Komatsu D85EX-18 Manual

D85EX -18
D85PX -18
SERIAL NUMBER
D85EX-18 - 22001 and up
D85PX-18 - 22001 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
EENAM03360
WARNING
ORIGINAL INSTRUCTIONS

FOREWORD
Komatsu recommends that any service parts used for maintenance, repair or
replacement of emission control systems be genuine new Komatsu or Ko-
matsu approved rebuilt parts or assemblies or others parts of equivalent
quality, and that the engine be serviced by an authorized Komatsu distribu-
tor. Failure to follow these recommendations could result in ineffective serv-
ice, damage to the product or safety risks (including personal injury or
death).
1-1

BEFORE READING THIS MANUAL
This manual gives details of the operation and methods of inspection and maintenance for this machine that
must be obeyed in order to use the machine safely. Most accidents are caused by the failure to follow funda-
mental safety rules for the operation and maintenance of machines.
Read, understand and follow all precautions and warnings in this manual and on the machine before performing
operation and maintenance. Failure to do so may result in serious injury or death.
Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
Therefore, the safety messages in this manual and on the machine may not include all possible safety precau-
tions.
If you perform any operation, inspection, or maintenance under conditions that are not described in this manual,
understand that it is your responsibility to take the necessary precautions to ensure safety. In no event should
you or others engage in the prohibited uses or actions described in this manual. It is dangerous to perform im-
proper operation and maintenance of the machine. It may cause serious injury or death.
If you sell the machine, be sure to give this manual to the new owner together with the machine.
Always keep this Operation and Maintenance Manual in the indicated location so that all relevant personnel can
read it at any time.
Operation and Maintenance Manual Storing Place:
It is provided on the back side of the operator's seat back.
If this manual is lost or damaged, contact Komatsu or your Komatsu distributor and tell them about the machine
model name and the serial No. immediately to arrange for its replacement.
For details regarding the machine model name and the serial No., see the machine serial No. plate. In order to
arrange the proper Operation and Maintenance Manual, you will need to provide the machine model name and
the serial No.
This manual uses the International System of Units (SI) for units of measurement. For reference, units that have
been used in the past are given in { }.
The explanations, values, and illustrations in this manual have been prepared based on the latest information
available as of the date of its publication. Continuing improvements in the design of this machine may lead to
additional changes that are not reflected in this manual. If there is any question or suggestion, consult your Ko-
matsu distributor.
The numbers in the illustrations correspond to the numbers in ( ) in the text. (Example: 1 → (1))
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, 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 your Komatsu distributor before
operating the machine.
BEFORE READING THIS MANUAL FOREWORD
1-2

SAFETY INFORMATION
To enable you to use the machine safely, and to prevent personal injury to operators, service personnel or by-
standers, the precautions and warnings included in this manual and the safety signs attached to the machine
must always be observed.
To identify important safety messages in the manual and on the machine labels, the following signal words are
used.
The "Safety Alert Symbol" identifies important safety messages on machines, in manuals, and elsewhere. When
you see this symbol, be alert to the risk of personal injury or death. Follow the instructions in the safety mes-
sage.
kk
DANGER
This signal word indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
kk
WARNING
This signal word indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
kk
CAUTION
This signal word indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to alert against unsafe
practices that may cause property damage.
The following signal words are used to alert you to information that must be followed to avoid damage to the
machine.
NOTICE If precautions described are not observed, the machine may be damaged or the service life may
be reduced.
REMARK This word is used for information that is useful to know.
FOREWORD SAFETY INFORMATION
1-3

NOISE
Two labels indicating the machine noise level are affixed on the machine.
• Sound pressure level at the operator’s station, measured
according to ISO 6396 (Dynamic test method, simulated
working cycle).
The maximum value of the standard deviation of the meas-
ured time-averaged A-weighted emission sound pressure
level at the operator’s position is 2.5dB, in accordance with
ISO 11201
• Sound power level emitted by the machine, measured ac-
cording to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.
This value includes an uncertainty of 1.5 dB.
NOISE FOREWORD
1-4

