Komatsu D85EX-15 Manual

D85EX -15
D85PX -15
SERIAL NUMBER
D85EX-15 - 10001 and up
D85PX-15 - 1001 and up
BULLDOZER
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
Operation &
Maintenance Manual
EEAM022804
WARNING

FOREWORD
11

FOREWORD FOREWORD
1-2
FOREWORD 0.
This manual provides rules and guidelines which will help you use this machine safely and effectively. The pre-
cautions 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. Acci-
dents can be prevented by knowing beforehand conditions that may cause a hazard when performing operation
and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or mainte-
nance.
Always be sure to read and understand this manual thoroughly before performing operation and
maintenance.
Read the safety messages given in this manual and the safety labels affixed to the machine thor-
oughly and be sure that you understand them fully.
Keep this manual at the storage location for the Operation and Maintenance Manual given below, and
have all personnel read it periodically.
If this manual has been lost or has become dirty and cannot be read, request a replacement manual
immediately from Komatsu or your Komatsu distributor.
If you sell the machine, be sure to give this manual to the new owners together with the machine.
Komatsu delivers machines that comply with all applicable regulations and standards of the country to
which it has been shipped. If this machine has been purchased in another country or purchased from
someone in another country, it may lack certain safety devices and specifications that are necessary for
use in your country. If there is any question about whether your product complies with the applicable
standards and regulations of your country, consult Komatsu or your Komatsu distributor before operat-
ing the machine.
Location to Keep Operation & Maintenance Manual
In Door Pocket Inside of Cab Door

FOREWORD SAFETY INFORMATION
1-3
SAFETY INFORMATION 0.
To enable you to use this machine safely, safety precautions and labels are given in this manual and affixed to the
machine to give explanations of situations involving potential hazards and of the methods of avoiding such situa-
tions.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to per-
sonal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the safety lock lever in the LOCK position.
If you accidentally touch the control levers when they are not locked, this may cause a serious injury or
death.
Other signal words
In addition to the above, the following signal words are used to indicate precautions that should be followed to pro-
tect the machine or to give information that is useful to know.
Indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. This word is used also to alert against unsafe practices that may
cause property damage.
NOTICE This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
REMARKS This word is used for information that is useful to know.
DANGER
WARNING
CAUTION

SAFETY INFORMATION FOREWORD
1-4
Safety labels
Safety labels are affixed to the machine to inform the operator or maintenance worker on the spot when carrying
out operation or maintenance of the machine that may involve hazard.
This machine uses “Safety labels using words“ and “Safety labels using pictograms“ to indicate safety procedures.
Example of safety label using words
Safety labels using pictogram
Safety pictograms use a picture to express a level of hazard-
ous condition equivalent to the signal word. These safety picto-
grams use pictures in order to let the operator or maintenance
worker understand the level and type of hazardous condition at
all times. Safety pictograms show the type of hazardous condi-
tion at the top or left side, and the method of avoiding the haz-
ardous condition at the bottom or right side. In addition, the
type of hazardous condition is displayed inside a triangle and
the method of avoiding the hazardous condition is shown
inside a circle.
Komatsu cannot predict every circumstance that might involve a potential hazard in operation and maintenance.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsi-
bility to take the necessary steps to ensure safety.
In no event should you engage in prohibited uses or actions described in this manual.
The explanations, values, and illustrations in this manual were prepared based on the latest information available
at that time. Continuing improvements in the design of this machine can lead to changes in detail which may not
be reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information of
your machine or for questions regarding information in this manual.
The numbers in circles in the illustrations correspond to the numbers in ( ) in the text. (For example: 1-> (1))
Part No.
Part No

FOREWORD SAFETY INFORMATION
1-5
Noise emission levels 0.
Two labels indicating the machine noise level are affixed on the
machine.
Sound pressure level at the operator's station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle)
Sound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.
Vibration levels 0.
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the opera-
tor’s seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with ISO
7096.
If equipped with air suspension seat
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration
value for the body is less than or equal to 0.5 m/s².
If equipped with mechanical suspension seat
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s². The actual acceleration
value for the body is 0.52 m/s².
These values were determined using a representative machine and measured during the typical operating condi-
tion indicated below according to the measurement procedures that are defined in the standards ISO 2631/1 and
ISO 5349.

