a 90 A alternator or larger one should be installed to types A and C to prevent
the battery from going flat.
108
1-3 Procedure for modification of each section

1-3-1 Types A and C (Without additional heater)
Weld lamp brackets 1A and clips 10 to the roof.
Where to weld bracket 1A

Type A:(10) (15)
Type B:(12) (15)
Type C:(10) (15)
Type D:(14), (15)
109
10
08036-41210
23
1A
198-978-6130
No.
Part No.
Qty
1-3-2
Type B (Without rotary lamp and with additional heater)

1) Similarly to types A and C explained in 1-3-1, weld lamp brackets 1A and clips 10 to the roof.
2) Install wiring harnesses 9 and lamps 8A to the ROPS roof.
3) Clamp the wiring harnesses securely with clips 5A, bolts 6A, and washers 7A.
4) Connect the added wiring harnesses to connectors CN-25 and CN-1 at the rear of the cab.
110
10
08036-41210
23
198-978-6180
8B
14X-911-3710
8A
17A-06-17920
1A
198-978-6130
No.
Part No.
Qty
1-3-3
Type D (With rotary lamp and additional heater)

1) Similarly to types A and C explained in 1-3-1, weld lamp brackets 1A and clips 10 to the roof.
2) Install wiring harnesses 9 and lamps 8A to the ROPS roof.
3) Connect the added wiring harness to connector CN-1 at the rear of the cab.
111
10
08036-41210
198-978-6180
8B
14X-911-3710
8A
17A-06-17920
1A
198-978-6130
No.
Part No.
Qty
2. Electric circuit diagram
112
3. Introduction of light
113
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
D375A-5
Service Meter Reading
Engine Serial No.
SA6D170E-3
Date of Inspection
Specification
Blade
Semi U
(Dual
Single)
Ripper or
counterweight
VGR.
VMR.
CW (
Shoe width
610 mm
Location of Machine at Inspection
Distributor's Name
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..... Abnormal
2. Enter actually measured values in parenthese, [
T ..... Correction made on abnormal point

T..... Not applied
].
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 REPORT.
Printed in Japan
2/8
Category
Battery
Criteria
Check of electrolyte level

Check of battery unit
Must be between L and H.

Must be free from grease, looseness of terminals, and
cracking.
Reserve tank water level
Low to Full
Antifreeze% 65 58 50
C -50 -40 -30
Water and oil level
Inspection
Inspection item
41 30
-20 -10
See operation
manual
Radiator
Must be contained.
Engine oil level
(H + L) / 2 to H + 10
Engine: Stopped
Power train oil level
(H + L) / 2 to H + 10
Engine: Stopped
(After 3 5 min)
Damper case oil level
(H + L) / 2 to H + 10
Hydraulic tank
oil level
Between H - L
Refer to Operation &

Maintenance Manual
Final drive oil level
LH
Engine: Stopped
Pitch back on the
ground. Ripper point
on the ground. (Shank
must be vertical.) Stop
the engine.
H to L sight gauge
H to H-20
See operation manual.

Stop the engine.
RH
Pivot shaft
oil level
LH
RH
Recoil spring
oil level
H + 5 to H + 25
from shaft end
LH
RH
H = 96 to 116
Use the diagram below for reference, and check if the

electrolyte reaches the bottom of the sleeve.
Correct level
(A)
Tool low
(B)
Window washer tank water level
LH
The electrolyte level is not up to

the bottom of the sleeve, so the
plate appears normal.
Full
Fuel tank
Full
Horn
Must be of no beat sound or sound deterioration.
Backup alarm
(Starting engine)
Backup alarm must sound when the T/M lever is at

the back position.
Monitor display
Monitor must be turned on with buzzer sound, than go

off after 3 seconds. After that all gauge lamps must
come on.
Operation of service meter

(Engine: Low idling)
Inspection
The electrolyte level is up to the

bottom of the sleeve, so the surface tension causes the surface
to rise and the plate appears to
be warped.
No error code indicated in the service meter.

Before engine start, meter must not operate when the
key switch turned on.
Charge lamp (Engine: Low 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.
Corrosion resistor cock.
Must be fully open.
Heater hose cock.
Must be fully open. (Fully open in summer)
Controller error code indication (make sure that error does not
recur)
Clear error code after confirming it.
Air bleeding of the hydraulic cylinder

1. Start and run the engine for 5 minutes at low idling.
2. With the engine at low idling, extract and retract the cylinder
4 to 5 times without bringing it to the stroke end.
3. With the engine at high idling, stop the cylinder at 100 mm
before the stroke end. Then slowly bring it to the stroke end.
Hold it at the position for 1 minute.
Perform air bleeding of the hydraulic cylinder.
3/8
Category
Inspection
Inspection item
Parking lever
(See shop manual)
Function/ operation
Free
Measurement of brake oil pressure on right and left

sides
(While running engine at high idling, measure brake oil
pressure on right and left sides. Brake oil pressure is 0
kg/cm.)
Do not start engine while parking brake lever is in
FREE position.
While parking brake lever in LOCK position, machine
cannot travel and gear speed cannot be changed.
Lock
Operability of the travel lever

Forward-reverse (a) - (b)
Steering (right/left) (R) / (L)
Must be of no pinching or abnormal sound. Notch must

not be released.
Check of the gear speed indication on the monitor panel.

