Komatsu Bulldozers D85EX-15 : Every 1000 Hours Service Maintenance

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.

Blade lift cylinder support yoke (4 places)

REMARK: These are at the front and rear of the left and right cylinders.

• Blade lift cylinder support shaft (2 places)

• Blade arm ball joint (4 places)

• Brace screw (2 places)

• Ripper lift cylinder bottom pin (2 places)

• Ripper lift cylinder rod end pin (2 places)

• Ripper arm pin (front) (6 places)

• Ripper arm pin (rear) (6 places)

ADJUSTING

• 1. Loosen bolts (1) and nuts (2), (4), and (5), then turn nut (4) and adjust the belt tension.

• 2. After adjusting, tighten bolts and nuts (2), (4), and (5), to secure alternator (3) in position.

• 3. Reinstall the cover removed in step 1. Confirm that no part of the cover touches any turning part of the alternator.

REMARK

• Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check that the V-belt is not touching the bottom of the V-groove.

• If any pulley is defective, ask your Komatsu distributor to replace it.

• If any belt has stretched and there is no allowance for adjustment, or if there are cuts or cracks on any belt, replace both belts at the same time.

• When adjusting the V-belt, do not push the tension pulley directly with a steel bar, etc., but put a wood piece, etc. between the pulley and bar.

• After replacing the V-belt, operate for 1 hour, then check and adjust the belt tension again.

CHECK LEVEL OF BATTERY ELECTROLYTE: Carry out this check before operating the machine.

WARNING

• Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This will accelerate deterioration of the inside of the battery and reduce the service life of the battery. In addition, it may also cause an explosion.

• The battery generates flammable gas and there is danger of explosion, so do not bring fire or sparks near the battery.

• Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a doctor.

• When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL line. If the electrolyte level is too high, it may leak and cause damage to the paint surface or corrode other parts.

NOTICE: When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from freezing.

Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.

• Open battery cover at the left side of the machine.

If it is possible to check the electrolyte level from the side of the battery, check as follows.

• Use a wet cloth to clean the area around the electrolyte level lines and check that the electrolyte level is between the UPPER LEVEL (U.L.) and LOWER LEVEL (L.L.) lines. If the battery is wiped with a dry cloth, static electricity may cause a fire or explosion.

• If the electrolyte level is below the midway point between the U.L and L.L lines, remove cap (1) and add distilled water to the U.L line.

• After adding distilled water, tighten cap (1) securely.

REMARK: If distilled water is added to above the U.L. line, use a syringe to lower the level to the U.L. line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker.

If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on the side of the battery, check as follows.

• Remove cap (1) at the top of the battery, look through the water filler port, and check the electrolyte surface. If the electrolyte does not reach the sleeve, add distilled water so that the level reaches the bottom of the sleeve (UPPER LEVEL line) without fail.

Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.

• After adding distilled water, tighten cap (3) securely.

REMARK: If distilled water is added to above the bottom of the sleeve, use a syringe to lower the level to the bottom of the sleeve. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your Komatsu distributor or battery maker.

If it is possible to use and indicator to check the electrolyte level, follow the instructions given.

WARNING: If the machine moves during the following operation, please contact your Komatsu distributor for repairs immediately.

NOTICE: Do not place the joystick in the 1st speed position. Otherwise, it will cause damage to the machine.

Before starting the engine, check that the area around the machine is safe, then do as follows.

• Start the engine.

• Start the engine, and after completing the warming-up operation, set fuel control dial (3) to the SLOW position.

• Set safety lever (1) to the FREE position then operate blade control lever (6) and ripper control lever (7) to raise the blade and ripper. Leave the safety lever (1) to the FREE position.

• Set parking lever (2) to the FREE position.

• Depress brake pedal (5), set joystick (4) in FORWARD, then press the shift up button to enter 2nd speed.

• Operate fuel control dial (3) and gradually raise the engine speed to full throttle. (Keep the brake pedal depressed.)

• Check that the machine does not move. This indicates that brake performance is normal.

CHECK OIL LEVEL IN DAMPER CASE, ADD OIL

• Open the engine side cover on the left side of the chassis.

• Remove dipstick (G) and wipe the oil off with a cloth.

• Insert dipstick (G) fully in the oil filler pipe, then take it out again.

• The oil should be between the H and L marks on dipstick (G). If the oil is below the L mark, add engine oil through the dipstick insertion port.

REMARK

• Check the oil level while the engine is stopped.

• If the machine is inclined, set it in a level position before checking the oil level.

(including engine by-pass filter cartridge)

WARNING: The oil is at high temperature after the engine has been operated, so never change the oil immediately after finishing operations. Wait for the oil to cool down before changing it.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS FILTER CARTRIDGE

• Refill capacity: 38 liters

• Prepare a socket wrench and filter wrench.

