Komatsu Bulldozers D85EX-15 : When Required Service Maintenance

WARNING: Immediately after the engine is stopped, the coolant is at a high temperature and the radiator is under high internal pressure. If the cap is removed to drain the coolant in this condition, there is a hazard of burns. Wait for the temperature to go down, then turn the cap slowly to release the pressure before removing it.

Cleaning is carried out with the engine running. When standing up or leaving the operator's seat, set the safety lock lever and the parking lever to the LOCK position.

Never enter front the machine when the engine is running.

There is danger of touching the fan.

Clean the inside of the cooling system, change the coolant and replace the corrosion resistor according to the table below.

• Stop the machine on level ground when cleaning or changing the coolant.

• Use a permanent type of antifreeze.

If, for some reason, it is impossible to use permanent type antifreeze, use an antifreeze containing ethylene glycol. Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect. The ratio of antifreeze to water depends on the ambient temperature, but to obtain the corrosion resistance effect, a minimum ratio of 30% by volume is necessary. When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing rate table given below. It is

WARNING: Antifreeze is flammable, so keep it away from flame. Antifreeze is toxic. When removing the drain plug, be careful not to get water containing antifreeze on you. If it gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once.

Use city water for the cooling water. If river water, well water or other such water supply must be used, contact your Komatsu distributor. We recommend use of an antifreeze density gauge to control the mixing proportions.

WARNING: When removing the drain plug, be careful not to be covered with the drained coolant.

• Stop the engine

• Wait for the coolant to cool completely

• Then turn valve (2) of corrosion resistor (1) to the Close stopper position.

• Turn main radiator cap (3) slowly, and remove.

WARNING

• Always wear protective glasses,dust mask,or other protective equipment.

• When removing the air cleaner element from the air cleaner body,it is dangerous to pull it out by force.

• When working at high places or where the foothold is poor, be careful not to fall because of the reaction when pulling out the outer element.

CHECKING

• If the internal yellow piston overlaps the red zone on the outside diameter of dust indicator (1), clean the air cleaner element.

• After cleaning, press the reset button to reset the piston.

NOTICE

• Always wait for the yellow piston in the dust indicator to overlap the red zone on the outside before cleaning the element.

• If the element is cleaned frequently before the yellow piston in the dust indicator overlaps the red zone on the outside, the air cleaner will be unable to display its normal performance and the cleaning effect will become poor.

• In addition, the frequency of dust stuck to the element falling inside the inner element during the cleaning operation will increase.

NOTICE: Before and after cleaning the element, do not leave or keep it in direct sunlight.

• 1. Remove 3 hooks (2). Then remove cover (3). Remove outer element.

• 2. Hold the outer element, rock it lightly up and down and to the left and right, and rotate the element to the left and right to pull it out.

NOTICE: Never remove the inner element. It will allow dirt to enter and cause failure of the engine. Do not use a screwdriver or other tool.

• 3. After removing the outer element, cover the air connector inside the air cleaner body with a clean cloth or tape to prevent dirt or dust from entering.

• 4. Use a clean cloth or brush to remove the dirt stuck to the cover and the inside of the air cleaner body.

• 5. Direct dry compressed air (Max. 0.69 MPa (7 kgf/cm2, 99.4 PSI)) from the inside of the outer element along its folds. Then direct the compressed air from the outside along the folds, and again from the inside.

• Check that the inner element is not loose. If it is loose, insert it securely.

• If the yellow piston overlaps the outer element red zone immediately after the outer element is cleaned, replace the inner and outer elements.

• 6. Remove the cloth or tape cover installed in Step 3.

• 7. If small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning and drying, replace the element.

NOTICE: Do not use an element whose folds or gasket or seal are damaged. When cleaning the element, do not hit it or beat it against something.

• After replacing the element, press the dust indicator button to reset it. The yellow piston will return to its original position.

REPLACING INNER ELEMENT

• 1. First remove the outer element, and then remove the inner element.

• 2. Cover the air connector side (outlet side) with a clean cloth or tape.

• 3. Clean the air cleaner body interior, then remove the cover installed in Step 2.

• 4. Fit a new inner element to the connector. Do not clean and reinstall a inner element.

• 5. Install the outer element and the cover.

