Technical Presentation Kit

Bulldozers

Maintenance

D85EX/PX-15

Komatsu D65EX/PX-15
Bulldozers
MN20030410
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 Prepared by; N,NAMIKI
D85EX-15 Mar.10.'03
MAINTENANCE SERVICE CHECK ITEMS Customer name :
Serial number :
●：Initial 250H Maintenance only
MAINTENANCE SCHEDULE CHART (Hr)
No I t e m Part No Q'ty 250 500 750 1000 1250 1500 1750 2000 Remarks
1 Change oil
・Engine oil pan (SAE30) 38L ○ ○ ○ ○ 10.04gal
・Power train case (SAE30) 60L ○ ○ 15.85gal
・Hydraulic tank (SAE10W) 67L ● ○ 17.7gal
・Final drive (RH & LH) (SAE30) 26L ● ○ 6.87gal
・Damper (SAE30) 1.5L ○ 0.4gal
2 Replace filt
・Engine oil filter 600-211-1340 1 ○ ○ ○ ○
・Fuel filter cartridge 600-319-3310 1 ○ ○ ○ ○
・Corrosion resistor cartridge 600-411-1151 1 ○ ○
・Power line filter 07063-01100 1 ○ ○ ○ ○
・Steering lubrication filter 07063-01100 1 ○ ○ ○ ○
・Hydraulic oil filter 207-60-71180 1 ● ○
3 Clean st
・Fuel tank strainer 1 ● ○ ○
・Power line strainer 1 ○ ○
・Scavenging pump strainer 1 ○ ○
・Hydraulic tank strainer 1 ● ○
4 Clean breat
・Engine breather element 1 ○
・Power line case breather 1 ○
・Damper case breather 1 ○
・Hydraulic tank breather 1 ○ ○ ○ ○
5 Clean or replace air cleaner element 600-185-5100 1 ○ ○ ○ ○ ○ ○ ○ ○ 600-185-5110
6 Drain water and sediment in fuel tank 1 ○ ○ ○ ○ ○ ○ ○ ○
7 Check water level & oil level
・Radiator reserve tank 1 ○ ○ ○ ○ ○ ○ ○ ○ (Daily)
・Engine oil pan 1 ○ ○ ○ ○ ○ ○ ○ ○ (Daily)
・Power train case 1 ○ ○ ○ ○ ○ ○ ○ ○ (Daily)
・Hydraulic tank 1 ○ ○ ○ ○ ○ ○ ○ ○ (Daily)
・Final drive case (LH & RH) 2 ○ ○ ○ ○ ○
・Damper 1 ○ ○ ○ ○ ○ ○ ○ ○
・Pivot shaft (LH & RH) 2 ○
・Battery electrolyte (LH) 2 ○ ○ ○ ○ ○ ○ ○ ○
8 Check alternator & air conditioner belt tension 1 ○ ○ ○ ○ ○ ○ ○ ○
9 Check all tightening of turbocharger 1 ○ ○
10 Check play of turbocharger rotor 1 ○
11 Check alternator, starting motor 1 ○
12 Check engine valve clearance, adjust 6 ○
13 Visual check track shoe tension (LH & RH) 2 ○ ○ ○ ○ ○ ○ ○ ○ Max.45mm
 D85EX. D85PX-15
USE OF FUEL , COOLANT AND LUBRICANTS
ACCORDING TO AMBIENT TEMPERATURE.
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.
AMBIENT TEMPERATURE CAPACITY
RESERVOIR KIND OF
FLUID -22 -4 14 32 50 68 86 104.F
-32 -20 -10 0 10 20 30 40.C Specified Refill

SAE 30

Engine oil pan SAE 10W 44 L 38 L

SAE 10W-30 (11.62 US gal) (10.04 US gal)

SAE 15W-40

Power train oil pan Engine oil SAE 30 90 L 60 L

incl, T/M, T/C, and (23.78 US gal) (15.85 US gal)
SAE 10W
bevel gear case.
1.5 L 1.5 L
Damper
Damp (0.4 US gal) (0.4 US gal)
SAE 30CD
7L 7 L
Pivot shaft ( each (1.85 US gal) (1.85 US gal)