Must be able to be shifted to any position with the engine at
low idling and the brake turned on.
N, F1, F2, F3, R1, R2 and R3 are all indicated.

Must be of no indication error.
Check of longitudinal adjustment

Free
of steering lever box
Lock
Adjustment of steps
Check of lock lever of box
(Upper and lower)
Must be adjustable.
Must not move after locking.
Case
Case
Case
Knob
Check of the L/U operation

With the T/M lever at the N position, engine idling must
change from low to high, then to low again.
High idling : L/U indicator ON

Low idling : L/U indicator OFF
L/U: ON ---- Check of speed when transmission is in F1

L/U: OFF --- Check of speed when transmission is in F1
Turning ON and OFF of L/U
Hydraulic pressure to turn L/U ON
1,180 1,280 rpm

1,150 1,200 rpm
L/U must be turned ON and OFF normally (When L/U is
ON, symbol lamp of monitor lights).
13 19 kg/cm
Check of the deceleration pedal operation

Set the fuel dial to high idle position.
Check the deceleration RPM
Must work smoothly.

Must be contained play at high idle.
950 25 rpm
Check of the fuel dial operation
Must move smoothly.
Check of dual tilt and pitch direction

Check of tilt direction
Dual
Criteria
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)
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
Category
Inspection
Inspection item
Clearance between straight frame and track
Left
mm
Right
mm
Check of the safety lever lock function
Work equipment
Lock
Check of the blade lever floating

Check of the blade lever floating notch release
Must be of no hydraulic drift (Engine: Low idling)

Engine stops at floating, then notch must be released.
Check of the quick drop valve operation

Quick dropping of the blade from top position.
At the engine full, set the blade lever at down position.

When the lever is set at the N position after the blade
drops by 1000 mm, it must stop.
Must be bridged with the blade and the ripper (Chassis)
Must function immediately after the engine stops then
drop from the top to the ground.
Main relief valve function (Engine: Low idling)

Check of the accumulator function (blade, ripper)
Blade cylinder OL
Leakage from U-packing, damaged rod, quick drop
valve, tube, flange or dust seal
Tilt cylinder/pitch cylinder OL
Leakage from U-packing, damaged rod, quick drop
valve, tube, flange or dust seal
Must be none.
LH
RH
Must be none.
LH
RH
End bit, cutting edge mounting bolt

Blade and bit stopper contact
1. End bit
2. Stopper
Ground peripherals
Difference between right and left must be 30 mm or

less (when measured on flat ground).
Move the blade up and down and stop it at 100 mm
above ground, then measure.
No actuator must work when the safety lock lever is at
ON position (Lever can move but work equipment
must not move)
Free
Cabin
Criteria
Track tension adjustment

With the gear at F1 and the engine at low idling, travel
on flat place for about 10 m, and when the grouser
comes over the first carrier roller, stop the machine by
depressing the brake pedal.
Carrier roller alignment
Travel on flat place with the gear at F1 and R1 for
about 10 m, repeatedly about 3 or 4 times, then gradually apply brake to stop.
Undercarriage OL
Leakage from idler, carrier roller, bogie, pivot shaft,
adjustment cylinder, and lubricated track (plug, seal)
Must be tightened.
Must be contacted
(partial contact is acceptable)
LH
RH
LH
RH
8 35 mm
8 35 mm
Tense a string or a bar between the first

carrier roller and the idler to measure distance between the string (bar) and the
grouser. Max. 20 mm
Flanges must be free from contact with links at all

times.
Must be none.
LH
RH
Beat noise inside the cabin, beat noise of the outer cover
Space between S/T lever and the cabin at forward travel + left
steering with the S/T lever at the front position.
Must be none.
Must be 40 mm or more.
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

Opening/closing and locking effect of the left/right side slide
glass
Lighting of the room lamp
Operation of the window wiper and the window washer
Must work smoothly to securely lock.

Must work smoothly to securely lock.
Operation of the radio and cassette system

(Volume, tuning, AM/FM switching, cassette)
Must come on/go off by turning the switch on/off.

