Komatsu Utility D65EX-15E0 Manual

D65EX -15E0
D65PX -15E0
SERIAL NUMBER
D65EX-15E0 - 69001 and up
D65PX-15E0 - 69001 and up
BULLDOZER
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
Operation &
Maintenance Manual
EEAM024400
WARNING

FOREWORD
11

BEFORE READING THIS MANUAL FOREWORD
1-2
BEFORE READING THIS MANUAL 1
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 precau-
tions. 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.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the location shown on the right so that all relevant person-
nel can read it at any time.
Operation and Maintenance Manual Storing Place
For a machine with a cab, a pocket is provided on the inside of
both right and left doors.
For a machine with a ROPS canopy, a pocket is provided at the
end of the floor.
If this manual is lost or damaged, contact your distributor immediately to arrange for its replacement. For details
regarding the machine serial No. you will need to provide your Komatsu distributor, see “TABLE TO ENTER
SERIAL NO. AND DISTRIBUTOR (1-13)“.
This manual uses the international units (SI) for units of measurement. For reference, units that have been used in
the past are given in ( ).

FOREWORD BEFORE READING THIS MANUAL
1-3
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to addi-
tional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest
available information concerning your machine or with questions regarding information contained in this manual.
qThe numbers in circles in the illustrations correspond to the numbers in ( ) in the text.
(For example:1→(1))
Komatsu delivers machines that comply with all applicable regulations and standards of the country to which it has
been shipped. If this machine has been purchased in another country, it may lack certain safety devices and spec-
ifications that are necessary for use in your country. If there is any question about whether your product complies
with the applicable standards and regulations of your country, consult Komatsu or your Komatsu distributor before
operating the machine.

IMPORTANT SAFETY INFORMATION FOREWORD
1-4
IMPORTANT SAFETY INFORMATION 1
To enable you to use the machine safely, and to prevent injury to operators, service personnel or bystanders, the
precautions and warnings included in this manual and the safety signs attached to the machine must always be
followed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The “Safety Alert Symbol“ identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety message.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
This signal word indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury
This signal word indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
This signal word indicates a potentially hazardous situation exists which, if not
avoided, may result in minor or moderate injury.
NOTICE This precaution is given where the machine may be damaged or the service life reduced if
the precaution is not followed.
REMARKS This word is used for information that is useful to know.
DANGER
WARNING
CAUTION

FOREWORD IMPORTANT SAFETY INFORMATION
1-5
Noise emission levels 1
Two labels indicating the machine noise level are affixed on the
machine.
qSound pressure level at the operator's station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle)
qSound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified
in European directive 2000/14/EC.
Vibration levels 1
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera-
tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
qIf equipped with air suspension seat
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration
value for the body is less than or equal to 0.5 m/s².
qIf equipped with mechanical suspension seat
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s².
D65EX-15 : the actual acceleration value for the body is 0.63 m/s².
D65EXL-15, D65PX-15 : the actual acceleration value for the body is 0.68 m/s².

IMPORTANT SAFETY INFORMATION FOREWORD
1-6
These values were determined using a representative machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.
Operating condition:
(WHEEL LOADER:) V-shape loading
(HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating)
(TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion
(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading, and
travelling without load)
Guide to Reduce Vibration Levels on Machine 1
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
qTire pressures (for wheeled machines), tension of crawler (for crawler machines)
qBrake and steering systems
qControls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
qRemove any large rocks or obstacles
qFill any ditches and holes
qSite manager should provide machine operators with machine and schedule time to maintain terrain con-
ditions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
qAdjust the seat and suspension for the weight and size of the operator
qWear seat belt
qInspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
qWhen pushing with bucket or blade, avoid sudden loading; load gradually
qDrive around obstacles and rough terrain conditions
qSlow down when it is necessary to go over rough terrain
qMake the curve radius of traveling path as large as possible
qTravel at low speed when traveling around sharp curves
7. Minimize vibrations for long work cycle or long distance traveling
qReduce speed to prevent bounce
qTransport machines long distances between worksites

FOREWORD IMPORTANT SAFETY INFORMATION
1-7
8. The following guidelines can be effective to minimize risks of low back pain
qOperate the machine only when you are in good health.
qProvide breaks to reduce long periods of sitting in the same posture
qDo not jump down from the cab or machine
qDo not repeatedly handle and lift loads.

