General • Inspections

Komatsu Bulldozers D65EX,PX-12 : Every 1000 Hours

Use this maintenance checklist for the proactive and preventive maintenance of your bulldozer. This has been proven to lower costs by catching small service issues before they blossom into giant repair headaches.

MaintainX

11/04/2022

Komatsu Bulldozers D65EX,PX-12 : Every 1000 Hours

DRAIN WATER, SEDIMENT FROM FUEL TANK

Open the inspection cover at the bottom of the fuel tank, loosen valve 1, and drain the fuel together with the water and sediment accumulated at the bottom of the tank.

DRAIN WATER, SEDIMENT FROM FUEL TANK

Open the inspection cover at the bottom of the fuel tank, loosen valve 1, and drain the fuel together with the water and sediment accumulated at the bottom of the tank.

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.

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)

GREASE EQUALIZER BAR SIDE PIN (LEFT AND RIGHT, 2 PLACES EACH: TOTAL 4 PLACES)

Remove cover 1.

Add grease to the grease fittings marked by the arrows.

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.

Install the cover.

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

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.

Stop the machine so that drain plug 1 is directly at the bottom.

Remove oil level plug 2 and check whether the final drive case is filled with oil to lower edge of the plug hole.

If the oil level is still too low, add engine oil through the plug hole until the oil overflows.

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

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.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (D60P, 65EX, PX ONLY)

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.

Remove the cover at the bottom of the machine and set a container to catch the oil under the drain plug.

Loosen drain plug P (with a slit) slowly to avoid getting oil on yourself, and drain the oil.

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

Install drain plug P.

Using a filter wrench, turn filter cartridge 1 counterclockwise to remove it. When doing this, to prevent getting oil on yourself, do not carry out this operation from immedi- ately under the cartridge. In particular, if this operation is carried out immediately after stopping the engine, a large amount of oil will come out, so wait for 10 minutes before starting the operation.

Clean the filter holder, coat the packing surface of a new filter cartridge with engine oil (or coat it thinly with grease), then install it to the filter holder.

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

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.

After replacing the filter cartridge, add engine oil through oil filler 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.

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.

CHECK LEVEL OF BATTERY ELECTROLYTE

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.

Open the battery cover.

Remove cap 1, and check that the electrolyte is at the specified level (10 to 12 mm above the plate). If the electrolyte level is low, add distilled water to the specified level. If the battery electrolyte is spilled, have dilute sulphuric acid added.

When adding distilled water to any cell at cap 1, add distilled water also to the other cells.

Clean the air hole in the battery cap, then tighten the cap securely.

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

CHECK FAN BELT TENSION, ADJUST

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.

DRAIN WATER AND SEDIMENT FROM FUEL FILTER

Open the engine side cover on the left side, loosen drain plug 1 at the bottom of the filter, and drain the fuel together with the water and sediment accumulated at the bottom of the tank.

Tighten drain plug 1.

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

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

CHECK, CLEAN ADDITIONAL FUEL STRAINER

Open the inspection cover at the bottom of the fuel tank.

Tighten the fuel supply valve, then remove the cap, and clean the strainer and strainer case. The strainer forms one unit with the cap.

Set the strainer in the case, then tighten the cap.

After installing, open the fuel supply valve.

REPLACE POWER TRAIN OIL FILTER ELEMENT

Remove top mounting bolts 2 of filter cover 1, then use the bottom hinge as the fulcrum to open the cover to the outside.

Remove seal 3 installed to the frame.

Remove mounting bolt 5 of filter 4, then remove cover 6.

Remove the grommet under the fender, loosen drain plug P, and drain the oil inside the filter case.

Take out element 7.

Clean the removed parts and the inside of the case, then install a new element. Set so that the side hole of cover 6 is in the direction to match hole A of filter case 4, then tighten with bolt 5.

Install drain plug P.

After installing, loosen air bleed plug 8, start the engine, and when oil spurts out, tighten the plug.

Close filter cover 1, and tighten bolt 2.

Install frame seal 3.

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.

CHECK BRAKE CAPACITY

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

Start the engine.

Set safety lever 1 in the FREE position, operate blade control lever 2, and raise the blade. Leave the safety lever in the FREE position.

Set brake lock lever 3 in the FREE position.

Depress brake pedal 4 and set gearshift lever 5 in 2nd.

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.

REPLACE FUEL FILTER CARTRIDGE

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.

After replacing the filter cartridge, check that the fuel control lever is at the low idling position.

Place the parking lever to the lock position.

Turn the starting switch key to the START position and rotate the starting motor for 15 - 20 seconds to crank the engine and bleed the air.

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.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (D65E ONLY)

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

Remove the cover at the bottom of the machine and set a container to catch the oil under the drain plug.

Loosen drain plug P (with a slit) slowly to avoid getting oil on yourself, and drain the oil.

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

Install drain plug P.

