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Komatsu Bulldozer D65E,P-12 D65EX,PX-12 Operator & Maintenance Manual SN 60001 and up – PDF DOWNLOAD
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Komatsu Bulldozer D65E,P-12 D65EX,PX-12 Operator & Maintenance Manual
Book Code :SEAM001202
SERIAL NUMBERS:
D65E,P :60001 and up
D65EX,PX :60001 and up
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Description
Komatsu Bulldozer D65E,P-12 D65EX,PX-12 Operator & Maintenance Manual
FILE DETAILS:
Komatsu Bulldozer D65E,P-12 D65EX,PX-12 Operator & Maintenance Manual
Fomat: PDF
Language: English
Brand: Komatsu
Type of machine: Bulldozer
Type of document: Operator & Maintenance Manual
Model: D65E_P-12
Serial: 60001 and up
Number of Page: 221
KOMATSU BULLDOZER D65E,P-12 D65EX,PX-12 OPERATOR & MAINTENANCE MANUAL SN 60001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Bulldozer D65E,P-12 D65EX,PX-12 Operator & Maintenance Manual
FOREWORD:
- This manual provides rules and guidelines which will help you use this machine safely and effectively. Keep this manual handy and have all personnel read it periodically. if this manual has been lost or has become dirty and can not be read, request a replacement manual from Komatsu or your Komatsu distributor.
- If you sell the machine, be sure to give this manual to the new owners. Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this manual.
- Consult Komatsu or your Komatsu distributor for the latest available information of your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult Komatsu or your Komatsu distributor for those items you may require.
TABLE OF CONTENTS:
Komatsu Bulldozer D65E,P-12 D65EX,PX-12 Operator & Maintenance Manual
MAIN MENU........................................................................................................................... 0 COVER PAGE.......................................................................................................................... 1 1. FOREWORD ........................................................................................................................ 2 2. SAFETY INFORMATION .............................................................................................................. 3 3. INTRODUCTION .................................................................................................................... 4 3.1 INTENDED USE ............................................................................................................... 4 3.2 FEATURES ................................................................................................................... 4 3.3 BREAKING IN THE MACHINE .................................................................................................... 4 4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR ................................................................... 5 4.1 MACHINE SERIAL NO. PLATE POSITION .......................................................................................... 5 4.2 ENGINE SERIAL NO. PLATE POSITION ........................................................................................... 5 4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR .................................................................................. 5 5. CONTENTS ........................................................................................................................ 6 SAFETY.............................................................................................................................. 9 6. GENERAL PRECAUTIONS ......................................................................................................... 10 7. PRECAUTIONS DURING OPERATION ................................................................................................ 17 7.1 BEFORE STARTING ENGINE ................................................................................................. 17 7.2 OPERATING MACHINE ...................................................................................................... 19 7.3 TRANSPORTATION ......................................................................................................... 22 7.4 BATTERY ................................................................................................................ 23 7.5 TOWING ................................................................................................................. 24 8. PRECAUTIONS FOR MAINTENANCE ................................................................................................. 25 8.1 BEFORE CARRYING OUT MAINTENANCE ........................................................................................ 25 8.2 DURING MAINTENANCE ..................................................................................................... 27 9. POSITION FOR ATTACHING SAFETY LABELS ........................................................................................ 32 OPERATION........................................................................................................................... 35 10. GENERAL VIEW ............................................................................................................... 36 10.1 GENERAL VIEW OF MACHINE ............................................................................................... 36 10.2 GENERAL VIEW OF CONTROLS AND GAUGES ................................................................................... 37 11. EXPLANATION OF COMPONENTS .................................................................................................. 40 11.1 FRONT PANEL (METERS, LAMPS, SWITCHES) ................................................................................. 41 11.1.1 MONITOR PANEL.................................................................................................... 41 11.2 SWITCHES .............................................................................................................. 54 11.3 CONTROL LEVERS AND PEDALS ............................................................................................. 56 11.4 FUSE BOX .............................................................................................................. 