INTENDED USE FOREWORD
1-8
INTENDED USE 1
USE OF MACHINE 1
This Komatsu machine is designed to be used mainly for the following work:
qDozing
qSmoothing
qCutting into hard or frozen ground or ditching
qFelling trees, removing stumps
See the section “WORK POSSIBLE USING BULLDOZER (3-88)“ for further details.
GENERAL VIEW AND DIRECTIONS OF MACHINE 1
In this manual, the directions of the machine (front,rear,left,right) are determined according to the view from the
operator's seat in the direction of travel (front) of the machine.
(1) Blade (7) Sprocket
(2) Tilt cylinder (8) Track frame
(3) Lift cylinder (9) Step
(4) Cab (10) Frame
(5) ROPS guard (11) Idler
(6) Track shoe (12) ROPS canopy
(A) Front (C) Left
(B) Rear (D) Right

FOREWORD INTENDED USE
1-9
VISIBILITY FROM OPERATOR'S SEAT 1
The visibility standards (ISO 5006) for this machine require a view shown in the diagram below.
PROXIMITY VISIBILITY 1
The figure bellows shows a front visibility from the machine at a spot 1.0 m away from the side and 1.5 m above
the ground. Shaded area (A) in the figure shows an area whose view is blocked by part of the machine. Operate
the machine, fully aware that the machine has a portion that an operator cannot see.
12M CIRCUMFERENCE VISIBILITY 1
The figure below shows a visibility from the machine within a circle of 12 m in radius. Shaded area (B) in the figure
shows an area whose view is blocked by part of the machine. Operate the machine, fully aware that the machine
has a portion that an operator cannot see.

INTENDED USE FOREWORD
1-10
BREAKING-IN THE NEW MACHINE 1
NOTICE
Your Komatsu machine has been thoroughly adjusted and tested before shipment from the factory. How-
ever, operating the machine under full load before breaking the machine in can adversely affect the perfor-
mance and shorten the machine life.
Be sure to break in the machine for the initial 100 hours (as indicated on the service meter).
Make sure that you fully understand the content of this manual, and pay careful attention to the following points
when breaking in the machine.
qRun the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
qIdle the engine for 5 minutes after starting it up.
qAvoid operation with heavy loads or at high speeds.
qImmediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops,
and sudden changes in direction.

FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
1-11
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO.
AND DISTRIBUTOR 1
When ordering replacement parts, please inform your Komatsu distributor of the following.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1
This is at the front bottom right of the operator's seat.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE POSITION 1
The engine serial No. plate is located on the side of the engine front cover on the left side of the machine.

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
1-12
ADDITIONAL EPA NAMEPLATE 1
The additional EPA nameplate is located on top of the engine head cover on the left side of the machine.
EPA: Environmental Protection Agency, U.S.A.
SERVICE METER POSITION 1
The service meter is provided at the lower part of the monitor
panel.

FOREWORD LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
1-13
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1
Machine serial No.
Engine serial No.
Product Identification Number
(PIN)
Manufacturers name:
Address:
KOMATSU LTD.
3-6 Akasaka
Minato-ku, 101 Tokyo
Japan
Distributor
Address
Phone
Service personnel for your
machine:

LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR FOREWORD
1-14
MACHINE SERIAL NUMBER PLATE 1
Model
Seriel Number
Manufacturing year
Weight
Engine power
Product Identification Number
Manufacturer

CONTENTS
1-15
CONTENTS
FOREWORD
BEFORE READING THIS MANUAL.................................................................................................................... 1-2
IMPORTANT SAFETY INFORMATION............................................................................................................... 1-4
Noise emission levels ................................................................................................................................. 1-5
Vibration levels............................................................................................................................................ 1-5
Guide to Reduce Vibration Levels on Machine.................................................................................. 1-6
INTENDED USE ................................................................................................................................................... 1-8
USE OF MACHINE..................................................................................................................................... 1-8
GENERAL VIEW AND DIRECTIONS OF MACHINE................................................................................. 1-8
VISIBILITY FROM OPERATOR'S SEAT.................................................................................................... 1-9
PROXIMITY VISIBILITY.................................................................................................................... 1-9
12M CIRCUMFERENCE VISIBILITY ................................................................................................ 1-9
BREAKING-IN THE NEW MACHINE ....................................................................................................... 1-10
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR........................................... 1-11
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ..................................... 1-11
ENGINE SERIAL NO. PLATE POSITION ................................................................................................1-11
ADDITIONAL EPA NAMEPLATE ............................................................................................................. 1-12
SERVICE METER POSITION .................................................................................................................. 1-12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................................................ 1-13
MACHINE SERIAL NUMBER PLATE....................................................................................................... 1-14
SAFETY
IMPORTANT SAFETY INFORMATION............................................................................................................... 2-2
SAFETY LABELS................................................................................................................................................. 2-4
POSITION FOR ATTACHING SAFETY LABELS....................................................................................... 2-5
SAFETY LABELS ....................................................................................................................................... 2-5
PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ............................................................... 2-10
PRECAUTIONS DURING OPERATION ............................................................................................................ 2-17
PRECAUTIONS FOR MAINTENANCE.............................................................................................................. 2-23
PRECAUTIONS FOR MACHINE........................................................................................................................ 2-29
OPERATION
GENERAL VIEW .................................................................................................................................................. 3-2
GENERAL VIEW OF MACHINE................................................................................................................. 3-2