SAFETY INFORMATION FOREWORD
1-6
Operating condition:
(WHEEL LOADER:) V-shape loading
(HYDRAULIC EXCAVATORS:) Excavating (Digging-loading-rotating-unloading-rotating)
(TRACTOR DOZER:) Dozing and spreading material through forward/reversing motion
(Rigid/Articulate dumper:) Work cycle (including waiting, travelling, loading, travelling with load, unloading, and
travelling without load)
Guide to Reduce Vibration Levels on Machine
The following guides can help an operator of this machine to reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
Tire pressures (for wheeled machines), tension of crawler (for crawler machines)
Brake and steering systems
Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling in good condition
Remove any large rocks or obstacles
Fill any ditches and holes
Site manager should provide machine operators with machine and schedule time to maintain terrain condi-
tions
4. Use a seat that meets ISO 7096 and keep the seat maintained and adjusted
Adjust the seat and suspension for the weight and size of the operator
Wear seat belt
Inspect and maintain the seat suspension and adjustment mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines), and move the attachment levers and pedals
slowly so that the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the vibration level
When pushing with bucket or blade, avoid sudden loading; load gradually
Drive around obstacles and rough terrain conditions
Slow down when it is necessary to go over rough terrain
Make the curve radius of traveling path as large as possible
Travel at low speed when traveling around sharp curves
7. Minimize vibrations for long work cycle or long distance traveling
Reduce speed to prevent bounce
Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of low back pain
Operate the machine only when you are in good health.
Provide breaks to reduce long periods of sitting in the same posture
Do not jump down from the cab or machine
Do not repeatedly handle and lift loads

FOREWORD INTRODUCTION
1-7
INTRODUCTION 0.
This Komatsu machine is designed to be used mainly for the following work:
Dozing
Cutting into hard or frozen ground or ditching
Felling trees, removing stumps
Pushing
Ripping
For further details, see “WORK POSSIBLE USING BULLDOZER ( 3-92 )“.
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 0.
In this manual, the terms front, rear, left, and right refer to the travel direction as seen from the operator's seat
when the operator's seat is facing the front and the sprocket is at the rear of the machine.
Front
Right
Sprocket
Left
Rear
Operator’s seat

NECESSARY INFORMATION FOREWORD
1-8
NECESSARY INFORMATION 0.
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
MACHINE SERIAL NO. PLATE AND POSITION 0.
Under the front of the console box on the right side of the operator's seat.
ENGINE SERIAL NO. PLATE AND POSITION 0.
This is at the rear of the starting motor on the rights side of the engine.
(The EMISSION CONTROL INFORMATION LABEL is at the front surface of the engine oil filler on the left side of
the engine.)
EPA: Environmental Protection Agency, U.S.A.

FOREWORD NECESSARY INFORMATION
1-9
BLADE SERIAL NO. PLATE POSITION 0.
This is located at the upper right of blade back surface.
RIPPER SERIAL NO. PLATE POSITION 0.
This is located at the left side surface of ripper beam.
ROPS, FOPS NO. PLATE POSITION 0.
This is located at the top left.
POSITION OF SERVICE METER 0.
On top of the machine monitor
ROPS
FOPS

NECESSARY INFORMATION FOREWORD
1-10
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR 0.
Machine serial No.
Engine serial No.
Product Identification Number
Manufacturers name:
Address:
KOMATSU LTD.
3-6 Akasaka
Minato-ku, 101 Tokyo
Japan
Distributor
Address
Phone
Service personnel for your
machine:

FOREWORD NECESSARY INFORMATION
1-11
MACHINE SERIAL NUMBER PLATE
Valid until 31 December 2003
Valid as of 1 January 2004
Komatsu Ltd. Tokyo, Japan
Model
Seriel Number
Manufacturing year
Engine power
Manuafacturer
Produced by Komatsu Tokyo, Japan
Weight
Model
Seriel Number
Manufacturing year
Weight
Engine power
Product Identification Number
Manuafacturer

