Komatsu D61EX-15, D61PX-15 Bulldozer Index:

CONTENTS
FOREWORD
FOREWORD……………………………………………………………………………………………………………………………………… 1-2
SAFETY INFORMATION…………………………………………………………………………………………………………………….. 1-5
INTRODUCTION………………………………………………………………………………………………………………………………… 1-7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…………………………………………………………….. 1-7
NECESSARY INFORMATION …………………………………………………………………………………………………………….. 1-8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…………………………………. 1-8
ENGINE SERIAL NO. PLATE……………………………………………………………………………………………………… 1-8
EMISSION CONTROL INFORMATION LABEL …………………………………………………………………………….. 1-9
POSITION OF SERVICE METER ……………………………………………………………………………………………….. 1-9
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR …………………………………………………………………… 1-9
NOISE EMISSION LEVELS ……………………………………………………………………………………………………….
VIBRATION LEVELS ………………………………………………………………………………………………………………..
CONTENTS …………………………………………………………………………………………………………………………………….. 1-11
1-10
1-10
SAFETY
SAFETY……………………………………………………………………………………………………………………………………………. 2-2
SAFETY LABELS………………………………………………………………………………………………………………………………. 2-4
POSITIONS OF SAFETY PICTOGRAMS …………………………………………………………………………………….. 2-4
SAFETY LABELS ……………………………………………………………………………………………………………………… 2-5
GENERAL PRECAUTIONS ………………………………………………………………………………………………………………… 2-9
PRECAUTIONS FOR OPERATION ……………………………………………………………………………………………………. 2-18
STARTING ENGINE ………………………………………………………………………………………………………………… 2-18
OPERATION…………………………………………………………………………………………………………………………… 2-20
TRANSPORTATION………………………………………………………………………………………………………………… 2-23
BATTERY ………………………………………………………………………………………………………………………………. 2-24
TOWING ………………………………………………………………………………………………………………………………… 2-26
PRECAUTIONS FOR MAINTENANCE……………………………………………………………………………………………….. 2-27
OPERATION
GENERAL VIEW ……………………………………………………………………………………………………………………………….. 3-2
GENERAL VIEW OF MACHINE………………………………………………………………………………………………….. 3-2
GENERAL VIEW OF CONTROLS AND GAUGES…………………………………………………………………………. 3-3
EXPLANATION OF COMPONENTS…………………………………………………………………………………………………….. 3-6
FRONT PANEL…………………………………………………………………………………………………………………………. 3-6

CHECK MONITOR SYSTEM ……………………………………………………………………………………………… 3-7
EMERGENCY CAUTION ITEMS ………………………………………………………………………………………… 3-8
CAUTION ITEMS…………………………………………………………………………………………………………….. 3-10
METER GROUP……………………………………………………………………………………………………………… 3-12
LAMPS…………………………………………………………………………………………………………………………… 3-17
SWITCHES…………………………………………………………………………………………………………………….. 3-19
METHOD OF USING MAINTENANCE MODE…………………………………………………………………….. 3-24
SWITCHES…………………………………………………………………………………………………………………………….. 3-33
CONTROL LEVERS AND PEDALS …………………………………………………………………………………………… 3-37
CIRCUIT BREAKER………………………………………………………………………………………………………………… 3-44
FUSE …………………………………………………………………………………………………………………………………….. 3-45
FUSIBLE LINK………………………………………………………………………………………………………………………… 3-47
ELECTRIC POWER TAKE-OUT ADAPTER ……………………………………………………………………………….. 3-48
MACHINE EQUIPPED WITH CAB…………………………………………………………………………………….. 3-48
MACHINE EQUIPPED WITH CANOPY ……………………………………………………………………………… 3-48
DOOR – OPEN LOCK………………………………………………………………………………………………………………. 3-49
SASH GLASS INTERMEDIATE LOCK……………………………………………………………………………………….. 3-49
CAP, COVER WITH LOCK……………………………………………………………………………………………………….. 3-50
METHOD OF OPENING AND CLOSING CAP WITH LOCK …………………………………………………. 3-50
METHOD OF OPENING AND CLOSING COVER WITH LOCK…………………………………………….. 3-51
DOOR POCKET ……………………………………………………………………………………………………………………… 3-51
OPENING AND CLOSING ENGINE SIDE COVER………………………………………………………………………. 3-52
