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(Replaces SEAW005000)
Field Assembly
Manual
BULLDOZER
-5
SERIAL NUMBERS D475A-5 20001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
You are required to execute full inspection and maintenance before starting the en-
gine and assembling the work equipment. Since the work is often carried out in dan-
gerous 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 exam-
ine the above point and take necessary measures.
Instruction system
Work leader
Director
Work supervisor Crane director and
deputy director
We hope that the all members will cooperate with each other and assemble the work
equipment quickly in the field, observing the safety, quality, and delivery time.
CONTENTS
SPECIFICATIONS ....................................................................................................................................... 1
PRECAUTIONS FOR FIELD ASSEMBLY ................................................................................................... 3
ASSEMBLY PROCEDURE, NECESSARY EQUIPMENT, AND SCHEDULE ............................................. 4
LAYOUT OF KIT ......................................................................................................................................... 5
STYLE FOR TRANSPORTATION .............................................................................................................. 6
TOOLS LIST FOR FIELD ASSEMBLY ........................................................................................................ 11
TIGHTENING TORQUE .............................................................................................................................. 18
COATING MATERIALS .............................................................................................................................. 22
A. ASSEMBLY PROCEDURE ..................................................................................................................... 25
A-1 Installation of undercarriage ................................................................................................... 26
A-2 Installation of ripper ................................................................................................................ 33
A-3 Installation of tracks ................................................................................................................. 37
A-4 Adding oil to pivot chamber ................................................................................................... 39
A-5 Installation of ripper shank ..................................................................................................... 40
A-6 Installation of blade lift cylinder ............................................................................................. 41
A-7 Installation of trunnion ............................................................................................................ 43
A-8 Assembly of blade ................................................................................................................... 44
A-9 Adjustment of arm joint (U-blade) ......................................................................................... 50
A-10 Installation of blade ................................................................................................................. 51
A-11 Installation of counterweight .................................................................................................. 53
A-12 Installation of operators cab .................................................................................................. 54
A-13 Installation of ROPS ................................................................................................................. 70
A-14 Adjustment of potentiometer rod ........................................................................................... 71
A-15 Procedure for adjusting blade tilt angle limit ........................................................................ 72
A-16 Method of checking auto-reset system (Superdozer) ........................................................... 81
A-17 Check track tension .................................................................................................................. 82
A-18 Check fuel, coolant and lubricants ......................................................................................... 84
A-19 Greasing of greasing point ..................................................................................................... 86
A-20 Installation of ORBCOMM antenna and wiring harness ....................................................... 89
A-21 Replacement of return filter
(Replacement of standard filter with flushing filter) ............................................................. 90
A-22 Installing direction of exhaust pipe ........................................................................................ 93
A-23 Bleeding air from hydraulic cylinders .................................................................................... 94
A-24 Installing lunchbox band (if equipped) .................................................................................. 95
M. CHECK AND MAINTENANCE PROCEDURES AFTER COMPLETION OF ASSEMBLY ..................... 97
M-1 Check and adjustment of operators cab ............................................................................... 98
M-2 Error code ................................................................................................................................. 105
M-3 Flushing of hydraulic circuit .................................................................................................... 114
APPENDIX 1
INSTALLATION OF SPILL GUARDS
APPENDIX 2
PRECAUTIONS FOR INITIALIZATION PROCEDURES
FOR VHMS CONTROLLER
FIELD ASSEMBLY INSPECTION REPORT (U-DOZER SPECIFICATION)
FIELD ASSEMBLY INSPECTION REPORT (SUPERDOZER SPECIFICATION)
SPECIFICATIONS
Semi-U-tiltdozer U-tiltdozer
Item Unit + Giant ripper + Giant ripper Superdozer
Operating weight
(excluding operator's weight) kg 103,900 (*1) 108,000 (*2)
Blade weight
(including cylinders) kg 13,600 14,600
Ripper weight
(including cylinders) kg 9,720
Counterweight kg 6,300
Engine model Komatsu SDA12V140E-1 diesel engine
Rated engine output kW/rpm {HP/rpm} 641/2,000{860/2,000}
Overall length mm 11,560 12,065 10,525
Overall height (with ROPS) mm 4,240 (4,600)
Overall width mm 5,265 6,205 6,465
Travel speed Forward km/h 3.5/6.3/10.9
(1st/2nd/3rd) Reverse km/h 4.7/8.4/14.3
*1: Blade + ripper + ROPS cab + air conditioner
*2: Superdozer + counterweight + ROPS cab + air conditioner
1
Superdozer + counterweight
2
PRECAUTIONS FOR FIELD ASSEMBLY
1. Selection of workplace
1) When selecting a workplace, consider the following items so that you can load and unload the machine.
Width
Hardness
Flatness
Access road, place for turn
2) Do not work in a place where dust, rainwater, etc. may enter the hydraulic circuit during assem-
bling work.
3) Do not assemble while a strong wind is blowing or it is raining.
4. Before starting the work, read this manual thoroughly and keep the precautions in your mind.
5. The supervisor shall write down the precautions for each work process and explain them to the workers.
6. Hold a meeting every morning to check today's work plan and safe work.
3
Schedule
No. 1st day 2nd day 3rd day 4th day 5th day
Item
Unloading
Installation of track
1 Installation of stand
Installation of chassis
Unloading of other parts
2 Installation of blade lift cylinder
3 Installation of track frame
4 Installation of ripper (Installation of counterweight)
5 Installation of track
Blade
Welding of spill guard (If equipped)
6
Assembly of blade
Installation of blade
7 Installation of operators cab
8 Installation of ROPS
4
9 Installation of exhaust pipe
10 Adjustment of blade tilt limit rod
11 Adjustment of tilt limit angle
The special work in the field shall be adjusted separately.
Approx. 30 m
Blade
Track
Track
Wrecker truck
Approx. 30 m
Chassis
Wrecker truck
Accessories
Ripper parts CAB assembly
ROPS guard
5
STYLE FOR TRANSPORTATION
Since the machine can be divided for transportation, ask us or our service shop before transportation.
Style of each KIT.