The wear of pins and bushings on the undercarriage will vary with the working conditions and types of soil. It is thus necessary to continually inspect the track tension so as to maintain the standard tension. Carry out the check and adjustment under the same conditions as when operating (on jobsites where the track becomes clogged with mud, measure with the track clogged with mud).

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 (A) 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.

WARNING: Grease inside adjusting mechanism is under high pressure. Grease coming from lubricator (1) under pressure can penetrate the body causing injury or death. For this reason, do not loosen lubricator (1) more than one turn. Do not loosen any part other than lubricator (1). Furthermore, do not get any part of your body in front of the grease fitting. If the track tension is not relieved by this procedure, please contact your Komatsu distributor.

WHEN INCREASING TENSION

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

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

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

• Continue to pump in grease until (S) becomes 0 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.

WARNING: It is extremely dangerous to release the grease by any method except the procedure given below. If the track tension is not relieved by this procedure, please contact your Komatsu distributor.

WHEN LOOSENING TENSION

• Loosen lubricator (1) gradually to release the grease.

• Turn lubricator (1) a maximum of one turn.

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

• Tighten lubricator (1).

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

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

WARNING: Depending on the situation, the operation to remove the track may be extremely dangerous. Before removing the track, if the procedure above “WHEN LOOSENING TENSION“ does not loosen the track tension, please contact your Komatsu distributor for repair.

CHECK AND TIGHTEN TRACK SHOE BOLTS

• If the machine is used with track shoe bolts being loose, they will break, so tighten any loose bolts immediately.

METHOD OF TIGHTENING SHOE BOLT

• First, tighten to the tightening torque below, then check that the nut and shoe are in close contact with the link mating surface. D85EX: 343 ± 39 N·m (35 ± 4 kgf·m) D85PX: 539 ± 49 N·m (55 ± 5 kgf·m)

• After checking, tighten a further 120° ± 10°.

METHOD OF TIGHTENING MASTER LINK CONNECTING BOLT

• First tighten to a tightening torque of 343 ± 39 N·m (35 ± 4 kgf·m) then check that the link contact surfaces are in close contact.

• After checking, tighten a further 160° to 180°.

ORDER FOR TIGHTENING

• Tighten the bolts in the order shown in the diagram.

The idler moves forward and backward under external pressure when this happens, side guide and guide plate become worn. As they become worn, there is side play in the idler, or the idler turns at an angle, causing the track to come off or resulting in uneven wear, so adjust as follows.

ADJUSTING IN SIDEWAYS DIRECTION

• Drive the machine for 8 to 12 m on flat ground, then measure clearance A (4 places: left, right, inside outside) between the track frame and side guide (1).

• If clearance A is more than 4 mm, remove bolt (1), then take out shim, and adjust to that the clearance on one side is less than 0.5 to 1 mm.

REMARK: There are two types of shim (thickness: 0.5 mm and 1.0 mm).

ADJUSTING IN VERTICAL DIRECTION

• 1. To determine the amount of adjustment, measure clearance B, then subtract 2 mm and record the result (amount of adjustment). Example If clearance B = 5 mm: Amount of adjustment = 5 - 2 = 3 mm

• 2. Loosen bolts (9) (inside, outside: Total 4) to a point where there is no more reaction from the spring.

• 3. Loosen bolt (1) (inside, outside: Total 8) . When doing this, do not loosen it more than 3 turns.

• 4. Using a bar, pull up up-down guide (5) to set clearance C to 0, then remove shims of a thickness equal to the amount of adjustment measured in Step 1.

• 5. After removing shims (7), add them on top of shim (8). (Left, right, inside, outside: Total 8 places) When doing this, check that the total thickness of shim (7) and shim (8) is the same after adjustment as it was before adjustment at all places. Discarding shims or adding shims will result in improper function of the built-in spring.

REMARK: There are two types of shim thickness: 1 mm and 2 mm.

WARNING: It is dangerous if the work equipment moves by mistake when the cutting edges and end bits are being reversed or replaced. Set the work equipment in a stable condition, then stop the engine and lock the blade control lever securely with the safety lever.

Reverse or replace the end bits and cutting edges before it is worn out to the blade end.

• Raise the blade to a proper height and apply a block to the frame so as to prevent fall of the blade.

• Operate the safety lock lever to the LOCK position. If the cutting edge and the end bit on both sides are worn out, replace with new one. If it has been worn out up to the fitting surface, repair the fitting surface and then reverse or replace.