VIBRATION LEVELS
When used for its intended purpose, levels of vibration for the earth-moving machine transmitted from the oper-
ator's seat are lower than or equal to the tested vibrations for the relative machinery class in compliance with
ISO 7096.
FOR D85EX-18 :
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s2 , the uncertainty for this
value is 0.73 m/s2 according to EN12096:1997.
The actual acceleration value for the body is less than or equal to 0.5 m/s2, the uncertainty for this value is 0.25
m/s2 according to EN12096:1997.
FOR D85PX-18 :
The actual acceleration value for the hands and arms is less than or equal to 2.5 m/s2 , the uncertainty for this
value is 0.73 m/s2 according to EN12096:1997.
The actual acceleration value for the body is less than or equal to 0.5 m/s2, the uncertainty for this value is 0.26
m/s2 according to EN12096:1997.
These values were determined using a representative machine and measured during the typical operating con-
dition indicated below according to the measurement procedures that are defined in the standards ISO 2631/1
and ISO 5349.
VIBRATION - OPERATING CONDITION
TRACTOR DOZER (Dozing and spreading material through forward/reversing motion)
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 travelling 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
conditions
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 travelling path as large as possible
• Travel at low speed when travelling around sharp curves
7. Minimize vibrations for long work cycle or long distance travelling
• Reduce speed to prevent bounce
FOREWORD VIBRATION LEVELS
1-5

• 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
VIBRATION LEVELS FOREWORD
1-6

INTRODUCTION
MAIN USE OF MACHINE
This Komatsu machine is designed to be used mainly for the following work:
•Dozing work
• Leveling work
• Cutting or ditching into hard or frozen ground
• Works of felling trees and removing stumps
• Pushing work
• Ripping work
For details of work procedure, see OPERATION, “RECOMMENDED APPLICATIONS (3-182)”.
DIRECTIONS OF MACHINE
In this Operation and Maintenance Manual, the directions of the machine (front, rear, right, left) are determined
according to the view from operator's seat (E) in the direction of travel (front) of the machine.
(A) Front
(B) Rear
(C) Left
(D) Right
(E) Operator's seat
(F) Sprocket
VISIBILITY FROM OPERATOR'S SEAT
The visibility of this machine required by visibility standards (ISO 5006) are shown in the drawing below.
Proximity visibility
The figure below shows a visibility from the machine at a spot 1.0m away from outside the machine and 1.5m
above the ground. Shaded area (A) in the figure shows an area whose view is blocked by a part of the machine
FOREWORD INTRODUCTION
1-7

when the machine is equipped with the mirrors and other visibility assistant devices. Be fully aware that there is
an area where the operator cannot see when operating the machine.
12m radius visibility
The figure below shows a visibility from the machine for a radius of 12m. Shaded area (B) in the figure shows an
area whose view is blocked by a part of the machine when the machine is equipped with the mirrors and other
visibility assistant devices. Be fully aware that there is an area where the operator cannot see when operating
the machine.
INTRODUCTION FOREWORD
1-8

ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS
EMISSION
About Engine Technology
This engine technology combines a Komatsu Diesel Particulate Filter (KDPF) and Komatsu’s Urea Selective
Catalytic Reduction (SCR) to conform EU Stage IV emission regulation in the European Union.
• Komatsu Diesel Particulate Filter (KDPF): A device which captures diesel particular matter or soot in the
exhaust gas to purify exhaust gas. If soot is accumulated to a certain level in the filter, a purification process
to burn the soot is performed automatically to keep the filtering performance of KDPF high.
• Komatsu’s Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the
exhaust gas into harmless nitrogen and water. Spraying the reagent (Diesel Exhaust Fluid) into the exhaust
gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and
decomposes the nitrogen oxides into nitrogen and water.
About Diesel Exhaust Fluid (DEF)
Diesel Exhaust Fluid is the reagent for the SCR system.
DEF is the abbreviation for Diesel Exhaust Fluid, and is represented as DEF throughout this manual.
DEF is a colorless transparent and aqueous urea solution made with 32.5 % urea (AUS32) and 67.5 % deion-
ized water. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical
products, and fertilizer, etc.
Commercial DEF, commonly referred to as AdBlue® in the European Union, that quality standards are main-
tained in accordance with DIN70070 and ISO 22241-1, to be used.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
FOREWORD ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION
1-9

PRODUCT INFORMATION
When requesting service or ordering replacement parts, inform your Komatsu distributor of the following items.
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERI-
AL NO. PLATE
This is at the bottom left at the front of the operator's seat.
The design of the nameplate differs according to the district.
LOCATION OF EPA REGULATIONS, ENGINE NUMBER PLATE
•This is located on top of the engine head cover on the right side of the machine.
EPA: Environmental Protection Agency, USA
PRODUCT INFORMATION FOREWORD
1-10

