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chapter 21 cleaning instructions – dozers

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UNCONTROLLED IF PRINTED 21-1 CHAPTER 21 CLEANING INSTRUCTIONS – DOZERS 21.1 This chapter provides basic cleaning requirements for selected vehicles. Where there is a specific requirement or need to highlight particular problem areas detailed cleaning guides are provided as tables and figures or as Annexes in this chapter. 21.2 Dozers are very complex pieces of machinery. While all contamination and QRM must be removed, the main areas of concern are: a. external areas; b. cabin; c. engine bay; d. tracks, rollers and track frames; e. hydraulics; f. scraper blade; g. ripper cradle; h. winch, wire ropes and slings; and i. other high risk areas; 21.3 All points are not specific to all dozers. ADF Force Extraction Cleaning Manual
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21-1

CHAPTER 21

CLEANING INSTRUCTIONS – DOZERS

21.1 This chapter provides basic cleaning requirements for selected vehicles. Where there is a specific requirement or need to highlight particular problem areas detailed cleaning guides are provided as tables and figures or as Annexes in this chapter.

21.2 Dozers are very complex pieces of machinery. While all contamination and QRM must be removed, the main areas of concern are:

a. external areas;

b. cabin;

c. engine bay;

d. tracks, rollers and track frames;

e. hydraulics;

f. scraper blade;

g. ripper cradle;

h. winch, wire ropes and slings; and

i. other high risk areas;

21.3 All points are not specific to all dozers.

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External Areas

21.4 The cleaning instructions for a dozer’s cabin include the points detailed in Table 21-1.

Table 21–1: Cleaning Instructions for the Dozer’s External Areas

Serial Comments or Tasks Technical Time (hours)

1 All CES is to be removed and independently cleaned. Do not refit until after the vehicle has been inspected by AQIS.

2 Lights are to be loosened and cleaned and any damaged lights are to be removed to allow cleaning of the fitting to ensure there is no soil, plant or insect matter.

3 Access panels and rock guards are to be removed and the track area cleaned of all soil, plant and insect matter with high-pressure water.

4 Remove floor panels and machine body access plates (if applicable) from underside of machine.

0.5

5 Clean areas on top of transmission and underneath the engine to remove dirt and dust that has accumulated in the body of the machine.

6 Pressure-wash the exterior of the vehicle to remove all dust and dirt.

7 The chassis is to be cleaned using flexible nozzle high-pressure water cleaning equipment. Particular attention is to be paid to small apertures which may act as reservoirs for soil, insect, snails and plant material. Additionally, check that no animals are hiding or nesting within the chassis.

8 Mounting points are to be disconnected, if necessary, to facilitate cleaning.

1.0

9 Hydraulic lines are to be wiped clean of all soil and fluid. Cable conduit is to be cleaned with high-pressure water or removed.

0.1

10 Hydraulic hose guards and hydraulic cylinder mounting points are to be cleaned with high-pressure water.

11 Toolboxes/stowage compartments are to be emptied and cleaned. The rubber seals around the doors are to be inspected to ensure all soil, plant and insect matter is removed.

0.5

12 Refer bellow for detailed cleaning guidelines for tyres and wheels.

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Cabin

21.5 The cleaning instructions for a dozer’s cabin include the points detailed in Table 21-2.

Table 21–2: Cleaning Instructions for the Dozer’s Cabin

Serial Comments or Tasks Technical Time (hours)

1 Remove any rubber floor mats and clean floor surface.

2 Remove and clean all door rubbers, internal door panelling and clean all windowsills.

3 Clean behind the dash lining/panelling. Access will be required for inspection.

4 Remove and clean under the seat, including the rubber seat shroud.

5 Remove any non-affixed floor panel if applicable and clean underneath.

6 Remove rubber pedal covers and clean.

7 Clean behind all cabin walls lining/panelling. Access will be required for inspection.

8 All air-conditioning vents must be internally cleaned. Access will be required for inspection

9 Clean inside all joystick controls. Access will be required for inspection.

10 Check cleanliness of cabin roof, both inside and out.

11 Clean ladder to cabin (may have hollow frame) and under each footstep.

12 Internally clean all light covers. Access will be required for inspection.

13 Empty windscreen reservoir.

14 Check for false floor under cabin and remove for cleaning, if applicable.

15 Check if the vertical cabin housing can be flushed via drainage holes.

15 Clean around roll over protection support structure.

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Engine Bay

21.6 The cleaning instructions for a dozer’s engine bay include the points detailed in Table 21-3.

Table 21–3: Cleaning Instructions for the Dozer’s Engine Bay

Serial Comments or Tasks Technical Time (hours)