SAE 10 120 L 67 L
Hydraulic system SAE 10W-30 (31.7 US gal) (17.7 US gal)

SAE 15W-40

Final drive case SAE 30 26 L 26 L

( each (6.87 US gal) (6.87 US gal)

　　　ASTM D975 No.2 490 L

Fuel tank
Fuel tan Diesel fuel
ASTM D9 7 5 No . 1 (129.5 US gal)

　Grease fitting Grease 　　 　NLGI, No.2

Cooling 82 L
Coolingsystem
syst Water Add antifreeze (AF-NAL)
(21.7 US gal)
1. Water level check
Reserve tank
Strainer (STD)

Water level sensor

Water drain cock

( 82 L )
2. Engine oil level check

Engine oil Engine oil filler

level gauge

Engine oil drain

(38 L)

Engine
Stopped
(Cold)
3. Power train case oil level check (Daily check)
Engine
Stopped
(Cold)

Filler and Level gauge

P/T Drain plug
60 L
4. Damper case oil level check

Damper oil level gauge

Damper oil drain plug 1.5 L

5. Hydraulic tank oil level check
Standard position for check machine
1.The blade completely, and lower the blade
and ripper to the ground in horizontal position
shown in the diagram at right
2. Stop the engine and wait for about 5 minutes
before checking oil level.
If oil level is between H and L in the sight gauge
it is normal.
3. If the level is below the Ｌ mark,
add engine oil through oil filler (F).

★Don't check oil level after operation.

Ripper shank : Vertical position

Oil level Oil filler (F)

Drain cock

Drain cock

Drain plug 67 L Hydraulic filter

6. Final drive oil level check 7. Pivot shaft oil level check

Oil level plug

Oil drain plug

There is danger that the oil may spurt out under

internal pressure.
So to the side, and gradually turn the plug to Measuring ruler
release the internal pressure before removing the Oil level
plug completely.
Oil filler has a slit Oil drain plug 20mm

7L
26 L
8. Battery electrolyte water level check. ( LH ) -- 250Hr
CORRECT
Filler port
The electrolyte level is up to
UPPER the bottom of the sleeve, so the surface
Sleeve tension causes the surface to rise
and the plate appears to be warped.
LOWER
The electrolyte level is not up to
the bottom of the sleeve, so the plate
appears normal.
165G51(STD) Too low

C200 (OPTION)
Wind washer tank
Filter element and Strainer
1. Engine oil filter (600-211-1340)

500Hr
 BLEEDING AIR FROM FUEL CIRCUIT
1. Replace fuel filter cartridge.
1. Set the container under the filter cartridge to catch the drained fuel. Air bleed plug③
2. Close valve ① of fuel strainer part.
3. Remove the drain plug at bottom of the filter to drain fuel.
After draining fuel, tighten the drain plug.
4. Using a filter wrench, turn filter cartridge ② counterclockwise
to remove it.
Plug⑤
5. Clean the filter holder, fill a new filter cartridge with clean fuel,
coat the packing surface with engine oil, then install it
to the filter holder.
6. When installing, tighten until the packing surface contacts
the seal surface of the filter holder, then tighten it up 3/4 to 1 of a turn.
7. Open valve① of fuel strainer part and loosen air bleeding plugs③
8. Loosen the knob of priming pump ④ , move it up and down,
Fuel filter② (600-319-3310)
and continue until no more bubbles come out with the fuel to air bleed plug ③ .
9. Tighten air bleed plug ③ , push in the knob of priming pump ④ , then tighten it.
10. After replacing the filter cartridge, start the engine and check for oil leakage
from the filter seal surface.
REMARK
When only the filter cartridge is replaced, it is sufficient 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.

Valve①

Priming pump④

Fuel strainer
2. Fuel filter (600-319-3310) 3. Corrojoun register
500Hr
(600-411-1151)

Close

Open
Cap
Add fuel through inlet port A.