SERVICE METER LOCATION
This is displayed on the machine monitor.
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number
(PIN)
Manufacturers name:
Address: KOMATSU LTD. 2-3-6 Akasaka
Minato-ku, Tokyo 107-8414
Japan
Authorised representative:
Address: KOMATSU EUROPE INT. Mechelsesteenweg 586
B-1800 Vilvoorde
Belgium
Distributor name
Address
Service personnel
Phone/Fax
FOREWORD PRODUCT INFORMATION
1-11

SERIAL PLATE
C
E
A
B
D
F
G
H
EI000001
A MACHINE DESIGNATION/TYPE E ENGINE POWER
B SERIAL NUMBER F PRODUCT IDENTIFICATION NUMBER
C YEAR OF CONSTRUCTION G MANUFACTURER
D OPERATING MASS H AUTHORISED REPRESENTATIVE
SERIAL PLATE FOREWORD
1-12

DECLARATION OF CONFORMITY
The manufacturer/Authorised representative
The manufacturer Authorised representative
KOMATSU LTD.
2-3-6 Akasaka
Minato-ku, Tokyo 107-8414
Japan
KOMATSU EUROPE INT.
Mechelsesteenweg 586
B-1800 Vilvoorde
Belgium
Declares that this machine:
D85EX-18
D85PX-18
Fulfils all the relevant provisions of following EC Directives:
Machinery Directive 2006/42/EC
Electro Magnetic Compatibility Directive 2004/108/EC
Outdoor Noise Directive 2001/14/EC amended by 2005/88/EC
FOREWORD DECLARATION OF CONFORMITY
1-13

TABLE OF CONTENTS
FOREWORD.................................................................................................................................................... 1-1
BEFORE READING THIS MANUAL ......................................................................................................... 1-2
SAFETY INFORMATION .......................................................................................................................... 1-3
NOISE....................................................................................................................................................... 1-4
VIBRATION LEVELS ................................................................................................................................ 1-5
VIBRATION - OPERATING CONDITION ........................................................................................... 1-5
GUIDE TO REDUCE VIBRATION LEVELS ON MACHINE ................................................................ 1-5
INTRODUCTION ...................................................................................................................................... 1-7
MAIN USE OF MACHINE .................................................................................................................. 1-7
DIRECTIONS OF MACHINE.............................................................................................................. 1-7
VISIBILITY FROM OPERATOR'S SEAT ............................................................................................ 1-7
ENGINE TECHNOLOGY TO CONFORM EXHAUST GAS EMISSION..................................................... 1-9
PRODUCT INFORMATION..................................................................................................................... 1-10
LOCATION OF PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE ...... 1-10
LOCATION OF EPA REGULATIONS, ENGINE NUMBER PLATE ................................................... 1-10
SERVICE METER LOCATION..........................................................................................................1-11
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR.............................................................1-11
SERIAL PLATE ....................................................................................................................................... 1-12
DECLARATION OF CONFORMITY ........................................................................................................ 1-13
SAFETY........................................................................................................................................................... 2-1
SAFETY.................................................................................................................................................... 2-2
SAFETY LABELS ..................................................................................................................................... 2-4
LOCATION OF SAFETY LABELS...................................................................................................... 2-5
CONTENTS OF SAFETY LABELS .................................................................................................... 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE .................................... 2-10
PRECAUTIONS BEFORE STARTING OPERATION........................................................................ 2-10
PREPARATIONS FOR SAFE OPERATION ..................................................................................... 2-10
PRECAUTIONS TO PREVENT FIRE................................................................................................2-11
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE............................................................. 2-13
DO NOT GET CAUGHT IN WORK EQUIPMENT ............................................................................ 2-15
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES........................................................ 2-15
UNAUTHORIZED MODIFICATION .................................................................................................. 2-15
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS .................................................... 2-15
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING..................................................... 2-16
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-17
PRECAUTIONS FOR JOBSITE....................................................................................................... 2-17
START ENGINE............................................................................................................................... 2-19
PRECAUTIONS FOR OPERATION ................................................................................................. 2-21
PRECAUTIONS FOR TRANSPORTATION...................................................................................... 2-24
TOWING AND BEING TOWED........................................................................................................ 2-25
PRECAUTIONS FOR MAINTENANCE................................................................................................... 2-26
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ................................... 2-26
PRECAUTIONS FOR INSPECTION AND MAINTENANCE............................................................. 2-29
PRECAUTIONS FOR DEF...................................................................................................................... 2-36
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING .................................................. 2-36
PRECAUTIONS FOR ADDING........................................................................................................ 2-36
PRECAUTIONS FOR STORING...................................................................................................... 2-36
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE .................................................................... 2-36
OTHER PRECAUTIONS.................................................................................................................. 2-36
OPERATION.................................................................................................................................................... 3-1
GENERAL VIEW....................................................................................................................................... 3-2
MACHINE EQUIPMENT NAME ......................................................................................................... 3-2
CONTROLS AND GAUGES NAMES................................................................................................. 3-4
EXPLANATION OF COMPONENTS......................................................................................................... 3-6
EXPLANATION OF MACHINE MONITOR EQUIPMENT ................................................................... 3-6
SWITCHES...................................................................................................................................... 3-82
TABLE OF CONTENTS FOREWORD
1-14

