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KOMATSU D61EX -15E0 D61PX-15E0 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:B46105 & UP) – PDF DOWNLOAD
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- KOMATSU D61EX -15E0 D61PX-15E0 BULLDOZER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:B46105 & UP
- PUBLICATION NUMBER:KEAM019001T
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Description
KOMATSU D61EX -15E0 D61PX-15E0 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:B46105 & UP)
KOMATSU D61EX -15E0 D61PX-15E0 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:B46105 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU D61EX -15E0 D61PX-15E0 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:B46105 & UP)
- 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
- 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.
TABLE OF CONTENTS:
KOMATSU D61EX -15E0 D61PX-15E0 BULLDOZER OPERATION & MAINTENANCE MANUAL (SN:B46105 & UP)
COVER................................................................................................................ 1 FOREWORD............................................................................................................. 2 FOREWORD......................................................................................................... 3 SAFETY INFORMATION............................................................................................... 6 INTRODUCTION..................................................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................................................................. 8 NECESSARY INFORMATION............................................................................................ 9 PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE................................................. 9 EPA REGULATION, ENGINE SERIAL NO. PLATE...................................................................... 9 POSITION OF SERVICE METER.................................................................................... 10 TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR.................................................................... 10 FOREWORD..................................................................................................... 11 SAFETY....................................................................................................... 11 OPERATION.................................................................................................... 11 MAINTENANCE.................................................................................................. 14 SPECIFICATIONS............................................................................................... 16 ATTACHMENTS, OPTIONS......................................................................................... 16 INDEX........................................................................................................ 17 COLOPHON..................................................................................................... 17 SAFETY............................................................................................................... 18 IMPORTANT SAFETY INFORMATION..................................................................................... 19 SAFETY LABELS.................................................................................................... 21 POSITION FOR ATTACHING SAFETY LABELS......................................................................... 21 SAFETY LABELS................................................................................................ 22 PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE.................................................................. 26 PRECAUTIONS DURING OPERATION..................................................................................... 33 PRECAUTIONS FOR MAINTENANCE...................................................................................... 38 PRECAUTIONS FOR MACHINE.......................................................................................... 45 OPERATION............................................................................................................ 46 GENERAL VIEW..................................................................................................... 47 GENERAL VIEW OF MACHINE...................................................................................... 47 GENERAL VIEW OF CONTROLS AND GAUGES.......................................................................... 48 EXPLANATION OF COMPONENTS........................................................................................ 51 FRONT PANEL.................................................................................................. 51 CHECK MONITOR SYSTEM..................................................................................... 52 EMERGENCY CAUTION ITEMS.................................................................................. 53 CAUTION ITEMS............................................................................................ 55 METER GROUP.............................................................................................. 57 LAMPS.................................................................................................... 62 SWITCHES................................................................................................. 64 METHOD OF USING MAINTENANCE MODE......................................................................... 69 SWITCHES..................................................................................................... 78 CONTROL LEVERS AND PEDALS.................................................................................... 82 CIRCUIT BREAKER.............................................................................................. 89 FUSE......................................................................................................... 89 FUSIBLE LINK................................................................................................. 91 ELECTRIC POWER TAKE-OUT ADAPTER.............................................................................. 92 MACHINE EQUIPPED WITH CAB................................................................................ 92 MACHINE EQUIPPED WITH CANOPY............................................................................. 92 DOOR - OPEN LOCK............................................................................................. 93 SASH GLASS INTERMEDIATE LOCK................................................................................. 93 CAP, COVER WITH LOCK......................................................................................... 94 METHOD OF OPENING AND CLOSING CAP WITH LOCK.............................................................. 94 METHOD OF OPENING AND CLOSING COVER WITH LOCK............................................................ 95 DOOR POCKET.................................................................................................. 96 OPENING AND CLOSING ENGINE SIDE COVER........................................................................ 96 ASHTRAY...................................................................................................... 97 TOOL BOX..................................................................................................... 97 CAR RADIO, HANDLING.......................................................................................... 98 EXPLANATION OF COMPONENTS................................................................................ 98 METHOD OF OPERATION...................................................................................... 