CONTENTS
1-12
CONTENTS
FOREWORD
FOREWORD.........................................................................................................................................................1-2
SAFETY INFORMATION......................................................................................................................................1-3
Noise emission levels .................................................................................................................................1-5
Vibration levels............................................................................................................................................1-5
Guide to Reduce Vibration Levels on Machine..................................................................................1-6
INTRODUCTION...................................................................................................................................................1-7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE.......................................................................1-7
NECESSARY INFORMATION .............................................................................................................................1-8
MACHINE SERIAL NO. PLATE AND POSITION.......................................................................................1-8
ENGINE SERIAL NO. PLATE AND POSITION..........................................................................................1-8
BLADE SERIAL NO. PLATE POSITION ....................................................................................................1-9
RIPPER SERIAL NO. PLATE POSITION...................................................................................................1-9
ROPS, FOPS NO. PLATE POSITION........................................................................................................1-9
POSITION OF SERVICE METER ..............................................................................................................1-9
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR ............................................................................1-10
MACHINE SERIAL NUMBER PLATE.......................................................................................................1-11
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...................................................................................................................2-16
BEFORE STARTING ENGINE .................................................................................................................2-16
OPERATION.............................................................................................................................................2-17
TRANSPORTATION.................................................................................................................................2-20
BATTERY .................................................................................................................................................2-20
TOWING ...................................................................................................................................................2-22
PRECAUTIONS FOR MAINTENANCE..............................................................................................................2-23
OPERATION
GENERAL VIEW ..................................................................................................................................................3-2

CONTENTS
1-13
GENERAL VIEW OF MACHINE................................................................................................................. 3-2
GENERAL VIEW OF CONTROLS AND GAUGES..................................................................................... 3-3
EXPLANATION OF COMPONENTS.................................................................................................................... 3-5
FRONT PANEL........................................................................................................................................... 3-5
CHECK MONITOR GROUP.............................................................................................................. 3-7
CAUTION MONITOR GROUP .......................................................................................................... 3-8
EMERGENCY CAUTION ITEMS .................................................................................................... 3-10
METER GROUP.............................................................................................................................. 3-12
SWITCH........................................................................................................................................... 3-16
LAMP............................................................................................................................................... 3-19
METHOD OF USING DISPLAY PANEL B (Multi-information) ........................................................ 3-21
SWITCH.................................................................................................................................................... 3-28
CONTROL LEVERS, PEDALS................................................................................................................. 3-31
DUST INDICATOR ................................................................................................................................... 3-36
FUSE BOX................................................................................................................................................ 3-37
CIRCUIT BREAKER........................................................................................................................ 3-38
FUSE CAPACITY AND NAME OF CIRCUIT................................................................................... 3-38
FUSIBLE LINK.......................................................................................................................................... 3-39
DOOR OPEN LOCK................................................................................................................................. 3-40
SASH GLASS INTERMEDIATE LOCK..................................................................................................... 3-40
DOOR POCKET ....................................................................................................................................... 3-41
ASHTRAY................................................................................................................................................. 3-41
CAR STEREO, HANDLING...................................................................................................................... 3-42
EXPLANATION OF COMPONENTS............................................................................................... 3-42
METHOD OF OPERATION.............................................................................................................3-47
PRECAUTION WHEN USING......................................................................................................... 3-49
AIR CONDITIONER.................................................................................................................................. 3-50
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL................................................ 3-50
METHOD OF OPERATION.............................................................................................................3-52
PRECAUTIONS WHEN USING ...................................................................................................... 3-53
SET SO THAT COLD AIR DOES NOT DIRECTLY BLOW ONTO THE GLASS SURFACE.......... 3-53
CHECKS DURING OFF-SEASON.................................................................................................. 3-53
PROCEDURE FOR REPLACING RECEIVER................................................................................ 3-53
CHECK COMPRESSOR BELT TENSION AND REFRIGERANT (GAS) LEVEL............................ 3-54
CLEANING AIR FILTER.................................................................................................................. 3-54
ACCUMULATOR, HANDLING.................................................................................................................. 3-54
METHOD OF RELEASING PRESSURE IN OPERATING CIRCUIT ON MACHINE EQUIPPED WITH
ACCUMULATOR............................................................................................................................. 3-54
OPERATION....................................................................................................................................................... 3-55
CHECK BEFORE STARTING ENGINE, ADJUST.................................................................................... 3-55
WALK-AROUND CHECK................................................................................................................ 3-55
CHECK BEFORE STARTING......................................................................................................... 3-56
ADJUSTMENT................................................................................................................................. 3-65
OPERATIONS AND CHECKS BEFORE STARTING ENGINE....................................................... 3-69
STARTING ENGINE................................................................................................................................. 3-71
NORMAL STARTING...................................................................................................................... 3-71