ASHTRAY………………………………………………………………………………………………………………………………. 3-53
TOOL BOX……………………………………………………………………………………………………………………………… 3-53
CAR STEREO, HANDLING………………………………………………………………………………………………………. 3-54
EXPLANATION OF COMPONENTS………………………………………………………………………………….. 3-54
METHOD OF OPERATION………………………………………………………………………………………………. 3-60
PRECAUTION WHEN USING…………………………………………………………………………………………… 3-62
AIR CONDITIONER, HANDLING………………………………………………………………………………………………. 3-63
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL ………………………………………… 3-63
METHOD OF OPERATION………………………………………………………………………………………………. 3-66
PRECAUTION WHEN USING AIR CONDITIONER……………………………………………………………… 3-67
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE ………. 3-67
INSPECTION DURING OFF-SEASON ………………………………………………………………………………. 3-67
PROCEDURE FOR REPLACING RECEIVER…………………………………………………………………….. 3-67
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL………………………. 3-67
CLEANING AIR FILTER…………………………………………………………………………………………………… 3-68
ACCUMULATOR, HANDLING…………………………………………………………………………………………………… 3-69
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH
ACCUMULATOR…………………………………………………………………………………………………………….. 3-69
OPERATION……………………………………………………………………………………………………………………………………. 3-70
CHECK BEFORE STARTING ENGINE, ADJUST………………………………………………………………………… 3-70
WALK-AROUND CHECK …………………………………………………………………………………………………. 3-70
CHECK BEFORE STARTING…………………………………………………………………………………………… 3-72
AIR SUSPENSION SEAT…………………………………………………………………………………………………. 3-81
OPERATION AND CHECK BEFORE STARTING ENGINE…………………………………………………… 3-86
STARTING ENGINE………………………………………………………………………………………………………………… 3-88
CONTENTS
1-12
ADJUSTMENT OF MIRRORS…………………………………………………………………………………………… 3-86
NORMAL STARTING ………………………………………………………………………………………………………. 3-88
STARTING IN COLD WEATHER………………………………………………………………………………………. 3-90
OPERATIONS AND CHECKS AFTER STARTING ENGINE …………………………………………………………. 3-93
BREAKING IN THE NEW MACHINE …………………………………………………………………………………. 3-93
WARMING UP OPERATIONS ………………………………………………………………………………………….. 3-93
STARTING IN COLD WEATHER………………………………………………………………………………………. 3-94
STOPPING ENGINE………………………………………………………………………………………………………………… 3-96
MACHINE OPERATION …………………………………………………………………………………………………………… 3-97
MOVING MACHINE…………………………………………………………………………………………………………. 3-97
STOPPING MACHINE……………………………………………………………………………………………………… 3-99
SHIFTING GEARS…………………………………………………………………………………………………………………. 3-100
GEARSHIFTING OPERATION………………………………………………………………………………………… 3-100
GEARSHIFTING OPERATION USING PRESET MODE FUNCTION……………………………………. 3-101
AUTO DOWN SHIFT OPERATION………………………………………………………………………………….. 3-102
SHIFTING BETWEEN FORWARD AND REVERSE…………………………………………………………………… 3-103
STEERING MACHINE……………………………………………………………………………………………………………. 3-105
NORMAL TURNING………………………………………………………………………………………………………. 3-105
PRECAUTIONS FOR OPERATION …………………………………………………………………………………………. 3-107
PAY ATTENTION TO GAUGES………………………………………………………………………………………. 3-107
PERMISSIBLE WATER DEPTH………………………………………………………………………………………. 3-107
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS……………………………………………….. 3-107
PRECAUTIONS ON SLOPES…………………………………………………………………………………………. 3-107
METHOD OF USING BRAKES ……………………………………………………………………………………….. 3-108
IT IS PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS…………………………… 3-108
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-108
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES……………. 3-108
WORK POSSIBLE USING BULLDOZER………………………………………………………………………………….. 3-109
DOZING……………………………………………………………………………………………………………………….. 3-109