• Loosen nut (1) and remove bolt (2). Then remove the cutting edge and the end bit and clean the mounting surface.

• Reverse or replace the cutting edge and the end bit when worn out. If bolt (1) and nut (2) are damaged, replace them with new ones at the same time.

• Install the edge to the blade, then tighten partially. Drop the blade three to five times on to the ground or rock to remove any play in bolt (2), then tighten it to the correct tightening torque. When installing end bit (3), put top surface (4) of the end bit in close contact with stopper (5), then tighten with the bolts. Tightening torque: 628 ± 79 N·m (64 ± 8 kgf·m)

• After several hours of running, retighten the nuts.

WARNING: For the cleaning and check, stop the engine without fail and confirm that the fan is not rotating, and carry out the work. Be sure to close the radiator grille before turning the radiator fan so that no one will touch the turning fan carelessly.

When the radiator fin block with mud, dirt or leaves, clean it as follows.

• Remove bolts (1) at the four corners of the radiator fins, then open radiator grill (2).

• Clean the radiator fins clogged with mud, dust and leaves with compressed air. Steam or water may be used instead of compressed air.

REMARK: Check the rubber hose. If the hose is found to have cracks to be hardened by ageing, replace such hose with new one. Further, loosen hose clamp should also be checked.

When cleaning the radiator fins, reverse the rotation of the fan and change the direction of the air flow. Set the Fan rotation selector switch to the CLN position (C) and start the engine. The fan rotates at 100% speed in reverse and cleans the fins. The Fan rotation selector switch cannot be operated when the engine is running.

REMARK: If dirt is caught in the radiator fins, blow with compressed air to clean.

CLEAN FUEL TANK STRAINER

• Clean the strainer if there is any dirt collected in it. Remove the filler cap (1) of the fuel tank and take out strainer. If the strainer is dirty, clean it with diesel fuel.

Carry out this procedure after the mchine has been at rest for a long time and after a long spell of rainy days.

• Loosen valve (1) at the bottom of the tank and drain sediment accumulated on the bottom together with mixed water and fuel.

CLEAN STEERING CLUTCH CASE BREATHER

• Open the valve cover.

• Remove the bolts, then remove cover (1).

• Remove breather (2) at the side of the hydraulic tank, remove the dirt stuck to the breather, then wash it in clean diesel oil or flushing oil.

REPLACE AIR CONDITIONER BELT

• Loosen 4 bolts (1) and jack bolt (2), then move compressor (3) to the side.

• Replace the V-belt. When adjusting the V-belt, do not push the compressor directly with the bar. Use jack bolt (2).

• Tighten jack bolt (2) and bolts (1), and apply tension to the V-belt. The standard deflection for the belt is approx. 10mm when pressed with a finger force of approx. 6 kg at a point midway between the air conditioner compressor pulley and fan pulley.

If the hydraulic cooler fins are clogged or there is dirt caught in the fins, clean and check the fins.

• Open the radiator mask.

• Use compressed air to remove the mud, dirt, and leaves clogging the hydraulic cooler fins. Steam or water may be used instead of compressed air.

REMARK: Check the rubber hose. If the hose is found to have cracks to be hardened by ageing, replace such hose with new one. Further, loosen hose clamp should also be checked.

CHECK UNDERCARRIAGE OIL

• Stop the machine on level ground, and check for any reduction in the oil at the idler (portion P), track roller (portion Q), and carrier roller (portion R).

• Loosen seal bolt (1) slowly and check if oil oozes out from the thread. If oil oozes out, the oil level has not gone down, so tighten the bolt.

• If no oil comes out even when seal bolt (1) is removed, the oil level is low, so please contact your Komatsu distributor for repair.

Clean the air conditioner air filter if it becomes clogged or if there is dirt or oil stuck to it.

• Open inspection cover (1) on top of the hood, then remove pressure air filter (2).

• Open inspection cover (3) under the front panel and pull up recirculation air filter (4) to remove it.

• Clean filters (2) and (4) with compressed air. If there is oil stuck to the filter, or it is extremely dirty, wash it in a neutral agent.

• After washing it, dry it completely before installing it again.

REMARK: If the filters cannot be cleaned with air or in water, replace them with new ones.