63 11.5 GREASE PUMP HOLDER .................................................................................................... 64 11.6 SHOVEL HOLDER ......................................................................................................... 64 11.7 DOOR-OPEN LOCK (MACHINES EQUIPPED WITH CAB) ........................................................................... 64 11.8 SASH GLASS INTERMEDIATE LOCK (MACHINES EQUIPPED WITH CAB) ............................................................. 65 11.9 CAP WITH LOCK ......................................................................................................... 65 11.10 HOT AND COOL BOX (MACHINES EQUIPPED WITH CAB) ........................................................................ 66 11.11 DOOR POCKET (MACHINES EQUIPPED WITH CAB) ............................................................................. 66 11.12 ASHTRAY (MACHINES EQUIPPED WITH CAB) ................................................................................. 66 11.13 TOOL BOX ............................................................................................................. 66 11.14 USING CAR RADIO (MACHINES EQUIPPED WITH CAB, CAR RADIO) .............................................................. 67 11.14.1 EXPLANATION OF PARTS............................................................................................ 67 11.15 USING CAR STEREO (MACHINES EQUIPPED WITH CAB, CAR STEREO) ............................................................ 71 11.15.1 EXPLANATION OF PARTS............................................................................................ 71 11.15.2 LISTENING THE RADIO (AM/FM)..................................................................................... 74 11.15.3 LISTENING TO CASSETTE TAPE...................................................................................... 75 11.15.4 PRECAUTIONS WHEN USING.......................................................................................... 75 11.15.5 SPECIFICATIONS.................................................................................................. 76 11.16 HANDLING AIR CONDITIONER (MACHINES EQUIPPED WITH CAB) ................................................................ 77 11.16.1 COOLING OPERATION............................................................................................... 77 11.16.2 HEATING OPERATION............................................................................................... 78 11.16.3 PRECAUTIONS WHEN USING AIR CONDITIONER.......................................................................... 79 11.16.4 INSPECTION DURING OFF-SEASON.................................................................................... 80 11.16.5 PROCEDURE FOR REPLACING RECEIVER................................................................................ 80 11.16.6 CLEANING AIR FILTER............................................................................................. 80 11.17 HANDLING HEATER (MACHINES EQUIPPED WITH CAB) ......................................................................... 81 11.17.1 METHOD OF OPERATION............................................................................................. 81 11.17.2 CLEANING AIR FILTER............................................................................................. 81 12. OPERATION .................................................................................................................. 82 12.1 CHECKS BEFORE STARTING ENGINE ......................................................................................... 82 12.1.1 WALK-AROUND CHECK................................................................................................ 82 12.1.2 CHECK BEFORE STARTING............................................................................................ 84 12.1.3 ADJUST OPERATOR’S SEAT........................................................................................... 89 12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE..................................................................... 90 12.2 STARTING ENGINE ....................................................................................................... 92 12.2.1 NORMAL STARTING.................................................................................................. 92 12.2.2 STARTING IN COLD WEATHER (MONITOR PANEL SPECIFICATION)........................................................... 93 12.2.3 STARTING IN COLD WEATHER (GUAGE PANEL SPECIFICATION)............................................................. 96 12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE ........................................................................... 98 12.3.1 NORMAL OPERATION ................................................................................................ 98 12.3.2 WHEN STARTING IN COLD WEATHER.................................................................................... 99 12.4 MOVING MACHINE ........................................................................................................100 12.5 SHIFTING GEAR .........................................................................................................101 12.6 SHIFTING BETWEEN FORWARD AND REVERSE ..................................................................................102 12.7 STEERING MACHINE ......................................................................................................103 12.7.1 NORMAL TURNING (D65E, P) ........................................................................................103 12.7.2 TURNING WHILE DESCENDING A SLOPE (D65E, P) ......................................................................104 12.7.3 NORMAL TURNING (D65EX, PX) ......................................................................................105 12.7.4 TURNING WHILE DESCENDING A SLOPE (D65EX, PX) ....................................................................106 12.8 STOPPING MACHINE ......................................................................................................107 12.9 PRECAUTIONS FOR OPERATION .............................................................................................108 12.9.1 METHOD OF