Komatsu D61EX-23M0 Bulldozer Index:

CONTENTS
FOREWORD…………………………………………………………………………………………………………………………1-1
BEFORE READING THIS MANUAL ……………………………………………………………………………………..1-2
SAFETY INFORMATION ……………………………………………………………………………………………………1-3
OPERATING CONDITION…………………………………………………………………………………………………..1-4
INTRODUCTION………………………………………………………………………………………………………………1-5
USE OF MACHINE……………………………………………………………………………………………………..1-5
DIRECTIONS OF MACHINE …………………………………………………………………………………………1-5
VISIBILITY FROM OPERATOR’S SEAT…………………………………………………………………………..1-6
PRODUCT INFORMATION…………………………………………………………………………………………………1-7
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ………………………….1-7
ENGINE SERIAL NO. PLATE ……………………………………………………………………………………………1-7
SERVICE METER LOCATION……………………………………………………………………………………….1-8
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR …………………………………………………..1-8
CONTENTS………………………………………………………………………………………………………………….. 1-10
SAFETY……………………………………………………………………………………………………………………………….2-1
SAFETY…………………………………………………………………………………………………………………………2-2
SAFETY LABELS……………………………………………………………………………………………………………..2-4
LOCATION OF SAFETY LABELS…………………………………………………………………………………..2-4
SAFETY LABELS……………………………………………………………………………………………………….2-5
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE …………………………… 2-10
PRECAUTIONS BEFORE STARTING OPERATION ………………………………………………………….2-10
PREPARATIONS FOR SAFE OPERATION ……………………………………………………………………..2-11
FIRE PREVENTION ………………………………………………………………………………………………….2-13
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE …………………………………………………2-15
DO NOT GET CAUGHT IN WORK EQUIPMENT ………………………………………………………………2-16
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES …………………………………………….2-17
UNAUTHORIZED MODIFICATION ……………………………………………………………………………….2-17
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ………………………………………….2-17
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING…………………………………………..2-17
PRECAUTIONS FOR OPERATION…………………………………………………………………………………… 2-18
PRECAUTIONS FOR JOBSITE………………………………………………………………………………….. 2-18
STARTING ENGINE …………………………………………………………………………………………………. 2-21
OPERATION……………………………………………………………………………………………………………2-23
TRANSPORTATION ………………………………………………………………………………………………….2-27
TOWING…………………………………………………………………………………………………………………2-28
PRECAUTIONS FOR MAINTENANCE ………………………………………………………………………………..2-29
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ……………………………2-29
PRECAUTIONS FOR INSPECTION AND MAINTENANCE …………………………………………………2-33
OPERATION …………………………………………………………………………………………………………………………3-1
GENERAL VIEW………………………………………………………………………………………………………………3-2
GENERAL VIEW OF MACHINE……………………………………………………………………………………..3-2
GENERAL VIEW OF CONTROLS AND GAUGES……………………………………………………………….3-4
EXPLANATION OF COMPONENTS……………………………………………………………………………………..3-6
MACHINE MONITOR…………………………………………………………………………………………………..3-6
SWITCHES……………………………………………………………………………………………………………..3-77
CONTROL LEVERS AND PEDALS ………………………………………………………………………………3-83
DUST INDICATOR ……………………………………………………………………………………………………3-89
FUSE …………………………………………………………………………………………………………………….3-90
FUSIBLE LINK …………………………………………………………………………………………………………3-92
AUXILIARY ELECTRIC POWER ………………………………………………………………………………….3-93
OIL FILLER CAP ………………………………………………………………………………………………………3-94
DOOR OPEN LOCK ………………………………………………………………………………………………….3-96
SASH GLASS INTERMEDIATE LOCK …………………………………………………………………………..3-96
ASHTRAY……………………………………………………………………………………………………………….3-97

LUNCH BOX FASTENING BELT ………………………………………………………………………………….3-97
FOREWORD CONTENTS
HANDLING AIR CONDITIONER……………………………………………………………………………………..3-99