CHECK TENSION OF COMPRESSOR BELT: If the belt is loose, it will slip and the cooling effect will be reduced. From time to time, press a point midway between the drive pulley and compressor pulley with your finger (approx. 6kg) and check that the tension is 15 to 18 mm. When the belt is new, there will be initial elongation, so always adjust again after 2 or 3 days.

WARNING

• When handling refrigerant gas, always follow local laws and regulations.

• The refrigerant used in the cooler is colorless and odorless and does not harm the atmosphere, but if the liquid gets into your eyes or on your hands, it may cause loss of sight or frostbite, so never loosen any part of the refrigerant circuit.

If the level of the refrigerant (gas) is low, the cooling effect will be reduced. Run the engine at high idling, and check the flow of the refrigerant in the refrigerant circuit through the sight glass of the receiver (1) when the cooler is running at high speed.

• No bubbles in refrigerant flow: Suitable (A)

• Some bubbles in flow (bubbles pass continuously): Lack of refrigerant (B)

• Colorless, transparent: No refrigerant (C)

REMARK: When there are bubbles, the refrigerant gas level is low, so contact your refrigerant dealer to have refrigerant added. If the air conditioner is run with the refrigerant gas level low, it will cause damage to the compressor. New Freon R134a is used as the refrigerant.

If the door makes a squeaking noise when it is opened or closed, spray lubricant in through the split in the hinge bushing. If the bushing is worn, replace the hinge.

WARNING: If the control lever is touched by accident during checking, the machine moves off suddenly, and this may lead to serious injury or death. Before checking door latch, stop the engine and set the parking lever securely to the LOCK position.

Check

• Hold the door open-locked, and check that there is still grease inside the latch.

• If the amount of grease is low or there is no more grease, coat the inside of the latch with grease from portion (1).

REMARK: If there is no more grease inside the latch, the movement will become poor because of dust inside the latch, and the handle may be stiff when opening the door.

CHECK DOOR LOCK STRIKER: If the wear of the door lock striker exceeds 0.5 mm, replace the striker. If it is used at it is, the play will increase and this may result in breakage of the hinge or door lock.

REPLACE DOOR DAMPER

• If the depth of the door damper rubber groove is less than 2mm, replace the damper. There are two dampers each at the top and bottom on the left and right doors.

CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID

• If there is air in the window washer fluid, check the level and add fluid.

• Open the battery cover, check the level of the fluid in window washer tank (1), and if it is low, add automobile window washer fluid.

• When adding fluid, be careful not to let any dust get in.

REPLACE WIPER BLADE

• If the blade is damaged, it will not wipe the window clean, so replace the blade.

FRONT, REAR WIPER

• It is hooked at portion (A), so move the blade in the direction of the arrow to remove it.

• Install the new blade and hook it securely.

REAR WIPER

• Remove E-ring(1). The blade can then be removed.

• Install a new blade, then install securely with E-ring (1).

DOOR WIPER

• It is hooked at portion (A), so move the blade in the direction of the arrow to remove it.

• Install the new blade and hook it securely.

BLEEDING AIR IN HYDRAULIC SYSTEM

• See “OPERATIONS AND CHECKS AFTER STARTING ENGINE ( 3-75 )“.

• Since the engine must be started and the blade must be operated, see OPERATION.

NOTICE: If the engine is run at high speed immediately after startup or a cylinder is pushed up to its stroke end, air taken inside the cylinder may cause damage to the piston packing.

Bleeding air from cylinders

• Run the engine at low idling, and extend and retract each cylinder 4 to 5 times, taking care so that a cylinder may not be brought up to its stroke end. (Stop the cylinder approx. 100 mm short of its stroke end)

• Next, operate each cylinder 3 to 4 times to the end of its stroke.

• Finally, operate each cylinder 4 to 5 times to the end of its stroke to completely remove the air.

CHECK ELECTRICAL INTAKE AIR HEATER

• Check before the cold season starts (once a year).

• Remove the electric heater from the engine intake manifold and check for wire disconnections and dirt clung to it.

• When checking and installing the electric heater, replace its gasket with a new part.

LUBRICATING

• Lower the work equipment to the ground, then stop the engine.

• Using a grease pump, pump in grease through the grease fittings shown by arrows.

• After greasing, wipe off any old grease that was pushed out.

Fuel control (1 place)