Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Bulldozer (60001 and up) Operation & Maintenance Manual

This manual PDF download describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment for the D65E-12, D65P-12, D65EX-12, D65PX-12 Komatsu Bulldozer (60001 and up). It will help the operator or anyone realize peak performance through effective, economical and safe machine operation and maintenance.


APPLICABLE MODELS :

Komatsu D65E-12 - S/N : 60001 and up
Komatsu D65P-12 - S/N : 60001 and up
Komatsu D65EX-12 - S/N : 60001 and up
Komatsu D65PX-12 - S/N : 60001 and up


TABLE OF CONTENTS :

- SAFETY
- OPERATION
- MAINTENANCE
- SPECIFICATIONS
- OPTIONS, ATTACHMENTS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEAM001202
Total Pages : 221


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.

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COVER PAGE
1. FOREWORD
2. SAFETY INFORMATION
3. INTRODUCTION
3.1 INTENDED USE
3.2 FEATURES
3.3 BREAKING IN THE MACHINE
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
4.1 MACHINE SERIAL NO. PLATE POSITION
4.2 ENGINE SERIAL NO. PLATE POSITION
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
5. CONTENTS

SAFETY
6. GENERAL PRECAUTIONS
7. PRECAUTIONS DURING OPERATION
7.1 BEFORE STARTING ENGINE
7.2 OPERATING MACHINE
7.3 TRANSPORTATION
7.4 BATTERY
7.5 TOWING
8. PRECAUTIONS FOR MAINTENANCE
8.1 BEFORE CARRYING OUT MAINTENANCE
8.2 DURING MAINTENANCE
9. POSITION FOR ATTACHING SAFETY LABELS