HANDLING RADIO……………………………………………………………………………………………………. 3-103
BATTERY DISCONNECT SWITCH ………………………………………………………………………………. 3-108
SYSTEM OPERATING LAMP………………………………………………………………………………………. 3-109
KOMTRAX ………………………………………………………………………………………………………………..3-110
MACHINE OPERATIONS AND CONTROLS …………………………………………………………………………. 3-112
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE…………………………………………….. 3-112
STARTING ENGINE ………………………………………………………………………………………………….. 3-132
OPERATIONS AND CHECKS AFTER STARTING ENGINE………………………………………………… 3-136
STOPPING ENGINE………………………………………………………………………………………………….. 3-140
MACHINE OPERATION……………………………………………………………………………………………… 3-141
SHIFTING GEARS ……………………………………………………………………………………………………. 3-144
SWITCH BETWEEN FORWARD AND REVERSE ……………………………………………………………. 3-147
STEERING THE MACHINE…………………………………………………………………………………………. 3-148
RULES FOR OPERATION ………………………………………………………………………………………….. 3-151
RECOMMENDED APPLICATIONS……………………………………………………………………………….. 3-154
RECOMMENDED MODE BY APPLICATION …………………………………………………………………… 3-156
ADJUST WORK EQUIPMENT……………………………………………………………………………………… 3-159
PARKING MACHINE …………………………………………………………………………………………………. 3-160
CHECK AFTER FINISHING WORK ………………………………………………………………………………. 3-162
LOCK …………………………………………………………………………………………………………………….. 3-163
TIPS FOR LONGER UNDERCARRIAGE LIFE ………………………………………………………………… 3-164
TRANSPORTATION………………………………………………………………………………………………………… 3-166
TRANSPORTATION PROCEDURE ………………………………………………………………………………. 3-166
REMOVAL OF CAB …………………………………………………………………………………………………… 3-166
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………………………………………………. 3-166
LOADING AND UNLOADING WITH TRAILER…………………………………………………………………. 3-167
LIFTING MACHINE …………………………………………………………………………………………………… 3-171
TRAVELING ON ROADS ……………………………………………………………………………………………. 3-172
COLD WEATHER OPERATION …………………………………………………………………………………………. 3-173
COLD WEATHER OPERATION INFORMATION………………………………………………………………. 3-173
AFTER DAILY WORK COMPLETION ……………………………………………………………………………. 3-174
AFTER COLD WEATHER SEASON ……………………………………………………………………………… 3-174
LONG-TERM STORAGE………………………………………………………………………………………………….. 3-175
BEFORE STORAGE………………………………………………………………………………………………….. 3-175
DURING STORAGE ………………………………………………………………………………………………….. 3-175
AFTER STORAGE ……………………………………………………………………………………………………. 3-175
STARTING MACHINE AFTER LONG-TERM STORAGE ……………………………………………………. 3-175
TROUBLES AND ACTIONS………………………………………………………………………………………………. 3-176
TOWING MACHINE…………………………………………………………………………………………………… 3-176
DISCHARGED BATTERY …………………………………………………………………………………………… 3-177
OTHER TROUBLE ……………………………………………………………………………………………………. 3-181
MAINTENANCE ……………………………………………………………………………………………………………………….4-1
RULES FOR MAINTENANCE………………………………………………………………………………………………..4-2
SERVICE METER READING …………………………………………………………………………………………..4-2
KOMATSU GENUINE REPLACEMENT PARTS……………………………………………………………………4-2
KOMATSU GENUINE LUBRICANTS …………………………………………………………………………………4-2
ALWAYS USE CLEAN WASHER FLUID……………………………………………………………………………..4-2
FRESH AND CLEAN LUBRICANTS ………………………………………………………………………………….4-2
CHECK DRAINED OIL AND USED FILTER…………………………………………………………………………4-2
CAUTION FOR REFILLING OIL OR FUEL ………………………………………………………………………….4-2
WELDING INSTRUCTIONS…………………………………………………………………………………………….4-2
DO NOT DROP THINGS INSIDE MACHINE………………………………………………………………………..4-2
DUSTY JOBSITES ………………………………………………………………………………………………………..4-3
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CUP HOLDER………………………………………………………………………………………………………….3-97
TOOLBOX ………………………………………………………………………………………………………………3-97
OPEN AND CLOSE REAR MASK ………………………………………………………………………………..

