The Komatsu D 65 Crawler Dozer delivers truly outstanding performance

Komatsu D65 is the basic line of modern crawler bulldozers, in which the main emphasis is on creating extremely comfortable working conditions, simplifying the control system and reducing the number of repetitive operations that the operator is forced to perform.

The index and number indicated after the series name (d65) indicate the type of bulldozer equipment. “E” – models with a fixed blade of adjustable skew, hemispherical or straight design. "EX" models are equipped with an adjustable skew rotary blade. In turn, the index “A” indicates that the bulldozer has an adjustable skew blade of a spherical or hemispherical design.

Features of operating the Komatsu D155A-5 bulldozer

The main purpose of the Komatsu D155A-5 bulldozer is to carry out excavation work to clear, level and level the territory, cutting and moving masses of soil in front of it. At the same time, excavation on slopes is most effective when the special vehicle moves from the top downhill. If the goal is to rake soil only on one side, then an angular (rotary) blade is used for this.

Cutting hard or frozen soil, or digging trenches, is done by tilting the dump. To fell trees, the blade (not skewed, but set straight) is raised and the tree is pushed with it 2-3 times. After that, reverse gear is given and the corner of the blade is buried in the ground to trim and uproot the roots. The bulldozer is successfully used as a pusher and towing vehicle for other heavy equipment.

When working to loosen the soil, the ripper stand is installed perpendicular to the ground surface (with a loosening angle: 45° / 50°). In relatively soft soil, loosening can also be done by tilting the ripper arm back. The ripper tooth is also used to pick up and turn out a stone or large piece of rock from the ground.

DESCRIPTION AND PURPOSE

The Komatsu D65EX-16 bulldozer is a heavy tracked vehicle from a well-known Japanese manufacturer. The model is one of the company's basic products and is very popular in various countries. Among the main advantages of the equipment are high power, reliability and ease of control.

The range of operations performed using the Komatsu D65EX-16 is quite wide:

• work on dismantling structures and buildings, various tasks within the framework of construction;
• mining and mining operations;
• road transport works;
• cleaning the area from garbage;
• clearing the site of stumps, trees, stones;
• creation and elimination of ditches, pits, trenches and quarries.

The Komatsu D65EX-16 is ideal for moving large volumes of earth and materials over short distances. The bulldozer demonstrates high efficiency when working with coal, gravel, crushed stone, soil of various categories and materials.

The reliable design allows the machine to be used in the most difficult conditions. The range of possible operating temperatures is from -40 to +40 degrees.

The series, in addition to the Komatsu D65EX-16 model, includes the Komatsu D65WX-16 and Komatsu D65PX-16 versions.

Frame and chassis

The design of the bulldozer uses such a progressive engineering solution as a flat bottom frame. The pivots and bearings of this frame effectively prevent the accumulation of earth and mud masses. This design option simplifies the process of maneuvering when moving a heavy special vehicle through muddy mud and muddy areas; and also reduces the likelihood of the tractor getting stuck on stumps or boulders.

The tractor suspension is made of swing, with a balancing beam, as well as swing axes located in the front part. The crawler frame is a supporting structure made of high-strength steel. The track rollers, filled with lubricant, are elastically mounted on a crawler carriage using a series of cross-shaped carriages of an original design. Their oscillatory movements are absorbed by special rubber cushions.

• Number of support rollers – 6 pcs. from each side.
• Number of support rollers – 2 pcs. from each side.
• Number of shoes – 41 pcs. from each side.
• The height of the lugs is 8 cm.
• Shoe width: standard – 56 cm, maximum – 71 cm.
• Support area – 35,950 cm2.
• Specific ground pressure – 76.5 kPa (0.78 kgf/cm2).
• Track width – 2.1 m.

The caterpillar tracks are made with lubricated joints. Unique dust seals prevent foreign materials that can act as abrasives from getting inside (into the gaps between pins and bushings), which significantly extends the life of the tracks. Adjusting the tension of the tracks is quite easy - using a grease gun.

Taking into account many years of experience in the production and operation of bulldozers, a balanced chassis was developed on an elastic suspension with cross-shaped carriages, which is capable of making independent oscillatory movements.