Must be on/off by turning the switch on/off.
Wiper: Must operate smoothly (without beat noise)
Must operate correctly
Operation of the cigar lighter

Ash tray installation
Power supply of 12 V (Accessory socket, etc.)
Check by connecting the ratio unit
Must be red-heated.
Must be installed.
Power of 12 V must be supplied.
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
Lubrication
Category
Inspection
Inspection item
Portions to be lubricated
Equalizer bar side pin shaft
Equalizer bar center pin shaft
Blade lift cylinder support shaft and yoke
Brace center pin
Blade oblique arm ball joint
Brace screw
Criteria
Qty
Example: When U-blade is used
2
1
6
1
3
2
Check of ripper direction

(a)
Raise
(c)
Lower
(A)
Tilt in
(B)
Tilt out
Raise
Lower
Ripper lift cylinder OL

U-packing, damaged rod, tube, flange, dust seal
loosing
TILT
IN
TILT
OUT
Must be none
LH
RH
Ripper tilt cylinder OL

U-packing, damaged rod, tube, flange, dust seal loosing
Must be of no contact.
LH
Ripper
RH
Contact with the hose at ripper operation
(Entire operation area must be checked)
Must be of no contact.
Creak of the ripper link pin
Must be of no creak.
Check of the pin puller switch direction

(a): Pin out
(b): Pin in
Must be the same as the pin puller cylinder operation

direction.
Machine front
Check of the pin puller cylinder hose cramp position
(Entire operation area must be checked)
Must be of no contact Must be of no excess hose tension.
Pin puller cylinder OL

Leakage from U-packing, damaged rod, tube of flange
Must be none
Check of ripper lubricated hose installation
LH
Must be of no contact or no excess bend.
RH
Portions to be lubricated
Ripper lift cylinder head
Ripper lift cylinder bottom
Ripper tilt cylinder head
Ripper tilt cylinder bottom
Ripper arm pin (front)
Ripper arm pin (rear)
Qty
(8)
(6)
(7)
(5)
(9)
(10)
2
2
2
2
2
2
Must be lubricated (right and left)
6/8
Engine speed
Category
Item
Engine
Engine speed
Condition
Unit
Standard
Run engine at low idling (low speed).
rpm
695 745
Run engine at high idling (at full throttle).
rpm
1875 1925
Set decelarator at low speed.
rpm
850 950
Stall torque converter.
rpm
1470 1570
Stall torque converter and work equipment relief.
rpm
1240 1360
Large pump relief (ripper lift relief)
rpm
1240 1360
Select economy mode (1), run engine at full throttle,

and set transmission in N.
rpm
1700 1800
Select economy mode (2), run engine at full throttle,

and set transmission in N.
rpm
1350 1450
Select SSC mode (1), run engine at full throttle, and

set transmission in N.
rpm
1630 1700

rpm
1550 1650

rpm
1450 1550

rpm
1250 1350

rpm
1150 1250
Run engine at full throttle and set transmission in N.
Mpa
{kg/cm}
0.05 0.25
{0.5 2.5}
Run engine at low speed and set transmission in N.
Mpa
{kg/cm}
0.78 0.98
{8 10}
Mpa
{kg/cm}
0.25 0.44
{2.5 4.5}
Mpa
{kg/cm}
0.39 0.64
{4.0 6.5}
Run engine at low speed and set T/C

transmission in N.
Mpa
{kg/cm}
0
{0}
Run engine at low speed and set L/U

transmission in N.
Mpa
{kg/cm}
0
{0}
Run engine at full throttle and

T/C
Mpa
{kg/cm}
0
{0}

L/U
Mpa
{kg/cm}
0
{0}
Stator clutch pressure Run engine at low speed and set T/C
transmission in N.
Mpa
{kg/cm}
2.25 2.65
{23.0 27.0}
Run engine at low speed and set L/U

transmission in N.
Mpa
{kg/cm}
0
{0}

T/C
Mpa
{kg/cm}
2.25 2.65
{23.0 27.0}

L/U
Mpa
{kg/cm}
0
{0}

Release pedal.
Mpa
{kg/cm}
0
{0}

Press pedal to
stroke end.
Mpa
{kg/cm}
{32 35}
Run engine at full throtlle and

Release pedal.
Mpa
{kg/cm}
2.55 3.04
{26 31}

Press pedal to
stroke end.
Mpa
{kg/cm}
0
{0}
Engine speed
(Only SSC specification)
Hydraulic pressure
Inlet pressure
Torque convertor
Outlet pressure
Lock-up clutch
pressure
Transmission
Clutch pressure
(L.H and R.H)
Brake pressure
(L.H and R.H)
Result
7/8
Hydraulic pressure
Oil pressure
Category
Item
Condition
Unit
Standard
Result
PPC pressure
(Only machine with pressure
pickup nipple)
Mpa
{kg/cm}
Work equipment pump (large

pump)
Ripper tilt
Single tilt relief
Mpa
{kg/cm}
19.6 20.6
{200 210}
Measure at monitor
Mpa
{kg/cm}
20.6 21.6
{210 220}
Measure at monitor
Run engine at low speed and set tronsmission in N.
Mpa
{kg/cm}
19.6 20.6
{200 210}
Measure at monitor
Run engine at lfull throttle and set tronsmission in N.
Mpa
{kg/cm}
20.6 21.6
{210 220}
Measure at monitor
sec
3.5 4.5
Work equipment pump (small

pump)
Ripper lift
(Measure by monitor panel)
Single tilt relief
4.2 4.8
{43.0 49.0}
Work equipment speed