1000Hr
Outlet port B
(Clean side)

Fuel strainer
4. Power line filter 5. Power line strainer

P/L Filter
P/L Strainer Scavenging pump
(07063-01100)
1000 Hr 1000 Hr
500 Hr
6. Clean the breather element

Engine breather element : 2000Hr P/L breather : When required

Hyd tank breather element :

500Hr

Damper breather : 2000Hr

Lubricating Grease nipple

Grease nipple

Grease nipple

1. Blade ass’y grease point (250Hr)

Grease nipple

Grease nipple
2. Blade cyl’ stay (250 Hr)

Grease nipple (LH) Grease nipple (RH)

3. Equalizer bar center pin 4. Equalizer bar side pin

250 Hr 250 Hr

Grease nipple Grease nipple

5. Brake pedal 6. Deceleration pedal

Remove the rubber cap

Grease nipple When required

Grease nipple
8. Brake valve
7. Parking lever

Grease nipple
Grease nipple
9. Ripper ass'y grease point (250 Hr)
Ripper arm pin

Ripper arm pin Ripper lift cyl' head pin

Grease nipple
Ripper lift cyl' bottom pin
 ALTERNATOR V-BELT ADJUSTMENT Bolt⑥

・ REPLACE V-BELT (Alternator) Alternator③

1.Loosen bolts①,⑥, and nuts②and④, then turn nut④
and adjust the belt tension. Nut④
2.After adjusting, tighten bolts and nuts②,④ and ,⑤,⑥
to secure alternator③ in position. Bolt①
4.Reinstall the cover removed in step 1. Confirm that no
part of the cover touches any turning part of the alternator.
＊ When adjusting the V-belt, do not push Nut⑤
alternator③ directly with the bar. Use nut④.
＊ The standard deflection for the V-belt is 13--16mm,
when pressed with a thumb with force of approx. (10Kg) Bolt②

AIR COMPRESSOR DRIVE V-BELT

ADJUSTMENT
・ REPLACE V-BELT (Air compressor)
1.Loosen 4 bolts① and jack bolt②, then remove Air compressor③
compressor③ to the side.
2.Replace the V-belt.
・ When adjusting the V-belt, do not push the compressor
directly with the bar. Use jack bolt② ．
3.Tighten jack bolt② and bolts①, and apply tension to the
V-belt. The standard deflection for the belt is approx. 10mm
when pressed with a finger force of approx. 6Kg

Bolt① Jack bolt②

 VISUAL CHECK BLADE ARM BALL JOINT CLEARANCE
When the play of blade become large and difficult to dozing or leveling
Adjust the shim at ball joint.
If some noise is coming
Shim adjustment.
from ball joint area.
1.Remove shim① and tighten bolts② to eliminate the ball joint play.
2.Measure clearance「Ａ」and remove bolts②． Apply grease to joint.
3.Install shim① having its thickness of「Ａ」mm to「Ａ＋１」mm
（「Ａ」in to「Ａ＋0.04in」）in place with bolts②．
4.Confirm the ball joint can move smoothly after tightening bolts.　 STD shim thickness:12mm

C
Single tilt dozer
Tilt cylinder (RH)
707-01-OU140

1287mm ＧＬ
Shim ①
1460mm
2762mm
Bolt ② A
H:535mm STD
STD shim
sh
thickness:4.5mm
VISUAL CHECK BLAD
E
1.Ground the blade and measure the clearance（Ａ
If the clearance（Ａ）is larger than 1.5mm remove the shim and adjust the clearance（Ａ）to 0.2～0.5mm.

ADJUSTING SHIM IN BLADE CYLINDER CAP

Set the standard shim adjustment in the blade cylinder cap to ４mm(0.16in)
Remove shims to balance the wear of the cap and the ball at the end of the piston rod.
The proper clearance to be maintained with the shims is 0.2 to 0.5mm(0.008 to 0.02in).