CONTENTS
1-16
GENERAL VIEW OF CONTROLS AND GAUGES.....................................................................................3-3
EXPLANATION OF COMPONENTS....................................................................................................................3-6
FRONT PANEL...........................................................................................................................................3-6
CHECK MONITOR SYSTEM ............................................................................................................3-7
EMERGENCY CAUTION ITEMS ......................................................................................................3-8
CAUTION ITEMS.............................................................................................................................3-10
METER GROUP..............................................................................................................................3-12
LAMPS.............................................................................................................................................3-16
SWITCHES......................................................................................................................................3-18
METHOD OF USING MAINTENANCE MODE................................................................................3-22
SWITCHES...............................................................................................................................................3-29
CONTROL LEVERS AND PEDALS .........................................................................................................3-33
CIRCUIT BREAKER .................................................................................................................................3-41
FUSE ........................................................................................................................................................3-41
FUSIBLE LINK..........................................................................................................................................3-43
ELECTRIC POWER TAKE-OUT ADAPTER ............................................................................................3-43
MACHINE EQUIPPED WITH CAB..................................................................................................3-43
MACHINE EQUIPPED WITH ROPS CANOPY...............................................................................3-44
DOOR - OPEN LOCK...............................................................................................................................3-44
SASH GLASS INTERMEDIATE LOCK.....................................................................................................3-45
DOOR POCKET .......................................................................................................................................3-45
OPENING AND CLOSING ENGINE SIDE COVER..................................................................................3-46
ASHTRAY.................................................................................................................................................3-46
CUP HOLDER ..........................................................................................................................................3-47
TOOL BOX................................................................................................................................................3-47
SHOVEL HOLDER ...................................................................................................................................3-47
AIR CONDITIONER, HANDLING .............................................................................................................3-48
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ................................................3-48
METHOD OF OPERATION.............................................................................................................3-50
PRECAUTIONS WHEN USING ......................................................................................................3-51
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE ..........3-51
INSPECTION DURING OFF-SEASON ...........................................................................................3-51
PROCEDURE FOR REPLACING RECEIVER................................................................................3-51
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL............................3-52
CLEANING AIR FILTER..................................................................................................................3-52
OPERATION.......................................................................................................................................................3-53
CHECK BEFORE STARTING ENGINE, ADJUST....................................................................................3-53
WALK-AROUND CHECK ................................................................................................................3-53
CHECK BEFORE STARTING ......................................................................................................... 3-54
ADJUSTMENT.................................................................................................................................3-62
OPERATION AND CHECK BEFORE STARTING ENGINE............................................................3-66
STARTING ENGINE.................................................................................................................................3-68
NORMAL STARTING ......................................................................................................................3-68
STARTING IN COLD WEATHER....................................................................................................3-70
OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................................3-73
WARMING UP OPERATIONS ........................................................................................................3-73