Blade lift
Semi U
RAISE
Run engine at full throttle.
LOWER
sec
1.1 1.6
Blade lift
Full U
RAISE
sec
3.5 4.5
LOWER
sec
1.0 1.5
Single tilt
Semi U Full U
LEFT tilt
sec
3.0 4.0
RIGHT tilt
sec
4.0 5.0
Single tilt (Dual tilt specification) LEFT tilt

Full U Semi U
RIGHT tilt
sec
3.0 4.0
sec
4.0 5.0
Dual tilt
LEFT tilt
sec
4.0 5.0
RIGHT tilt
sec
4.0 5.0
Dual tilt
Pitch DUMP
sec
4.0 5.0
Pitch BACK
sec
3.0 4.0
RAISE
sec
2.5 3.5
Ripper lift
LOWER
sec
2.0 3.0
Ripper tilt
Tilt IN
sec
4.5 5.5
Tilt BACK
sec
3.0 4.0
Pin puller
Push
sec
Max. 3.0
Pull
sec
Max. 3.0
Hydraulic drift of work equipment

Blade lift
Cutting edge height: 500 800 mm.
mm/min
Max. 200/15
Ripper lift
Ripper point height: 300 600 mm.
mm/min
Max. 80/15
8/8
Check sheet for tightening torque for bolts of ROPS and roof
Sketch
Record
1. Tightening torque of roop
From right to left of machine rear A J
From right to left of machine front K T
(rear 10 + front 10, total 20)
Location
Record
Standard tightening torque
A
B
C
D
E
F
G
H
I
J
245 309 Nm
{25.0 31.5 kgm}
K
L
M
N
O
P
Q
R
S
T
2. Tightening torque of rops

From right to left of machine rear a f
From right to left of machine front g i
(rear 6 + front 6, total 12)
Location
Record
Standard tightening torque
a
b
c
d
e
f
g
h
i
j
k
l
1519 1911 Nm
{155 195 kgm}
GEN00062-00

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Field Assembly Instruction

Operator for assembly

IInstalling track shoes....................................................................................................................... 31

Charging recoil chamber and pivot chamber with oil ....................................................................... 32

Installation of blade lift cylinder ........................................................................................................ 33

Installation of tilt hose & trunnion ..................................................................................................... 34

Assembly of blade assembly............................................................................................................ 36

Checking of arm joint clearance (U blade) ....................................................................................... 39

Installation of blade .......................................................................................................................... 40

Adjusting of lift cylinder joint area..................................................................................................... 45

A-10 Checking installation of dual tilt cylinder (If equipped) ..................................................................... 46

Check and adjustment of operator's cab.......................................................................................... 82

Measuring engine speed.................................................................................................................. 88

Adjust control logic to specification .................................................................................................. 89

Error code ........................................................................................................................................ 90

APPENDIX 1. Installation of spill guards to u-blade ........................................................................................ 97

Rated engine output

Overall height (with ROPS)

Komatsu SA6D170E-3 diesel engine

Fell U-tiltdozer + variable giant ripper

Semi-U-tiltdozer + variable multi ripper

Precautions for field assembly

Precautions for field assembly

3. k Check of actual work

45-ton wrecker 1 unit

45-ton wrecker 1 unit

8:00 10:00 12:00 14:00 16:00 18:00

45-ton wrecker 2 units

Installing under cover

Installing pivot shaft and

Assembly procedure, necessary equipment, and schedule

Assembly procedure, necessary equipment, and schedule

Style for transportation

Style for transportation

Overall length (mm)

Overall height (mm)

Overall width (mm)

Overall length (mm)

Overall height (mm)

Overall width (mm)

Overall length (mm)

Overall height (mm)

Overall width (mm)

Style for transportation

(2) Blade (semi U)

A Overall length (mm)

B Overall height (mm)

C Overall width (mm)

A Overall length (mm)

B Overall height (mm)

C Overall width (mm)

Style for transportation

Blade lift cylinder

Overall length (mm)

Overall height (mm)

Overall width (mm)

Overall length (mm)

Overall height (mm)

Overall width (mm)

Overall length (mm)

Overall height (mm)

Overall width (mm)