99 PRECAUTIONS WHEN USING...................................................................................101 CAR STEREO, HANDLING.........................................................................................102 EXPLANATION OF COMPONENTS................................................................................102 METHOD OF OPERATION......................................................................................107 PRECAUTION WHEN USING....................................................................................109 AIR CONDITIONER, HANDLING....................................................................................110 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL..........................................................110 METHOD OF OPERATION......................................................................................113 PRECAUTION WHEN USING AIR CONDITIONER....................................................................114 SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE.......................................114 INSPECTION DURING OFF-SEASON.............................................................................114 PROCEDURE FOR REPLACING RECEIVER.........................................................................114 CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL................................................114 CLEANING AIR FILTER......................................................................................115 OPERATION........................................................................................................116 CHECK BEFORE STARTING ENGINE, ADJUST.........................................................................116 WALK-AROUND CHECK........................................................................................116 CHECK BEFORE STARTING....................................................................................117 ADJUSTMENT...............................................................................................125 OPERATION AND CHECK BEFORE STARTING ENGINE...............................................................129 STARTING ENGINE..............................................................................................131 NORMAL STARTING..........................................................................................131 STARTING IN COLD WEATHER.................................................................................132 OPERATIONS AND CHECKS AFTER STARTING ENGINE..................................................................135 WARMING UP OPERATIONS....................................................................................135 STARTING IN COLD WEATHER.................................................................................136 STOPPING ENGINE..............................................................................................138 MACHINE OPERATION............................................................................................139 MOVING MACHINE...........................................................................................139 STOPPING MACHINE.........................................................................................141 SHIFTING GEARS...............................................................................................142 GEARSHIFTING OPERATION...................................................................................142 GEARSHIFTING OPERATION USING PRESET MODE FUNCTION........................................................143 AUTO DOWN SHIFT OPERATION................................................................................144 SHIFTING BETWEEN FORWARD AND REVERSE.........................................................................145 STEERING MACHINE.............................................................................................147 NORMAL TURNING...........................................................................................147 PRECAUTIONS FOR OPERATION....................................................................................149 PAY ATTENTION TO GAUGES..................................................................................149 PERMISSIBLE WATER DEPTH..................................................................................149 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS..............................................................149 PRECAUTIONS ON SLOPES....................................................................................149 METHOD OF USING BRAKES...................................................................................150 IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS.................................................150 IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW..........................150 PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES............................................150 WORK POSSIBLE USING BULLDOZER................................................................................151 DOZING...................................................................................................151 SMOOTHING................................................................................................151 CUTTING INTO HARD OR FROZEN GROUND OR DITCHING...........................................................152 ADJUSTING POSTURE OF WORK EQUIPMENT..........................................................................153 ADJUST ANGLE OF BLADE EDGE...............................................................................153 ADJUST AMOUNT OF TILT....................................................................................154 CHECK AFTER FINISHING WORK...................................................................................156 BEFORE STOPPING ENGINE...................................................................................156 AFTER STOPPING ENGINE....................................................................................156 LOCKING......................................................................................................156 TIPS FOR LONGER UNDERCARRIAGE LIFE...........................................................................157 OPERATION METHOD.........................................................................................157 TRANSPORTATION...................................................................................................158 TRANSPORTATION MEANS.........................................................................................158 REMOVING CAB.................................................................................................158 PRECAUTIONS WHEN REMOVING WORK EQUIPMENT.....................................................................158 POWER ANGLE, POWER TILTDOZER.............................................................................158 POWER TILTDOZER..........................................................................................158 PRECAUTIONS WHEN REMOVING ROPS...............................................................................159 LOADING, UNLOADING WORK......................................................................................160 METHOD OF LIFTING MACHINE....................................................................................163 TRAVELING ON ROADS...........................................................................................167 COLD WEATHER OPERATION...........................................................................................168 PRECAUTIONS FOR LOW TEMPERATURE..............................................................................168 AFTER COMPLETION OF WORK.....................................................................................169 AFTER COLD WEATHER...........................................................................................169 LONG-TERM STORAGE................................................................................................170 BEFORE STORAGE...............................................................................................170 DURING STORAGE...............................................................................................170 AFTER STORAGE................................................................................................170 TROUBLESHOOTING..................................................................................................171 AFTER RUNNING OUT OF FUEL....................................................................................171 METHOD OF TOWING