Komatsu GALEO D65EX-15 Manual

TEN00013-00
(Replaces SEAM049901T)
Operation&Maintenance
Manual
D65EX -15
D65PX -15
D65WX -15
BULLDOZER
SERIAL NUMBERS D65EX-15 67001and up
D65PX-15 67001and up
D65WX-15 67001and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2004 Komatsu
Printed in U.S.A.
Komatsu America Corp.
December 2004

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FOREWORD
FOREWORD
FOREWORD
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 a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
Always be sure to read and understand this manual thoroughly before performing operation and maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thoroughly and be sure that you
understand them fully.
Keep this manual at the storage location for the operation and maintenance manual given below, and have all personnel read it
periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual immediately from Komatsu
or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsudeliversmachinesthatcomplywithallapplicableregulationsandstandardsofthecountry towhichithasbeen shipped.
If this machine has been purchased in another country or purchased from someone in another country, it may lack certain safety
devices and specifications 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.
Storage location for the Operation and Maintenance Manual:
If machine is equipped with a cab.
Inside of right and left doors
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FOREWORD FOREWORD FOREWORD FOREWORD
If machine is not equipped with cab.
Rear face of floor
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FOREWORD
FOREWORD
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FOREWORD FOREWORD
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FOREWORD
SAFETY INFORMATION
SAFETY INFORMATION
To enable you to use this machine safely, safety precautions and labels are given in this manualand affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may cause
property damage.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the work equipment lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD SAFETY INFORMATION
Safety labels
Safety labels areaffixed to the machineto informthe operatoror maintenanceworker on the spotwhen carrying out
operation or maintenance of the machine that may involve hazard.
This machine uses "Safety labels using words" and "Safety labels using pictograms" to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazardous
condition equivalent to the signal word. These safety pictograms
use pictures in order to let the operator or maintenance worker
understand the level and type of hazardous condition at all times.
Safety pictograms show thetype of hazardouscondition at the top
or left side, and the methodof avoiding the hazardouscondition at
thebottomorrightside.Inaddition,thetypeofhazardouscondition
is displayed inside a triangle and the method of avoiding the
hazardous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore,the safety messages in this manual and on the machine may not include all possible safety precautions.
Ifanyproceduresoractionsnotspecificallyrecommendedorallowedinthismanualareused,itisyourresponsibility
to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected inthis manual. Consult Komatsu or your Komatsu distributorfor the latest availableinformation of your
machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1-> (1))
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FOREWORD
INTRODUCTION
INTRODUCTION
This Komatsu machine is designed to be used mainly for the following work:
Dozing
Smoothing
Cutting into hard or frozen ground or ditching
Felling trees, removing stumps
See the section "WORK POSSIBLE USING BULLDOZER (PAGE 3-103)" for further details.
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat when
the operator's seat is facing the front and the sprocket is at the rear of the machine.
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FOREWORD NECESSARY INFORMATION
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE
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
The nameplate for this machine is provided at the center of the left side of the engine cylinder block.
EPA: Environmental Protection Agency, U.S.A.
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FOREWORD
NECESSARY INFORMATION
POSITION OF SERVICE METER
Theservicemeterisprovidedatthelowerpartofthemonitorpanel.
