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KOMATSU D65EX-12 D65PX-12 BULLDOZER OPERATION & MAINTENANCE MANUAL (SEAM007207T) – PDF DOWNLOAD
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- KOMATSU D65EX-12 D65PX-12 BULLDOZER OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:SEAM007207T
- SERIAL NUMBER:
D65EX-63403 and Up
D65PX-63304 and Up
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Description
KOMATSU D65EX-12 D65PX-12 BULLDOZER OPERATION & MAINTENANCE MANUAL (SEAM007207T)
KOMATSU D65EX-12 D65PX-12 BULLDOZER OPERATION & MAINTENANCE MANUAL (SEAM007207T) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D65EX-12 D65PX-12 BULLDOZER OPERATION & MAINTENANCE MANUAL (SEAM007207T)
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
KOMATSU D65EX-12 D65PX-12 BULLDOZER OPERATION & MAINTENANCE MANUAL (SEAM007207T)
COVER........................................................................................................ 1 FOREWORD..................................................................................................... 2 FOREWORD................................................................................................. 3 SAFETY INFORMATION....................................................................................... 7 INTRODUCTION............................................................................................. 9 FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHINE.......................................................... 9 NECESSARY INFORMATION.................................................................................... 10 MACHINE SERIAL NO. PLATE AND POSITION................................................................ 10 ENGINE SERIAL NO. PLATE AND POSITION................................................................. 10 POSITION OF SERVICE METER............................................................................ 11 TABLE OF ENTER SERIAL NO.AND DISTRIBUTORN............................................................ 11 CONTENTS..................................................................................................... 12 SAFETY....................................................................................................... 15 SAFETY................................................................................................... 16 SAFETY LABELS............................................................................................ 18 POSITIONS OF SAFETY PICTOGRAMS....................................................................... 19 SAFETY LABLES........................................................................................ 20 GENERAL PRECAUTIONS...................................................................................... 23 SAFETY RULES......................................................................................... 23 IF ABNORMALITIES ARE FOUND........................................................................... 23 CLOTHING AND PERSONAL PROTECTIVE ITEMS............................................................... 23 FIRE EXTINGUISHER AND FIRST AID KIT.................................................................. 23 SAFETY FEATURES...................................................................................... 23 KEEP MACHINE CLEAN................................................................................... 24 INSIDE OPERATOR'S COMPARTMENT........................................................................ 24 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT....................................................... 24 HANDRAILS AND STEPS.................................................................................. 25 MOUNTING AND DISMOUNTING............................................................................. 25 NO PEOPLE ON ATTACHMENTS............................................................................. 25 CRUSHING OR CUTTING PREVENTION....................................................................... 25 PREVENTION OF BURNS.................................................................................. 26 FIRE PREVENTION...................................................................................... 26 ACTION IF FIRE OCCURS................................................................................ 27 WINDOW WASHER LIQUID................................................................................. 27 PRECAUTIONS WHEN USING ROPS.......................................................................... 27 PRECAUTIONS FOR ATTACHMENTS.......................................................................... 27 UNAUTHORIZED MODIFICATION............................................................................ 28 SAFETY AT WORKSITE................................................................................... 28 WORKING ON LOOSE GROUND.............................................................................. 28 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES............................................................... 28 ENSURE GOOD VISIBILITY............................................................................... 29 VENTILATION FOR ENCLOSED AREAS....................................................................... 29 CHECKING SIGNALMAN'S SIGNALS AND SIGNS............................................................... 29 BE CAREFUL ABOUT ASBESTOS DUST....................................................................... 30 PRECAUTIONS FOR OPERATION................................................................................ 31 BEFORE STARTING ENGINE............................................................................... 31 CHECKS BEFORE STARTING ENGINE.................................................................... 31 PRECAUTIONS WHEN STARTING........................................................................ 31 PRECAUTIONS IN COLD AREAS........................................................................ 31 AFTER STARTING ENGINE................................................................................ 33 CHECKS AFTER STARTING ENGINE..................................................................... 33 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE............................................. 33 PRECAUTIONS WHEN TRAVELING....................................................................... 34 TRAVELING ON SLOPES.............................................................................. 35 PROHIBITED OPERATIONS............................................................................ 35 USING BRAKES..................................................................................... 35 OPERATE CAREFULLY ON SNOW........................................................................ 35 PARKING MACHINE.................................................................................. 36 TRANSPORTATION....................................................................................... 37 LOADING AND UNLOADING............................................................................ 37 SHIPPING......................................................................................... 37 BATTERY.............................................................................................. 38 BATTERY HAZARD PREVENTION........................................................................ 38 STARTING WITH BOOSTER CABLE...................................................................... 39 TOWING............................................................................................... 40 WHEN TOWING...................................................................................... 40 PRECAUTIONS FOR MAINTENANCE.............................................................................. 41 WARNING TAG.......................................................................................... 41 KEEP WORK PLACE CLEAN AND TIDY....................................................................... 41 APPOINT LEADER WHEN WORKING WITH OTHERS.............................................................. 41 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE........................................... 41 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING................................................... 42 PROPER TOOLS......................................................................................... 