Excellent traction with the ground surface can be achieved even when the bulldozer is moving on uneven surfaces - due to the fact that the track shoes continuously and accurately follow the topography of the surface on which the heavy special vehicle is moving.

A rubber shock absorber is mounted on the cross-shaped carriage, which reduces vibration load and softens shock load. The cross-shaped carriage and the rubber cushion are able to manifest their damping qualities differently, depending on the current relief on the ground surface. When moving the bulldozer on a flat surface, the balanced undercarriage with elastic suspension works as a conventional rigid undercarriage.

This design improves the adhesion of the caterpillar tracks to the ground, extends the service life of the components and mechanisms of the special vehicle, and guarantees the most comfortable working conditions for the operator in the cab.

The slippage of the shoes is also minimal. Combined with the tight grip on the ground and the significant power of the diesel engine, this provides a powerful pulling force on the hook. Due to the low center of gravity, the special vehicle has a high degree of dynamic stability.

The lineup

The Komatsu bulldozer model line contains special vehicles adapted to work in various road, weather and climatic conditions: on wheels or tracks, as well as swamp models and even amphibious bulldozers.

Tracked

The first tracked models were produced by Komatsu in the late 40s of the 20th century. Now these are units with a power range from 85 to 899 hp, some of which are among the largest bulldozers created by manufacturers around the world.

Photo of Komatsu D 375 A crawler bulldozer

Peculiarities

Komatsu tracked models are all-terrain vehicles that are not afraid of both off-road and rough terrain. They have the following design features:

• Installation of high-power engines with a water cooling system with forced circulation and complemented by reverse fans.
• Wide tracks reinforced with heavy-duty lugs.
• Relatively small turning radius, giving large vehicles high maneuverability.
• The presence of high ground clearance, increasing the cross-country ability of the bulldozer.
• Equipped with a proprietary transmission with a forced lubrication system.

Heavy-duty double-glazed cabs provide operator protection in emergency situations.

• Air purifiers with automatic dust discharge and air pollution control.
• Lighting in the form of headlights, sun visors above the window and rear view mirrors.
• Equipping the standard kit with a single-tooth ripper in addition to the blade.

Specifications

Technical characteristics of Komatsu crawler bulldozers Table 1:

In the video, the Komatsu D 355 bulldozer in action:

Technical characteristics of Komatsu crawler bulldozers Table 2:

Video review of the Komatsu D 475 bulldozer:

Swamp walkers

Komatsu swamp vehicles are specialized units presented for sale for the Russian market in 3 models.

Peculiarities

Komatsu swamp vehicles, in fact, are a type of special tracked vehicles, characterized by a particularly large support area and, therefore, reduced pressure on the ground surface.

They are characterized by:

• The width of the tracks is more than 900 mm, while that of conventional tracked models is about 600 mm.
• The pressure on the soil surface is less than 0.35 kg/cm2.
• Ability to perform more delicate and precise work.

Photo of Komatsu D65PX swamp bulldozer

Specifications

Technical characteristics of Komatsu swamp bulldozers:

On wheels

Komatsu wheeled bulldozer equipment currently comes in several models weighing from 20 to 100 tons.

Komatsu WD420 Wheel Dozer

Peculiarities

Komatsu wheeled bulldozers, in comparison with tracked and swamp equipment, have:

• Slightly greater pressure on the ground surface.
• But - much higher maneuverability.
• High speed of all operations.
• Possibility of movement with general transport.
• Greater efficiency in terms of replacing worn out running parts.

Specifications

Technical characteristics of Komatsu bulldozers on wheels:

The video shows the operating principle of Komatsu bulldozers using the D375A model as an example:

D155A-5 Controls and Brakes

The movement of the bulldozer is controlled by a joystick lever. It is enough to ensure control of any maneuvers of a heavy special vehicle. To make a left turn, you just need to tilt the joystick to the left. Accordingly, by tilting the joystick to the right, the special vehicle will also make a right turn. When you move the joystick forward, the bulldozer moves in the same direction, and if you pull the joystick towards you, it will begin to move in reverse.

