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Komatsu D65EX-15E0 D65PX-15E0 BullDozer Operation & Maintenance Manual – PDF Download
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- Komatsu D65EX-15E0 D65PX-15E0 BullDozer Operation & Maintenance Manual
- SERIAL NUMBER
D65EX-15E0 – 69001 and up
D65PX-15E0 – 69001 and up - EEAM024400
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Description
Komatsu D65EX-15E0 D65PX-15E0 BullDozer Operation & Maintenance Manual
Description:
Komatsu D65EX-15E0 D65PX-15E0 BullDozer Operation & Maintenance Manual
This manual gives details of the operation and methods of inspection and maintenance for this machine that must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of machines. Read, understand and follow all precautions and warnings in this manual and on the machine before performing operation and maintenance. Failure to do so may result in serious injury or death. Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used. Therefore, the safety messages in this manual and on the machine may not include all possible safety precautions. If you carry out any operation, inspection, or maintenance under conditions that are not described in this manual, understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should you or others engage in the prohibited uses or actions described in this manual. Improper operation and maintenance of the machine can be hazardous and could result in serious injury or death.
Table Of Contents:
Komatsu D65EX-15E0 D65PX-15E0 BullDozer Operation & Maintenance Manual
FOREWORD............................................................................................................. 3 BEFORE READING THIS MANUAL....................................................................................... 4 IMPORTANT SAFETY INFORMATION..................................................................................... 6 Noise emission levels........................................................................................ 7 Vibration levels............................................................................................. 7 Guide to Reduce Vibration Levels on Machine.............................................................. 8 INTENDED USE..................................................................................................... 10 USE OF MACHINE............................................................................................... 10 GENERAL VIEW AND DIRECTIONS OF MACHINE....................................................................... 10 VISIBILITY FROM OPERATOR'S SEAT.............................................................................. 11 PROXIMITY VISIBILITY..................................................................................... 11 12M CIRCUMFERENCE VISIBILITY............................................................................. 11 BREAKING-IN THE NEW MACHINE.................................................................................. 12 LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................... 13 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE................................................. 13 ENGINE SERIAL NO. PLATE POSITION............................................................................. 13 ADDITIONAL EPA NAMEPLATE..................................................................................... 14 SERVICE METER POSITION....................................................................................... 14 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................................... 15 MACHINE SERIAL NUMBER PLATE.................................................................................. 16 FOREWORD..................................................................................................... 17 SAFETY....................................................................................................... 17 OPERATION.................................................................................................... 17 MAINTENANCE.................................................................................................. 20 SPECIFICATIONS............................................................................................... 22 ATTACHMENTS, OPTIONS......................................................................................... 22 INDEX........................................................................................................ 23 COLOPHON..................................................................................................... 23 SAFETY............................................................................................................... 25 IMPORTANT SAFETY INFORMATION..................................................................................... 26 SAFETY LABELS.................................................................................................... 28 POSITION FOR ATTACHING SAFETY LABELS......................................................................... 29 SAFETY LABELS................................................................................................ 29 PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.................................................................. 34 PRECAUTIONS DURING OPERATION..................................................................................... 41 PRECAUTIONS FOR MAINTENANCE...................................................................................... 47 PRECAUTIONS FOR MACHINE.......................................................................................... 53 OPERATION............................................................................................................ 55 GENERAL VIEW..................................................................................................... 56 GENERAL VIEW OF MACHINE...................................................................................... 56 GENERAL VIEW OF CONTROLS AND GAUGES.......................................................................... 57 EXPLANATION OF COMPONENTS........................................................................................ 60 FRONT PANEL.................................................................................................. 60 CHECK MONITOR SYSTEM..................................................................................... 61 EMERGENCY CAUTION ITEMS.................................................................................. 62 CAUTION ITEMS............................................................................................ 64 METER GROUP.............................................................................................. 66 LAMPS.................................................................................................... 70 SWITCHES................................................................................................. 72 METHOD OF USING MAINTENANCE MODE......................................................................... 76 SWITCHES..................................................................................................... 83 CONTROL LEVERS AND PEDALS.................................................................................... 87 CIRCUIT BREAKER.............................................................................................. 95 FUSE......................................................................................................... 95 FUSIBLE LINK................................................................................................. 97 ELECTRIC POWER TAKE-OUT ADAPTER.............................................................................. 97 MACHINE EQUIPPED WITH CAB................................................................................ 97 MACHINE EQUIPPED WITH ROPS CANOPY........................................................................ 98 DOOR - OPEN LOCK............................................................................................. 98 SASH GLASS INTERMEDIATE LOCK................................................................................. 99 DOOR POCKET.................................................................................................. 