USING STEERING CLUTCH (D65E, P ONLY) ..................................................................108 12.9.2 PERMISSIBLE WATER DEPTH .........................................................................................108 12.9.3 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS .....................................................................108 12.9.4 PRECAUTIONS ON SLOPES ...........................................................................................108 12.9.5 IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS (MACHINES EQUIPPED WITH CAB) ...........................109 12.9.6 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW (MACHINES EQUIPPED WITH CAB) ....109 12.9.7 PRECAUTIONS REGARDING BLIND SPOTS CAUSED BY CAB STAYS ...........................................................109 12.10 WORK POSSIBLE USING BULLDOZER ........................................................................................110 12.10.1 DOZING .........................................................................................................110 12.10.2 SMOOTHING ......................................................................................................110 12.10.3 CUTTING INTO HARD OR FROZEN GROUND OR DITCHING..................................................................110 12.10.4 FELLING TREES, REMOVING STUMPS..................................................................................110 12.11 ADJUSTING POSTURE OF WORK EQUIPMENT ..................................................................................111 12.11.1 METHOD OF ANGLING BLADE (ANGLEDOZER ONLY) ......................................................................111 12.11.2 ADJUSTING AMOUNT OF TILT (ANGLEDOZER ONLY) .....................................................................112 12.11.3 ADJUST ANGLE OF BLADE EDGE .....................................................................................113 12.12 PARKING MACHINE ......................................................................................................114 12.13 CHECK AFTER FINISHING WORK ...........................................................................................115 12.14 STOPPING ENGINE ......................................................................................................116 12.15 CHECK AFTER STOPPING ENGINE ..........................................................................................117 12.16 LOCKING ..............................................................................................................117 12.17 TIPS FOR LONGER UNDERCARRIAGE LIFE ...................................................................................118 12.17.1 OPERATION METHOD ...............................................................................................118 12.17.2 INSPECTION AND ADJUSTMENT ......................................................................................119 12.17.3 INSPECTION AND REPAIR ..........................................................................................119 13. TRANSPORTATION .............................................................................................................121 13.1 LOADING, UNLOADING WORK ...............................................................................................121 13.2 PRECAUTIONS FOR LOADING ...............................................................................................122 13.3 PRECAUTIONS FOR TRANSPORTATION ........................................................................................122 13.4 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT ..............................................................................123 13.5 REMOVING CAB (MACHINES EQUIPPED WITH CAB) .............................................................................123 14. COLD WEATHER OPERATION .....................................................................................................124 14.1 PRECAUTIONS FOR LOW TEMPERATURE .......................................................................................124 14.1.1 FUEL AND LUBRICANTS .............................................................................................124 14.1.2 COOLANT .........................................................................................................124 14.1.3 BATTERY .........................................................................................................125 14.2 AFTER COMPLETION OF WORK ..............................................................................................126 14.3 AFTER COLD WEATHER ....................................................................................................126 15. LONG-TERM STORAGE (MORE THAN ONE MONTH) ....................................................................................127 15.1 BEFORE STORAGE ........................................................................................................127 15.2 DURING STORAGE ........................................................................................................127 15.3 AFTER STORAGE .........................................................................................................128 16. TROUBLESHOOTING ............................................................................................................129 16.1 AFTER RUNNING OUT OF FUEL .............................................................................................129 16.2 IF BATTERY IS DISCHARGED ..............................................................................................129 16.2.1 STARTING ENGINE WITH BOOSTER CABLE ..............................................................................129 16.3 OTHER TROUBLE .........................................................................................................132 16.3.1 ELECTRICAL SYSTEM ...............................................................................................132 16.3.2 CHASSIS .........................................................................................................134 MAINTENANCE.........................................................................................................................136 