CONTROL LEVERS AND PEDALS................................................................................................. 3-88
OTHER EQUIPMENT ...................................................................................................................... 3-95
MACHINE OPERATIONS AND CONTROLS ........................................................................................ 3-131
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...................................................... 3-131
METHOD FOR STARTING ENGINE.............................................................................................. 3-158
METHOD FOR OPERATIONS AND CHECKS AFTER STARTING ENGINE ................................. 3-163
METHOD FOR STOPPING ENGINE ............................................................................................. 3-166
METHOD FOR STARTING MACHINE (TRAVEL FORWARD AND REVERSE) AND STOPPING MA-
CHINE........................................................................................................................................ 3-168
SHIFT GEARS............................................................................................................................... 3-170
METHOD FOR SWITCHING BETWEEN FORWARD AND REVERSE.......................................... 3-175
METHOD FOR STEERING MACHINE........................................................................................... 3-176
RECOMMENDED WORKING MODES FOR WORKS ................................................................... 3-178
PRECAUTIONS FOR OPERATION ............................................................................................... 3-180
PRECAUTIONS WHEN OPERATING ON SLOPE......................................................................... 3-180
PRECAUTIONS FOR USING BRAKE ........................................................................................... 3-181
DO NOT OPEN DOOR WHILE OPERATING MACHINE ............................................................... 3-181
DO NOT MODIFY CAB GLASS IN ANY WAY THAT WILL OBSTRUCT THE VIEW ...................... 3-181
PRECAUTIONS FOR FLOATING OPERATION............................................................................. 3-181
PRECAUTIONS FOR BLIND SPOTS CAUSED BY CAB AND ROPS STRUCTURES .................. 3-182
RECOMMENDED APPLICATIONS................................................................................................ 3-182
METHOD FOR ADJUSTING WORK EQUIPMENT........................................................................ 3-183
TIPS FOR LONGER UNDERCARRIAGE LIFE.............................................................................. 3-186
METHOD FOR PARKING MACHINE............................................................................................. 3-189
METHOD FOR CHECKING AFTER FINISHING WORK................................................................ 3-190
LOCK............................................................................................................................................. 3-191
HANDLE AIR CONDITIONER............................................................................................................... 3-196
EXPLANATION OF AIR CONDITIONER EQUIPMENT.................................................................. 3-197
METHOD FOR OPERATING AIR CONDITIONER......................................................................... 3-201
HANDLING RADIO ............................................................................................................................... 3-210
EXPLANATION OF RADIO EQUIPMENT ...................................................................................... 3-210
METHOD FOR CONTROLLING RADIO ........................................................................................ 3-212
ANTENNA...................................................................................................................................... 3-214
TRANSPORTATION.............................................................................................................................. 3-215
TRAVEL ON ROAD........................................................................................................................ 3-215
PRECAUTIONS FOR TRANSPORTING MACHINE ...................................................................... 3-215
TRANSPORTATION PROCEDURE ............................................................................................... 3-215
LOADING AND UNLOADING WITH TRAILER .............................................................................. 3-215
METHOD FOR LIFTING MACHINE............................................................................................... 3-218
COLD WEATHER OPERATION............................................................................................................ 3-220
COLD WEATHER OPERATION INFORMATION ........................................................................... 3-220
PRECAUTIONS AFTER DAILY WORK COMPLETION ................................................................. 3-221
AFTER COLD WEATHER SEASON .............................................................................................. 3-221
PRECAUTIONS FOR LONG-TERM STORAGE ................................................................................... 3-223
PREPARATION FOR LONG-TERM STORAGE............................................................................. 3-223
MAINTENANCE DURING LONG-TERM STORAGE...................................................................... 3-223
STARTING MACHINE AFTER LONG-TERM STORAGE............................................................... 3-223
TROUBLES AND ACTIONS ................................................................................................................. 3-225
ACTIONS WHEN RUNNING OUT OF FUEL ................................................................................. 3-225
PRECAUTIONS FOR TOWING MACHINE.................................................................................... 3-225
PRECAUTIONS FOR DISCHARGED BATTERY ........................................................................... 3-227
OTHER TROUBLE......................................................................................................................... 3-230
MAINTENANCE............................................................................................................................................... 4-1
PRECAUTIONS FOR MAINTENANCE..................................................................................................... 4-2
CHECK SERVICE METER READING ............................................................................................... 4-2
KOMATSU GENUINE REPLACEMENT PARTS ................................................................................ 4-2
KOMATSU GENUINE LUBRICANTS................................................................................................. 4-2
ALWAYS USE CLEAN WASHER FLUID............................................................................................ 4-2
FOREWORD TABLE OF CONTENTS
1-15