• Remove the covers at the bottom left at the front of the machine and on the side face, and put a container directly underneath to catch the drained oil.

• Remove drain plug (1) slowly to avoid getting oil on yourself, and drain the oil. Take care not to loosen drain valve (1) so much that the stopper pin in the valve is distorted. Tightening torque for drain plug (1): 68.6 ± 9.81 N·m (7 ± 1 kgf·m)

• Check the drained oil, and if there are excessive metal particles of foreign material, please contact your Komatsu distributor.

• Tighten drain valve (1).

• Using the filter wrench, turn engine oil filter cartridge (2) to the left and remove it.

• Clean the filter holder, fill the new filter cartridge with engine oil, coat the packing surface and thread with engine oil (or coat it thinly with grease), then install the filter cartridge.

• When installing the filter cartridge, bring the packing surface into contact with the filter holder, then tighten a further 3/4 to 1 turn.

• After replacing the filter cartridge, add engine oil through oil filler port (F) until the oil level is between the H and L marks on the dipstick.

• Run the engine at idling for a short time, then stop the engine, and check that the oil level is between the H and L marks on the dipstick.

Even if the machine has not been operated for 500 hours, the oil and filter cartridge must be replaced when the machine has been operated for 12 months. In the same way, even if the machine has not been oper- ated for 12 months, the oil and filter cartridge must be replaced when the machine has been operated for 500 hours.

Prepare a filter wrench and a container to catch the fuel.

WARNING

• Engine is at high temperature immediately after the machine has been operated. Wait for engine to cool down before replacing the filter.

• Do not bring fire or sparks near the fuel.

• When bleeding the air, be careful not to let the fuel overflow. It may cause a fire.

NOTICE

• Genuine Komatsu fuel filter cartridges use a special filter that has highly efficient filtering ability. When replacing the filter cartridge, always use a genuine Komatsu part.

• The common rail fuel injection system used on this machine consists of more precise parts than the conventional injection pump and nozzle.

• If any part other than a genuine Komatsu filter cartridge is used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts.

• When carrying out inspection or maintenance of the fuel system, pay more attention than normal to the entry of dirt. If dirt is stuck to any part, use fuel to wash it off completely.

If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter car- tridge is too loose, fuel will also leak from the packing, so always tighten to the correct amount.

REMARK: When only the filter cartridge is replaced, it is suffficient that air bleeding is carried out for the filter head alone. But when the fuel piping is removed, air bleeding should also be carried out for the injection pump air-bleeding valve.

WARNING

• Before opening the filter cases, depress the brake pedal several times to release the pressure

• Then lock the brake pedal. If there is still pressure inside the filter, the oil may spurt out.

WARNING: There is danger that the oil may spurt out under internal pressure, so to the side, and gradually turn the plug to release the internal pressure before removing the plug completely.

WARNING:

• Replace the element when the oil is cold.

• When removing breather cap (1), turn it slowly to release the internal pressure before removing it.

WARNING

• The oil is at high temperature immediately after operations, so wait for the temperature to go down before starting the operation.

• The undercover is heavy. Do not go directly under the cover when opening or closing it. When removing bolts (5), carry out the operation at the rear of the point immediately under the cover so that it is possible to escape at any time.

Prepare the following.

• Refill capacity: 60 liters

• Remove drain cover (1) at the bottom Right of the power train case, then loosen drain plug (2) and drain the oil. After draining the oil, tighten drain plug (2). Do not remove drain plug (2).

CHECK, CLEAN FUEL STRAINER

• Tighten valve (1).

• Remove cap (2), and wash the strainer and strainer case. The strainer forms one unit with the cap.

• After checking and cleaning, set the strainer in the case, then tighten cap (2).

• After installing, open valve (1).

WARNING: If the engine has been operated, all parts will be at a high temperature, so never try to replace the car- tridge immediately after stopping the engine. Always wait for the engine and other parts to cool down.

REPLACE CORROSION RESISTOR CARTRIDGE

• Container to catch drained coolant

• Prepare a filter wrench for fuel filter element.

• Turn valve (2) of corrosion resistor (1) as far as the CLOSE stopper.

• Set a container to catch the coolant under the cartridge.

• Using a filter wrench, turn cartridge (3) to the left to remove it.

• Clean the filter holder, coat the packing surface and thread of the new cartridge with engine oil, then install it to the filter holder.

• When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it up 2/3 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of coolant. If the filter cartridge is too loose, coolant will also leak from the packing, so always tighten to the correct amount.

• Turn valve (2) of the cartridge to the OPEN position.

• After replacing the cartridge, start the engine and check for any leakage of water from the filter seal surface. If there is any water leakage, check if the cartridge is tightened properly.

CHECK TIGHTENING PARTS OF TURBOCHARGER

• Please contact your Komatsu distributor to have the tightening portions checked.