SMOOTHING………………………………………………………………………………………………………………… 3-109
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING ………………………………………….. 3-110
FELLING TREES, REMOVING STUMPS …………………………………………………………………………. 3-110
ADUSTING POSTURE OF WORK EQUIPMENT ………………………………………………………………………. 3-111
ADJUST ANGLE OF BLADE EDGE…………………………………………………………………………………. 3-111
ADJUST AMOUNT OF TILT POWER TILT……………………………………………………………………….. 3-112
PARKING MACHINE ……………………………………………………………………………………………………………… 3-113
CHECK AFTER FINISHING WORK …………………………………………………………………………………………. 3-114
BEFORE STARTING ENGINE ………………………………………………………………………………………… 3-114
AFTER STARTING ENGINE …………………………………………………………………………………………… 3-114
LOCKING……………………………………………………………………………………………………………………………… 3-115
TIPS FOR LONGER UNDERCARRIAGE LIFE ………………………………………………………………………….. 3-116
OPERATION METHOD………………………………………………………………………………………………….. 3-116
TRANSPORTATION……………………………………………………………………………………………………………………….. 3-117
TRANSPORTATION MEANS………………………………………………………………………………………………….. 3-117
REMOVING CAB …………………………………………………………………………………………………………………… 3-117
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…………………………………………………………. 3-117
POWER ANGLE, POWER TILTDOZER …………………………………………………………………………… 3-117

POWER TILTDOZER…………………………………………………………………………………………………….. 3-117
PRECAUTIONS WHEN REMOVING ROPS ……………………………………………………………………………… 3-118
LOADING, UNLOADING WORK……………………………………………………………………………………………… 3-119
LIFTING MACHINE………………………………………………………………………………………………………………… 3-123
COLD WEATHER OPERATION ………………………………………………………………………………………………………. 3-127
PRECAUTIONS FOR LOW TEMPERATURE……………………………………………………………………………. 3-127
AFTER COMPLETION OF WORK …………………………………………………………………………………………… 3-129
AFTER COLD WEATHER ………………………………………………………………………………………………………. 3-129
LONG-TERM STORAGE…………………………………………………………………………………………………………………. 3-130
BEFORE STORAGE………………………………………………………………………………………………………………. 3-130
DURING STORAGE………………………………………………………………………………………………………………. 3-130
AFTER STORAGE…………………………………………………………………………………………………………………. 3-130
TROUBLESHOOTING…………………………………………………………………………………………………………………….. 3-131
AFTER RUNNING OUT OF FUEL……………………………………………………………………………………………. 3-131
MACHINE TOWING METHOD………………………………………………………………………………………………… 3-131
WHEN IT IS POSSIBLE TO START ENGINE……………………………………………………………………. 3-132
WHEN ENGINE DOES NOT START ……………………………………………………………………………….. 3-133
IF BATTERY IS DISCHARGED……………………………………………………………………………………………….. 3-137
REMOVE AND INSTALL BATTERY ………………………………………………………………………………… 3-137
PRECAUTIONS FOR BATTERY CHARGING …………………………………………………………………… 3-138
STARTING ENGINE WITH BOOSTER CABLE …………………………………………………………………. 3-138
OTHER TROUBLE ………………………………………………………………………………………………………………… 3-141
ELECTRICAL SYSTEM………………………………………………………………………………………………….. 3-141
MONITOR PANEL…………………………………………………………………………………………………………. 3-142
CHASSIS……………………………………………………………………………………………………………………… 3-143
ENGINE……………………………………………………………………………………………………………………….. 3-144
MAINTENANCE
GUIDE TO MAINTENANCE ………………………………………………………………………………………………………………… 4-2
OUTLINE OF SERVICE………………………………………………………………………………………………………………………. 4-5
OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ………………………………………….. 4-5
OIL ………………………………………………………………………………………………………………………………….. 4-5
FUEL……………………………………………………………………………………………………………………………….. 4-5
COOLANT ……………………………………………………………………………………………………………………….. 4-6
GREASE………………………………………………………………………………………………………………………….. 4-6
CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ………………………………………………………….. 4-6
STORING OIL AND FUEL………………………………………………………………………………………………….. 4-7
