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Komatsu Bulldozer D61EX-12 D61PX-12 Operator & Maintenance Manual SN 1106, 1112 and up – PDF DOWNLOAD
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Komatsu Bulldozer D61EX-12 D61PX-12 Operator & Maintenance Manual
Book Code: SEAM035003T
SERIAL NUMBERS:
- D61EX-12-1106 and up
- D61PX-12-1112 and up
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Description
Komatsu Bulldozer D61EX-12 D61PX-12 Operator & Maintenance Manual
FILE DETAILS:
Komatsu Bulldozer D61EX-12 D61PX-12 Operator & Maintenance Manual
Size: 8.16 MB
Fomat: PDF
Language: English
Brand: Komatsu
Type of machine: Bulldozer
Type of document: Operator & Maintenance Manual
Model: D61EX_PX
Serial: 1106 1112 and up
Number of Page: 247
KOMATSU BULLDOZER D61EX-12 D61PX-12 OPERATOR & MAINTENANCE MANUAL SN 1106, 1112 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Bulldozer D61EX-12 D61PX-12 Operator & Maintenance Manual
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 forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu Bulldozer D61EX-12 D61PX-12 Operator & Maintenance Manual
MAIN MENU....................................................................................................... 0 COVER........................................................................................................... 1 FOREWORD........................................................................................................ 2 FOREWORD.................................................................................................... 3 SAFETY INFORMATION.......................................................................................... 6 INTRODUCTION................................................................................................ 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE............................................................ 8 NECESSARY INFORMATION....................................................................................... 9 MACHINE SERIAL NO. PLATE AND POSITION................................................................... 9 ENGINE SERIAL NO. PLATE AND POSITION.................................................................... 9 POSITION OF SERVICE METER............................................................................... 10 TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR............................................................... 10 CONTENTS.................................................................................................... 11 SAFETY.......................................................................................................... 16 SAFETY...................................................................................................... 17 SAFETY LABELS............................................................................................... 19 POSITIONS OF SAFETY PICTOGRAMS.......................................................................... 19 SAFETY LABELS........................................................................................... 20 GENERAL PRECAUTIONS......................................................................................... 23 SAFETY RULES............................................................................................ 23 IF ABNORMALITIES ARE FOUND.............................................................................. 23 CLOTHING AND PERSONAL PROTECTIVE ITEMS.................................................................. 23 FIRE EXTINGUISHER AND FIRST AID KIT..................................................................... 23 SAFETY FEATURES......................................................................................... 24 KEEP MACHINE CLEAN...................................................................................... 24 INSIDE OPERATOR'S COMPARTMENT........................................................................... 24 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.......................................................... 24 HANDRAILS AND STEPS..................................................................................... 25 MOUNTING AND DISMOUNTING................................................................................ 26 NO PEOPLE ON ATTACHMENTS................................................................................ 26 PREVENTION OF BURNS..................................................................................... 27 FIRE PREVENTION......................................................................................... 27 ACTION IF FIRE OCCURS................................................................................... 28 WINDOW WASHER LIQUID.................................................................................... 28 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)............................................ 28 PRECAUTIONS FOR ATTACHMENTS............................................................................. 29 UNATHORIZED MODIFICATION................................................................................ 29 SAFETY AT WORKSITE...................................................................................... 29 WORKING ON LOOSE GROUND................................................................................. 30 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES.................................................................. 30 ENSURE GOOD VISIBILITY.................................................................................. 30 VENTILATION FOR ENCLOSED AREAS.......................................................................... 31 CHECKING SIGNALMAN'S SIGNALS AND SIGNS.................................................................. 31 EMERGENCY EXIT FROM OPERATOR'S CAB...................................................................... 31 BE CAREFUL ABOUT ASBESTOS DUST.......................................................................... 31 PRECAUTIONS FOR OPERATION................................................................................... 32 STARTING ENGINE......................................................................................... 32 CHECKS BEFORE STARTING ENGINE....................................................................... 32 PRECAUTIONS WHEN STARTING........................................................................... 33 PRECAUTIONS IN COLD AREAS........................................................................... 33 OPERATION............................................................................................... 34 CHECKS AFTER OPERATION.............................................................................. 34 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE................................................ 34 PRECAUTIONS WHEN TRAVELING.......................................................................... 35 TRAVELING ON SLOPES................................................................................. 36 OPERATE CAREFULLY ON SNOW.......................................................................... 36 PARKING MACHINE..................................................................................... 37 TRANSPORTATION.......................................................................................... 38 LOADING AND UNLOADING............................................................................... 38 SHIPPING............................................................................................ 38 BATTERY................................................................................................. 39 BATTERY HAZARD PREVENTION........................................................................... 39 STARTING WITH BOOSTER CABLE......................................................................... 40 TOWING.................................................................................................. 41 WHEN TOWING......................................................................................... 41 PRECAUTIONS FOR MAINTENANCE............................................................................. 42 WARNING TAG......................................................................................... 42 KEEP WORK PLACE CLEAN AND TIDY...................................................................... 42 APPOINT LEADER WHEN WORKING WITH OTHERS............................................................. 42 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.......................................... 43 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.................................................. 44 PROPER TOOLS........................................................................................ 44 PERSONNEL........................................................................................... 