(Ａ) ４ｍｍ (0.16in)

2.Check the movement by moving blade raise / lower and RH / LH tilt after adjustment.
If some noise is coming from above ball joint area, Re-adjust above.
INSPECTION AND ADJUSTMENT FOR TRACK TENSION.
INSPECTION. Clearance Ａ： 20-30mm
1. Stop the machine on level ground.
( Stop with the transmission in FORWARD with applying the brake slowly ).
2. Place a straight bar on the track shoes between first carrier roller
and idler as shown in the figure.
3. Measure the clearance between the bar and the grouser at the midpoint.
・ Properly adjust track tension.
Tension should be measured at clearance Ａ shown in the diagram Top of grouser
--- usually ２０ to ３０ ｍｍ ( 0.8 to 1.2 in ) at this point.
For rocky terrain, tighten tracks slightly.
In clay or sandy areas, slightly loosen them.
★ Adjusting the track tension ３０ ｍｍ when the machine is new.
ADJUSTMENT. ( Initial 250Hr ) Ｓ
・ When increasing tension..
1. Remove the cover.
2. Pump in grease through grease fitting② with a grease pump.
3. To check that the correct tension has been achieved.
move the machine backwards and forwards.
4. Check the track tension again, and if the tension is not correct, adjust it again. Fitting②
5. Grease may be pressurized till Ｓ will be 0mm ( 0 in ).
In case the tension is yet loose after applying pressurized injection of grease till
the above mentioned limit, it indicates that pin bush is reduced by too much abrasion.
So it is necessary either to turn or replace the pin and bushings.
Consult your Komatsu distributor for repair.
・ When loosing tension..
1. Loosen plug① gradually to release the grease.
2. Turn the plug① a maximum one turn.
3. If the grease does not come out smoothly, Plug①
move the machine backwards and forwards a short distance.
4. Tighten plug①.
5. To check the correct tension has been achieved,
move the machine backwards and forwards.
Ｓ
Adjust idler clearance
The idler moves forward and backward under external pressure Clearance: 2mm
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. Clearance: 0.5-.1.0mm
Adjustment in sideways directions
1 ． Drive the machine for 8 to 12m (24.4 to 36.6 ft) on flat ground,
then measure clearance A (4 places:left, right, inside outside) Clearance: 0mm
between the track frame and side guide(1).
2 ． If clearance A is more than 4 mm (0.16in), remove bolt(1),
⑤
then take out shim, and adjust to that the clearance on one side is
less than 0.5 to 1.0 mm (0.02 to 0.04 in).
There are two types of shim thickness: 0.5 mm (0.02in) and 1.0 mm(0.04in)
Adjustment 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 (0.2 in):
Amount of adjustment = 5-2 = 3 mm (o.12 in)
⑤ ⑨
2 ． Loosen bolts (9) (inside, outside : Total 4) to a point where there is no more
reaction from the spring. ⑧
3 ． Loosen bolts (1). 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 steps 1.
⑦
5 ． After removing shims (7), add them on top of shims (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.
There are two types of shim thickness: 1mm (0.04 in) and 2 mm (0.08 in) ①
TIGHTEN TRACK SHOE BOLTS
When asembling parts marked* shown,
1.Method for tightening coat treated and seat portion of bolt and
Master-link with anti-burning together
1.Tighten torque uniforml
Master bolt:３５±４Kg・m (253 Ib･ft) (MARUZEN MORIMAX No.2 or
EQUIVALLENTS.)
Regular bolt:３５±４ Kg・m ( Ib･ft)
・Don't use impact wrench. Check the link contact surface.
2.Check the link contact surface are
in close contact by thickness gauge.
3.Tighten torque
Master bolt:１６０ ～１８０°
Regular bolt:１２０±１０°
* *
2.Tighten in the following sequence.
Master bolt(119.5-M22*2) Regular bolt
(154-32-71250) (154-32-71210)
①→②→③→④ When disassembly
shoe ass'y,
At first loosen the
shoe tension.
32
Disassemble ability
Comparison of brake system