17. GUIDES TO MAINTENANCE ......................................................................................................137 18. OUTLINES OF SERVICE ........................................................................................................140 18.1 OUTLINE OF OIL, FUEL, COOLANT .........................................................................................140 18.1.1 OIL..............................................................................................................140 18.1.2 FUEL ............................................................................................................141 18.1.3 COOLANT .........................................................................................................141 18.1.4 GREASE ..........................................................................................................142 18.1.5 STORING OIL AND FUEL ............................................................................................142 18.1.6 FILTERS .........................................................................................................142 18.2 RELATING TO ELECTRIC SYSTEM ...........................................................................................143 19. WEAR PARTS LIST ............................................................................................................144 20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE .......................................................145 21. STANDARD TIGHTENING TORQUES FOR BOLTS AND BOLTS.............................................................................149 21.1 INTRODUCTION OF NECESSARY TOOLS .......................................................................................149 21.2 TORQUE LIST ...........................................................................................................150 22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ..............................................................................151 23. MAINTENANCE SCHEDULE CHART .................................................................................................155 23.1 MAINTENANCE SCHEDULE CHART ............................................................................................155 24. SERVICE PROCEDURE ..........................................................................................................158 24.1 WHEN REQUIRED .........................................................................................................158 24.1.1 CLEAN INSIDE OF COOLING SYSTEM ..................................................................................158 24.1.2 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT ....................................................................162 24.1.3 CHECK TRACK TENSION .............................................................................................164 24.1.4 CHECK AND TIGHTEN TRACK SHOE BOLTS .............................................................................166 24.1.5 CHECK ELECTRICAL INTAKE AIR HEATER ..............................................................................166 24.1.6 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES ..............................................................167 24.1.7 CLEAN, CHECK RADIATOR FINS ......................................................................................169 24.1.8 ADJUST IDLER CLEARANCE ..........................................................................................170 24.1.9 ADJUSTING TENSION OF CENTER BRACE (POWER TILT DOZER ONLY) (POWER TILT, POWER PITCH DOZER ONLY) ..................171 24.1.10 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (MACHINES EQUIPPED WITH CAB) ............................172 24.1.11 CHECK, ADJUST AIR CONDITIONER (MACHINES EQUIPPED WITH CAB) .....................................................173 24.1.12 GREASE DOOR HINGE (MACHINES EQUIPPED WITH CAB)..................................................................173 24.1.13 CHECK DOOR LOCK STRIKER (MACHINES EQUIPPED WITH CAB) ...........................................................174 24.1.14 REPLACE DOOR DAMPER (MACHINES EQUIPPED WITH CAB) ...............................................................174 24.1.15 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (MACHINES EQUIPPED WITH CAB) ........................................174 24.1.16 BLEED AIR FROM HEAD END OF RIGHT PITCH CYLINDER (POWER TILT, POWER PITCH DOZER ONLY) ...........................174 24.1.17 REPLACE WIPER BLADE (MACHINES EQUIPPED WITH CAB) ...............................................................175 24.1.18 CHECK IDLER OIL LEVEL, ADD OIL .................................................................................176 24.2 CHECK BEFORE STARTING .................................................................................................177 24.2.1 CHECK COOLANT LEVEL, ADD WATER ..................................................................................177 24.2.2 CHECKING WITH MACHINE MONITOR (MONITOR PANEL SPECIFICATION) .....................................................177 24.2.3 CHECK FUEL LEVEL, ADD FUEL (MONITOR PANEL SPECIFICATION) ........................................................178 24.2.4 CHECK FUEL LEVEL, ADD FUEL (GAUGE PANEL SPECIFICATION) .........................................................178 24.2.5 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL .....................................................................179 24.2.6 CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL ....................................................................180 24.2.7 CHECK BRAKE PEDAL TRAVEL ........................................................................................180 24.2.8 CHECK DUST INDICATOR ............................................................................................180 24.2.9 CHECK THAT LAMPS LIGHT UP .......................................................................................181 24.2.10 CHECK HORN SOUND ...............................................................................................181 24.2.11 CHECK BACKUP ALARM SOUND .......................................................................................181 