MACHINE.....................................................................................171 WHEN ENGINE DOES NOT START...............................................................................172 IF BATTERY IS DISCHARGED.....................................................................................175 REMOVE AND INSTALL BATTERY...............................................................................176 PRECAUTIONS FOR BATTERY CHARGING.........................................................................176 STARTING ENGINE WITH BOOSTER CABLE.......................................................................177 OTHER TROUBLE................................................................................................179 ELECTRICAL SYSTEM........................................................................................179 MONITOR PANEL............................................................................................180 CHASSIS..................................................................................................181 ENGINE...................................................................................................182 MAINTENANCE..........................................................................................................184 GUIDE TO MAINTENANCE.............................................................................................185 OUTLINE OF SERVICE...............................................................................................188 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.......................................................188 OIL......................................................................................................188 FUEL.....................................................................................................189 COOLANT AND WATER FOR DILUTION...........................................................................189 GREASE...................................................................................................190 CARRYING OUT KOWA (Komatsu Oil Wear Analysis)............................................................190 STORING OIL AND FUEL.....................................................................................191 FILTERS..................................................................................................191 RELATING TO ELECTRIC SYSTEM..................................................................................191 HANDLING HYDRAULIC SYSTEM....................................................................................192 WEAR PARTS LIST..................................................................................................193 WEAR PARTS LIST..............................................................................................193 RECOMMENDED FUEL, COOLANT, AND LUBRICANT.........................................................................194 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.........................................195 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL..........................196 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...................................................................197 TORQUE LIST..................................................................................................197 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................................198 SAFETY CRITICAL PARTS........................................................................................198 MAINTENANCE SCHEDULE CHART.......................................................................................199 MAINTENANCE SCHEDULE CHART...................................................................................199 WHEN REQUIRED............................................................................................199 CHECK BEFORE STARTING....................................................................................199 EVERY 50 HOURS SERVICE...................................................................................199 EVERY 250 HOURS SERVICE..................................................................................199 EVERY 500 HOURS SERVICE..................................................................................199 EVERY 1000 HOURS SERVICE.................................................................................200 EVERY 2000 HOURS SERVICE.................................................................................200 EVERY 4000 HOURS SERVICE.................................................................................200 SERVICE PROCEDURE................................................................................................201 WHEN REQUIRED................................................................................................201 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.............................................................201 CLEAN INSIDE OF COOLING SYSTEM...........................................................................205 CHECK TRACK SHOE TENSION, ADJUST.........................................................................208 CHECK AND TIGHTEN TRACK SHOE BOLTS.......................................................................210 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................................210 REVERSE AND REPLACE END BITS AND CUTTING EDGES...........................................................211 CLEANING AND INSPECTION OF FINS OF RADIATOR, OIL COOLER, CONDENSER AND AFTER-COOLER......................213 CHECK, ADJUST AIR CONDITIONER............................................................................216 GREASE DOOR HINGE........................................................................................217 CHECK DOOR LOCK STRIKER..................................................................................217 REPLACE DOOR DAMPER......................................................................................217 CHECK DOOR LATCH.........................................................................................218 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...............................................................218 PROPORTION FOR MIXING FLUID WITH WATER...................................................................218 REPLACE WIPER BLADE......................................................................................219 CHECK IDLER OIL LEVEL, ADD OIL...........................................................................220 ADJUST IDLER CLEARANCE...................................................................................220 CHECK LINK PITCH.........................................................................................221 CHECK OUTSIDE DIAMETER OF TRACK ROLLER...................................................................221 CHECK HEIGHT OF GROUSER..................................................................................222 ADJUST PLAY IN CENTER BALL...............................................................................222 LUBRICATING UNIVERSAL JOINT..............................................................................223 PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM...........................................................224 PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM............................................224 CHECK BEFORE STARTING........................................................................................225 EVERY 50 HOURS SERVICE.......................................................................................226 DRAIN WATER, SEDIMENT FROM FUEL TANK.....................................................................226 LUBRICATING..............................................................................................226 EVERY 250 HOURS SERVICE......................................................................................227 LUBRICATING..............................................................................................227 GREASE EQUALIZER BAR SIDE PIN............................................................................229 