Body
Track frame
WORK EQUIPMENT
(1) U-blade
6
(2) Semi U-blade
Super blade
Track shoe
7
Straight frame
Semi-U, U Super
A Overall length (mm) 4,857 5,020
B Overall height (mm) 674 682
C Overall width (mm) 638 681
Weight (kg) 1,770 1,868
Hydraulic cylinder
(1) Pitch, tilt cylinder
Semi-U, U Super
A Overall length (mm) 1,930 1,754
C Overall width (mm) 351 351
Weight (kg) 504 508
Lift Tilt
A Overall length (mm) 1,748 1,698
C Overall width (mm) 304 304
Weight (kg) 389 394
8
Giant ripper beam
9
Cab
ROPS
Counterweight
10
TOOLS LIST FOR FIELD ASSEMBLY
No. Tool name Specification Q'ty Remarks
1 Crane truck Capacity: 441kN {45 tons} 2
2 Service car 2
3 Air compressor 0.74 MPa {7.5 kg/cm2}, 15 m3/min 1
4 Welder 2 For welding blade spill guard (If equipped)
5 Lever block 19.6 kN {2 ton}, 58.8 kN {6 ton} each 1
6 Wire 26 x 6 m 6 For body
36 x 5 m 1 For body
30 x 3 m 2 For body
7 Wire sling 20 x 5 m 2
12 x 2 m 4
8 Nylon sling 25 mm wide x 3 m 2
50 mm wide x 3 m 1
9 Hydraulic wrench 5,884 Nm {600 kgm} 1 For master link bolt
10 Impact wrench 4,413 Nm {450 kgm} 1 For master link bolt
3,138 Nm {320 kgm} 1 KW45FG
2,542 Nm {250 kgm} 1 KW40F
196 Nm {20 kgm} 1 KW20PI
157 Nm {16 kgm} 1 KW14PI
137 Nm {14 kgm} 1 KW12PI
11 Sockets set 50 46 41 36 each 1 M 38.1
36 32 30 27 each 1 M 25.4
12 Extension bar M 38.1 x L300 1
13 Torque wrench 2,059 Nm {210 kgm} 1
1,373 Nm {140 kgm} 1
588 Nm {60 kgm} 1
14 Eyebolt M 12 x P 1.75 4
M 16 x P 2 2 For blade center link
15 Shackle SD22 4
BC36 2
SA60 1 For front hook
16 Sledge hammer 10P 1
17 Bar L = 1000 mm 1
18 Tap M 33 x P 2 1 For master link
M 30 x P 3 1
M 24 x P 3 1
19 Jack 147 kN {15 ton} 2 For assembling track frame
20 Hydraulic jack 785 kN {80 ton} 1 For assembling body
21 Chain block 78 kN {8 ton} x 4 m 2 For assembling blade
22 Spanner wrenches set Width: 19 50 mm each 1
23 Standard tools set 1
24 Hydraulic oil SAE30-CD 50 For pivot
SAE10W-CD 400 For hydraulic tank
25 Grease G2-LI 10
26 Lubricant LM-P (09940-00040) 1 For master link
27 Detergent 20
28 Paint remover 5
29 Paint for repair Natural yellow 5
Black grey 5
30 Glass cleaner 1
11
No. Tool name Specification Q'ty Remarks
31 Cloth Bunch 5
32 Angle meter 1 For dual tilt (If equipped)
33 Grease pump Air type 1
34 Oil pump Manual or air type 1
35 Oil jack 5 1
36 Waste oil receiving pan 1
37 Step Height: 2 m 1
38 Stand Front 1 See attached tool drawing
Rear 1 See attached tool drawing
39 Sling for track frame 1 See attached tool drawing
40 Wood block 350 mm x 750 mm 4
350 mm x 400 mm 4
100 mm x 750 mm 4
41 Vinyl hose (Transparent) 3,000 mm (O.D. 10 mm) 1 For measuring cab pressurization
42 Packaging tape 1
43 Steel plate 1,000 mm x 1,700 mm x 19 t 2 For setting under stand
12
Sketch of tools
13
No. Material Qty Remarks
01 SS400C 4 C150 x 75 x t91432
02 SS400C 2 C150 x 75 x t9925
03 SS400C 2 C150 x 75 x t9925
04 SS400C 2 C150 x 75 x t9425
05 SS400C 2 C150 x 75 x t9459
06 SS400C 2 C150 x 75 x t9378
07 SS400C 2 C150 x 75 x t9250
08 SS400B 4 50-75
09 SS400 4 t25 x 180 x 250
10 SS400 4 t12 x 200 x 739.5
11 SS400 10 t12 x 60 x 128
12 SS400 2 t16 x 124 x 130
13 SS400 2 t25 x 70 x 85
Note) We are not liable for any result of use of tools manufactured according to these drawings.
Chassis stand (Rear side)
14
Material
Total weight
2-36 drill
Do not
weld
15
Sling (track frame) : Detail 02
393.5
2-36 drill
16
Dimension of shackle (Unit: mm)
Shackle t d B D d1 Diameter L1
(Nominal (Nominal
value) value)
6 6 6 11 17 9 M8 24
8 8 8 14 21 11 M10 32
10 10 10 17 25 13 M12 40
12 12 12 20 32 16 M14 48
14 14 14 24 36 18 M16 56
16 16 16 26 40 20 M18 64
18 18 18 29 45 22 M20 72
20 20 20 31 50 25 M24 80
Shackle for
ripper shank 22 22 22 34 55 27 M24 88
24 24 24 39 62 31 M30 96
26 26 26 41 66 33 M30 104
28 28 28 43 70 35 M33 112
30 30 30 45 75 37 M36 120
32 32 32 48 80 39 M36 128
34 34 34 50 85 41 M39 136
36 36 36 54 90 43 M42 144
38 38 38 57 95 47 M45 152
17
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.
Table 1
Unit: Nm {kgm}
Material S43C, SCM435H or equivalent
Nominal size of thread (mm) Range Target
8.8 - 14.7 12
6 {0.9 - 1.5} {1.2}
14.7 - 34 25
8 {1.5 - 3.5} {2.5}
34 - 74 54
10 {3.5 - 7.5} {5.5}
54 - 123 89
12 {5.5 - 12.5} {9}
84 - 196 137
14 {8.5 - 20} {14}
147 - 309 230
16 {15 - 31.5} {23.5}
201 - 427 315
18 {20.5 - 43.5} {32}
319 - 608 460
20 {32.5 - 62} {47}
471 - 829 650
22 {48 - 84.5} {66.5}
588 - 1030 810
24 {60 - 105} {82.5}
883 - 1470 1180
27 {90 - 150} {120}
1130 - 1910 1520
30 {115- 195} {155}
1470 - 2450 1960
33 {150 - 250} {200}
1860 - 3040 2450
36 {190 - 310} {250}
2260 - 3630 2940
39 {230 - 370} {300}
18
When tightening the bolts with a torque wrench, apply Table 2.
Apply Table 2 when the proper tightening torque range is particularly narrow.
Table 2
Unit: Nm {kgm}
Material
S43C, SCM435H or equivalent
Nominal size of thread (mm)
11.8 - 14.7
6 {1.2 - 1.5}
27 - 34
8 {2.8 - 3.5}
59 - 74
10 {6 - 7.5}
98 - 123
12 {10 - 12.5}
157 - 196
14 {16 - 20}
245 - 309
16 {25 - 31.5}
343 - 427
18 {35 - 43.5}
490 - 608
20 {50 - 62}
662 - 829
22 {67.5 - 84.5}
824 - 1030
24 {84 - 105}
1180 - 1470
27 {120 - 150}
1520 - 1910
30 {155- 195}
1960 - 2450
33 {200 - 250}
2450 - 3040
36 {250 - 310}
2890 - 3630
39 {295 - 370}
19
2. Tightening torque of pipe threads
Tighten taper male pipe threads of nominal sizes of R1/8 - R1 and Rc1/8 - Rc1 and parallel female
pipe threads of nominal size of Rp1/8 - Rp1 (coated with adhesive) according to the following
standard.
If tightening torque is specified particularly, however, do not apply the following standard.
2-1. If the material of male threads is SS400, FC, or SGP, apply Table 1.
Table 1
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size
3.9 - 6.9 2.9 - 5.9 2.0 - 3.9
1/8 {0.4 - 0.7} {0.3 - 0.6} {0.2 - 0.4}
5.9 - 11.8 4.9 - 9.8 3.9 - 7.8
1/4 {0.6 - 1.2} {0.5 - 1.0} {0.4 - 0.8}
16.7 - 26.5 13.7 - 21.6 9.8 - 16.7
3/8 {1.7 - 2.7} {1.4 - 2.2} {1.0 - 1.7}
32.3 - 52.9 26.5 - 43.1 19.6 - 32.3
1/2 {3.3 - 5.4} {2.7 - 4.4} {2.0 - 3.3}
51.0 - 85.3 42.1 - 70.6 31.4 - 52.9
3/4 {5.2 - 8.7} {4.3 - 7.2} {3.2 - 5.4}
86.2 - 173.5 72.5 - 146.0 54.9 - 111.7
1 {8.8 - 17.7} {7.4 - 14.9} {5.6 - 11.4}
Table 2
Unit: Nm {kgm}
Material of female thread
Steel Cast iron Light alloy
Nominal size
16.7 - 29.4 9.8 - 19.6 6.9 - 14.7
1/8 {1.7 - 3.0} {1.0 - 2.0} {0.7 - 1.5}
19.6 - 44.1 16.7 - 37.2 12.7 - 28.4
1/4 {2.0 - 4.5} {1.7 - 3.8} {1.3 - 2.9}
44.1 - 93.1 37.2 - 77.4 27.4 - 58.8
3/8 {4.5 - 9.5} {3.8 - 7.9} {2.8 - 6.0}
98.0 - 188.2 83.3 - 157.8 60.8 - 115.6
1/2 {10.0 - 19.2} {8.5 - 16.1} {6.2 - 11.8}
170.5 - 316.5 141.1 - 247.0 105.8 - 186.2
3/4 {17.4 - 32.3} {14.4 - 25.2} {10.8 - 19.0}
367.5 - 612.5 309.7 - 514.5 235.2 - 392.0
1 {37.5 - 62.5} {31.6 - 52.5} {24.0 - 40.0}
20
3. Tightening torque of hoses (with taper/face seal)
Unit: Nm {kgm}
Tightening torque
Nominal diameter Width across
of hose flatse. Range Target
21
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Qty Container Main applications, featuresr
22
Category Komatsu code Part No. Qty Container Main applications, featuresr
23
24
A. ASSEMBLY PROCEDURE
25
Assembly procedure
Installation of undercarriage (1/7)
A-1
26
Assembly procedure
Installation of undercarriage (2/7)
A-1
Shackle
26t
27
Assembly procedure
Installation of undercarriage (3/7)
A-1
O-ring
O-ring
28
Assembly procedure
Installation of undercarriage (4/7)
A-1
3m
100 mm
29
Assembly procedure
Installation of undercarriage (5/7)
A-1
30
Assembly procedure
Installation of undercarriage (6/7)
A-1
There is UP mark
31
Assembly procedure
Installation of undercarriage (7/7)
A-1
Sling the rear section, pull out the stand, and place
the chassis on the tracks.