PRECAUTIONS FOR OPENING AND CLOSING REAR MASK ……………………………………………….4-3
LOCKING INSPECTION COVERS ……………………………………………………………………………………4-3
BLEEDING AIR FROM HYDRAULIC CIRCUIT …………………………………………………………………….4-3
CONTENTS FOREWORD
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES……………………………………………………4-3
CHECKS AFTER INSPECTION AND MAINTENANCE…………………………………………………………..4-3
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ……………………………………4-4
OUTLINE OF MAINTENANCE ……………………………………………………………………………………………….4-5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ……………………………………….4-5
HANDLING ELECTRICAL COMPONENTS …………………………………………………………………………4-8
HYDRAULIC COMPONENTS ………………………………………………………………………………………….4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS…………………………………………………….4-10
TIGHTENING TORQUE LIST …………………………………………………………………………………………4-10
MAINTENANCE SCHEDULE………………………………………………………………………………………………. 4-11
MAINTENANCE SCHEDULE TABLE………………………………………………………………………………. 4-11
MAINTENANCE PROCEDURE…………………………………………………………………………………………….4-13
WHEN REQUIRED………………………………………………………………………………………………………4-13
EVERY 50 HOURS MAINTENANCE………………………………………………………………………………..4-40
EVERY 250 HOURS MAINTENANCE………………………………………………………………………………4-42
EVERY 500 HOURS MAINTENANCE………………………………………………………………………………4-50
EVERY 1000 HOURS MAINTENANCE…………………………………………………………………………….4-55
EVERY 2000 HOURS MAINTENANCE…………………………………………………………………………….4-61
EVERY 4000 HOURS MAINTENANCE…………………………………………………………………………….4-67
EVERY 8000 HOURS MAINTENANCE…………………………………………………………………………….4-69
SPECIFICATIONS …………………………………………………………………………………………………………………….5-1
SPECIFICATIONS ………………………………………………………………………………………………………………5-2
ATTACHMENTS , OPTIONS AND MISCELNEOUS…………………………………………………………………………..6-1
GENERAL PRECAUTIONS …………………………………………………………………………………………………..6-2
PRECAUTIONS FOR SAFETY…………………………………………………………………………………………6-2
HANDLING HYDRAULIC RIPPER ………………………………………………………………………………………….6-3
GENERAL VIEW…………………………………………………………………………………………………………..6-3
EXPLANATION OF COMPONENTS ………………………………………………………………………………….6-4
MACHINE OPERATION AND CONTROLS………………………………………………………………………….6-5
TROUBLES AND ACTIONS…………………………………………………………………………………………….6-7
CHECK AND MAINTENANCE………………………………………………………………………………………….6-8
SPECIFICATIONS…………………………………………………………………………………………………………6-9
GREASE PUMP HOLDER……………………………………………………………………………………………………6-10
FIRE EXTINGUISHER…………………………………………………………………………………………………………6-10
FIRST AID KIT…………………………………………………………………………………………………………………..6-10
REPLACEMENT PARTS…………………………………………………………………………………………………………….7-1
SAFETY CRITICAL PARTS …………………………………………………………………………………………………..7-2
SAFETY CRITICAL PARTS LIST………………………………………………………………………………………7-2
CONSUMABLE PARTS………………………………………………………………………………………………………..7-3
CONSUMABLE PARTS LIST …………………………………………………………………………………………..7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ………………………………………………………………7-4
LUBRICATION CHART…………………………………………………………………………………………………..7-4
USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT
TEMPERATURE……………………………………………………………………………………………….7-6
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE
OIL…………………………………………………………………………………………………………………7-8
INDEX ……………………………………………………………………………………………………………………………………8-1
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