Komatsu Bulldozers D65E,P-12 : Every 1000 Hours

Power tilt dozer

• Lift cylinder support yoke (4 places)

• Lift cylinder support shaft (2 places)

• Lift cylinder ball joint (2 places)

• Tilt cylinder ball joint (1 place)

• Tilt brace ball joint (1 place)

• Brace ball joint (2 places)

• Tilt brace thread (1 place)

Power tilt power pitch dozer

• Lift cylinder support yoke (4 places)

• Lift cylinder support shaft (2 places)

• Lift cylinder ball joint (2 places)

• Tilt cylinder ball joint (1 place)

• Pitch cylinder ball joint (1 place)

• Brace ball joint (2 places)

Angledozer

• Lift cylinder support yoke (4 places)

• Lift cylinder support shaft (2 places)

• Lift cylinder ball joint (2 places)

• Tilt brace ball joint (2 places)

• Tilt brace thread (2 places)

REMARK

• When adding grease, pump in three shots (pump the grease gun lever three times) for each fitting, and check that grease is newly discharged from the seal lip.

• If no grease is newly discharged from the seal lip, continue to pump in grease until grease is discharged.

WARNING: The oil is at high temperature immediately after the machine has been operated. Walt for the oil to cool down before starting the operation.

WARNING: When removing the oil filler cap, oil may spurt out, so stop the engine and wait for the oil temperature to go down, then turn the cap slowly to release the internal pressure before removing the cap. If oil has been added to above the H mark, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from the drain plug.

NOTICE

• Do not add oil if the level is above the H line. This will damage the hydraulic equipment and cause the oil to spurt out.

Lower the blade to the ground, stop the engine and wait for about 5 minutes before checking oil level. If oil level is between H and L in sight gauge G.

If the level is below the L mark, add engine oil through oil filler F.

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.

WARNING: When draining the oil, do not remove drain plug P.

Prepare the following.

• Container to catch drained oil: Min 38 & capacity

• Refill capacity: 38 &

• Socket wrench, filter wrench.

Before installing a filter cartridge, be sure to fill the cartridge with engine oil.

NOTICE: Even if the machine has not been operated for 250 hours, the oil and filter cartridge must be replaced when the machine has been operated for 6 months. In the same way, even if the machine has not been oper- ated for 6 months, the oil and filter cartridge must be replaced when the machine has been operated for 250 hours.

Carry out this check before operating the machine.

WARNING: To avoid gas explosions, 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 large amounts of water, and consult a doctor.

Checking

• The belt should normally deflect by 6 - 10 mm when pressed with the finger (with a force of approx. 6 kg) at a point midway between the alternator pulley and fan pulley.

Adjusting

• Loosen bolts and nuts 1, 2 and 3.

• Turn nut 4 clockwise, then move alternator 5 to adjust the belt tension so that the deflection is approx. 6 mm when pushed with a force of 6 kg.

• Tighten the bolts and nuts 1, 2 and 3 to fix alternator 5 in position.

• 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 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 the new belt is set, readjust it after operation for an hour.

NOTICE: When installing seal 3, always close filter cover 1 first. If the filter cover is closed after the seal is installed, the seal will be damaged.

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

NOTICE: Never place the gearshift lever in 1st. This will damage the machine.

Operate fuel control lever h and gradually raise the engine speed to high idling.

If the machine does not move when the above operation is carried out, the brake is normal.

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.

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

• 1. Set the container to catch the fuel under the filter cartridge.

• 2. Using a filter wrench, turn filter cartridge 1 counterclockwise to remove it.

• 3. 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.

• 4. When installing, tighten until the packing surface contacts the seal surface of the filter holder, then tighten it up 1/2 to 314 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten to the correct amount.

• 5. Loosen the knob of feed pump 2 and operate it 50 - 60 times up and down, This will bleed the air.

• 6. Push in the knob of feed pump 2 and tighten it.

• 7. After replacing the filter cartridge, start the engine and check that there is no leakage of fuel from the filter seal surface. If there is any leakage of fuel, check the tightening of the filter cartridge. Whenever there is leakage of fuel, follow Steps 1 and 2 to remove the filter cartridge, then check the packing surface for damage or foreign material. If any damage or foreign material is found in the packing, replace the packing with a new part, then repeat Steps 3 - 6 to install the filter cartridge.

Method of using automatic air bleed mechanism

It is possible to bleed the air from the fuel circuit simply by rotating the starting motor with the starting switch. Bleed the air as follows.

NOTICE: When the engine has run out of fuel, carry out the same procedure and crank the engine for 15 - 20 seconds. Repeat this operation 2 - 3 times to bleed the air. Do not rotate the starting motor continuously for more than 20 seconds. Wait for 1 - 2 minutes before rotating again. The time taken to bleed the air is shorter when the fuel tank is full.

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.

CAUTION: When draining the oil, do not remove drain plug P.

Prepare the following.

• Container to catch drained oil: Min 38 & capacity

• Refill capacity: 38 &

• Socket wrench, filter wrench

Before installing a filter cartridge, be sure to fill the cartridge with engine oil.

NOTICE: Even if the machine has not been operated for 500 hours, the oil and filter cartridge must be replaced when the ma- chine has been operated for 6 months. In the same way, even if the machine has not been operated for 6 months, the oil and filter cartridge must be replaced when the machine has been operated for 500 hours.

WARNING: The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down before starting the operation. The undercover is heavy. Never try to open or close the cover when directly be- neath it. When removing bolts 2, carry out the work from the rear below the cover so that you can easily get out of the way.

Prepare the following.

• Container to catch drained oil: Min 50 & capacity

• Refill capacity: 50 &

Remove the undercover at the bottom rear of the machine as follows.

• Remove 2 bolts 1 at the front of the machine.

• Support the cover with your elbow while gradually removing 2 bolts 2 at the rear of the machine.

• Lower the cover gradually to open it.

WARNING: The oil is at high temperature immediately after the machine has been operated. Wait for the oil to cool down I before starting the operation.

Prepare the following.

• Container to catch drained oil: Min. 30 & capacity

• Refill capacity: D65E, EX-12: each 24 & | D65P, PX-12: each 27 &

Power train (transmission) case breather (1 place)

Apply grease to the grease fittings (2 places) shown by arrows.

WARNING: The undercover is heavy. Never try to open or close the cover when directly beneath it. When removing bolts 2, carry out the work from the rear below the cover so that you can easily get out of the way.

Remove the undercover at the bottom rear of the machine as follows.

• Remove 2 bolts 1 at the front of the machine.

• Support the cover with your elbow while gradually removing 2 bolts 2 at the rear of the machine.

• Lower the cover gradually to open it.

Check for loose and damaged bolts. If any loose bolt is found, tighten to a torque of 94.5 + 10.5 kgm. If any damaged bolt is found, replace the bolt with a genuine Komatsu bolt.