32
A-2 Installation of ripper (1/4)
1. Preparation
Removal of paint and rust prevention oil from
mounting parts
Style
2. Installation of arm
Sling the arm by 3 points. Set its right and left
parts in parallel accurately.
Set a wood block under the arm as shown in the
photo.
33
A-2 Installation of ripper (2/4)
Straight openings
L-adapters
6. Sub beam
Assemble the right and left grease hoses and
elbows before installing them to cylinder head pin.
34
A-2 Installation of ripper (3/4)
35
A-2 Installation of ripper (4/4)
36
Assembly procedure
Installation of tracks (1/2)
A-3
3. Sling the rear end of the track with a crane and lay it
over the sprocket.
37
Assembly procedure
Installation of tracks (2/2)
A-3
7. Insert the key in the link and place the shoe, then
tighten and seat the 4 bolts evenly first with an
impact wrench of 196 Nm {20 kgm}.
Retightening method
1. Tighten the bolts to torque of 980 98 Nm {100
10 kgm} first and check that the mating faces
of the link are fitted.
2. Make match marks (at the places pointed out
with the arrow).
3. Retighten the bolt by an angle of 180 10.
Tightening order
Tighten the bolts in the order shown at right.
38
Assembly procedure
Adding oil to pivot chamber
A-4
Pivot chamber
Add engine oil through the hole of plug (1).
Quantity of oil: 26 /each side
Oil level (B): 10 30 mm from oil level (2)
39
Assembly procedure
Installation of ripper shank
A-5
Steel block
Other remarks
40
Assembly procedure
Installation of blade lift cylinder (1/2)
A-6
2. Installation of cylinder
Install the cylinder with the right and left tubes
out down.
Install the upper cap and bushing to the cylinder
first. After tightening the bolts temporarily, install
the lower cap and bushing, lifting them up.
3. Installation of hoses
Install the hoses so that they will not interfere with
each other as shown in the photo.
Installation angle
41
Assembly procedure
Installation of blade lift cylinder (2/2)
A-6
42
Assembly procedure
Installation of trunnion
A-7
43
Assembly procedure
Assembly of blade (1/6)
A-8
Joint
Correct Wrong
44
Assembly procedure
Assembly of blade (2/6)
A-8
45
Assembly procedure
Assembly of blade (3/6)
A-8
46
Assembly procedure
Assembly of blade (4/6)
A-8
Hose
Intermediate cover Step cover
Hose
Step cover
47
Assembly procedure
Assembly of blade (5/6)
A-8
3980
980
48
Assembly procedure
Assembly of blade (6/6)
A-8
2) Tilting to the right and left in the operators seat, rotate the brace.
3) Adjust the length of the brace so that the tilting distances on both sides will be the same.
49
Assembly procedure
Adjustment of arm joint (U-blade)
A-9
Adjustment of shim
1. Remove shim (1) and tighten bolt (2) until the Shim (1)
play of the ball joint is eliminated.
Bolt (2)
2. Measure clearance A and remove bolt (2).
Adjustment of shim
Adjustment of shim
Adjustment of shim
50
Assembly procedure
Installation of blade (1/2)
A-10
Caution
Checking the inside clearance between the track
and straight frame on the right and left sides,
move the chassis forward until it touches the
trunnion.
51
Assembly procedure
Installation of blade (2/2)
A-10
Nylon sling
Hanging bracket
Adjustment rod
Potentiometer
52
Assembly procedure
Installation of counterweight
A-11
Other remarks
53
Assembly procedure
Installation of operators cab (1/16)
A-12
Fig. 1
Other remarks
54
A-12 Installation of operators cab (2/16)
55
A-12 Installation of operators cab (3/16)
(2) Remove dirt, oil, and grease from the seal sticking faces.
(3) Remove the release paper from seals (15), (16), and (17), and then stick the seals, referring
to Fig. 4 on the next page.
Other remarks
56
A-12 Installation of operators cab (4/16)
Front
Overlap here.
Sealing sponge
57
A-12 Installation of operators cab (5/16)
Photo 1 Photo 2
Photo 3
Other remarks
58
A-12 Installation of operators cab (6/16)
Flange
Cab body
Fig. 5
No. Part No. Q'ty
18 01010-81275 15
19 124-54-26540 21 Lower cab in direction
of arrow.
20 01010-81245 6
55 198-Z11-3960 1
59
A-12 Installation of operators cab (7/16)
Face C
Dashboard assembly
Air conditioner duct
on dashboard side
Fig. 7
Air conditioner duct
on cab side
Monitor
Dashboard
Fig. 8
Precautions Necessary tools Necessary equipment
Name Qty Name Qty
Other remarks
60
A-12 Installation of operators cab (8/16)
Fig. 9
Other remarks
61
A-12 Installation of operators cab (9/16)
(12) Referring to Fig. 10, bind the windshield washer hoses, windshield washer connector, and
cab power supply wiring harnesses with strings. Pass them through holes (A) and (B), and
then connect the wiring harnesses on the chassis side from the decorative cover above the
left fender.
Marks at 15 places
Marks at 6 places
Floor frame
assembly
Wiring harness
4-pole connector ............................ Windshield washer
From floor From cab Red (Nominal JIS size: 5) ............... Power supply
Yellow (Nominal JIS size: 0.85) ..... Backup power supply (For radio)
Fig. 10
View X (sean from rear)
After connecting the hoses and connectors, fit the grommet on the wiring harness side securely.
62
A-12 Installation of operators cab (10/16)
Panel
Knob (Lever)
Fig. 11
63
A-12 Installation of operators cab (11/16)
Correct Wrong
Fig. 16
Other remarks
64
A-12 Installation of operators cab (12/16)
1. Install plate (36) on cover (32) as shown in the Name Qty Name Qty
photo.
65
A-12 Installation of operators cab (13/16)
Correct installation
Wrong installation
Other remarks
66
A-12 Installation of operators cab (14/16)
(6) Install sensor (52) to cover (51), and then install them with screws (53) and washers 54. (4
pieces)
(7) Install plates (47) and (48) with screws (49) and washers (50). (8 pieces)
(8) Install cab door plate (56). (On both sides).
(9) After installing cab door plate (56), apply liquid sealant (55) all around the plate. (On both
sides) Before opening and closing the door, wait until the sealant dries up.
Other remarks
67
A-12 Installation of operators cab (15/16)
Fig. 15
Other remarks
68
A-12 Installation of operators cab (16/16)
Antenna (198-Z11-4610)
Left window
Directed down when delivered
Rear window
Fig. 17
Fig. 18
Other remarks
69
A-13 Installation of ROPS
4 ROPS: 918 kg
Other remarks
70
Assembly procedure
Adjustment of potentiometer rod
A-14
Other remarks
71
Assembly procedure
Procedure for adjusting blade tilt angle limit (1/9)
A-15
1. Dual-tiltdozer
1-1 Set the machine under the standard condition.
Set the potentiometer rod to 425 mm.
Keep the machine horizontally.
1-2 Run the engine at low idling and set the blade
in the following standard position.
1) Set the tilt angle to 0.
2) Set the pitch angle to the maximum pitch
back.
3) Lower the blade to the ground.
4) Set the toggle switch of the blade lever to
the dual tilt position.
Tilt switch
Dual tilt
Other remarks
72
Assembly procedure
Procedure for adjusting blade tilt angle limit (2/9)
A-15
Other remarks
73
Assembly procedure
Procedure for adjusting blade tilt angle limit (3/9)
A-15
1-6 Tilt the blade to the left with the blade control
lever and set the left tilt angle to 12. (User
adjustment mode)
Since the tilt limiting function does not work,
operate slowly so that the tilt angle will not
increase too much.