CONTENTS
1-14
STARTING IN COLD WEATHER....................................................................................................3-72
OPERATIONS AND CHECKS AFTER STARTING ENGINE...................................................................3-75
BREAKING IN THE MACHINE........................................................................................................3-75
NORMAL OPERATION ...................................................................................................................3-75
IN COLD AREAS.............................................................................................................................3-77
STOPPING ENGINE.................................................................................................................................3-78
CHECK AFTER STOPPING ENGINE ......................................................................................................3-78
MOVING MACHINE OFF..........................................................................................................................3-79
STOPPING MACHINE..............................................................................................................................3-81
SHIFTING GEAR......................................................................................................................................3-82
SHIFTING BETWEEN FOEWARD AND REVERSE ................................................................................3-84
STEERING MACHINE..............................................................................................................................3-86
NORMAL TURNING........................................................................................................................3-86
TURNING WHILE DESCENDING A SLOPE...................................................................................3-87
PRECAUTIONS FOR OPERATION .........................................................................................................3-88
PAY ATTENTION TO GAUGES......................................................................................................3-88
PERMISSIBLE WATER DEPTH......................................................................................................3-88
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS..........................................................3-88
PRECAUTIONS ON SLOPE ...........................................................................................................3-88
METHOD OF USING BRAKES .......................................................................................................3-88
PROHIBITED TO KEEP THE DOOR OPEN DURING OPERATIONS ...........................................3-89
IT IS PROHIBITED TO MODIFY THE CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW
3-89
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB STAY AND ROPS STAY.......................3-89
PARKING MACHINE ................................................................................................................................3-89
CHECK AFTER FINISHING WORK .........................................................................................................3-91
LOCKING..................................................................................................................................................3-91
WORK POSSIBLE USING BULLDOZER.................................................................................................3-92
DOZING...........................................................................................................................................3-92
CUTTING INTO HARD OR FROZEN GROUND OR DITCHING....................................................3-92
FELLING TREES, REMOVING STUMPS .......................................................................................3-92
PUSHER OPERATIONS .................................................................................................................3-92
SMOOTHING...................................................................................................................................3-93
ADJUSTING POSTURE OF WORK EQUIPMENT...................................................................................3-94
BLADE ADJUSTMENT....................................................................................................................3-94
However, the more the digging angle is changed, the more the change becomes in the amount of tilt on the
left and right sides provided by the tilt cylinder. ........................................................................................3-95
ADJUSTING RIPPER......................................................................................................................3-96
TIPS FOR LONGER UNDERCARRIAGE LIFE........................................................................................3-98
OPERATION METHOD...................................................................................................................3-98
INSPECTION AND ADJUSTING.....................................................................................................3-98
INSPECTION AND REPAIR............................................................................................................3-99
TRANSPORTATION.........................................................................................................................................3-100
TRANSPORTATION PROCEDURE.......................................................................................................3-100
LOADING, UNLOADING WORK ............................................................................................................3-100
PRECAUTIONS FOR LOADING ............................................................................................................3-100
METHOD OF LIFTING MACHINE..........................................................................................................3-101