FILTERS………………………………………………………………………………………………………………………….. 4-7
RELATING TO ELECTRIC SYSTEM …………………………………………………………………………………………… 4-8
WEAR PARTS LIST …………………………………………………………………………………………………………………………… 4-9
WEAR PARTS LIST…………………………………………………………………………………………………………………… 4-9
CONTENTS
1-14
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE………………… 4-10
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ………………………………………………… 4-10
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…………………………………………………………… 4-14
TORQUE LIST………………………………………………………………………………………………………………………… 4-14
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ……………………………………………………………….. 4-15
SAFETY CRITICAL PARTS………………………………………………………………………………………………………. 4-15
MAINTENANCE SCHEDULE CHART ………………………………………………………………………………………………… 4-17
MAINTENANCE SCHEDULE CHART………………………………………………………………………………………… 4-17
WHEN REQUIRED………………………………………………………………………………………………………….. 4-17
CHECK BEFORE STARTING …………………………………………………………………………………………… 4-17
EVERY 50 HOURS SERVICE…………………………………………………………………………………………… 4-17
EVERY 250 HOURS SERVICE…………………………………………………………………………………………. 4-17
EVERY 500 HOURS SERVICE…………………………………………………………………………………………. 4-17
EVERY 1000 HOURS SERVICE……………………………………………………………………………………….. 4-18
EVERY 2000 HOURS SERVICE……………………………………………………………………………………….. 4-18
EVERY 4000 HOURS SERVICE……………………………………………………………………………………….. 4-18
SERVICE PROCEDURE …………………………………………………………………………………………………………………… 4-19
WHEN REQUIRED………………………………………………………………………………………………………………….. 4-19
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT………………………………………………… 4-19
CLEAN INSIDE OF COOLING SYSTEM ……………………………………………………………………………. 4-23
CHECK TRACK SHOE TENSION, ADJUST……………………………………………………………………….. 4-26
CHECK AND TIGHTEN TRACK SHOE BOLTS…………………………………………………………………… 4-28
CHECK ELECTRICAL INTAKE AIR HEATER …………………………………………………………………….. 4-28
REVERSE AND REPLACE END BITS AND CUTTING EDGES…………………………………………….. 4-29
CLEAN, CHECK RADIATOR FINS ……………………………………………………………………………………. 4-31
CHECK, ADJUST AIR CONDITIONER………………………………………………………………………………. 4-33
GREASE DOOR HINGE…………………………………………………………………………………………………… 4-34
CHECK DOOR LOCK STRIKER……………………………………………………………………………………….. 4-34
REPLACE DOOR DAMPER……………………………………………………………………………………………… 4-34
CHECK DOOR LATCH…………………………………………………………………………………………………….. 4-35
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…………………………………………………….. 4-35
REPLACE WIPER BLADE ……………………………………………………………………………………………….. 4-36
CHECK IDLER OIL LEVEL, ADD OIL ………………………………………………………………………………… 4-37
ADJUST IDLER CLEARANCE ………………………………………………………………………………………….. 4-37
CHECK LINK PITCH ……………………………………………………………………………………………………….. 4-38
CHECK OUTSIDE DIAMETER OF TRACK ROLLER…………………………………………………………… 4-39
CHECK HEIGHT OF GROUSER ………………………………………………………………………………………. 4-39
ADJUST PLAY IN CENTER BALL …………………………………………………………………………………….. 4-40
LUBRICATING UNIVERSAL JOINT…………………………………………………………………………………… 4-41
PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM…………………………………………….. 4-42
PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM…………….. 4-42
CHECK BEFORE STARTING …………………………………………………………………………………………………… 4-43
EVERY 50 HOURS SERVICE …………………………………………………………………………………………………… 4-44
DRAIN WATER, SEDIMENT FROM FUEL TANK………………………………………………………………… 4-44
LUBRICATING………………………………………………………………………………………………………………… 4-44

EVERY 250 HOURS SERVICE…………………………………………………………………………………………………. 4-45
LUBRICATING………………………………………………………………………………………………………………… 4-45
GREASE EQUALIZER BAR SIDE PIN……………………………………………………………………………….. 4-47