Adjust the tilt angle accurately with angle
gauge.
Single tilt
Dual tilt
Other remarks
74
Assembly procedure
Procedure for adjusting blade tilt angle limit (4/9)
A-15
Other remarks
75
Assembly procedure
Procedure for adjusting blade tilt angle limit (5/9)
A-15
1-11 Tilt the blade to the right with the blade control
lever and set the right tilt angle to 12.
Since the tilt limiting function does not work,
operate slowly so that the tilt angle will not
increase too much.
Adjust the tilt angle accurately with angle
gauge.
1-12 Set the toggle switch of the blade control lever in the single tilt position, and then set it in
the dual tilt position again to save the right tilt limit in the system.
When the saving operation is finished, the buzzer sounds.
1-13 The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( )
to leave the adjustment mode, and then lower the work equipment to the ground and stop
the engine.
1-14 Start the engine again and tilt the blade to the right and left and check that the blade does
not interfere with the track shoe, regardless of its height.
Other remarks
76
Assembly procedure
Procedure for adjusting blade tilt angle limit (6/9)
A-15
2. Superdozer
2-1 Set the machine under the standard condition.
Set the potentiometer rod to 425 mm.
Keep the machine horizontally.
2-2 Run the engine at low idling and set the blade
in the following standard position.
1) Set the tilt angle to 0.
2) Set the pitch angle to the maximum pitch
back.
3) Lower the blade to the ground.
Other remarks
77
Assembly procedure
Procedure for adjusting blade tilt angle limit (7/9)
A-15
Other remarks
78
Assembly procedure
Procedure for adjusting blade tilt angle limit (8/9)
A-15
Other remarks
79
Assembly procedure
Procedure for adjusting blade tilt angle limit (9/9)
A-15
2-9 The adjustment work is finished. Set the buzzer cancel switch in the cancel position ( )
to leave the adjustment mode, and then lower the work equipment to the ground and stop
the engine.
2-10 Start the engine again and tilt the blade to the right and left and check that the blade stops
tilting to the right and left in the following range automatically, regardless of its height.
Automatic tilt stopping angle: 7 1
Other remarks
80
Assembly procedure
Method of checking auto-reset system
A-16 (Superdozer)
The auto-reset system is used to set the blade in the digging position automatically (to lower the
blade to the ground and set its angle to 52). To reset this system, press the pitch button.
Controller
Valve
Other remarks
81
Assembly procedure
Check track tension (1/2)
A-17
82
Assembly procedure
Check track tension (2/2)
A-17
INSPECTION
Stop the machine on level ground (stop with the
transmission in FORWARD without applying the brake).
Then place a straight bar on the track shoes between
the carrier roller and the idler as shown in the figure,
and measure the clearance is 20 to 30 mm, the tension
is standard.
If the track tension is not at the standard value, adjust it
in the following manner.
Other remarks
83
Assembly procedure
Checking oil/coolant levels (1/2)
A-18
The rated capacity is the total quantity of oil in each device and its piping. The refill capacity is
the quantity of oil replaced for inspection or maintenance.
When starting the engine at a temperature below 0C, be sure to use SAE10W, SAE10W-30, or
SAE15W-40, even if the temperature rises to about 10C during the daytime.
Even if single-grade oil is mixed in multi-grade oil (SAE10W-30, SAE15W-40), no problem occurs.
Add the single-grade oil matched to the atmospheric temperature shown in the following table,
however.
Coolant
The coolant is a mixture of Komatsu genuine Super Coolant (AF-NAC) and water, so it does not
need to be changed as long as the atmospheric temperature does not lower below 10C.
If the atmospheric temperature lowers below 10C, adjust the ratio of Super Coolant to water.
84
Assembly procedure
Checking oil/coolant levels (2/2)
A-18
Check the lowest atmospheric temperature in the past and decide the ratio of antifreeze to water
according to the following mixing ratio table. Actually, set the mixing ratio for a temperature about
10C below the recorded lowest atmospheric temperature.
Min. atmospheric
temperature (C)
10 15 20 25 30
Quantity ()
Antifreeze 73.5 88 100.5 113 122.5
WARNING
Since antifreeze is flammable, take care of fire.
WARNING
When removing the drain plug, take care that the
coolant will not splash over you.
Other remarks
85
Assembly procedure
Greasing of greasing point (1/3)
A-19
86
Assembly procedure
Greasing of greasing point (2/3)
A-19
Support shaft
LH and RH
4. Ripper
LH & RH LH & RH
LH & RH
87
Assembly procedure
Greasing of greasing point (3/3)
A-19
88
Assembly procedure
Installation of ORBCOMM antenna and wiring harness
A-20
Other remarks
89
Replacement of return filter
A-21 (Replacement of standard filter with flushing filter)
(1/3)
Strainer
Flushing element
Absolute filtration rating 6
Hydraulic tank
(Note 1) When the atmospheric temperature is below 15C,
install the valve and strainer (without installing oil
stopper plate (2)) and flush the piping with the engine
speed at low idling.
(Note 2) For the flushing procedure, see Testing and No. Part No. Q'ty
maintenance procedure after completing assembly 1 208-60-71170 1
M-3. 2 21T-60-13730 1
Other remarks
90
Replacement of return filter
A-21 (Replacement of standard filter with flushing filter)
(2/3)
Valve
Replacement
Strainer
Standard element
Hydraulic tank
Other remarks
91
Replacement of return filter
A-21 (Replacement of standard filter with flushing filter)
(3/3)
Element
Do not install the element with its bottom on the elevated part of the case bottom as shown in
Fig. 2. In particular, if the filter case is filled with oil, it is difficult to see if the element is installed
normally. In this case, turn the element with your hand. If you can turn it smoothly, it is installed
normally.
Other remarks
92
Assembly procedure
Installing direction of exhaust pipe
A-22
After installing the exhaust pipe, connect komaclone tube (4), using gasket (1), bolt (2), and
washer (3).
Right of chassis
Left of chassis
Front of chassis
Other remarks
93
Assembly procedure
Bleeding air from hydraulic cylinders
A-23
After disassembling for transpotation, changing the oil in the hydraulic tank, or removing the
hydraulic cylinders or work equipment piping, bleed the air from the hydraulic circuit as follows.
1) 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.
Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the
circuit under any circumstance.
3) Keeping the engine at low idling, extend the cylinder to a point approx. 100 mm before the end
of the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of
stroke. Hold it in this position for 3 minutes.
4) With the engine at high idling, extend the cylinder to a point approx. 100 mm before the end of
the stroke, then use fine control (at least 10 seconds) to operate the cylinder to the end of its
stroke. Hold it in this position for 1 minute.
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.
Operate the piston rod to approx. 100 mm from the end of the stroke; do not relieve the
circuit under any circumstance.
3) Repeat this operation with the engine at full throttle, then run the engine at low idling and
operate the piston rod to the end of its stroke to relieve the circuit.
If from the beginning the engine is run at full throttle; or the cylinders are operated to the end of
their stroke, the piston packing may be damaged, so never operate in this way.
Check the oil level, and add oil to the specified level if necessary.
Other remarks
94
Assembly procedure
Installing lunchbox band (if equipped) (1/2)
A-24
Note) When performing the following procedure, refer to A-12 Installing operator's cab (12/15), too.
1. After installing plate (1) to the operator's cab, pass the band through the rear U-hook as shown
below.
Other remarks
95
Assembly procedure
Installing lunchbox band (if equipped) (2/2)
A-24
3. Referring to A-12 Installing operator's cab (12/15), install the lining and rubber plate.
Lining
Front
Rubber plate
Other remarks
96
M. CHECK AND MAINTENANCE PROCEDURES
AFTER COMPLETION OF ASSEMBLY
97
M-1 Check and adjustment of operators cab (1/7)
1) Depress air outlet selector switch (2) on the air Front-Rear-Foot area
conditioner control panel to select the front-rear- (including defroster)
foot area mode (shown at right).