43 ACCUMULATOR.......................................................................................... 43 NO UNAUTHORIZED PERSONNEL INTO AREA.................................................................. 43 ATTACHMENTS.......................................................................................... 43 WORK UNDER THE MACHINE............................................................................... 44 NOISE................................................................................................ 44 PRECAUTIONS WHEN USING HAMMER........................................................................ 44 REPAIR WELDING....................................................................................... 44 REMOVING BATTERY TERMINAL............................................................................ 44 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION.................................. 45 DO NOT DISASSEMBLE RECOIL SPRING..................................................................... 45 PRECAUTION WITH HIGH-PRESSURE OIL.................................................................... 45 HANDLING HIGH-PRESSURE HOSES......................................................................... 46 WASTE MATERIAL....................................................................................... 46 MAINTENANCE FOR AIR CONDITIONER...................................................................... 46 COMPRESSED AIR....................................................................................... 46 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS........................................................ 46 OPERATION.................................................................................................... 47 GENERAL VIEW............................................................................................. 48 GENERAL VIEW OF MACHINE.............................................................................. 48 GENERAL VIEW OF CONTROLS AND GAUGES.................................................................. 49 EXPLANATION OF COMPONENTS................................................................................ 52 MONITOR PANEL........................................................................................ 52 SWITCHES............................................................................................. 58 LAMP................................................................................................. 64 CONTROL LEVERS AND PEDALS............................................................................ 65 FUSE................................................................................................. 73 ELECTRIC POWER TAKE-OUT ADAPTER...................................................................... 74 GREASE PUMP HOLDER................................................................................... 75 SHOVEL HOLDER........................................................................................ 75 DOOR-OPEN LOCK....................................................................................... 76 SASH GLASS INTERMEDIATE LOCK......................................................................... 76 CAP,COVER WITH LOCK.................................................................................. 77 HOT AND COOL BOX..................................................................................... 78 DOOR POCKET.......................................................................................... 79 ASHTRAY.............................................................................................. 79 TOOL BOX............................................................................................. 79 CAR RADIO,HANDLING................................................................................... 80 AIR CONDITIONER,HANDLING............................................................................. 85 HANDLING HEATER...................................................................................... 91 OPERATION................................................................................................ 94 CHECK BEFORE STARTING ENGINE,ADJUST.................................................................. 94 STARTING ENGINE......................................................................................113 OPERATIONS AND CHECKS AFTER STARTING ENGINE..........................................................121 STOPPING ENGINE......................................................................................125 CHECK AFTER STOPPING ENGINE..........................................................................126 MACHINE OPERATION....................................................................................127 SHIFTING GEAR........................................................................................131 SHIFTING BETWEEN FORWARD AND REVERSE.................................................................132 STEERING MACHINE.....................................................................................134 PRECAUTIONS FOR OPERATION............................................................................138 WORK POSSIBLE USING BULLDOZER........................................................................140 ADJUSTING POSTURE OF WORK EQUIPMENT..................................................................142 PARKING MACHINE......................................................................................146 CHECK AFTER FINISHING WORK...........................................................................148 LOCKING..............................................................................................148 TIPS FOR LONGER UNDERCARRIAGE LIFE...................................................................149 TRANSPORTATION...........................................................................................152 TRANSPORTATION MEANS.................................................................................152 REMOVING CAB.........................................................................................152 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT.............................................................153 LOADING,UNLOADING WORK...............................................................................154 LIFTING MACHINE......................................................................................157 COLD WEATHER OPERATION...................................................................................159 PRECAUTIONS FOR LOW TEMPERATURE......................................................................159 AFTER COMPLETION OF WORK.............................................................................161 AFTER COLD WEATHER...................................................................................161 LONG-TERM STORAGE........................................................................................162 BEFORE STORAGE.......................................................................................162 DURING STORAGE.......................................................................................162 AFTER STORAGE........................................................................................162 STARTING MACHINE AFTER LONG-TERM STORAGE.............................................................162 TROUBLESHOOTING..........................................................................................163 AFTER RUNNING OUT OF FUEL............................................................................163 MACHINE TOWING METHOD................................................................................163 IF BATTERY IS DISCHARGED.............................................................................164 OTHER TROUBLE........................................................................................168 MAINTENANCE..................................................................................................173 GUIDE TO MAINTENANCE.....................................................................................174 OUTLINE