99 OPENING AND CLOSING ENGINE SIDE COVER........................................................................100 ASHTRAY......................................................................................................100 CUP HOLDER...................................................................................................101 TOOL BOX.....................................................................................................101 SHOVEL HOLDER................................................................................................101 AIR CONDITIONER, HANDLING....................................................................................102 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL..........................................................102 METHOD OF OPERATION......................................................................................104 PRECAUTIONS WHEN USING...................................................................................105 SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE.......................................105 INSPECTION DURING OFF-SEASON.............................................................................105 PROCEDURE FOR REPLACING RECEIVER.........................................................................105 CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL................................................106 CLEANING AIR FILTER......................................................................................106 OPERATION........................................................................................................107 CHECK BEFORE STARTING ENGINE, ADJUST.........................................................................107 WALK-AROUND CHECK........................................................................................107 CHECK BEFORE STARTING....................................................................................108 ADJUSTMENT...............................................................................................116 OPERATION AND CHECK BEFORE STARTING ENGINE...............................................................120 STARTING ENGINE..............................................................................................122 NORMAL STARTING..........................................................................................122 STARTING IN COLD WEATHER.................................................................................124 OPERATIONS AND CHECKS AFTER STARTING ENGINE..................................................................127 WARMING UP OPERATIONS....................................................................................127 STARTING IN COLD WEATHER.................................................................................128 STOPPING ENGINE..............................................................................................129 MACHINE OPERATION............................................................................................131 MOVING MACHINE...........................................................................................131 STOPPING MACHINE.........................................................................................133 SHIFTING GEARS...............................................................................................133 GEARSHIFTING OPERATION...................................................................................134 GEARSHIFTING OPERATION USING PRESET MODE FUNCTION........................................................134 AUTO DOWN SHIFT OPERATION................................................................................136 SHIFTING BETWEEN FORWARD AND REVERSE.........................................................................137 STEERING MACHINE.............................................................................................139 NORMAL TURNING...........................................................................................139 PRECAUTIONS FOR OPERATION....................................................................................140 PAY ATTENTION TO GAUGES..................................................................................140 PERMISSIBLE WATER DEPTH..................................................................................140 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS..............................................................140 PRECAUTIONS ON SLOPES....................................................................................141 METHOD OF USING BRAKES...................................................................................141 IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS.................................................141 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW..........................141 PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES............................................142 WORK POSSIBLE USING BULLDOZER................................................................................142 DOZING...................................................................................................142 SMOOTHING................................................................................................143 CUTTING INTO HARD OR FROZEN GROUND OR DITCHING...........................................................143 FELLING TREES, REMOVING STUMPS...........................................................................143 ADJUSTING POSTURE OF WORK EQUIPMENT..........................................................................144 ADJUST ANGLE OF BLADE EDGE...............................................................................144 ADJUSTING SHIMS IN ASSEMBLING WORK EQUIPMENT.............................................................145 ADJUSTING TENSION OF CENTER BRACE........................................................................145 ADJUST AMOUNT OF TILT....................................................................................146 METHOD OF ANGLING BLADE..................................................................................147 PARKING MACHINE..............................................................................................148 CHECK AFTER FINISHING WORK...................................................................................149 BEFORE STOPPING ENGINE...................................................................................149 AFTER STOPPING ENGINE....................................................................................149 LOCKING......................................................................................................150 TIPS FOR LONGER UNDERCARRIAGE LIFE...........................................................................150 OPERATION METHOD.........................................................................................150 INSPECTION AND ADJUSTMENT................................................................................151 INSPECTION AND REPAIR....................................................................................151 TRANSPORTATION...................................................................................................154 TRANSPORTATION MEANS.........................................................................................154 REMOVING CAB.................................................................................................154 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT.....................................................................154 PRECAUTIONS WHEN REMOVING ROPS...............................................................................155 LOADING, UNLOADING WORK......................................................................................156 LIFTING MACHINE..............................................................................................159 TRAVELING ON ROADS...........................................................................................161 COLD WEATHER OPERATION...........................................................................................162 PRECAUTIONS FOR LOW TEMPERATURE..............................................................................162 AFTER COMPLETION OF WORK.....................................................................................163 AFTER COLD WEATHER...........................................................................................163 