<Indication on LCD and air flow>
2) Select the fresh air mode with the RECIRC/FRESH
air selector switch (3). Indication on LCD Air flow
Low
3) Depress fan switch (1) to set the blower to the
high (Hi). Medium 1
Medium 2
Medium 3
Medium 4
Blower
High
at high (Hi)
If the standard pressure is not obtained, check the
seals around the dashboard and the seals of the
fitting faces of the cab and floor for an opening.
(Run water over outside to see if it enters the cab.)
If there is an opening, fill it with liquid seal.
98
M-1 Check and adjustment of operators cab (2/7)
10 mm or more
(e) Match the water levels of the beginning part and
the ending part of the water cloumn inside the
transparent vinyl hose at the outside of the
operators cab.
(f) Start the engine and run it at full speed to read
the difference between the two water levels.
Vinyl hose
99
M-1 Check and adjustment of operators cab (3/7)
(Sealed surface)
Other remarks
100
M-1 Check and adjustment of operators cab (4/7)
Shim (14X-911-1761)
(2) Check the correlation between the door latch and the striker (on both, L.H and R.H side).
Moving the door toward the closing direction, observe the engaging state between the
latch and the striker.
Latch
Striker
Latch
Make the observation to Center of the striker
check the engagement from Center of the latch
this side.
Striker
101
M-1 Check and adjustment of operators cab (5/7)
3.2 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.
Damper rubber
Shims
(2) Adjusting the correlation between the latch and the striker
(a) Loosening the striker mounting bolts to a temporarily tightened state, open and
close the door 2 to 3 times to aligh the centers of the latch and the striker.
(b) Check the engaging state between the latch and the striker.
(c) Tighten the striker mounting bolts back to their original tightened state.
(d) Try to open and close the door to see if the door lock can be released smoothly.
When the door lock cannot be released smoothly (when the turning effort to move
the knob feels too heavy), repeat the adjustment all over again. (Appropriate knob
turning effort: 68.6 19.6 N {7 2 kg}
When the grease adhering over the latch surface dries Name Qty Name Qty
out, the turning effort for the knob will become heavier.
Therefore, apply grease sufficiently in order not to allow
it to become dried up.
Other remarks
102
M-1 Check and adjustment of operators cab (6/7)
Releasing lever
The status is normal if the latch
is not riding over the bent
Shake the door section of the striker.
back and forth.
Latch (20Y-54-36380)
Bolt (01435-30820)
Make the
Striker (14X-911-1921)
observation
through this Nut (01580-11008)
direction Washer (01643-31032)
Bracket
(198-Z11-3341)
(198-Z11-3351)
(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.
Other remarks
103
M-1 Check and adjustment of operators cab (7/7)
4.2 Adjustment
(1) Adjusting the correlation between the latch and the striker
Loosen the striker mounting nut and adjust the position of the striker so that it does not
interfere with the latch nor the overriding over the bent section occurs before tightening
the nut back to its original state.
When the interference cannot be corrected by the adjustment on the striker side, loosen
the latch side mounting bolts to make the adjustment from the latch side.
Latch
Clearence
Striker
Door structure
Striker
Stopper rubber
Latch
Other remarks
104
Assembly procedure
Error code (1/9)
M-2
105
Assembly procedure
Error code (2/9)
M-2
106
Assembly procedure
Error code (3/9)
M-2
107
Assembly procedure
Error code (4/9)
M-2
Caution Caution
Failure code Failure Trouble Controller Action code lamp buzzer
1500L0 Double failure of transmission * See separate list (LO) TM CALL E03
15SAL1 Forward clutch oil pressure * See separate list (L1) TM CALL E03
15SALH Forward clutch oil pressure * See separate list (LH) TM CALL E03
15SBL1 Reverse clutch oil pressure * See separate list (L1) TM CALL E03
15SBLH Reverse clutch oil pressure * See separate list (LH) TM CALL E03
15SEL1 1st clutch oil pressure * See separate list (L1) TM CALL E03
15SELH 1st clutch oil pressure * See separate list (LH) TM CALL E03
15SFL1 2nd clutch oil pressure * See separate list (L1) TM CALL E03
15SFLH 2nd clutch oil pressure * See separate list (LH) TM CALL E03
15SGL1 3rd clutch oil pressure * See separate list (L1) TM CALL E03
15SGLH 3rd clutch oil pressure * See separate list (LH) TM CALL E03
1800MW Power train clutch slip Slip (MV) TM E02
2201L1 Right clutch oil pressure * See separate list (L1) ST CALL E04
2201LH Right clutch oil pressure * See separate list (LH) ST CALL E04
2202L1 Left clutch oil pressure * See separate list (L1) ST CALL E04
2202LH Left clutch oil pressure * See separate list (LH) ST CALL E04
2300NR Brake thermal load Abnormal heating (NR) ST E00
2301L1 Right brake oil pressure * See separate list (L1) ST CALL E04
2301LH Right brake oil pressure * See separate list (LH) ST CALL E04
2301NR Right steering brake thermal load Abnormal heating (NR) ST E00
2302L1 Left brake oil pressure * See separate list (L1) ST CALL E04
2302LH Left brake oil pressure * See separate list (LH) ST CALL E04
2302NR Left steering brake thermal load Abnormal heating (NR) ST E00
A000N1 Engine speed sensor abnormality Over run (N1) VHMS E00
A70XLK Governor servo system right abnormality * See separate list (LK) ENG CALL E04
A70YLK Governor servo system left abnormality * See separate list (LK) ENG CALL E04
AA1ANX Air cleaner clogging Clogging (NX) Machine E00
AB00MA Battery charge abnormality Malfunction (MA) Machine E00
B@BAZG Engine oil pressure lowering Lowering of oil pressure (ZC) Machine E00
B@BAZK Engine oil level lowering Lowering of level (ZK) Machine E00
B@BCNS Coolant overheating Overheating (NS) Machine E00
B@BCZK Coolant water level lowering Lowering of level (ZK) Machine E00
B@CENS Power train overheating Overheating (NS) Machine E00
B@HANS Hydraulic oil overheating Overheating (NS) Machine E00
B@HAZK Hydraulic oil level lowering Lowering of level (ZK) Machine E00
D110KA BR relay holding Disconnection (KA) ST E00
D110KB BR relay holding Short circuit (KB) ST E00
D130KA N safety relay Disconnection (KA) TM E02
D130KB N safety relay Short circuit (KB) TM E02
D161KA Backup alarm relay Disconnection (KA) TM E01
D161KB Backup alarm relay Short circuit (KB) TM E01
D182KZ Preheating relay Lowering of level (ZK) ST E01
D1D0KA Governor cut relay right disconnection Disconnection (KA) ENG E01
D1D0KB Governor cut relay right short circuit Short circuit (KB) ENG E01
D1D1KA Governor cut relay left disconnection Disconnection (KA) ENG E01
108
Assembly procedure
Error code (5/9)
M-2
DB45KP Rack sensor power supply abnormality Lowering of output voltage (KP) ENG CALL E03
DB49KM Connector wrong connection Mistake in operation or setting (KM) ENG CALL E04
Disagreement of model selection ENG E02
DB49KQ Model selection abnormality signals (KQ)
109
Assembly procedure
Error code (6/9)
M-2
110
Assembly procedure
Error code (7/9)
M-2
111
Assembly procedure
Error code (8/9)
M-2
Caution Caution
Failure code Failure Trouble Controller Action code lamp buzzer
DKF0KX Fuel injection pump rack sensor Out of input signal range (KX) VHMS E00
DKF1KX Rack sensor right abnormality Out of input signal range (KX) ENG CALL E03
DKF2KX Rack sensor left abnormality Out of input signal range (KX) ENG CALL E03
DKH1KA Pitch angle sensor Disconnection (KA) ST CALL E03