24.2.12 CHECK SEAT BELT FOR WEAR OR DAMAGE .............................................................................181 24.2.13 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER ...................................................181 24.3 EVERY 50 HOURS SERVICE ................................................................................................182 24.3.1 DRAIN WATER, SEDIMENT FROM FUEL TANK ............................................................................182 24.4 EVERY 250 HOURS SERVICE ...............................................................................................183 24.4.1 LUBRICATING .....................................................................................................183 24.4.2 GREASE EQUALIZER BAR SIDE PIN (LEFT AND RIGHT, 2 PLACES EACH: TOTAL 4 PLACES) ...................................186 24.4.3 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ....................................................................186 24.4.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL ......................................................................187 24.4.5 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (D60P, 65EX, PX ONLY) .........................188 24.4.6 CHECK LEVEL OF BATTERY ELECTROLYTE ..............................................................................190 24.4.7 CHECK FAN BELT TENSION, ADJUST ..................................................................................191 24.4.8 DRAIN WATER AND SEDIMENT FROM FUEL FILTER .......................................................................192 24.4.9 CHECK, CLEAN ADDITIONAL FUEL STRAlliER ..........................................................................192 24.4.10 REPLACE POWER TRAIN OIL FILTER ELEMENT .........................................................................193 24.4.11 BRAKE CAPACITY CHECK ...........................................................................................194 24.5 EVERY 500 HOURS SERVICE ...............................................................................................195 24.5.1 REPLACE FUEL FILTER CARTRIDGE....................................................................................195 24.5.2 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (D65E ONLY) ...................................197 24.6 EVERY 1000 HOURS SERVICE ..............................................................................................199 24.6.1 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER, SCAVENGING PUMP STRAINER) ................199 24.6.2 CHANGE OIL IN FINAL DRIVE CASE ..................................................................................201 24.6.3 CLEAN BREATHER ..................................................................................................202 24.6.4 GREASE UNIVERSAL JOINT ..........................................................................................202 24.6.5 REPLACE CORROSION RESISTOR CARTRIDGE (D65P, D65EX, PX ONLY) .....................................................203 24.6.6 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER (D65P, D65EX, PX ONLY) ...............................................203 24.6.7 CHECK PLAY OF TURBOCHARGER ROTOR (D65P, D65EX, PX ONLY) ........................................................203 24.6.8 CHECK FOR LOOSE ROPS MOUNT BOLTS ................................................................................203 24.7 EVERY 2000 HOURS SERVICE ..............................................................................................204 24.7.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT ..............................................204 24.7.2 CLEAN, CHECK TURBOCHARGER (D65P, D65EX, PX ONLY) ................................................................206 24.7.3 CLEAN ENGINE BREATHER ELEMENT....................................................................................206 24.7.4 CHECK VIBRATION DAMPER ..........................................................................................206 24.7.5 CHECK ALTERNATOR, STARTING MOTOR ................................................................................206 24.7.6 CHECK ENGINE VALVE CLEARANCE, ADJUST ............................................................................206 24.8 EVERY 4000 HOURS SERVICE ..............................................................................................207 24.8.1 CHECK WATER PUMP ................................................................................................207 SPECIFICATIONS......................................................................................................................208 25. SPECIFICATIONS .............................................................................................................209 OPTIONS, ATTACHMENTS................................................................................................................214 26. GENERAL PRECAUTIONS ........................................................................................................215 26.1 PRECAUTIONS RELATED TO SAFETY .........................................................................................215 27. USING SEAT BELT ............................................................................................................216 27.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER .................................................................216 27.2 ADJUST THE BELT LENGTH IN THE FOLLOWING MANNER ........................................................................217 27.2.1 TO SHORTEN THE BELT .............................................................................................217 27.2.2 TO LENGTHEN THE BELT ............................................................................................217 28. HANDLING DELUXE SEAT .......................................................................................................218 29. HANDLING ACCUMULATOR .......................................................................................................220 29.1 METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR ................................220
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