OPERATION
10. GENERAL VIEW
10.1 GENERAL VIEW OF MACHINE
10.2 GENERAL VIEW OF CONTROLS AND GAUGES
11. EXPLANATION OF COMPONENTS
11.1 FRONT PANEL (METERS, LAMPS, SWITCHES)
11.1.1 MONITOR PANEL
11.2 SWITCHES
11.3 CONTROL LEVERS AND PEDALS
11.4 FUSE BOX
11.5 GREASE PUMP HOLDER
11.6 SHOVEL HOLDER
11.7 DOOR-OPEN LOCK (MACHINES EQUIPPED WITH CAB)
11.8 SASH GLASS INTERMEDIATE LOCK (MACHINES EQUIPPED WITH CAB)
11.9 CAP WITH LOCK
11.10 HOT AND COOL BOX (MACHINES EQUIPPED WITH CAB)
11.11 DOOR POCKET (MACHINES EQUIPPED WITH CAB)
11.12 ASHTRAY (MACHINES EQUIPPED WITH CAB)
11.13 TOOL BOX
11.14 USING CAR RADIO (MACHINES EQUIPPED WITH CAB, CAR RADIO)
11.14.1 EXPLANATION OF PARTS
11.15 USING CAR STEREO (MACHINES EQUIPPED WITH CAB, CAR STEREO)
11.15.1 EXPLANATION OF PARTS
11.15.2 LISTENING THE RADIO (AM/FM)
11.15.3 LISTENING TO CASSETTE TAPE
11.15.4 PRECAUTIONS WHEN USING
11.15.5 SPECIFICATIONS
11.16 HANDLING AIR CONDITIONER (MACHINES EQUIPPED WITH CAB)
11.16.1 COOLING OPERATION
11.16.2 HEATING OPERATION
11.16.3 PRECAUTIONS WHEN USING AIR CONDITIONER
11.16.4 INSPECTION DURING OFF-SEASON
11.16.5 PROCEDURE FOR REPLACING RECEIVER
11.16.6 CLEANING AIR FILTER
11.17 HANDLING HEATER (MACHINES EQUIPPED WITH CAB)
11.17.1 METHOD OF OPERATION
11.17.2 CLEANING AIR FILTER
12. OPERATION
12.1 CHECKS BEFORE STARTING ENGINE
12.1.1 WALK-AROUND CHECK
12.1.2 CHECK BEFORE STARTING
12.1.3 ADJUST OPERATOR’S SEAT
12.1.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE
12.2 STARTING ENGINE
12.2.1 NORMAL STARTING
12.2.2 STARTING IN COLD WEATHER (MONITOR PANEL SPECIFICATION)
12.2.3 STARTING IN COLD WEATHER (GUAGE PANEL SPECIFICATION)
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE
12.3.1 NORMAL OPERATION
12.3.2 WHEN STARTING IN COLD WEATHER
12.4 MOVING MACHINE
12.5 SHIFTING GEAR
12.6 SHIFTING BETWEEN FORWARD AND REVERSE
12.7 STEERING MACHINE
12.7.1 NORMAL TURNING (D65E, P)
12.7.2 TURNING WHILE DESCENDING A SLOPE (D65E, P)
12.7.3 NORMAL TURNING (D65EX, PX)
12.7.4 TURNING WHILE DESCENDING A SLOPE (D65EX, PX)
12.8 STOPPING MACHINE
12.9 PRECAUTIONS FOR OPERATION
12.9.1 METHOD OF USING STEERING CLUTCH (D65E, P ONLY)
12.9.2 PERMISSIBLE WATER DEPTH
12.9.3 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS
12.9.4 PRECAUTIONS ON SLOPES
12.9.5 IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS (MACHINES EQUIPPED WITH CAB)
12.9.6 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW (MACHINES EQUIPPED WITH CAB)
12.9.7 PRECAUTIONS REGARDING BLIND SPOTS CAUSED BY CAB STAYS
12.10 WORK POSSIBLE USING BULLDOZER
12.10.1 DOZING
12.10.2 SMOOTHING
12.10.3 CUTTING INTO HARD OR FROZEN GROUND OR DITCHING
12.10.4 FELLING TREES, REMOVING STUMPS
12.11 ADJUSTING POSTURE OF WORK EQUIPMENT
12.11.1 METHOD OF ANGLING BLADE (ANGLEDOZER ONLY)
12.11.2 ADJUSTING AMOUNT OF TILT (ANGLEDOZER ONLY)
12.11.3 ADJUST ANGLE OF BLADE EDGE
12.12 PARKING MACHINE
12.13 CHECK AFTER FINISHING WORK
12.14 STOPPING ENGINE
12.15 CHECK AFTER STOPPING ENGINE
12.16 LOCKING
12.17 TIPS FOR LONGER UNDERCARRIAGE LIFE
12.17.1 OPERATION METHOD
12.17.2 INSPECTION AND ADJUSTMENT
12.17.3 INSPECTION AND REPAIR
13. TRANSPORTATION
13.1 LOADING, UNLOADING WORK
13.2 PRECAUTIONS FOR LOADING
13.3 PRECAUTIONS FOR TRANSPORTATION
13.4 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT
13.5 REMOVING CAB (MACHINES EQUIPPED WITH CAB)
14. COLD WEATHER OPERATION
14.1 PRECAUTIONS FOR LOW TEMPERATURE
14.1.1 FUEL AND LUBRICANTS
14.1.2 COOLANT
14.1.3 BATTERY
14.2 AFTER COMPLETION OF WORK
14.3 AFTER COLD WEATHER
15. LONG-TERM STORAGE (MORE THAN ONE MONTH)
15.1 BEFORE STORAGE
15.2 DURING STORAGE
15.3 AFTER STORAGE
16. TROUBLESHOOTING
16.1 AFTER RUNNING OUT OF FUEL
16.2 IF BATTERY IS DISCHARGED
16.2.1 STARTING ENGINE WITH BOOSTER CABLE
16.3 OTHER TROUBLE
16.3.1 ELECTRICAL SYSTEM
16.3.2 CHASSIS