Gear shifting is also done using a single drive control lever. Multi-disc onboard clutches, which operate in oil, are closed and unlocked, engaged and disengaged under the influence of variable pressure from the hydraulic system. Onboard clutch brakes are used both as working brakes (with pedal control) and as parking brakes. The minimum turning radius, which is measured along the track tracks on the ground surface, is 3.7 m. Wet multi-disc onboard brakes are spring-loaded. When turning, the brakes work in conjunction with the side clutches.

Ease of operation and maintenance

Komatsu D65E is designed to perform various types of work in any climatic conditions, which makes it possible to use productive equipment in Russia.

The main functional components of the machine are developed by the manufacturer and have the corresponding patents. They are high-tech and characterized by high cost, but changing units and maintaining them is carried out without effort. By installing a control system over machine elements, all problems are displayed on the monitor.

A microcomputer installed on the bulldozer processes information received from sensors. This allows you to display operator-friendly information on the equipment dashboard. In addition to using a fault tracking system, a system for managing the working life of the main elements is installed. The units are protected from mechanical influences.

To access the engine compartment, there are side doors that open using a gas spring cylinder.

Thanks to all the features of the machine, it is cost-effective and efficient, which is important for continuous technological processes. The company's service centers are open in Russia, where you can get serviced and purchase original parts.

Engine and torque converter of Komatsu D155A-5 bulldozer

The bulldozers of this model are equipped with six-cylinder four-stroke Komatsu SA6D140E-2 diesel engines with a liquid cooling system, turbocharging and charge air cooling. The engine of this model is equipped with a direct diesel fuel injection system, as well as a mechanical regulator for the entire speed range. Forced lubrication of parts is carried out from a gear pump. A full-flow lube oil filter and a dry-type air cleaner with automatic discharge and dust indicator are installed.

The SA6D140E-2 power unit is unpretentious and reliable in operation, designed to work in difficult conditions, under constant heavy load. It delivers the solid power and high torque needed for efficient excavation and dozing work.

This engine is fully EPA compliant, has high reliability and low diesel fuel consumption. In the basic configuration of the bulldozer, its engine is equipped with an automatic preheating system. The required time for preheating is set automatically based on changes in ambient temperatures. This simplifies preheating.

Also, the Komatsu D155A-5 bulldozer implements the principle of modular design of power transmission components. This type of design facilitates the removal/installation of components and power transmission mechanisms and helps reduce downtime of the special vehicle.

Technical parameters of the Komatsu SA6D140E-2 engine

• Cylinder displacement – ​​15.24 l;
• Maximum power - 225 kW (306 hp), at 1900 rpm;
• Maximum torque – 160 kgf/m, at 1250 min;
• Cylinder diameter – 140 mm, piston stroke – 165 mm.
• Electric starter – 11 kW / 24V.
• Alternator – 35A / 24 V/
• Rechargeable batteries – 170 Ah, 2 pcs. 12 V each.

Device

To ensure the reliability and durability of the main systems of the Komatsu D65E-12 bulldozer, units of our own production are installed. This applies to the power plant, transmission and hydraulic drives.

By installing a supporting structure of tracks, a swing axis and a flat bottom, excellent maneuverability is achieved when moving over any type of soil, including wetlands. This also has a beneficial effect on the absence of dirt sticking to the caterpillar tracks. The power transmission has a block structure, which ensures high speed of reinstallation of elements.

The straight frame of the core is made of steel of increased thickness, which makes it possible to reduce the number of individual structures and increase the reliability of the equipment. The installation of a larger cross-section track frame and a box-type return beam resulted in an increase in the strength of these elements to the maximum.

Komatsu Torqflow transmission

The Komatsu Torqflow transmission consists of a liquid-cooled, three-element single-stage hydraulic transformer (single-phase) and a planetary gearbox with multi-plate clutch. The gearbox is equipped with a hydraulic drive. It is lubricated under pressure to ensure optimal heat transfer. Shifting gears (3rd - forward and 3rd - reverse), as well as changing the direction of movement, is done using a joystick. The gear shift lock lever with the neutral lock switch prevents the possibility of accidental movement of the tractor.