1 Remove air-filter pre-cleaner cover and clean.

2 Remove air-filter and clean with air.

3 Clean inside fan-belt flywheels (harmonic balancer).

4 Check all surfaces of engine block including between tappet covers.

5 Remove belly plates if applicable and clean.

6 Remove all non-affixed engine covers to allow access for cleaning and inspection.

7 Remove all engine cover rubbers for cleaning and inspection.

8 Check engine housing for open-ended or spot-welded hollow support framework - flush to verify cleanliness.

9 Chassis rails either side of engine are hollow and maybe flushed via drainage holes on underside of the rail (Access maybe available once belly plate bolts have been removed).

10 Flush radiator and oil cooler from both sides to verify fin/core cleanliness.

11 Loosen radiator shroud to let any loose debris fall through after flushing.

12 Check battery boxes for cleanliness. Loosen batteries and clean … under.

13 Check either side of radiator for vertical hollow support structures. Flush to verify internal cleanliness if present.

14 Check all wiring harnesses for internal cleanliness.

15 Check under all hydraulic looming for cleanliness.

16 Ensure all engine mounts are clean.

17 Ensure that all surfaces of sump and engine block are clean.

18 All water reservoirs must be emptied (excluding radiator).

19 Remove all contaminated grease from universal joints.

20 Internally clean all light covers. Access will be required for inspection.

21 Removing zip-ties and electrical tape that hold electric and process hydraulic hoses together can facilitate the cleaning and inspection

22 Check above the sway bar – for cleanliness.

23 Flush under all checker-plate (non-slip footings) to ensure clean

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Tracks, Rollers and Track Frame

21.7 The cleaning instructions for an excavator’s tracks, rollers and track frame include the points detailed in Table 21-4.

Table 21–4: Cleaning Instructions for the Dozer’s Tracks, Rollers and Track Frame

Serial Comments or Tasks Technical Time (hours)

1 Stone / Rock guards (if present) must be removed to allow cleaning and inspection access to inside track frames.

2 Remove all other non-affixed panels to allow cleaning and inspection.

3 Once rock guards have been removed, check where bolts attach to frame as it may be a hollow cavity, which requires flushing.

4 Remove bearing covers (only on Caterpillar models).

5 Rollers – each countersunk bolt hole must be individually cleaned.

6 Remove Track guides (below rollers), if present and clean.

7 Roll tracks – one revolution required to check cleanliness of each track pad & countersunk bolts on rollers and idler wheels

8 Clean the track spring adjuster inside track frame.

9 Clean all internal ledges and hollow cavities inside track frames.

10 Carrier rollers above tracks – can have hollow vertical support structure, which requires cleaning.

Hydraulic and Electrical Cables

21.8 The cleaning instructions for the Dozer’s hydraulic and electrical cables include the point detailed in Table 21-5.

Table21–5: Cleaning Instructions for the a Dozer’s Hydraulic and Electrical Cables

Serial Comments or Tasks Technical Time (hours)

1 All electrical and hydraulic lines are to be separated and all grease and soil debris cleaned from in between them.

2.0

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Scraper Blade

21.9 The cleaning instructions for a dozer’s scraper blade include the points detailed in Table 21-6.

Table 21–6: Cleaning Instructions for the Scraper’s Scraper Blade

Serial Comments or Tasks Technical Time (hours)

1 Ensure that the cutting teeth along the front of the blade are removed and clean.

2 The sides of the blade may be hollow and can harbour hundreds of litres of contamination. If hollow, check for cracks or splits and ensure that these sides are free of all contamination.

3 Remove any cover plates, check for cracks or splits and ensure that these sides are free of all contamination.

4 The floor of the scraper blade may also be hollow and can harbour contamination. Check both topside and bottom for any cracks or splits and ensure that the scraper blade floor is clean.

Ripper Cradle

21.10 The cleaning instructions for a dozer’s ripper cradler include the points detailed in Table 21-7.

Table 21–7: Cleaning Instructions for the Dozer’s Ripper Cradle

Serial Comments or Tasks Technical Time (hours)

1 Ripper cradles are hollow – check for drainage hole or cracks & flush.

2 All cutting teeth must be removed for internal cleaning and inspection. Flush through the tyne pockets (red arrows) to verify cleanliness.

3 Loosen any wear plates from ripper blades.

4 All contaminated grease must be removed from all pivot points

5 Check all surfaces of the cradle bar for cracks, splits, evidence of repair or for drainage holes on the underside. Flush if drainage holes are present.