MAINTENANCE
17. GUIDES TO MAINTENANCE
18. OUTLINES OF SERVICE
18.1 OUTLINE OF OIL, FUEL, COOLANT
18.1.1 OIL
18.1.2 FUEL
18.1.3 COOLANT
18.1.4 GREASE
18.1.5 STORING OIL AND FUEL
18.1.6 FILTERS
18.2 RELATING TO ELECTRIC SYSTEM
19. WEAR PARTS LIST
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND BOLTS
21.1 INTRODUCTION OF NECESSARY TOOLS
21.2 TORQUE LIST
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
23. MAINTENANCE SCHEDULE CHART
23.1 MAINTENANCE SCHEDULE CHART
24. SERVICE PROCEDURE
24.1 WHEN REQUIRED
24.1.1 CLEAN INSIDE OF COOLING SYSTEM
24.1.2 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT
24.1.3 CHECK TRACK TENSION
24.1.4 CHECK AND TIGHTEN TRACK SHOE BOLTS
24.1.5 CHECK ELECTRICAL INTAKE AIR HEATER
24.1.6 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES
24.1.7 CLEAN, CHECK RADIATOR FINS
24.1.8 ADJUST IDLER CLEARANCE
24.1.9 ADJUSTING TENSION OF CENTER BRACE (POWER TILT DOZER ONLY) (POWER TILT, POWER PITCH DOZER ONLY)
24.1.10 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (MACHINES EQUIPPED WITH CAB)
24.1.11 CHECK, ADJUST AIR CONDITIONER (MACHINES EQUIPPED WITH CAB)
24.1.12 GREASE DOOR HINGE (MACHINES EQUIPPED WITH CAB)
24.1.13 CHECK DOOR LOCK STRIKER (MACHINES EQUIPPED WITH CAB)
24.1.14 REPLACE DOOR DAMPER (MACHINES EQUIPPED WITH CAB)
24.1.15 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (MACHINES EQUIPPED WITH CAB)
24.1.16 BLEED AIR FROM HEAD END OF RIGHT PITCH CYLINDER (POWER TILT, POWER PITCH DOZER ONLY)
24.1.17 REPLACE WIPER BLADE (MACHINES EQUIPPED WITH CAB)
24.1.18 CHECK IDLER OIL LEVEL, ADD OIL
24.2 CHECK BEFORE STARTING
24.2.1 CHECK COOLANT LEVEL, ADD WATER
24.2.2 CHECKING WITH MACHINE MONITOR (MONITOR PANEL SPECIFICATION)
24.2.3 CHECK FUEL LEVEL, ADD FUEL (MONITOR PANEL SPECIFICATION)
24.2.4 CHECK FUEL LEVEL, ADD FUEL (GAUGE PANEL SPECIFICATION)
24.2.5 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL
24.2.6 CHECK OIL LEVEL IN POWER TRAIN CASE, ADD OIL
24.2.7 CHECK BRAKE PEDAL TRAVEL
24.2.8 CHECK DUST INDICATOR
24.2.9 CHECK THAT LAMPS LIGHT UP
24.2.10 CHECK HORN SOUND
24.2.11 CHECK BACKUP ALARM SOUND
24.2.12 CHECK SEAT BELT FOR WEAR OR DAMAGE
24.2.13 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER
24.3 EVERY 50 HOURS SERVICE
24.3.1 DRAIN WATER, SEDIMENT FROM FUEL TANK
24.4 EVERY 250 HOURS SERVICE
24.4.1 LUBRICATING
24.4.2 GREASE EQUALIZER BAR SIDE PIN (LEFT AND RIGHT, 2 PLACES EACH: TOTAL 4 PLACES)
24.4.3 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL
24.4.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL
24.4.5 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (D60P, 65EX, PX ONLY)
24.4.6 CHECK LEVEL OF BATTERY ELECTROLYTE
24.4.7 CHECK FAN BELT TENSION, ADJUST
24.4.8 DRAIN WATER AND SEDIMENT FROM FUEL FILTER
24.4.9 CHECK, CLEAN ADDITIONAL FUEL STRAlliER
24.4.10 REPLACE POWER TRAIN OIL FILTER ELEMENT
24.4.11 BRAKE CAPACITY CHECK
24.5 EVERY 500 HOURS SERVICE
24.5.1 REPLACE FUEL FILTER CARTRIDGE
24.5.2 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE (D65E ONLY)
24.6 EVERY 1000 HOURS SERVICE
24.6.1 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER, SCAVENGING PUMP STRAINER)
24.6.2 CHANGE OIL IN FINAL DRIVE CASE
24.6.3 CLEAN BREATHER
24.6.4 GREASE UNIVERSAL JOINT
24.6.5 REPLACE CORROSION RESISTOR CARTRIDGE (D65P, D65EX, PX ONLY)
24.6.6 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER (D65P, D65EX, PX ONLY)
24.6.7 CHECK PLAY OF TURBOCHARGER ROTOR (D65P, D65EX, PX ONLY)
24.6.8 CHECK FOR LOOSE ROPS MOUNT BOLTS
24.7 EVERY 2000 HOURS SERVICE
24.7.1 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT
24.7.2 CLEAN, CHECK TURBOCHARGER (D65P, D65EX, PX ONLY)
24.7.3 CLEAN ENGINE BREATHER ELEMENT
24.7.4 CHECK VIBRATION DAMPER
24.7.5 CHECK ALTERNATOR, STARTING MOTOR
24.7.6 CHECK ENGINE VALVE CLEARANCE, ADJUST
24.8 EVERY 4000 HOURS SERVICE
24.8.1 CHECK WATER PUMP

SPECIFICATIONS
25. SPECIFICATIONS

OPTIONS, ATTACHMENTS
26. GENERAL PRECAUTIONS
26.1 PRECAUTIONS RELATED TO SAFETY
27. USING SEAT BELT
27.1 FASTEN THE BELT AND REMOVE IT IN THE FOLLOWING MANNER
27.2 ADJUST THE BELT LENGTH IN THE FOLLOWING MANNER
27.2.1 TO SHORTEN THE BELT
27.2.2 TO LENGTHEN THE BELT
28. HANDLING DELUXE SEAT
29. HANDLING ACCUMULATOR
29.1 METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR

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