CONTENTS
1-15
PRECAUTIONS FOR TRANSPORTATION........................................................................................... 3-102
TRAVELING ON ROADS ....................................................................................................................... 3-102
REMOVAL OF CAB................................................................................................................................ 3-102
INSTALLATION OF CAB........................................................................................................................ 3-103
INSTALLATION OF ROPS..................................................................................................................... 3-103
COLD WEATHER OPERATION ...................................................................................................................... 3-104
PRECAUTIONS FOR LOW TEMPERATURE........................................................................................ 3-104
FUEL AND LUBRICANTS............................................................................................................. 3-104
COOLANT ..................................................................................................................................... 3-104
BATTERY...................................................................................................................................... 3-104
AFTER COMPLETION OF WORK.........................................................................................................3-105
AFTER COLD WEATHER...................................................................................................................... 3-105
LONG-TERM STORAGE.................................................................................................................................. 3-106
BEFORE STORAGE............................................................................................................................... 3-106
DURING STORAGE............................................................................................................................... 3-106
AFTER STORAGE.................................................................................................................................. 3-106
TROUBLESHOOTING...................................................................................................................................... 3-107
AFTER RUNNING OUT OF FUEL.......................................................................................................... 3-107
PROCEDURE FOR BLEEDING AIR............................................................................................. 3-107
METHOD OF TOWING MACHINE.........................................................................................................3-108
IF BATTERY IS DISCHARGED.............................................................................................................. 3-109
STARTING ENGINE WITH BOOSTER CABLE............................................................................ 3-109
OTHER TROUBLE ................................................................................................................................. 3-112
ELECTRICAL SYSTEM................................................................................................................. 3-112
MONITOR PANEL......................................................................................................................... 3-113
CHASSIS....................................................................................................................................... 3-114
ENGINE......................................................................................................................................... 3-116
MAINTENANCE
GUIDES TO MAINTENANCE...............................................................................................................................4-2
OUTLINES OF SERVICE..................................................................................................................................... 4-5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ..................................................... 4-5
OIL..................................................................................................................................................... 4-5
FUEL.................................................................................................................................................. 4-5
COOLANT ......................................................................................................................................... 4-5
GREASE............................................................................................................................................ 4-6
CARRYING OUT KOWA (Komatsu Oil Wear Analysis).................................................................... 4-6
STORING OIL AND FUEL................................................................................................................. 4-7
FILTERS............................................................................................................................................ 4-7
OUTLINE OF ELECTRIC SYSTEM............................................................................................................ 4-7
WEAR PARTS LIST............................................................................................................................................. 4-8
WEAR PARTS LIST.................................................................................................................................... 4-8

CONTENTS
1-16
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.......................4-9
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ...........................................................4-9
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....................................................................4-13
TORQUE LIST..........................................................................................................................................4-13
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ..........................................................................4-14
SAFETY CRITICAL PARTS......................................................................................................................4-15
MAINTENANCE SCHEDULE CHART ...............................................................................................................4-17
MAINTENANCE SCHEDULE CHART......................................................................................................4-17
INTIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS) ......................................4-17
WHEN REQUIRED..........................................................................................................................4-17
CHECK BEFORE STARTING ......................................................................................................... 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
EVERY 8000 HOURS SERVICE.....................................................................................................4-18
SERVICE PROCEDURE ....................................................................................................................................4-19
INITIAL 250 HOURS SERVICE(ONLY AFTER THE FIRST 250 HOURS)...............................................4-19
WHEN REQUIRED...................................................................................................................................4-19
CHECK BEFORE STARTING ..................................................................................................................4-37
EVERY 250 HOURS SERVICE................................................................................................................4-38
EVERY 500 HOURS SERVICE................................................................................................................4-45
EVERY 1000 HOURS SERVICE..............................................................................................................4-49
EVERY 2000 HOURS SERVICE..............................................................................................................4-53
EVERY 4000 HOURS SERVICE..............................................................................................................4-58
EVERY 8000 HOURS SERVICE..............................................................................................................4-61
SPECIFICATIONS
SPECIFICATIONS................................................................................................................................................5-2
ATTACHMENTS, OPTIONS
GENERAL PRECAURIONS.................................................................................................................................6-2
PRECAUTIONS RELATED TO SAFETY ...................................................................................................6-2
SELECTION OF TRACK SHOE...........................................................................................................................6-3
SELECTION OF TRACK SHOES...............................................................................................................6-3
PROCEDURE FOR SELECTING RIPPER POINT...............................................................................................6-4
PROCEDURE FOR SELECTING RIPPER POINT.....................................................................................6-4

CONTENTS
1-17
CAP WITH LOCK, HANDLING............................................................................................................................ 6-5
METHOD OF OPENING AND CLOSING CAP WITH LOCK...................................................................... 6-5
INDEX
COLOPHON

CONTENTS
1-18