44 ATTACHMENTS......................................................................................... 45 PRECAUTIONS FOR WORK UNDER MACHINE AND WORK EQUIPMENT............................................... 45 NOISE............................................................................................... 45 PRECAUTIONS WHEN USING HAMMER....................................................................... 45 REPAIR WELDING...................................................................................... 46 REMOVING BATTERY TERMINAL........................................................................... 46 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION................................. 46 DO NOT DISASSEMBLE RECOIL SPRING.................................................................... 46 PRECAUTION WITH HIGH-PRESSURE OIL................................................................... 47 HANDLING HIGH-PRESSURE HOSES........................................................................ 47 WASTE MATERIALS..................................................................................... 47 MAINTENANCE FOR AIR CONDITIONER..................................................................... 48 COMPRESSED AIR...................................................................................... 48 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................... 48 OPERATION....................................................................................................... 50 GENERAL VIEW................................................................................................ 51 GENERAL VIEW OF MACHINE................................................................................. 51 GENERAL VIEW OF CONTROLS AND GAUGES..................................................................... 52 EXPLANATION OF COMPONENTS................................................................................... 54 MONITOR PANEL........................................................................................... 54 SWITCHES................................................................................................ 58 LAMP.................................................................................................... 63 CONTROL LEVERS AND PEDALS............................................................................... 64 FUSE.................................................................................................... 71 ELECTRIC POWER TAKE-OUT ADAPTER......................................................................... 73 DOOR-OPEN LOCK.......................................................................................... 74 SASH GLASS INTERMEDIATE LOCK............................................................................ 74 CAP, COVER WITH LOCK.................................................................................... 75 HOT AND COOL BOX........................................................................................ 76 OPERATION MANUAL STORAGE................................................................................ 76 ASHTRAY................................................................................................. 77 TOOL BOX................................................................................................ 77 AIR CONDITIONER......................................................................................... 78 HEATER.................................................................................................. 84 OPERATION................................................................................................... 87 CHECK BEFORE STARTING ENGINE, ADJUST.................................................................... 87 STARTING ENGINE.........................................................................................103 OPERATIONS AND CHECKS AFTER STARTING ENGINE.............................................................108 STOPPING ENGINE.........................................................................................111 CHECK AFTER STOPPING ENGINE.............................................................................112 MACHINE OPERATION.......................................................................................113 SHIFTING GEAR...........................................................................................117 SHIFTING BETWEEN FORWARD AND REVERSE....................................................................118 STEERING MACHINE........................................................................................120 PRECAUTIONS FOR OPERATION...............................................................................124 WORK POSSIBLE USING BULLDOZER...........................................................................126 ADJUSTING POSTURE OF WORK EQUIPMENT.....................................................................128 PARKING MACHINE.........................................................................................130 CHECK AFTER FINISHING WORK..............................................................................132 LOCKING ................................................................................................132 TIPS FOR LONGER UNDERCARRIAGE LIFE......................................................................133 TRANSPORTATION..............................................................................................137 TRANSPORTATION PROCEDURE................................................................................137 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT................................................................137 REMOVING CAB............................................................................................138 LOADING, UNLOADING WORK.................................................................................139 LIFTING MACHINE.........................................................................................143 COLD WEATHER OPERATION......................................................................................146 PRECAUTIONS FOR LOW TEMPERATURE.........................................................................146 AFTER COMPLETION OF WORK................................................................................148 AFTER COLD WEATHER......................................................................................148 LONG-TERM STORAGE...........................................................................................149 BEFORE STORAGE..........................................................................................149 DURING STORAGE..........................................................................................149 AFTER STORAGE...........................................................................................149 STARTING MACHINE AFTER LONG-TERM STORAGE................................................................150 TROUBLESHOOTING.............................................................................................151 AFTER RUNNING OUT OF FUEL...............................................................................151 TOWING THE MACHINE......................................................................................151 IF BATTERY IS DISCHARGED................................................................................152 OTHER TROUBLE...........................................................................................156 MAINTENANCE.....................................................................................................160 GUIDE TO MAINTENANCE........................................................................................161 OUTLINE OF SERVICE..........................................................................................164 OUTLINE OF OIL, FUEL, COOLANT...........................................................................164 RELATING TO ELECTRIC SYSTEM.............................................................................166 HANDLING HYDRAULIC SYSTEM...............................................................................166 WEAR PARTS..................................................................................................168 WEAR PARTS LIST.........................................................................................168 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE........................................169 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS........................................................169 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..............................................................173 TORQUE LIST.............................................................................................173 