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 6
INTRODUCTION 1- 8
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 8
NECESSARY INFORMATION 1- 9
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 9
ENGINE SERIAL NO. PLATE 1- 9
POSITION OF SERVICE METER 1- 10
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR 1- 10
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 4
POSITIONS OF SAFETY PICTOGRAMS 2- 4
SAFETY LABELS 2- 5
GENERAL PRECAUTIONS 2- 9
PRECAUTIONS FOR OPERATION 2- 17
STARTING ENGINE 2- 17
OPERATION 2- 19
TRANSPORTATION 2- 22
BATTERY 2- 23
TOWING 2- 25
PRECAUTIONS FOR MAINTENANCE 2- 26
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 6
FRONT PANEL 3- 6
SWITCHES 3- 33
CONTROL LEVERS AND PEDALS 3- 37
CIRCUIT BREAKER 3- 45
FUSE 3- 46
FUSIBLE LINK 3- 47
ELECTRIC POWER TAKE-OUT ADAPTER 3- 48
DOOR - OPEN LOCK 3- 49
SASH GLASS INTERMEDIATE LOCK 3- 49
DOOR POCKET 3- 50
OPENING AND CLOSING ENGINE SIDE COVER 3- 50
ASHTRAY 3- 51
CUP HOLDER 3- 51
TOOL BOX 3- 51
CAR STEREO, HANDLING 3- 52
AIR CONDITIONER, HANDLING 3- 60
ACCUMULATOR, HANDLING 3- 65
OPERATION 3- 66
CHECK BEFORE STARTING ENGINE, ADJUST 3- 66
STARTING ENGINE 3- 82
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3- 87
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FOREWORD
CONTENTS
STOPPING ENGINE 3- 90
MACHINE OPERATION 3- 91
SHIFTING GEARS 3- 94
SHIFTING BETWEEN FORWARD AND REVERSE 3- 97
STEERING MACHINE 3- 99
PRECAUTIONS FOR OPERATION 3-101
WORK POSSIBLE USING BULLDOZER 3-103
ADJUSTING POSTURE OF WORK EQUIPMENT 3-105
PARKING MACHINE 3-109
CHECK AFTER STOPPING ENGINE 3-110
CHECK AFTER FINISHING WORK 3-110
LOCKING 3-111
TIPS FOR LONGER UNDERCARRIAGE LIFE 3-112
TRANSPORTATION 3-115
TRANSPORTATION MEANS 3-115
REMOVING CAB 3-115
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT 3-115
PRECAUTIONS WHEN REMOVING ROPS 3-116
LOADING, UNLOADING WORK 3-117
LIFTING MACHINE 3-120
TRAVELING ON ROADS 3-121
COLD WEATHER OPERATION 3-122
PRECAUTIONS FOR LOW TEMPERATURE 3-122
AFTER COMPLETION OF WORK 3-124
AFTER COLD WEATHER 3-124
LONG-TERM STORAGE 3-125
BEFORE STORAGE 3-125
DURING STORAGE 3-125
AFTER STORAGE 3-125
TROUBLESHOOTING 3-126
AFTER RUNNING OUT OF FUEL 3-126
MACHINE TOWING METHOD 3-127
IF BATTERY IS DISCHARGED 3-128
OTHER TROUBLE 3-132
MAINTENANCE 4- 1
GUIDE TO MAINTENANCE 4- 2
OUTLINE OF SERVICE 4- 5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 5
RELATING TO ELECTRIC SYSTEM 4- 8
WEAR PARTS LIST 4- 9
WEAR PARTS LIST 4- 9
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 11
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 12
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS
KOMATSU GENUINE OIL 4- 13
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 14
TORQUE LIST 4- 14
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS 4- 15
SAFETY CRITICAL PARTS 4- 15
MAINTENANCE SCHEDULE CHART 4- 17
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OTHER THAN

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FOREWORD CONTENTS
MAINTENANCE SCHEDULE CHART 4- 17
ADJUST INJECTOR 4- 19
SERVICE PROCEDURE 4- 20
WHEN REQUIRED 4- 20
CHECK BEFORE STARTING 4- 40
EVERY 50 HOURS SERVICE 4- 41
EVERY 250 HOURS SERVICE 4- 42
EVERY 500 HOURS SERVICE 4- 52
EVERY 1000 HOURS SERVICE 4- 56
EVERY 2000 HOURS SERVICE 4- 61
EVERY 4000 HOURS SERVICE 4- 65
EVERY 8000 HOURS SERVICE 4- 67