Onboard gearboxes with double speed reduction are made with straight-cut cylindrical and planetary gears. They are designed to further increase traction. The segmented drive gear makes it easy to change bolt-on segments in the field.

The speeds of movement of the bulldozer in various gears are as follows: in the first – 3.7 (2.3) km/h; on the second – 5.0 (3.1) km/h; on the third – 11.0 (13.9; 8.6) km/h.

Hydraulic system Komatsu D155A-5

The hydraulic system of the Komatsu D155A-5 bulldozer is load-sensitive, capable of accurately and quickly controlling the efficient operation of the special machine (CLSS system with a closed center).

All control spool valves are mounted externally, next to the hydraulic tank. A gear-type hydraulic pump provides a pressure of 255 liters per minute at a nominal engine speed of 20.6 MPa (210 kgf/cm2). There is a safety valve.

The design uses a spool-type hydraulic distributor for a hemispherical or straight blade, with a variable blade skew angle. The additional control valve is designed for a multi-shank ripper with a variable ripening angle and for a single-shank ripper. The hydraulic cylinders are piston type, 2-way acting.

The capacity of the hydraulic system is: bulldozer blade – 97 liters; single-shank or multi-shank ripper - 35 liters.

Optional equipment

Bulldozer blade Komatsu D65E

The price of Komatsu D65E-12 depends on the options that are installed on the machine. These include:

• protective shields for various purposes;
• operator seats;
• air purification systems in two versions, additional air cooling system;
• caterpillar tracks, rigid traction bar, designed to work in difficult conditions;
• additional site lighting;
• hook, drawbar;
• radiator mesh, etc.

Working equipment of Komatsu D155A-5 bulldozer

The bulldozer blade frame for the D155A-5 is made of high-strength steel and further strengthens its structure. Blade skew hoses are located on the inside of the blade to protect them from damage.

Types of bulldozer blades that are used in combination with Komatsu D155A-5:

• Hemispherical blade with variable skew angle. Capacity – 8.8 m3. The length of the dump is 3.955 m, its height is 1.72 m. The greatest height of rise above ground level is 1.25 m. The greatest descent below ground level is 590 mm.
• Spherical blade with variable skew angle. Capacity – 11.8 m3. The length of the blade is 4.265 m, its height is 1.76 m. The greatest height of rise above ground level is 1.25 m. The greatest descent below ground level is 590 mm.
• Conventional blade with variable angle of rotation and skew. Capacity – 4.9 m3. The length of the blade is 4.85 m, its height is 1.205 m. The maximum lifting height above ground level is 1295 mm. The greatest drop below ground level is 745 mm.

In addition to bulldozer blades, single-tooth or multi-shank soil rippers with a maximum depth of 1.22 m (single-tooth) or 0.87 m (multi-shank) are also used.

Other technical characteristics in numbers

• The operating weight of the tractor is 27.9 tons. When installing rock shoes - 28.6 tons. Operating weight of the bulldozer including the blade – 38.7 kg
• Specific ground pressure – 105.9 kPa (1.08 kgf/m2).
• Overall dimensions, with a hemispherical blade: tractor length - 4.975 m, bulldozer with blade and ripper tooth - 8.155 m; tractor width – 2.695 m, bulldozer with blade – 3.955 m; height from ground level to the top of the tractor cabin – 3.5 m.
• Ground clearance is the smallest - 485 mm.
• Volume of refueling tanks: fuel tank - 500 liters, engine lubrication system - 37 liters, cooling system - 99 liters, hydromechanical transmission, main gear and final clutches - 60 liters, final drive housing (on each side) - 58 liters, shock absorber for each – 1.5 liters.

ENGINE

In the engine compartment of the Komatsu D65PX 16 there is a 4-stroke diesel engine produced by Komatsu SAA6D114E-3. The unit has turbocharging, charge air cooling, a liquid cooling system and direct fuel injection. The lubrication system involves forced lubrication driven by a gear pump. Access to engine elements is easier, which allows you to perform maintenance and repairs with minimal time.