FRESH AND CLEAN LUBRICANTS .................................................................................................. 4-2
CHECK DRAINED OIL AND USED FILTER....................................................................................... 4-2
PRECAUTIONS FOR REFILLING OIL OR FUEL .............................................................................. 4-2
PRECAUTIONS FOR ADDING DEF ................................................................................................. 4-2
WELDING INSTRUCTIONS............................................................................................................... 4-2
DO NOT DROP THINGS INSIDE MACHINE ..................................................................................... 4-2
PRECAUTIONS FOR KDPF .............................................................................................................. 4-2
PRECAUTIONS FOR SCR ASSEMBLY ............................................................................................ 4-3
DUSTY JOBSITES............................................................................................................................. 4-3
AVOID MIXING OIL............................................................................................................................ 4-3
LOCK INSPECTION COVERS .......................................................................................................... 4-3
PRECAUTIONS FOR OPENING AND CLOSING ENGINE SIDE COVER......................................... 4-3
BLEED AIR FROM HYDRAULIC CIRCUIT ........................................................................................ 4-3
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
HANDLE OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC .................................................. 4-5
HANDLE ELECTRICAL COMPONENTS ........................................................................................... 4-9
HANDLE HYDRAULIC COMPONENTS............................................................................................. 4-9
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...............................................................4-11
MAINTENANCE SCHEDULE.................................................................................................................. 4-13
MAINTENANCE SCHEDULE TABLE............................................................................................... 4-13
MAINTENANCE PROCEDURE .............................................................................................................. 4-15
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ............................ 4-15
WHEN REQUIRED .......................................................................................................................... 4-15
CHECKS BEFORE STARTING........................................................................................................ 4-40
EVERY 250 HOURS MAINTENANCE ............................................................................................. 4-40
EVERY 500 HOURS MAINTENANCE ............................................................................................. 4-47
EVERY 1000 HOURS MAINTENANCE ........................................................................................... 4-52
EVERY 2000 HOURS MAINTENANCE ........................................................................................... 4-60
EVERY 4000 HOURS MAINTENANCE ........................................................................................... 4-72
EVERY 4500 HOURS MAINTENANCE ........................................................................................... 4-75
EVERY 8000 HOURS MAINTENANCE ........................................................................................... 4-76
EVERY 9000 HOURS MAINTENANCE ........................................................................................... 4-76
SPECIFICATIONS ........................................................................................................................................... 5-1
SPECIFICATIONS .................................................................................................................................... 5-2
D85EX-18 SPECIFICATIONS ............................................................................................................ 5-2
D85PX-18 SPECIFICATIONS ............................................................................................................ 5-2
ATTACHMENTS AND OPTIONS ..................................................................................................................... 6-1
GENERAL PRECAUTIONS ...................................................................................................................... 6-2
PRECAUTIONS FOR SAFETY.......................................................................................................... 6-2
TRACK SHOES SELECTION ................................................................................................................... 6-3
SELECTION PROCEDURE OF RIPPER POINT ...................................................................................... 6-4
REPLACEMENT PARTS.................................................................................................................................. 7-1
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS.......................................................................... 7-2
DEFINED LIFE PARTS LIST.............................................................................................................. 7-2
CONSUMABLE PARTS ............................................................................................................................ 7-3
CONSUMABLE PARTS ..................................................................................................................... 7-3
RECOMMENDED FUEL, COOLANT, AND LUBRICANT .......................................................................... 7-6
LUBRICATION CHART...................................................................................................................... 7-6
METHOD FOR USING FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERA-
TURE ............................................................................................................................................. 7-8
RECOMMENDED BRANDS AND QUALITIES OTHER THAN KOMATSU GENUINE OILS .............. 7-9
INDEX.............................................................................................................................................................. 8-1
TABLE OF CONTENTS FOREWORD
1-16