LONG-TERM STORAGE................................................................................................164 BEFORE STORAGE...............................................................................................164 DURING STORAGE...............................................................................................164 AFTER STORAGE................................................................................................164 TROUBLESHOOTING..................................................................................................165 AFTER RUNNING OUT OF FUEL....................................................................................165 PROCEDURE FOR BLEEDING AIR...............................................................................165 METHOD OF TOWING MACHINE.....................................................................................166 IF BATTERY IS DISCHARGED.....................................................................................167 REMOVE AND INSTALL BATTERY...............................................................................168 PRECAUTIONS FOR BATTERY CHARGING.........................................................................168 STARTING ENGINE WITH BOOSTER CABLE.......................................................................169 OTHER TROUBLE................................................................................................171 ELECTRICAL SYSTEM........................................................................................171 MONITOR PANEL............................................................................................172 CHASSIS..................................................................................................173 ENGINE...................................................................................................175 MAINTENANCE..........................................................................................................179 GUIDE TO MAINTENANCE.............................................................................................180 OUTLINE OF SERVICE...............................................................................................183 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.......................................................183 OIL......................................................................................................183 FUEL.....................................................................................................184 COOLANT AND WATER FOR DILUTION...........................................................................184 GREASE...................................................................................................185 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)............................................................185 STORING OIL AND FUEL.....................................................................................186 FILTERS..................................................................................................186 RELATING TO ELECTRIC SYSTEM..................................................................................186 HANDLING HYDRAULIC SYSTEM....................................................................................187 WEAR PARTS LIST..................................................................................................188 WEAR PARTS LIST..............................................................................................188 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.........................................................................190 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........................................191 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL..........................193 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...................................................................194 TORQUE LIST..................................................................................................194 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................................195 SAFETY CRITICAL PARTS........................................................................................195 MAINTENANCE SCHEDULE CHART.......................................................................................197 MAINTENANCE SCHEDULE CHART...................................................................................197 WHEN REQUIRED............................................................................................197 CHECK BEFORE STARTING....................................................................................197 EVERY 50 HOURS SERVICE...................................................................................197 EVERY 250 HOURS SERVICE..................................................................................197 EVERY 500 HOURS SERVICE..................................................................................197 EVERY 1000 HOURS SERVICE.................................................................................197 EVERY 2000 HOURS SERVICE.................................................................................198 EVERY 4000 HOURS SERVICE.................................................................................198 EVERY 8000 HOURS SERVICE.................................................................................198 SERVICE PROCEDURE................................................................................................199 WHEN REQUIRED................................................................................................199 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.............................................................199 CLEAN INSIDE OF COOLING SYSTEM...........................................................................202 CHECK TRACK SHOE TENSION, ADJUST.........................................................................205 CHECK AND TIGHTEN TRACK SHOE BOLTS.......................................................................207 REVERSE AND REPLACE END BITS AND CUTTING EDGES...........................................................208 CLEANING AND INSPECTION OF FINS OF RADIATOR, OIL COOLER, CONDENSER AND AFTER-COOLER......................210 CHECK, ADJUST AIR CONDITIONER............................................................................213 GREASE DOOR HINGE........................................................................................214 CHECK DOOR LOCK STRIKER..................................................................................215 REPLACE DOOR DAMPER......................................................................................215 CHECK DOOR LATCH.........................................................................................215 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...............................................................216 REPLACE WIPER BLADE......................................................................................217 CHECK IDLER OIL LEVEL, ADD OIL...........................................................................218 ADJUST IDLER CLEARANCE...................................................................................218 LUBRICATING UNIVERSAL JOINT..............................................................................219 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM...........................................................220 CHECK BEFORE STARTING........................................................................................221 EVERY 50 HOURS SERVICE.......................................................................................221 DRAIN WATER, SEDIMENT FROM FUEL TANK.....................................................................221 EVERY 250 HOURS SERVICE......................................................................................222 LUBRICATING..............................................................................................222 GREASE EQUALIZER BAR SIDE PIN............................................................................223 GREASE EQUALIZER BAR CENTER PIN..........................................................................224 