GREASE EQUALIZER BAR CENTER PIN..........................................................................229 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL.............................................................230 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................................230 CHECK LEVEL OF BATTERY ELECTROLYTE.......................................................................231 CHECK BRAKE PERFORMANCE..................................................................................234 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....................................................235 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)...................................................236 EVERY 500 HOURS SERVICE......................................................................................237 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................................237 REPLACE POWER TRAIN OIL FILTER ELEMENT...................................................................239 REPLACE FUEL PRE-FILTER CARTRIDGE........................................................................239 EVERY 1000 HOURS SERVICE.....................................................................................242 REPLACE FUEL MAIN FILTER CARTRIDGE.......................................................................242 CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER)....245 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL..................................................................247 CHANGE OIL IN FINAL DRIVE CASE...........................................................................248 CLEAN BREATHER...........................................................................................248 CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS................................................249 CHECK FOR LOOSE ROPS MOUNT BOLTS.........................................................................249 EVERY 2000 HOURS SERVICE.....................................................................................250 CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT.................................................250 REPLACE HYDRAULIC TANK BREATHER ELEMENT..................................................................251 CHANGE OIL IN DAMPER CASE................................................................................252 CLEAN, CHECK TURBOCHARGER................................................................................253 CHECK VIBRATION DAMPER...................................................................................253 CHECK ALTERNATOR, STARTING MOTOR.........................................................................253 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................................253 EVERY 4000 HOURS SERVICE.....................................................................................254 CHECK WATER PUMP.........................................................................................254 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER.......................................255 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......................................256 SPECIFICATIONS.......................................................................................................258 SPECIFICATIONS...................................................................................................259 ATTACHMENTS, OPTIONS.................................................................................................260 GENERAL PRECAUTIONS..............................................................................................261 PRECAUTIONS RELATED TO SAFETY................................................................................261 HANDLING HYDRAULIC RIPPER........................................................................................262 GENERAL VIEW.................................................................................................262 EXPLANATION OF COMPONENTS....................................................................................263 OPERATION....................................................................................................264 CHECK BEFORE STARTING ENGINE, ADJUST.....................................................................264 PRECAUTIONS WHEN OPERATING...............................................................................264 ADJUSTING POSTURE OF WORK EQUIPMENT......................................................................264 TROUBLESHOOTING..............................................................................................266 OTHER TROUBLE............................................................................................266 MAINTENANCE..................................................................................................267 EVERY 250 HOURS SERVICE..................................................................................267 SPECIFICATIONS...............................................................................................267 AIR SUSPENSION SEAT..............................................................................................268 DELUXE SEAT......................................................................................................270 HEADREST.........................................................................................................271 EQUIPPING FIRE EXTINGUISHER......................................................................................272 HANDLING MACHINES EQUIPPED WITH KOMTRAX..........................................................................273 BASIC PRECAUTIONS............................................................................................273 INDEX................................................................................................................274 <A>..............................................................................................................276 <C>..............................................................................................................276 <D>..............................................................................................................276 <E>..............................................................................................................276 <F>..............................................................................................................276 <G>..............................................................................................................276 <H>..............................................................................................................276 <I>..............................................................................................................276 <L>..............................................................................................................276 <M>..............................................................................................................276 <N>..............................................................................................................276 <O>..............................................................................................................276 <P>..............................................................................................................277 <R>..............................................................................................................277 <S>..............................................................................................................277 <T>..............................................................................................................277 <W>..............................................................................................................277 COLOPHON.............................................................................................................278
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⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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