SAFETY
Please read and make sure that you fully understand the precautions descri-
bed in this manual and the safety labels on the machine. When operating or
servicing the machine, always follow these precautions strictly.
2-1

SAFETY
SAFETY LABELS ............................................................................................................................................ 2-4
LOCATION OF SAFETY LABELS............................................................................................................. 2-5
CONTENTS OF SAFETY LABELS ........................................................................................................... 2-6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ........................................... 2-10
PRECAUTIONS BEFORE STARTING OPERATION............................................................................... 2-10
ENSURE SAFE OPERATION .......................................................................................................... 2-10
UNDERSTAND THE MACHINE....................................................................................................... 2-10
PREPARATIONS FOR SAFE OPERATION ............................................................................................ 2-10
PRECAUTIONS FOR SAFETY-RELATED EQUIPMENT ................................................................. 2-10
INSPECT MACHINE........................................................................................................................ 2-10
WEAR WELL-FITTING CLOTHES AND PROTECTIVE EQUIPMENT............................................. 2-10
KEEP MACHINE CLEAN ................................................................................................................. 2-10
PRECAUTIONS FOR INSIDE OPERATOR'S COMPARTMENT .......................................................2-11
PROVIDE FIRE EXTINGUISHER AND FIRST AID KIT ....................................................................2-11
IF ANY PROBLEM IS FOUND ..........................................................................................................2-11
PRECAUTIONS TO PREVENT FIRE.......................................................................................................2-11
ACTIONS IF FIRE OCCURS ............................................................................................................2-11
PREVENT FIRE............................................................................................................................... 2-12
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE.................................................................... 2-13
USE HANDRAILS AND STEPS WHEN GETTING ON OR OFF MACHINE..................................... 2-13
NO JUMPING ON OR OFF MACHINE............................................................................................. 2-13
LIFTING OF PERSONNEL PROHIBITED........................................................................................ 2-14
NO PEOPLE ON ATTACHMENTS................................................................................................... 2-14
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT.............................................. 2-14
WHEN LEAVING MACHINE ............................................................................................................ 2-14
EMERGENCY EXIT FROM OPERATOR'S CAB.............................................................................. 2-15
DO NOT GET CAUGHT IN WORK EQUIPMENT ................................................................................... 2-15
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES............................................................... 2-15
UNAUTHORIZED MODIFICATION ......................................................................................................... 2-15
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ........................................................... 2-15
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING............................................................ 2-16
PRECAUTIONS FOR OPERATION ............................................................................................................... 2-17
PRECAUTIONS FOR JOBSITE.............................................................................................................. 2-17
INVESTIGATE AND CONFIRM JOBSITE CONDITIONS................................................................. 2-17
PRECAUTIONS WHEN WORKING ON LOOSE GROUND............................................................. 2-17
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES........................................................................ 2-17
ENSURE GOOD VISIBILITY............................................................................................................ 2-18
CHECK SIGNS AND SIGNALMAN'S SIGNALS............................................................................... 2-18
BEWARE OF ASBESTOS DUST..................................................................................................... 2-18
START ENGINE...................................................................................................................................... 2-19
USE WARNING TAGS ..................................................................................................................... 2-19
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ........................................................ 2-19
PRECAUTIONS WHEN STARTING ENGINE .................................................................................. 2-20
IN COLD WEATHER........................................................................................................................ 2-20
START ENGINE WITH JUMPER CABLES ...................................................................................... 2-20
PRECAUTIONS FOR OPERATION ........................................................................................................ 2-21
CHECKS BEFORE OPERATION..................................................................................................... 2-21
PRECAUTIONS FOR TRAVELING IN FORWARD OR REVERSE .................................................. 2-21
PRECAUTIONS WHEN TRAVELING............................................................................................... 2-21
PRECAUTIONS WHEN TRAVELING ON SLOPES ......................................................................... 2-22
WHEN OPERATING ........................................................................................................................ 2-23
PROHIBITED OPERATIONS ........................................................................................................... 2-23
METHOD OF USING BRAKES........................................................................................................ 2-23
PRECAUTIONS WHEN OPERATING ON SNOW OR FROZEN SURFACES.................................. 2-23
PRECAUTIONS WHEN PARKING MACHINE ................................................................................. 2-23
PRECAUTIONS FOR TRANSPORTATION............................................................................................. 2-24
SAFETY SAFETY
2-2