DKH1KB Pitch angle sensor Short circuit (KB) ST CALL E03
DLE1KA Engine speed sensor Disconnection (KA) ST E01
DLE4LC Engine speed sensor A abnormality * See separate list (LC) ENG CALL E03
DLE5LC Engine speed sensor B abnormality * See separate list (LC) ENG CALL E03
DLF1KA Transmission speed sensor Disconnection (KA) TM E01
DLT3KA Transmission output shaft speed sensor Disconnection (KA) TM E01
DV00KB Caution buzzer Short circuit (KB) MON E01
DW55KA Pitch back solenoid Disconnection (KA) TM CALL E03
DW55KB Pitch back solenoid Short circuit (KB) TM CALL E03
DW56KA Pitch dump solenoid Disconnection (KA) TM CALL E03
DW56KB Pitch dump solenoid Short circuit (KB) TM CALL E03
DW57KA Left tilt limit solenoid Disconnection (KA) TM E02
DW57KB Left tilt limit solenoid Short circuit (KB) TM E02
DW58KA Right tilt limit solenoid Disconnection (KA) TM E02
DW58KB Right tilt limit solenoid Short circuit (KB) TM E02
DW59KA Dual tilt selection solenoid Disconnection (KA) TM E01
DW59KB Dual tilt selection solenoid Short circuit (KB) TM E01
DW5AKA Pitch selection solenoid Disconnection (KA) TM E02
DW5AKB Pitch selection solenoid Short circuit (KB) TM E02
DW5DKA Pitch selection solenoid Disconnection (KA) TM CALL E03
DW5DKB Pitch selection solenoid Short circuit (KB) TM CALL E03
DW7BKA Fan reverse solenoid Disconnection (KA) TM E01
DW7BKB Fan reverse solenoid Short circuit (KB) TM E01
DWJ0KA Pump merge-divider solenoid Disconnection (KA) ST CALL E03
DWJ0KB Pump merge-divider solenoid Short circuit (KB) ST CALL E03
DWN3KA Sudden stop prevention solenoid Disconnection (KA) ST CALL E04
DWN3KB Sudden stop prevention solenoid Short circuit (KB) ST CALL E04
DWN5KA Fan control solenoid 1 Disconnection (KA) TM E01
DWN5KB Fan control solenoid 1 Short circuit (KB) TM E01
DWNCKA Fan control solenoid 2 Disconnection (KA) TM E01
DWNCKB Fan control solenoid 2 Short circuit (KB) TM E01
DXE0KA LS set selector solenoid (LSV) Disconnection (KA) TM E02
DXE0KB LS set selector solenoid (LSV) Short circuit (KB) TM E02
DXH1KA Lockup solenoid Disconnection (KA) TM E01
DXH1KB Lockup solenoid Short circuit (KB) TM E01
DXH4KA 1st clutch ECMV Disconnection (KA) TM CALL E03
DXH4KB 1st clutch ECMV Short circuit (KB) TM CALL E03
DXH5KA 2nd clutch ECMV Disconnection (KA) TM CALL E03
DXH5KB 2nd clutch ECMV Short circuit (KB) TM CALL E03
DXH6KA 3rd clutch ECMV Disconnection (KA) TM CALL E03
DXH6KB 3rd clutch ECMV Short circuit (KB) TM CALL E03
112
Assembly procedure
Error code (9/9)
M-2
Caution Caution
Failure code Failure Trouble Controller Action code lamp buzzer
DXH7KA Reverse clutch ECMV Disconnection (KA) TM CALL E03
DXH7KB Reverse clutch ECMV Short circuit (KB) TM CALL E03
DXH8KA Forward clutch ECMV Disconnection (KA) TM CALL E03
DXH8KB Forward clutch ECMV Short circuit (KB) TM CALL E03
DXH9KA Right clutch ECMV Disconnection (KA) ST CALL E03
DXH9KB Right clutch ECMV Short circuit (KB) ST CALL E03
DXHAKA Left clutch ECMV Disconnection (KA) ST CALL E03
DXHAKB Left clutch ECMV Short circuit (KB) ST CALL E03
DXHBKA Right brake ECMV Disconnection (KA) ST CALL E04
DXHBKB Right brake ECMV Short circuit (KB) ST CALL E04
DXHCKA Left brake ECMV Disconnection (KA) ST CALL E04
DXHCKB Left brake ECMV Short circuit (KB) ST CALL E04
DXHDKA Governor solenoid right disconnection Disconnection (KA) ENG CALL E04
DXHDKB Governor solenoid right short circuit Short circuit (KB) ENG CALL E04
DXHEKA Governor solenoid left disconnection Disconnection (KA) ENG CALL E04
DXHEKB Governor solenoid left short circuit Short circuit (KB) ENG CALL E04
DXHFKA Pre-stroke solenoid left disconnection Disconnection (KA) ENG CALL E03
DXHFKB Pre-stroke solenoid left short circuit Short circuit (KB) ENG CALL E03
DXHGKA Pre-stroke solenoid left disconnection Disconnection (KA) ENG CALL E03
DXHGKB Pre-stroke solenoid left short circuit Short circuit (KB) ENG CALL E03
F@BBZL Blow-by pressure sensor abnormality Over pressure (ZL) VHMS E00
Left bank exhaust temperature sensor
F@BYNR (2) abnormality Abnormal heating (NR) VHMS E00
113
Assembly procedure
Flushing of hydraulic circuit
M-3
(1) Run the engine at low idling with the lever in neutral for 30 minutes.
(2) Run the engine at medium speed with the lever in neutral for 30 minutes.
(3) Run the engine at about 1,700 rpm and operate the levers (Hold the lever for 1 minute - 1minute
30 seconds in each operation). Repeat the following operation pattern 4 times.
Raise blade Lower blade Tilt blade to left Tilt blade to right
114
APPENDIX 1.
DESCRIPTION
1. Introduction
When installing the spill guards in field, refer to the installation procedure described in this installation
procedure.
2. Additional parts
1
3. Spill guard fabrication drawings
3-1. For semi-U blade
(1) Spill guard
2
3
(2) Spill guard (for semi-U, center) 198-71-61710 fabrication drawing
4
dimensions and leg length for manual welding
per KES 04.351
2. Flatness of surfaces A, B, C, D and E in drawing
to be within 2.
Sym. Part Name Material Qty Weight (kg) Remarks
6
7
(2) Spill guard (for full-U, center) 198-72-63910 fabrication drawing
8
per KES 04.351
2. Flatness of surfaces A, B, C, D and E in drawing
to be within 2.
Sym. Part Name Material Qty Weight (kg) Remarks
01 PLATE SS400F 1 14.2 t 19 65
(3) Spill guard (for full-U, left) 198-72-63920 fabrication drawing
9
per KES 04.351
2. Flatness of surfaces A, B, C, D and E in drawing
to be within 2.
Sym. Part Name Material Qty Weight (kg) Remarks
01 PLATE SS400F 1 14.2 t 19 65
02 PLATE SS400F 1 13.5 t 19 65
(4) Spill guard (for full-U, right) 198-72-63930 fabrication drawing
10
11
(2) Spill guard (for superdozer, center) 198-72-63810 fabrication drawing
4-1 For disassembly and assembly procedures which are not described in this manual, see the
Shop Manual.
4-2 Weld the spill guard to the blade according to the drawing.
4-3-1 Remove all dirt, rust, and paint from the parts to be removed with a grinder.
4-3-2 If the parts to be welded are wet, dry them with a gas burner.
4-3-4 Use coated welding rods specified by JIS 4316 (Low-hydrogen welding rod for mild steel)
or welding wires specified by JIS YGW11.
4-3-5 Before using coated welding rods, dry them at 300 - 350C for 30 - 60 minutes.
4-3-6 Preheat the area about 50 mm from the beat to be laid at 150 - 200C. When the ambient
temperature is below 10C, post-heat the same area, too, at 150 - 200C.
4-3-7 Set the welding current to the lower limit of the current range specified for the diameter
of the welding rod or wire.
4.3.9 Do not weld by letting the melted metal flow, but weld from below to above with sufficient
penetration. Keep the arc length as short as possible, and take care not to make an
overlap, undercut, etc.
4.3.10 Before welding the spill guard, remove all the paint (or rust) from the parts to be welded
with a grinder. Then, perform tack welding, permanent welding and finishing in order.
4.3.11 Connect the ground cable to a part of the blade where paint is removed or a part where
the ground cable can be connected securely electrically.
(Remark) If a painted part is welded, hydrogen in the paint will be mixed in the welded
part, and that can cause cold cracking.
14
APPENDIX 2.
1
PRECAUTIONS FOR INITIALIZATION OF VHMS CONTROLLER
AND ORBCOMM TERMINAL (OPTIONAL)
When a machine equipped with VHMS controller is delivered to a customer,
2
1. Registration of WebCARE machine information
Fill the attached "Application for registration in WebCARE" and send it to VHMS/WebCARE Global Support
Center.