6 Check the ripper cradle surfaces for drainage holes cracks, splits or any evidence of repair. If breached, it will have to be investigated and verified clean.

7 All surfaces and welding seams on the underside of the ripper cradle must be checked for breaches.

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Winch, Wire Ropes and Slings

21.11 The cleaning instructions for the winch, wire ropes and slings include the point detailed in Table 21–8.

Table 21–8: Cleaning Instructions for Winch, Wire Ropes and Slings

Serial Comments or Tasks Technical Time (hours)

1 All items are to be extended to full length and subject to a high-pressure water clean using degreaser, if required, to remove all soil, plant and insect matter

2 The winch drum is to be degreased and subject to a high-pressure water clean

3 All winch ropes, wire ropes and slings are to be re-oiled after inspection. An application of a protective covering (plastic bag) may be required to protect the refurbished ropes and cables

Other High Risk Areas

21.12 The cleaning instruction for a dozer’s other high risk areas include the points detailed in Table 21-9.

Table 21–9: Cleaning Instructions for the Dozer’s Other High Risk Areas

Serial Comments or Tasks Technical Time (hours)

1 Check battery box – loosen batteries and clean under.

2 Check all surfaces of oil tank to ensure clean.

3 Check all surfaces of fuel cell to ensure clean.

4 Fuel cells from Komatsu & models must be removed to allow access under for cleaning and inspection.

5 Flush under all checker-plate (non-slip footings) to ensure clean

6 Check the internal of all light covers & cavities behind.

Annexes:

A. Cleaning Instructions - Komatsu D155A Dozer B. Cleaning Instructions - Caterpillar D3C Dozer C. Cleaning Instructions - Caterpillar D6 D. Cleaning Instructions - Caterpillar 933 Dozer E. Cleaning Instructions - John Deere 850J Dozer F. Cleaning Instructions - International TD15C Dozer G. Cleaning Checklist – Dozers

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ANNEX A TO CHAPTER 21

CLEANING INSTRUCTIONS – KOMATSU DOZER D155A

1. This Annex provides specific cleaning requirements for selected vehicles. Where there is a specific requirement or need to highlight particular problem areas detailed cleaning guides are provided as tables and figures in this Annex.

2. The cleaning requirements that follow are in addition to those points for dozers included in Chapter 21 of this publication.

External Areas

3. The cleaning instructions for the Komatsu Dozer D155A’s external areas, as illustrated in Figure 21A-1, include the points detailed in Table 21A-1.

Figure 21A-1: Komatsu Dozer D155A’s External Areas

Table 21A-1: Cleaning Instructions for the Komatsu Dozer D155A’s External Areas

Serial Comments or Tasks Technical Time (hours)

1 All CES is to be removed and independently cleaned. Do not refit until after the vehicle has been inspected by AQIS.

2 The chassis is to be cleaned using flexible nozzle high-pressure water cleaning equipment. Particular attention is to be paid to small apertures which may act as reservoirs for soil, insect, snails and plant material. Additionally, check that no animals are hiding or nesting within the chassis.

3 Refer to Chapter 21 for detailed cleaning guidelines.

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Cabin Internal Areas

4. The cleaning instructions for the Komatsu Dozer D155A’s cabin and internal areas, as illustrated in Figures 21A-2 to 21A-7, include the points detailed in Table 21A-2.

Figure 21A-2: Komatsu Dozer D155A’s Seat

Figure 21A-3: Komatsu Dozer D155A’s External Seat Shroud

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Figure 21A-4: Komatsu Dozer D155A’s Foot Controls

Figure 21A-5: Komatsu Dozer D155A’s Instrument Panel and Side Hydraulic Controls

Figure 21A-6: Komatsu Dozer D155A’s Cabin Roof

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Figure 21A-7: Komatsu Dozer D155A’s Air-conditioning Vents

Table 21A-2: Cleaning Instructions for the Komatsu Dozer D155A’s Cabin and Internal Areas

Serial Comments or Tasks Technical Time (hours)

1 Remove the floor mats and floor plates to access the transmission compartment.

With the hull access and inspection covers removed, clean the rear of the engine including the torque converter housing and pump drive power take-off, transmission exterior, filter housings, and transmission/torque converter hydraulic lines with high-pressure water. Continue to flush water through the transmission compartment until clean water runs from the hull access apertures in the bottom of the machine body.

Do not leave the hose unattended.