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.............................................................224 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................................225 CHECK LEVEL OF BATTERY ELECTROLYTE.......................................................................226 CHECK, CLEAN ADDITIONAL FUEL STRAINER....................................................................227 CHECK BRAKE PERFORMANCE..................................................................................228 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)...................................................229 EVERY 500 HOURS SERVICE......................................................................................230 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................................230 REPLACE POWER TRAIN OIL FILTER ELEMENT...................................................................232 REPLACE FUEL PRE-FILTER CARTRIDGE........................................................................232 EVERY 1000 HOURS SERVICE.....................................................................................235 REPLACE FUEL MAIN FILTER CARTRIDGE.......................................................................235 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER)....238 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL..................................................................240 CHANGE OIL IN FINAL DRIVE CASE...........................................................................241 CLEAN BREATHER...........................................................................................241 REPLACE CORROSION RESISTOR CARTRIDGE.....................................................................242 CHECK FOR LOOSE ROPS MOUNT BOLTS.........................................................................242 INSPECTION OF AFTER-COOLER CIRCUIT FOR LOOSENED BOLTS AND NUTS...........................................242 EVERY 2000 HOURS SERVICE.....................................................................................243 CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT.................................................243 REPLACE HYDRAULIC TANK BREATHER ELEMENT..................................................................244 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)............................244 CHANGE OIL IN DAMPER CASE................................................................................247 CHECK VIBRATION DAMPER...................................................................................248 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................248 EVERY 4000 HOURS SERVICE.....................................................................................249 REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)................................................................249 CHECK WATER PUMP.........................................................................................249 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......................................250 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......................................251 EVERY 8000 HOURS SERVICE.....................................................................................252 REPLACE HIGH-PRESSURE PIPING CLAMP.......................................................................252 REPLACE FUEL SPLAY PREVENTION CAPS.......................................................................252 SPECIFICATIONS.......................................................................................................253 SPECIFICATIONS...................................................................................................254 ATTACHMENTS, OPTIONS.................................................................................................255 GENERAL PRECAUTIONS..............................................................................................256 PRECAUTIONS RELATED TO SAFETY................................................................................256 HANDLING HYDRAULIC RIPPER........................................................................................257 GENERAL VIEW.................................................................................................257 EXPLANATION OF COMPONENTS....................................................................................258 OPERATION....................................................................................................259 CHECK BEFORE STARTING ENGINE, ADJUST.....................................................................259 PRECAUTIONS WHEN OPERATING...............................................................................259 ADJUSTING POSTURE OF WORK EQUIPMENT......................................................................259 TROUBLESHOOTING..............................................................................................261 OTHER TROUBLE............................................................................................261 MAINTENANCE..................................................................................................261 EVERY 250 HOURS SERVICE..................................................................................261 SPECIFICATIONS...............................................................................................262 AIR SUSPENSION SEAT..............................................................................................263 DELUXE SEAT......................................................................................................266 HEADREST.........................................................................................................268 EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT....................................................................269 INDEX................................................................................................................271 <A>..............................................................................................................273 <B>..............................................................................................................273 <C>..............................................................................................................273 <D>..............................................................................................................273 <E>..............................................................................................................273 <F>..............................................................................................................273 <G>..............................................................................................................273 <H>..............................................................................................................273 <I>..............................................................................................................273 <L>..............................................................................................................273 <M>..............................................................................................................273 <O>..............................................................................................................273 <P>..............................................................................................................274 <R>..............................................................................................................274 <S>..............................................................................................................274 <T>..............................................................................................................274 <V>..............................................................................................................274 <W>..............................................................................................................274 COLOPHON.............................................................................................................275
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KOMATSU D65EX-15E0 D65PX-15E0 BULLDOZER OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:
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