OF SERVICE.......................................................................................176 OUTLINE OF OIL,FUEL,COOLANT..........................................................................176 RELATING TO ELECTRIC SYSTEM..........................................................................178 WEAR PARTS LIST..........................................................................................179 WEAR PARTS LIST......................................................................................179 USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE......................................181 PROPER SELECTION OF FUEL,COOLANT AND LUBRICANTS......................................................181 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...........................................................186 TORQUE LIST..........................................................................................186 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................................187 SAFETY CRITICAL PARTS................................................................................188 MAINTENANCE SCHEDULE CHART...............................................................................189 MAINTENANCE SCHEDULE CHART...........................................................................189 SERVICE PROCEDURE........................................................................................191 WHEN REQUIRED........................................................................................191 CHECK,CLEAN AND REPLACE AIR CLEANER ELEMNET......................................................191 CLEAN INSIDE OF COOLING SYSTEM...................................................................194 CHECK TRACK TENSION..............................................................................196 CHECK AND TIGHTEN TRACK SHOE BOLTS...............................................................198 CHECK ELECTRICAL INTAKE AIR HEATER...............................................................198 REVERSE AND REPLACE END BITS AND CUTTING EDGES...................................................199 CLEAN,CHECK RADIATOR FINS........................................................................201 ADJUST IDLER CLEARANCE...........................................................................201 ADJUSTING TENSION OF CENTER BRACE................................................................202 CHECK,ADJUST AIR CONDITIONER.....................................................................203 GREASE DOOR HINGE................................................................................204 CHECK DOOR LOCK STRIKER..........................................................................204 REPLACE DOOR DAMPER..............................................................................204 CHECK WINDOW WASHER FLUID LEVEL,ADD FLUID........................................................205 REPLACE WIPER BLADE..............................................................................205 CHECK IDLER OIL LEVEL,ADD OIL....................................................................207 CHECK OIL LEVEL IN DAMPER CASE,ADD AND CHANGE OIL................................................208 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM...................................................210 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM....................................211 CHECK BEFORE STARTING................................................................................212 EVERY 50 HOURS SERVICE...............................................................................213 DRAIN WATER,SEDIMENT FROM FUEL TANK..............................................................213 EVERY 250 HOURS SERVICE..............................................................................214 LUBRICATING......................................................................................214 GREASE EQUALIZER BAR SIDE PIN....................................................................216 GREASE EQUALIZER BAR CENTER PIN..................................................................216 CHECK OIL LEVEL IN FINAL DRIVE CASE,ADD OIL......................................................216 CHECK OIL LEVEL IN HYDRAULIC TANK,ADD OIL........................................................217 CHECK LEVEL OF BATTERY ELECTROLYTE...............................................................218 CHECK FAN BELT TENSION,ADJUST....................................................................219 CHECK,CLEAN FUEL STRAINER........................................................................220 REPLACE POWER TRAIN OIL FILTER ELEMENT...........................................................220 CHECK BRAKE PERFORMANCE..........................................................................222 CLEAN AIR CONDITIONER AIR FILTER(FRESH/RECIRC FILTER)............................................223 EVERY 500 HOURS SERVICE..............................................................................224 REPLACE FUEL FILTER CARTRIDGE....................................................................224 CHANGE OIL IN ENGINE OIL PAN,REPLACE ENGINE OIL FILTER CARTRIDGE.................................226 EVERY 1000 HOURS SERVICE.............................................................................227 CHANGE OIL IN POWER TRAIN CASE,CLEAN STRAINERS(POWER TRAIN STRAINER,SCAVENGING PUMP STRAINER)....227 CHANGE OIL IN FIANL DRIVE CASE...................................................................229 CLEAN BREATHER...................................................................................229 GREASE UNIVERSAL JOINT...........................................................................230 REPLACE CORROSION RESISTOR CARTRIDGE.............................................................231 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER.......................................................231 CHECK PLAY OF TURBOCHARGER ROTOR.................................................................231 CHECK FOR LOOSE ROPS MOUNT BOLTS.................................................................231 EVERY 2000 HOURS SERVICE.............................................................................232 CHANGE OIL IN HYDRAULIC TANK,REPLACE HYDRAULIC OIL FILTER ELEMENT................................232 CLEAN,CHECK TURBOCHARGER.........................................................................234 CLEAN ENGINE BREATHER ELEMENT....................................................................234 CHECK VIBRATION DAMPER...........................................................................234 CHECK ALTERNATOR,STARTING MOTOR..................................................................235 CHECK ENGINE VALVE CLEARANCE,ADJUST..............................................................235 EVERY 4000 HOURS SERVICE.............................................................................236 CHECK WATER PUMP.................................................................................236 SPECIFICATIONS...............................................................................................237 SPECIFICATIONS...........................................................................................238 ATTACHMENTS,OPTIONS..........................................................................................239 GENERAL PRECAUTIONS......................................................................................240 PRECAUTIONS RELATED TO SAFETY........................................................................240 SUSPENSION SEAT..........................................................................................241 HEADREST.................................................................................................242 HANDLING ACCUMULATOR.....................................................................................243 METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR...............243 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT............................................................244 INDEX........................................................................................................245
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