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAUTIONS 6- 2
PRECAUTIONS RELATED TO SAFETY 6- 2
HANDLING HYDRAULIC RIPPER 6- 3
GENERAL VIEW 6- 3
EXPLANATION OF COMPONENTS 6- 4
OPERATION 6- 5
TROUBLESHOOTING 6- 7
MAINTENANCE 6- 8
SPECIFICATIONS 6- 8
HANDLING TRIMMING DOZER 6- 9
GENERAL VIEW 6- 9
EXPLANATION OF COMPONENTS 6- 10
OPERATION 6- 12
MAINTENANCE 6- 15
SPECIFICATIONS 6- 19
DELUXE SEAT 6- 20
HEADREST 6- 22
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT 6- 23
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
SAFETY LABELS 2- 4
POSITIONS OF SAFETY PICTOGRAMS 2- 4
SAFETY LABELS 2- 5
GENERAL PRECAUTIONS
Safety rules 2- 9
If abnormalities are found 2- 9
Clothing and personal protective items 2- 9
Fire extinguisher and first aid kit 2- 9
Safety features 2- 9
Keep machine clean 2- 10
Inside operator's compartment 2- 10
Always apply lock when leaving operator's seat 2- 10
Handrails and steps 2- 11
Mounting and dismounting 2- 11
No people on attachments 2- 11
Crushing or cutting prevention 2- 11
Prevention of burns 2- 12
Fire prevention 2- 12
Action if fire occurs 2- 13
Window washer liquid 2- 13
Precautions when using ROPS (Roll Over Protective Structure) 2- 13
Precautions for attachments 2- 13
Unauthorized modification 2- 14
Safety at worksite 2- 14
Working on loose ground 2- 14
Do not go close to high-voltage cables 2- 14
Ensure good visibility 2- 15
Ventilation for enclosed areas 2- 15
Checking signalman's signals and signs 2- 15
Emergency exit from operator's cab 2- 15
Be careful about asbestos dust 2- 16
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SAFETY SAFETY
PRECAUTIONS FOR OPERATION 2- 17
STARTING ENGINE 2- 17
Checks before starting engine 2- 17
Precautions when starting 2- 17
Precautions in cold areas 2- 17
OPERATION 2- 19
Checks before operation 2- 19
Precautions for moving machine forward or in reverse 2- 19
Precautions when traveling 2- 19
Traveling on slopes 2- 20
Using brakes 2- 20
Operate carefully on snow 2- 20
Parking machine 2- 21
TRANSPORTATION 2- 22
Loading and unloading 2- 22
Shipping 2- 22
BATTERY 2- 23
Battery hazard prevention 2- 23
Starting with booster cable 2- 24
TOWING 2- 25
When towing 2- 25
PRECAUTIONS FOR MAINTENENCE 2- 26
Warning tag 2- 26
Keep work place clean and tidy 2- 26
Appoint leader when working withothers 2- 26
Stop engine before carrying out inspention and maintenance 2- 26
Two workers for maintenance when engine is running 2- 27
Proper tools 2- 28
Accumulator 2- 28
No unauthorized personnel into area 2- 28
Attachments 2- 28
Work under the machine 2- 29
Noise 2- 29
Precautions when using hammer 2- 29
Repair welding 2- 29
Removing battery terminal 2- 29
Precautions when using high-pressure grease to adjust track tension 2- 30
Do not disassemble recoil spring 2- 30
Precaution with high-pressure oil 2- 30
Handling high-pressure hoses 2- 31
Waste material 2- 31
Maintenance for air conditioner 2- 31
Compressed air 2- 31
Periodic replacement of safety critical parts 2- 32
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
POSITIONS OF SAFETY PICTOGRAMS
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SAFETY SAFETY LABELS
SAFETY LABELS
(1) Caution before operating or maintaining machine
(09651-03001)
(2) Caution before moving in reverse (09802-13000)
(3) Caution for leaving operator's seat (09654-33001)
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