The model name, serial No., customer information, etc. will be registered in the WebCARE server of the sup-
port center.
a If you have not obtained an ID and a password for reading WebCARE, fill the attached "Application for reg-
istration of WebCARE user" and send it to VHMS/WebCARE Global Support Center.
After you are registered, your ID and password will be sent you.
Komatsus distributor
Model
Serial No.
User
etc.
3
2. Application for opening ORBCOMM terminal (Optional)
If the ORBCOMM is installed optionally, an application for opening a communication terminal is necessary.
The "Request for opening ORBCOMM terminal" and "terminal part No. seal" (which is the same as one stuck
to the terminal) are packed together with the terminal or the machine.
Stick the seal to the request and fill it, and then send it to KOMTRAX Service Hot Line.
After a contract is made with ORBCOMM Co., Ltd., the date of opening the terminal will be notified.
IMPORTANT: It takes 1 2 weeks to make a contract with ORBCOMM Co., Ltd. after the application is
received. Keep the antenna removed and do not set the terminal until the date of opening the
terminal is notified.
Komatsus distributor
ORBCOMM terminal
4
Set the ORBCOMM terminal after the date of opening the terminal.
Case 1: Procedure for operating the machine before opening the terminal
Step 1) Initialize only the VHMS controller.
VHMS controller
Step 2) After receiving notification of date of opening the terminal (After that date), set ORB-
COMM.
Connection of antenna
ORBCOMM terminal
Case 2:Procedure for operating the machine after opening the terminal
Initialize of both VHMS controller and ORBCOMM simultaneously.
5
3. Preparation of tools and items to be executed after initialization (IMPORTANT)
a A cable to connect a personal computer and the VHMS controller is necessary for setting VHMS/ORB-
COMM. Purchase and prepare it.
a A setting program to be installed to the personal computer is also necessary. (This program is contained in
the VHMS analysis tool software.) Purchase the VHMS analysis tool software.
Service kit 799-608-3101
Components
Analysis tool CD & FD 799-608-3211
Cable 799-608-3220
1) The initialization procedures of VHMS controller are entered in the Shop Manual for each model.
2) Initialize the VHMS controller according the Shop Manual or the field assembly manual.
3) Fax the check sheet filled when the VHMS controller is initialized.
4) When performing step 3) above, send the first setting downloaded data to VHMS/WebCARE Global
Support Center by E-mail.
6
PLACE TO STORE DOWNLOADED DATA
1. Open the "VHMS_DATA" icon in drive C (or the drive specified when the software was installed).
2. Open the icon of the applicable model. Next, open the icon of the serial No., and then open the icon of the
date and time of downloading.
Caution:
All of the files downloaded
today are stored in the icons.
The icon of the largest number
has the latest file.
3. After finishing initialization and downloading the data, send all the files in this icon by E-mail.
7
METHOD OF INSTALLING VHMS SETTING TOOL
1. Insert the CD-ROM in the CD drive, and installation of the analysis tool is started automatically. Perform the
shown procedures, and the analysis tool icon is made on the desktop.
Now, installation of the analysis (including download and FTP) tool is completed.
2. Insert the CD-ROM again, and installation of the analysis tool is started automatically again. When the fol-
lowing screen is displayed, click "Cancel" and interrupt the operation by clicking "Exit Setup".
8
3. Select the drive of the CD-ROM by "My computer" (or "Explorer") and click "Open".
a Do not double-click.
6. Installation of the setting tool is started automatically and the icon is made on the desktop. Now, installation
of the setting tool is completed.
9
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER
a Initialization tools for VHMS controller a The VHMS controller and ORBCOMM termi-
nal are in the VHMS controller box under the
Symbol Part No. Part name
left side cover of the floor.
799-608-3101 Service kit
1 799-608-3211 Diskette
10
4. Startup of VHMS initialization tool
1) Switch on the personal computer and start
the OS.
2) Click the icon of [VHMS Initialization Tool]
on the personal computer screen to start the
VHMS initialization tool.
11
5. Performance check of ORBCOMM terminal
Decimal point
[For only ORBCOMM specification] Indication
at right bottom
1) Judge the operation of the ORBCOMM con-
troller by the state of the dot at the right bot- Power is not applied to ORBCOMM
OFF
controller.
tom of the LED digit of the VHMS controller.
2) The dot at the right bottom of the LED digit ON Satellite is not captured.
of the VHMS controller can be checked in ORBCOMM controller does not
the multi-information display unit of the mon- Quick flashing have transmission data.Satellite is
itor by the following method. captured.
i) Set the starting switch to the ON posi-
ORBCOMM controller has transmis-
tion. Slow flashing
sion data.Satellite is captured.
ii) For monitor panel specification: Refer-
ring to 10 "Real-time monitoring mode"
6. Initialization of VHMS controller
or 11 "Dual display monitoring mode"
[Machine information]
above, input ID = 20300.
1) Open the [Machine information] tab.
a The [Machine information] tab is dis-
played first in the [Data clear and Set up]
menu.
2) Check all the data.
12
4) When information in the [Machine informa- [For ORBCOMM specification only]
tion] box is not correct, change it according a Set the ORBCOMM terminal after the date of
to the following procedures: opening the terminal.
i) Click on [Edit] (2) located in the right 1) Open the VHMS Setting Tool according to
lower part of the [Machine information] the procedure for "Start of VHMS initializa-
box to display the correction screen. tion tool".
ii) Correct the information, then click [OK]. 2) Open the [Communication Setting] tab.
13
a At initialization, select [20h] at [SMR]
screen, and set the function to [ON].
14
PROCEDURES FOR EXECUTING QUICK PM
a The Quick Pm means the Pm Clinic executed
with the snap shot function of the monitor panel.
k Stop the machine on a flat place.
15
5) After starting the snap shot function, operate
the machine according to Table 1.
a Check that the engine coolant and torque
converter oil temperatures are in operating
range.
a After 10 " " are displayed (After 5 minutes),
"#" is added up to 5.
" ": The data sampling interval is 10
seconds.
"#": The data sampling interval is 1 sec-
ond.
Operation of machine
Time (sec)
Finish
Start
Fuel
No.
(Note 1): Press the brake pedal fully and shift the gear to F3, then run the engine at full throttle.
(Note 2): Keep running the engine at low idling until the oil temperature is lowered to the normal level.
a While the torque converter is stalled and the 1st gear speed is selected, do not heighten the engine speed
to high idling.
a After stalling the torque converter, watch the power train oil temperature gauge and take care not to overheat
the power train oil.
(The torque converter stall time of 30 seconds is a reference time. When the power train oil temperature
gauge reaches the top of the green range, return the transmission to the N (Neutral) position and run the
engine at high idling to lower the oil temperature.)
16
6) The screen shown below appears 7 minutes 8) Open the data of the Quick Pm and trans-
30 seconds after the snap shot is started, late them into a graph.
and then the initial screen appears 5 sec- a Set the time to the X-axis and set the follow-
onds after. (End of snap shot) ing items to the Y-axis.
Engine Speed
Fuel Inject
Blowby Press
Exhaust Temp RB (Exhaust tempera-
ture of right bank: 1, 2, 3, 4, 5, 6)
Exhaust Temp LB (Exhaust temperature
of left bank: 1, 2, 3, 4, 5, 6)
Engine Oil Press
Engine Oil Temp
Eng Coolant Temp
Ambient Temp
Demand Eng Speed
(Engine speed demanded by controller)
T/C Oil Temp
Important (Torque converter oil temperature)
The data of the Quick Pm is recorded on once. T/M Main Press
If the Quick Pm is executed again, the current (Transmission main relief pressure)
data are overwritten. Accordingly, be sure to T/M Output Speed
save the data in the personal computer after (Transmission output speed)
executing the Quick Pm. Shift Position
(Transmission, travel, gear speed)
7) Using the analysis tool, read the data of the S/T Clutch Pos.
Quick Pm. (Steering clutch position)
a For the usage of the analysis tool, see the S/T Brake Pos. (Steering brake position)
operation manual. Hydr Oil Temp
(Hydraulic oil temperature)
Pump 1 Press
(Work equipment pump 1 oil pressure)
Pump 2 Press
(Work equipment pump 2 oil pressure)
Body Pitch Angle (Pitch angle)
17
9) Check "Click position graphic value display".