In terms of harmful emissions, the unit complies with the environmental class EPA Tier 3/EU Stage 3A.

Characteristics of the Komatsu SAA6D114E-3 motor:

• working volume – 8.27 l;
• power – 155 (207) kW (hp);
• rated speed – 1950 rpm;
• number of cylinders – 6;
• cylinder diameter – 114 mm.

The average fuel consumption for this equipment is within the range of 19-25 l/hour.

Cabin and workplace of the Komatsu D155A-5 bulldozer

As already noted, turning or any other change in the direction of movement of the bulldozer, as well as changing gears, can be done using one joystick-type lever. If the operator needs to direct the special vehicle forward/to the left, then he needs to move the joystick away from himself and tilt it to the left. To change gear, he only needs to bend his wrist. The tractor immediately responds to movements of the joystick lever.

Since the diesel engine, power transmission components and control valves are mounted on the frame on rubber cushions, and there are also protective barriers that remove noise from the engine, decent noise and vibration insulation is maintained in the cabin. The use of air filters and the creation of excess pressure inside the cabin prevent dust from entering the cabin. The chassis, balanced on an elastic suspension, in combination with the oil shock absorber of the cab suspension, softens the shock loads perceived by the operator. The visibility from the cab is very good - both forward and around the tractor in general.

The following main indicators and lamps are located on the dashboard: engine hour meter, engine coolant temperature indicator, gearbox oil temperature indicator, fuel level indicator, warning lights - coolant temperature, charge level, engine oil pressure, gearbox oil temperature, glow plug warning light, warning light.

Operator workstation: human-machine interface

The machine's cabin ensures complete safety for the operator when objects fall from above due to the powerful one-piece frame. The cabin itself is hermetically sealed, and the air supply system maintains a slightly increased pressure in it. Therefore, even in the dustiest object there will be clean air inside the car. This was the case in the fifth generation D375A. The new version of the bulldozer features a color monitor inside and a fully controlled working environment.

The sixth generation D375A introduced a large color monitor. A liquid crystal system was chosen as the matrix for the screen. It has fairly good color rendering for construction purposes, and its main advantage is a wide viewing angle. A user-friendly interface makes it easier to interact with the machine and allows you to perform operations more accurately and quickly. In total, the operator has 10 interaction languages ​​available, including Russian and English. If an error occurs in the system, a message about it is displayed on the screen. Thanks to this, you can fix minor problems without causing major breakdowns.

The PCCS (joystick control system) is now responsible for working with the chassis. Gears are downshifted and upshifted at the touch of a button. To start moving, you need to move the joystick in the appropriate direction. An important detail: the console on which this control element is located can be adjusted along three axes, choosing a position convenient for operation. The same joystick is used to control the blade. Moreover, it is even compatible with a double-skew blade, which is installed optionally.

The hydraulically suspended seat absorbs vibrations more effectively. Additionally, you can order the installation of air suspension and shock absorber, which work even better. The chair can be adjusted to suit your needs:

• move along the cabin along special guides. Their length is designed so that it is possible to provide comfortable working conditions for a person of any height;
• separately adjust the height of the armrests, backrest tilt and seat height;
• adjust the position of the ripper control lever;
• turning to the right by 15° is convenient when moving backwards. The controls move with the chair.

Safety

Safety is the most important thing in any technology. This model has improved various aspects and paid special attention to safety when working at night, in quarries and in mining.

• The headlights are mounted high, so they illuminate a large area. Xenon lighting can be ordered as an additional option.
• There is a rear view camera.
• Manual switches for emergency stop of the motor.
• De-energizing box for disconnecting the battery from the network during maintenance.
• Uninterruptible power supply for radio communications and cabin lighting.
• Access lamps for safe boarding and disembarking at night.
• There is a headlight under the hood for easy maintenance and repair of the car in the dark.
• Cartridge type breathers are installed - they are easier to maintain.
• The drain service panel allows you to add and drain oil/coolant without leaving the machine.
• Concentrated oil and coolant sampling points make testing these consumables quick and easy.
• There is space to install a platform.