Using a filter wrench, turn filter cartridge 1 counterclock-wise to remove it. When doing this, to prevent getting oil on yourself, do not carry out this operation from immediately under the cartridge. In particular, if this operation is carried out immediately after stopping the engine, a large amount of oil will come out, so wait for 10 minutes before starting the operation.

Clean the filter holder, coat the packing surface of a new filter cartridge with engine oil (or coat it thinly with grease), then install it to the filter holder.

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

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.

After replacing the filter cartridge, add engine oil through oil filler 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.

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.

CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER, SCAVENGING PUMP STRAINER)

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 &

Loosen drain plug P (with a slit), drain the oil, then tighten drain plug P again. Do not remove drain plug P.

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.

Loosen mounting bolt 3 of the power train strainer, then remove cover 4

Take out spring 5, then take out strainer 6.

Remove all dirt from strainer 6, then wash in clean diesel oil or flushing oil. Clean the case interior and the removed parts.

Loosen mounting bolt 7 of the scavenging pump strainer, then remove cover 8.

Take out spring 9, then take out strainer 10.

Remove all dirt from strainer 10, then wash in clean diesel oil or flushing oil. Clean the case interior and the removed parts.

Install the strainers to their original position.

After installing, replace the element in the power train oil filter.

Refill the specified quantity of engine oil through oil filler F.

Check that the oil is at the specified level.

If the spring or strainer are damaged, replace them.

CHANGE OIL IN FINAL DRIVE CASE

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 &

Stop the machine so that drain plug 3 is directly at the bottom.

Remove oil level plug 2 and oil filler plug 1, then remove drain plugs 3 and 4, and drain the oil. After draining the oil, tighten the plugs.

Add engine oil to the specified level through the hole in oil filler plug 1.

Check that the oil is at the specified level.

CLEAN BREATHER

Remove the breather and wash out dust remaining inside with diesel oil and flushing oil.

Power train (transmission) case breather (1 place)

GREASE UNIVERSAL JOINT

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.

REPLACE CORROSION RESISTOR CARTRIDGE (D65P, D65EX, PX ONLY)

Screw in valve 1 at the top of the corrosion resistor.

Using a filter wrench, turn cartridge 2 to the left, and remove it.

Coat the seal surface of the new cartridge with engine oil, then install it to the filter holder.

When installing, bring the packing surface into contact with the seal surface of the filter holder, then tighten approx. 2/3 turns.

Open valve 1. Always use a genuine Komatsu cartridge.

CHECK ALL TIGHTENING PARTS OF TURBOCHARGER (D65P, D65EX, PX ONLY)

Contact your Komatsu distributor to have the tightening portions checked.

CHECK PLAY OF TURBOCHARGER ROTOR (D65P, D65EX, PX ONLY)

Contact your Komatsu distributor to have the play checked.

CHECK FOR LOOSE ROPS MOUNT BOLTS

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.

Source: MaintainX (Community Member)

DRAIN WATER, SEDIMENT FROM FUEL TANK

Open the inspection cover at the bottom of the fuel tank, loosen valve 1, and drain the fuel together with the water and sediment accumulated at the bottom of the tank.

DRAIN WATER, SEDIMENT FROM FUEL TANK

Open the inspection cover at the bottom of the fuel tank, loosen valve 1, and drain the fuel together with the water and sediment accumulated at the bottom of the tank.

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.

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)

GREASE EQUALIZER BAR SIDE PIN (LEFT AND RIGHT, 2 PLACES EACH: TOTAL 4 PLACES)

Remove cover 1.

Add grease to the grease fittings marked by the arrows.

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.

Install the cover.

CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

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.

Stop the machine so that drain plug 1 is directly at the bottom.

Remove oil level plug 2 and check whether the final drive case is filled with oil to lower edge of the plug hole.

If the oil level is still too low, add engine oil through the plug hole until the oil overflows.

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL

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.

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (D60P, 65EX, PX ONLY)

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.

Remove the cover at the bottom of the machine and set a container to catch the oil under the drain plug.

Loosen drain plug P (with a slit) slowly to avoid getting oil on yourself, and drain the oil.

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

Install drain plug P.

Clean the filter holder, coat the packing surface of a new filter cartridge with engine oil (or coat it thinly with grease), then install it to the filter holder.

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

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.

After replacing the filter cartridge, add engine oil through oil filler 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.

CHECK LEVEL OF BATTERY ELECTROLYTE

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.

Open the battery cover.

Remove cap 1, and check that the electrolyte is at the specified level (10 to 12 mm above the plate). If the electrolyte level is low, add distilled water to the specified level. If the battery electrolyte is spilled, have dilute sulphuric acid added.

When adding distilled water to any cell at cap 1, add distilled water also to the other cells.

Clean the air hole in the battery cap, then tighten the cap securely.

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

CHECK FAN BELT TENSION, ADJUST

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.