GREASE EQUALIZER BAR CENTER PIN …………………………………………………………………………. 4-47
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL ………………………………………………………… 4-48
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL………………………………………………………….. 4-48
CHECK LEVEL OF BATTERY ELECTROLYTE ………………………………………………………………….. 4-49
CLEAN WATER SEPARATOR STRAINER ………………………………………………………………………… 4-51
CHECK BRAKE PERFORMANCE…………………………………………………………………………………….. 4-52
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST………………………………. 4-53
CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER) ……………………………………. 4-54
EVERY 500 HOURS SERVICE…………………………………………………………………………………………………. 4-55
REPLACE FUEL FILTER CARTRIDGE ……………………………………………………………………………… 4-55
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE……………….. 4-56
REPLACE CORROSION RESISTOR CARTRIDGE …………………………………………………………….. 4-57
REPLACE POWER TRAIN OIL FILTER ELEMENT …………………………………………………………….. 4-57
EVERY 1000 HOURS SERVICE……………………………………………………………………………………………….. 4-58
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN STRAINER,
SCAVENGING PUMP STRAINER)……………………………………………………………………………………. 4-58
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL………………………………………………………………. 4-60
CHANGE OIL IN FINAL DRIVE CASE……………………………………………………………………………….. 4-61
CLEAN BREATHER ………………………………………………………………………………………………………… 4-61
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER………………………………………………….. 4-62
CHECK PLAY OF TURBOCHARGER ROTOR …………………………………………………………………… 4-62
CHECK FOR LOOSE ROPS MOUNT BOLTS…………………………………………………………………….. 4-62
EVERY 2000 HOURS SERVICE……………………………………………………………………………………………….. 4-63
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER ELEMENT………………………………. 4-63
REPLACE HYDRAULIC TANK BREATHER ELEMENT……………………………………………………….. 4-64
CHANGE OIL IN DAMPER CASE……………………………………………………………………………………… 4-65
CLEAN, CHECK TURBOCHARGER………………………………………………………………………………….. 4-66
CHECK VIBRATION DAMPER …………………………………………………………………………………………. 4-66
CHECK ALTERNATOR, STARTING MOTOR …………………………………………………………………….. 4-66
CHECK ENGINE VALVE CLEARANCE, ADJUST……………………………………………………………….. 4-66
EVERY 4000 HOURS SERVICE……………………………………………………………………………………………….. 4-67
CHECK WATER PUMP……………………………………………………………………………………………………. 4-67
SPECIFICATIONS
SPECIFICATIONS……………………………………………………………………………………………………………………………… 5-2
ATTACHMENTS, OPTIONS
GENERAL PRECAUTIONS ………………………………………………………………………………………………………………… 6-2
PRECAUTIONS RELATED TO SAFETY ……………………………………………………………………………………… 6-2
HANDLING HYDRAULIC RIPPER……………………………………………………………………………………………………….. 6-3
CONTENTS
1-16
GENERAL VIEW……………………………………………………………………………………………………………………….. 6-3
EXPLANATION OF COMPONENTS……………………………………………………………………………………………. 6-4
OPERATION…………………………………………………………………………………………………………………………….. 6-5
CHECK BEFORE STARTING ENGINE, ADJUST………………………………………………………………….. 6-5
PRECAUTIONS WHEN OPERATING………………………………………………………………………………….. 6-5
ADJUSTING POSTURE OF WORK EQUIPMENT…………………………………………………………………. 6-5
TROUBLESHOOTING……………………………………………………………………………………………………………….. 6-7
OTHER TROUBLE ……………………………………………………………………………………………………………. 6-7
MAINTENANCE………………………………………………………………………………………………………………………… 6-8
EVERY 250 HOURS SERVICE…………………………………………………………………………………………… 6-8
SPECIFICATIONS…………………………………………………………………………………………………………………….. 6-8
ADJUSTMENT…………………………………………………………………………………………………………………………………… 6-9
DELUXE SEAT………………………………………………………………………………………………………………………………… 6-12
HEADREST …………………………………………………………………………………………………………………………………….. 6-14
EQUIPPING FIRE EXTINGUISHER AND FIRST-AID KIT……………………………………………………………………… 6-15