1.0

2 Remove the top cover of the instrument panel to expose the instrument wiring, automatic priming system resistors, and the safety relay.

Clean the area with compressed air and ensure it is clear of dust, dirt, plant and insect material.

0.1

3 Ensure the pockets under the arm rests and document bins in the cabin area are free of dust, dirt, plant and insect material.

4 Refer to Chapter 21 for detailed cleaning guidelines.

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Engine Bay

5. The cleaning instructions for a dozer’s engine bay, as illustrated in Figure 21A-8, include the points detailed in Table 21A-3.

Figure 21A-8: Komatsu Dozer D155A’s Battery Bay

Table 21A–3: Cleaning Instructions for the Dozer’s Engine Bay

Serial Comments or Tasks Technical Time (hours)

1 Ensure that all surfaces of sump and engine block are clean.

2 Check battery boxes for cleanliness. Loosen batteries and clean … under.

3 Refer to Chapter 21 for detailed cleaning guidelines.

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Blade

6. The cleaning instructions for the Komatsu Dozer D155A’s blade face, as illustrated in Figures 21A-9 to 21A-11, include the points detailed in Table 21A-4.

Figure 21A-9: Komatsu Dozer D155A’s Blade

1

Figure 21A-10: Komatsu Dozer D155A’s Blade Face

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Figure 21A-11: Komatsu Dozer D155A’s Hydraulic Rams

Table 21A-4: Cleaning Instructions for the Komatsu Dozer D155A’s Blade Face

Serial Comments or Tasks Technical Time (hours)

1 if the blade face is damaged, cut a section of the blade away and remove all soil, plant and insect matter;

2 The damaged area is to be high-pressure cleaned and scraped to remove and soil and plant material. AQIS may not pass items where soil cannot be removed.

3 Cutting edges are to be removed and cleaned with a high-pressure water cleaner;

4 Refer to Chapter 21 for detailed cleaning guidelines.

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Tracks, Rollers and Track Frame

7. The cleaning instructions for the Komatsu Dozer D155A’s tracks, rollers and track frame, as illustrated in Figures 21A-12 to Figure 21A-14, include the point detailed in Table 21A-5.

Figure 21A-12: Komatsu Dozer D155A’s Tracks

Figure 21A-13: Komatsu Dozer D155A’s Running Set

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1

Figure 21A-14: Komatsu Dozer D155A’s Running Gear

Table 21A-5: Cleaning Instructions for the Komatsu Dozer D155A’s Running Gear

Serial Comments or Tasks Technical Time (hours)

1 The area of track showing soil build-up will require extensive cleaning with high-pressure water to remove all soil and plant material.

2 Idler covers to be removed to allow access to rollers below

3 Refer to Chapter 21 for detailed cleaning guidelines.

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Ripper Cradle

8. The cleaning instructions for the Komatsu Dozer D155A’s rear external areas, as illustrated in Figure 21A-15, include the points detailed in Table 21A-6.

Figure 21A-15: Komatsu Dozer D155A’s Rear External Areas

Table 21A-6: Cleaning Instructions for the Komatsu Dozer D155A’s Rear External Areas

Serial Comments or Tasks Technical Time (hours)

1 Rippers are to be dropped and the attachments are to be cleaned with high-pressure water.

2 Refer to Chapter 21 for detailed cleaning guidelines.

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Cable Winch

9. The cleaning instructions for the Komatsu Dozer D155A’s cable winch, as illustrated in Figure 21A-16, include the points detailed in Table 21A-7.

Figure 21A-16: Komatsu Dozer D155A’s Cable Winch

Table 21A–7: Cleaning Instructions for the Komatsu Dozer D155A’s Cable Winch

Serial Comments or Tasks Technical Time (hours)

1 All items are to be extended to full length and subject to a high-pressure water clean using degreaser, if required, to remove all soil, plant and insect matter

3.0

2 Refer to Chapter 21 for detailed cleaning guidelines.

Other High Risk Areas

10. Cleaning instructions for a Komatsu D155A Dozer’s other high risk areas include the points detailed in Table 21A-8.

Table 21A-8: Cleaning Instructions for the Komatsu Dozer D155A’s Other High Risk Areas

Serial Comments or Tasks Technical Time (hours)

1 Fuel cells from Komatsu must be removed to allow access under for cleaning and inspection.

2 Check all surfaces of fuel cell to ensure clean.

3 Refer to Chapter 21 for detailed cleaning guidelines.

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ANNEX B TO CHAPTER 21

CLEANING INSTRUCTIONS – CATERPILLAR D3C DOZER

1. This Annex provides specific cleaning requirements for selected vehicles. Where there is a specific requirement or need to highlight particular problem areas detailed cleaning guides are provided as tables and figures in this Annex.