18
10) Click a point in the graph, and the value of
each measurement item at that point on the
X-axis is displayed under the graph.
(Example of displayed graph: This is differ-
ent from the actual graph.)
19
11) Enter the above value in the Pm Clinic Inspection Sheet.
a The relationship between the data necessary for the Pm Clinic and the measurement conditions is as
follows.
Measurement items
20
4. Downloading of Set Data 5. Check of Downloaded Data
1) Turn the starting switch to the ON position. a This step applies to works in the cab (on the
2) Click the icon of [VHMS Technical Analysis personal computer).
Tool] on the personal computer to start the 1) Check the set data with [View] function.
VHMS analysis tool. a For the operation procedures, refer to
the Operation and Maintenance Manual
for VHMS Technological Analysis Tool.
a Make sure that the [MFA0] code at the
time of snapshot is displayed in [Fault
History].
a Make sure that the SNAPSHOT data
has been recorded.
21
7. Communication to Komatsu
After having completed Steps 1 to 15 success-
fully, please send the check sheet and the
VHMS data to VHMS/WebCARE Support Cen-
ter of Komatsu, Tokyo.
a Since Komatsu has to arrange the setting for
satellite communication on the receiving
side, please be sure to inform Komatsu of
the completion of the setting.
a Fax the check sheet to Komatsu.
a Send the VHMS data by Notes (LAN) or E-
mail (WAN).
22
23
24
25
26
27
U-dozer specification 1/5
Report No.
D475A-5 SDA12V140
Others
Inspectors Comments
Signature : Remark :
Note :
(1) Criteria are based on the standards when the machine is shipped out of the factory
Hydraulic tank oil level Refer to Operation Center to upper level Pitch back on the ground.
Between H - L & Maintenance of sight gauge Ripper point on the ground.
Manual Engine : stopped
Final draive oil level LH H to (H20) See operation manual.
RH Engine : stopped
Pivot shaft oil level Oil level (H+10) to (H+30) See operation manual.
LH
from shaft end
RH
RH
Lamp ON (Head lamp, tail lamp and work lamp) Must light up when turned on.
Preheating switch (Auto preheating when at ON position) Preheating lamp (green) must light up
(Manual preheating when turned to left)
Main corrosion resistor cock Must be fully open.
Sub corrosion resistor cock Must be fully open.
Heater hose cock Must be fully open.
Controller error code indication (make sure that error does not recur) Clear error code after confirming it.
Air bleeding of the hydraulic cylinder Perform air bleeding of the hydraulic cylinder
Measurement of cab pressurization Max. 0.10 kPa {10 mm Aq.}
(If pressure is below standard value, adjust it,
referring to M-1, pages 4/7 - 7/7.)
Confirmation of VHMS controller initialization Must be done.
q Distributor copy
U-dozer specification 5/5
Check of the gear speed indication on the monitor panel. N, F1, F2, F3, R1, R2 and R3 are indicated.
Must be able to be shifted to any position with the engine at low Must be no indication error.
idling and the brake turned on.
FUNCTION / OPERATION
Free
Lock Case
Case
LH tilt
q Distributor copy
U-dozer specification 7/5
Check of the blade lever floating notch release Engine stops at floating, then notch must be released.
Check of the quick drop valve operation At the engine full, set the blade lever at down
Quick dropping of the blade from top position. position. When the lever is set at the N position after
the blade drops by 1000 mm, it must stop.
Main relief valve function (Engine: Low ilding) Must be bridged with the blade and the ripper (Chassis)
Check of the accumulator function (blade, ripper) Must function immediately after the engine
stops then drop from the top to the ground.
Cabin door-open lock release lever Must work smoothly to securely lock
Opening/closing and locking effect of the left/right side slide glass Must work smoothly to securely lock.
Lighting of the room lamp Must come on/go off by turning the switch on/off.
Operation of the window wiper and the window washer Must be on/off by turning the switch on/off.
Wiper: Must operate smoothly (without beat noise)
Operation of the radio and cassette system Must operate correctly
CABIN
Air flow amount must be able to be adjusted (Hi, Mid or Lo) Air comes out from each blowout port.
Louver must be smoothly switched
q Distributor copy
U-dozer specification 9/5
Check of the pin puller switch direction Must be the same as the pin puller cylinder
A: Pin out operation direction
B: Pin in
Check of the pin puller cylinder hose clamp position Must be of no contact
(Entire operation area must be checked) Must be of no excess hose tension.
Pin puller cylinder oil leakage Must be none
Leakage from U-packing, damaged rod, tube or flange
Check of ripper lubricated hose installation LH Must be no contact or no excess bend.
RH
Portions to be lubricated Qty Must be lubricated (right and left)
Ripper lift cylinder head i 2
Ripper lift cylinder bottom y 2
Ripper tilt cylinder head u 2
Ripper tilt cylinder bottom t 2
Ripper arm pin (front) o 2
Ripper arm pin (rear) !0 2
q Distributor copy
Superdozer specification 1/5
Report No.
D475A-5 SDA12V140
Blade Super.
Location of Machine at Inspection Ripper or
VGR. VMR. CW ( )
counterweight
Others
Inspectors Comments
Signature : Remark :
Note :
(1) Criteria are based on the standards when the machine is shipped out of the factory
Hydraulic tank oil level Refer to Operation Center to upper level Pitch back on the ground.
of sight gauge
COOLANT AND OIL LEVEL
RH
RH
Lamp ON (Head lamp, tail lamp and work lamp) Must light up when turned on.
Preheating switch (Auto preheating when at ON position) Preheating lamp (green) must light up
(Manual preheating when turned to left)
Main corrosion resistor cock Must be fully open.
Sub corrosion resistor cock Must be fully open.
Heater hose cock Must be fully open.
Controller error code indication (make sure that error does not recur) Clear error code after confirming it.
Air bleeding of the hydraulic cylinder Perform air bleeding of the hydraulic cylinder
Measurement of cab pressurization Max. 0.10 kPa {10 mm Aq.}
(If pressure is below standard value, adjust it,
referring to M-1, pages 4/7 - 7/7.)
Confirmation of VHMS controller initialization Must be done.
q Distributor copy
Superdozer specification 5/5
Check of the gear speed indication on the monitor panel. N, F1, F2, F3, R1, R2 and R3 are indicated.
Must be able to be shifted to any position with the engine at low Must be no indication error.
idling and the brake turned on.
Free
Lock Case
FUNCTION / OPERATION
Case
LH tilt
q Distributor copy
Superdozer specification 7/5
Check of the blade lever floating notch release Engine stops at floating, then notch must be released.
Check of the quick drop valve operation At the engine full, set the blade lever at down
Quick dropping of the blade from top position. position. When the lever is set at the N position after
the blade drops by 1000 mm, it must stop.
Main relief valve function (Engine: Low ilding) Must be bridged with the blade and the ripper (Chassis)
Check of the accumulator function (blade, ripper) Must function immediately after the engine
stops then drop from the top to the ground.
Cabin door-open lock release lever Must work smoothly to securely lock
Opening/closing and locking effect of the left/right side slide glass Must work smoothly to securely lock.
Lighting of the room lamp Must come on/go off by turning the switch on/off.
Operation of the window wiper and the window washer Must be on/off by turning the switch on/off.
Wiper: Must operate smoothly (without beat noise)
Operation of the radio and cassette system Must operate correctly
CABIN
Air flow amount must be able to be adjusted (Hi, Mid or Lo) Air comes out from each blowout port.
Louver must be smoothly switched
q Distributor copy
Superdozer specification 9/5
Check of the pin puller switch direction Must be the same as the pin puller cylinder
A: Pin out operation direction
B: Pin in
Check of the pin puller cylinder hose clamp position Must be of no contact
(Entire operation area must be checked) Must be of no excess hose tension.
Pin puller cylinder oil leakage Must be none
Leakage from U-packing, damaged rod, tube or flange
Check of ripper lubricated hose installation LH Must be no contact or no excess bend.
RH
Portions to be lubricated Qty Must be lubricated (right and left)
Ripper lift cylinder head i 2
Ripper lift cylinder bottom y 2
Ripper tilt cylinder head u 2
Ripper tilt cylinder bottom t 2
Ripper arm pin (front) o 2
Ripper arm pin (rear) !0 2
q Distributor copy