CONTENTS
1-17
STARTING IN COLD WEATHER.................................................................................................... 3-74
STOPPING ENGINE................................................................................................................................. 3-75
MACHINE OPERATION........................................................................................................................... 3-77
MOVING MACHINE......................................................................................................................... 3-77
STOPPING MACHINE..................................................................................................................... 3-79
SHIFTING GEARS.................................................................................................................................... 3-79
GEARSHIFTING OPERATION........................................................................................................ 3-80
GEARSHIFTING OPERATION USING PRESET MODE FUNCTION ............................................ 3-80
AUTO DOWN SHIFT OPERATION................................................................................................. 3-82
SHIFTING BETWEEN FORWARD AND REVERSE................................................................................ 3-83
STEERING MACHINE.............................................................................................................................. 3-85
NORMAL TURNING........................................................................................................................ 3-85
PRECAUTIONS FOR OPERATION......................................................................................................... 3-86
PAY ATTENTION TO GAUGES...................................................................................................... 3-86
PERMISSIBLE WATER DEPTH...................................................................................................... 3-86
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS.......................................................... 3-86
PRECAUTIONS ON SLOPES......................................................................................................... 3-87
METHOD OF USING BRAKES....................................................................................................... 3-87
IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS................................... 3-87
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-87
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES.................. 3-88
WORK POSSIBLE USING BULLDOZER................................................................................................. 3-88
DOZING........................................................................................................................................... 3-88
SMOOTHING................................................................................................................................... 3-89
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING.................................................... 3-89
FELLING TREES, REMOVING STUMPS....................................................................................... 3-89
ADJUSTING POSTURE OF WORK EQUIPMENT................................................................................... 3-90
ADJUST ANGLE OF BLADE EDGE................................................................................................ 3-90
ADJUSTING SHIMS IN ASSEMBLING WORK EQUIPMENT ........................................................ 3-91
ADJUSTING TENSION OF CENTER BRACE................................................................................ 3-91
ADJUST AMOUNT OF TILT............................................................................................................ 3-92
METHOD OF ANGLING BLADE..................................................................................................... 3-93
PARKING MACHINE................................................................................................................................ 3-94
CHECK AFTER FINISHING WORK......................................................................................................... 3-95
BEFORE STOPPING ENGINE........................................................................................................ 3-95
AFTER STOPPING ENGINE...........................................................................................................3-95
LOCKING.................................................................................................................................................. 3-96
TIPS FOR LONGER UNDERCARRIAGE LIFE........................................................................................ 3-96
OPERATION METHOD................................................................................................................... 3-96
INSPECTION AND ADJUSTMENT................................................................................................. 3-97
INSPECTION AND REPAIR............................................................................................................ 3-97
TRANSPORTATION......................................................................................................................................... 3-100
TRANSPORTATION MEANS................................................................................................................. 3-100
REMOVING CAB.................................................................................................................................... 3-100
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT................................................................... 3-100
PRECAUTIONS WHEN REMOVING ROPS.......................................................................................... 3-101

CONTENTS
1-18
LOADING, UNLOADING WORK ............................................................................................................3-102
LIFTING MACHINE.................................................................................................................................3-105
TRAVELING ON ROADS .......................................................................................................................3-107
COLD WEATHER OPERATION ......................................................................................................................3-108
PRECAUTIONS FOR LOW TEMPERATURE........................................................................................3-108
AFTER COMPLETION OF WORK .........................................................................................................3-109
AFTER COLD WEATHER ......................................................................................................................3-109
LONG-TERM STORAGE..................................................................................................................................3-110
BEFORE STORAGE...............................................................................................................................3-110
DURING STORAGE ...............................................................................................................................3-110
AFTER STORAGE..................................................................................................................................3-110
TROUBLESHOOTING......................................................................................................................................3-111
AFTER RUNNING OUT OF FUEL..........................................................................................................3-111
PROCEDURE FOR BLEEDING AIR.............................................................................................3-111
METHOD OF TOWING MACHINE.........................................................................................................3-112
IF BATTERY IS DISCHARGED..............................................................................................................3-113
REMOVE AND INSTALL BATTERY .............................................................................................3-114
PRECAUTIONS FOR BATTERY CHARGING ..............................................................................3-114
STARTING ENGINE WITH BOOSTER CABLE ............................................................................3-115
OTHER TROUBLE .................................................................................................................................3-117
ELECTRICAL SYSTEM.................................................................................................................3-117
MONITOR PANEL.........................................................................................................................3-118
CHASSIS.......................................................................................................................................3-119
ENGINE.........................................................................................................................................3-121
MAINTENANCE
GUIDE TO MAINTENANCE .................................................................................................................................4-2
OUTLINE OF SERVICE........................................................................................................................................4-5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................4-5
OIL.....................................................................................................................................................4-5
FUEL..................................................................................................................................................4-6
COOLANT AND WATER FOR DILUTION.........................................................................................4-6
GREASE............................................................................................................................................4-7
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ....................................................................4-7
STORING OIL AND FUEL.................................................................................................................4-8
FILTERS............................................................................................................................................4-8
RELATING TO ELECTRIC SYSTEM .........................................................................................................4-8
HANDLING HYDRAULIC SYSTEM............................................................................................................4-9
WEAR PARTS LIST ...........................................................................................................................................4-10
WEAR PARTS LIST..................................................................................................................................4-10
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .................................................................................4-12