2. The cleaning requirements that follow are in addition to those points for dozers included in Chapter 21 of this publication.

External Areas

3. The cleaning instructions for the Caterpillar D3C Dozer’s external areas, as illustrated in Figure 21B-1, include the points detailed in Table 21B-1.

Figure 21B-1: Caterpillar D3C Dozer

Table 21B –1: Cleaning Instructions for the Caterpillar D3C Dozer’s External Areas

Serial Comments or Tasks Technical Time (hours)

1 The chassis is to be cleaned using flexible nozzle high-pressure water cleaning equipment. Particular attention is to be paid to small apertures which may act as reservoirs for soil, insect, snails and plant material. Additionally, check that no animals are hiding or nesting within the chassis.

2 Refer to Chapter 21 for detailed cleaning guidelines.

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Cabin

4. The cleaning instructions for the Caterpillar D3C Dozer’s cabin areas, as illustrated in Figures 21B-2 to 21B-4, include the points detailed in Table 21B-3.

Figure 21B-2: Caterpillar D3C Dozer’s Seat

Figure 21B-3: Caterpillar D3C Dozer’s Instrument Panel

Figure 21B-4: Caterpillar D3C Dozer’s Foot Pedals

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Table 21B -3: Cleaning Instructions for the Caterpillar D3C Dozer’s Cabin

Serial Comments or Tasks Technical Time (hours)

1 Remove and clean under the seat, including the rubber seat shroud.

2 Clean inside all joystick controls. Access will be required for inspection.

3 Remove rubber pedal covers and clean.

4 Refer to Chapter 21 for detailed cleaning guidelines.

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Engine Bay

The cleaning instructions for the Caterpillar D3C Dozer’s rear external areas, as illustrated in Figure 21B-5, include the points detailed in Table 21B-4.

Figure 21B-5: Dozer Caterpillar D3C

Table 21B–4: Cleaning Instructions for the Caterpillar D3C Dozer’s Engine Bay

Serial Comments or Tasks Technical Time (hours)

1 Ensure that all surfaces of sump and engine block are clean.

2 Refer to Chapter 21 for detailed cleaning guidelines.

Blade

5. The cleaning instructions for the Caterpillar D3C Dozer’s rear external areas, as illustrated in Figures 21B-6 and 21B-7, include the points detailed in Table 21B-5.

Figure 21B-6: Caterpillar D3C Dozer’s Blade

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Figure 21B-7: Caterpillar D3C Dozer’s Hydraulic Rams

Table 21B–5: Cleaning Instructions for the Caterpillar D3C Dozer’s Rear External Areas

Serial Comments or Tasks Technical Time (hours)

1 Remove any cover plates, check for cracks or splits and ensure that these sides are free of all contamination.

2 Hydraulic lines are to be wiped clean of all soil and fluid. Cable conduit is to be cleaned with high-pressure water or removed.

3 Refer to Chapter 21 for detailed cleaning guidelines. 1.0

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Tracks, Rollers and Track Frame

The cleaning instructions for the Caterpillar D3C Dozer’s tracks, rollers and track frame, as illustrated in Figure 21B-8, include the points detailed in Table 21B-6.

Figure 21B-8: Caterpillar D3C Dozer’s Tracks

Table 21B-6: Cleaning Instructions for the Caterpillar D3C Dozer’s Tracks, Rollers and Track Frame

Serial Comments or Tasks Technical Time (hours)

1 Roll tracks – one revolution required to check cleanliness of each track pad & countersunk bolts on rollers and idler wheels

2 Stone / Rock guards (if present) must be removed to allow cleaning and inspection access to inside track frames.

3 Refer to Chapter 21 for detailed cleaning guidelines.

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Ripper Cradle

The cleaning instructions for the Caterpillar D3C Dozer’s ripper cradle, as illustrated in Figure 21B-9, include the points detailed in Table 21B-7.

Figure 21B-9: Caterpillar D3C Dozer’s Ripper Cradle

Table 21B–7: Cleaning Instructions for the Caterpillar D3C Dozer’s Ripper Cradle

Serial Comments or Tasks Technical Time (hours)

1 Rippers are to be removed and the attachment points are to be cleaned with high-pressure water.

3.0

2 Refer to Chapter 21 for detailed cleaning guidelines.

ADF Force Extraction Cleaning Manual


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