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...............................................................174 SAFETY CRITICAL PARTS...................................................................................175 MAINTENANCE SCHEDULE CHART..................................................................................176 MAINTENANCE SCHEDULE CHART..............................................................................176 WHEN REQUIRED...........................................................................................178 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT........................................................178 CLEAN INSIDE OF COOLING SYSTEM......................................................................182 CHECK TRACK TENSION.................................................................................184 CHECK AND TIGHTEN TRACK SHOE BOLTS..................................................................185 CHECK ELECTRICAL INTAKE AIR HEATER..................................................................186 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES..................................................187 CLEAN, CHECK REDIATOR FINS..........................................................................188 ADJUST IDLER CLEARANCE..............................................................................189 ADJUSTING TENSION OF CENTER BRACE...................................................................190 CHECK, INSPECTION AIR CONDITIONER (MACHINE EQUIPPED WITH CAB).......................................191 GREASE DOOR HINGE (MACHINE EQUIPPED WITH CAB).......................................................192 CHECK DOOR LOCK STRIKER (MACHINE EQUIPPED WITH CAB).................................................192 REPLACE DOOR DAMPER (MACHINE EQUIPPED WITH CAB).....................................................192 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID (MACHINE EQUIPPED WITH CAB).............................193 REPLACE WIPER BLADE (MACHINE EQUIPPED WITH CAB).....................................................194 CHECK IDLER OIL LEVEL, ADD OIL......................................................................195 CHECK OIL LEVEL IN DAMPER CASE, ADD AND CHANGE OIL..................................................196 PROCEDURE FOR BLEEDING AIR OF HYDRAULIC SYSTEM......................................................197 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM.......................................198 CHECK BEFORE STARTING...................................................................................199 EVERY 50 HOURS SERVICE..................................................................................200 DRAIN WATER, SEDIMENT FROM FUEL TANK................................................................200 LUBRICATING.........................................................................................200 EVERY 250 HOURS SERVICE................................................................................201 LUBRICATING.........................................................................................201 GREASE EQUALIZER BAR SIDE PIN.......................................................................202 GREASE EQUALIZER BAR CENTER PIN.....................................................................202 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL........................................................203 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL..........................................................203 CHECK LEVEL OF BATTERY ELECTROLYTE..................................................................204 CHECK FAN BELT TENSION, ADJUST......................................................................205 CHECK, CLEAN FUEL STRAINER..........................................................................206 CHECK BRAKE PERFORMANCE.............................................................................206 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) (MACHINE EQUIPPED WITH CAB)..................207 EVERY 500 HOURS SERVICE.................................................................................208 REPLACE FUEL FILTER CARTRIDGE.......................................................................208 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...................................209 REPLACE CORROSION RESISTOR CARTRIDGE................................................................210 REPLACE POWER TRAIN OIL FILTER ELEMENT..............................................................210 EVERY 1000 HOURS SERVICE................................................................................211 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER, SCAVENGING PUMP STRAINER)....211 CHANGE OIL IN FINAL DRIVE CASE......................................................................213 CLEAN BREATHER......................................................................................213 GREASE UNIVERSAL JOINT..............................................................................214 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER..........................................................215 CHECK PLAY OF TURBOCHARGER ROTOR....................................................................215 CHECK FOR LOOSE ROPS MOUNT BOLTS (IF EQUIPPED)......................................................215 EVERY 2000 HOURS SERVICE................................................................................216 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT AND CLEAN SUCTION STRAINER.......216 CLEAN, CHECK TURBOCHARGER...........................................................................217 CHECK VIBRATION DAMPER..............................................................................217 CHECK ALTERNATOR, STARTING MOTOR....................................................................217 EVERY 4000 HOURS SERVICE................................................................................218 CHECK WATER PUMP....................................................................................218 SPECIFICATIONS..................................................................................................220 SPECIFICATIONS..............................................................................................221 ATTACHMENTS, OPTIONS............................................................................................222 GENERAL PRECAUTIONS.........................................................................................223 PRECAUTIONS RELATED TO SAFETY...........................................................................223 HANDLING HYDRAULIC RIPPER...................................................................................224 GENERAL VIEW............................................................................................224 EXPLANATION OF COMPONENTS...............................................................................225 OPERATiON...............................................................................................226 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE........................................................226 ADJUSTMENT OF WORK EQUIPMENT............................................................................226 TROUBLESHOOTING.........................................................................................228 INSPECTION AND MAINTENANCE..............................................................................229 SPECIFICATIONS..........................................................................................229 HANDLING TOWING WINCH.......................................................................................230 EXPLANATION OF COMPONENTS...............................................................................230 OPERATION...............................................................................................232 INSPECTION AND ADJUSTMENT BEFORE STARTING ENGINE........................................................233 ADJUSTING ..............................................................................................236 HANDLING WIRE ROPE......................................................................................237 SERVICE PROCEDURE.......................................................................................238 SPECIFICATIONS..........................................................................................240 HEADREST....................................................................................................242 EQUIPPING THE FIRE EXTINGUISHER AND THE FIRST-AID KIT.......................................................243 INDEX.......................................................................................................244
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