Komatsu D85EX -15 Manual

BULLDOZER
PEN00025-02
D85EX -15
D85PX -15
SERIAL NUMBERS D85EX- 10250
D85PX- 1109 and up
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 near the machine for
reference and periodically reviewed by all personnel
who will come into contact with it .
WARNING
Komatsu has Operation & Maintenance Manuals written
in some other languages . If a foreign language manual
is necessary , contact your local distributor for
availability .
NOTICE

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FOREWORD
FOREWORD
FOREWORD
This manual provides rules and guidelines which will help you use this machine safely and effectively. The
precautions in this manual must be followed at all times when performing operation and maintenance. Most
accidents are caused by the failure to follow fundamental safety rules for the operation and maintenance of
machines. Accidents can be prevented by knowing beforehand conditions that may cause a hazard when
performing operation and maintenance.
WARNING
Operators and maintenance personnel must always do as follows before beginning operation or maintenance.
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 thoroughly and be sure that you
understand them fully.
Keep this manual in 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
operating the machine.
Location to keep operation & maintenance manual
In door pocket inside of cab door
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FOREWORD FOREWORD
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FOREWORD
FOREWORD
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FOREWORD SAFETY INFORMATION
SAFETY INFORMATION
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
situations.
Signal words
The following signal words are used to inform you that there is a potential hazardous situation that may lead to
personal injury or damage.
In this manual and on machine labels, the following signal words are used to express the potential level of hazard.
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.
Example of safety message using signal word
WARNING
When standing up from the operator's seat, always place the parking brake
lever and work equipment 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
protect the machine or to give information that is useful to know.
This word is used for precautions that must be taken to avoid actions which could shorten
the life of the machine.
This word is used for information that is useful to know.
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FOREWORD
SAFETY INFORMATION
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 hazardous
condition equivalent to the signal word. These safety pictograms
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 condition at the top
or left side, and the method of avoiding the hazardous 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 precautions.
If any procedures or actions not specifically recommended or allowed in this manual are used, it is your responsibility
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: 1J(1))
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FOREWORD INTRODUCTION
INTRODUCTION
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 (PAGE 3-118)".
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE
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.
BREAKING IN THE MACHINE
CAUTION
Your Komatsu machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe
conditions at the beginning can adversely affect the performance and shorten the machine life.
Be sure to break-in the machine for the initial 100 hours (as indicated by the service meter).
During break-in operations, follow the precautions described in this manual.
Run the engine at idle for 15 seconds after starting it. During this time, do not operate the control levers or fuel
control dial.
Idle the engine for 5 minutes after starting it up.
Avoid operation with heavy loads or at high speeds.
Immediately after starting the engine, avoid sudden starts, sudden acceleration, unnecessary sudden stops, and
sudden changes in direction.
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FOREWORD
NECESSARY INFORMATION
NECESSARY INFORMATION
When requesting service or ordering replacement parts, please inform your Komatsu distributor of the following
items.
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE
Under the front of the console box on the right side of the operator's seat.
The design of the nameplate differs according to the territory.
ENGINE SERIAL NO. PLATE
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.
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FOREWORD NECESSARY INFORMATION
POSITION OF SERVICE METER
On top of the machine monitor
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
Machine serial No.
Engine serial No.
Product identification number (PIN)
Distributor name
Address
Service Personnel
Phone/Fax
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FOREWORD
CONTENTS
CONTENTS
FOREWORD 1- 1
FOREWORD 1- 2
SAFETY INFORMATION 1- 5
INTRODUCTION 1- 7
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 7
BREAKING IN THE MACHINE 1- 7
NECESSARY INFORMATION 1- 8
PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE 1- 8
ENGINE SERIAL NO. PLATE 1- 8
POSITION OF SERVICE METER 1- 9
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 9
SAFETY 2- 1
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- 17
BEFORE STARTING ENGINE 2- 17
OPERATION 2- 19
TRANSPORTATION 2- 23
BATTERY 2- 24
TOWING 2- 26
PRECAUTIONS FOR MAINTENANCE 2- 27
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 5
FRONT PANEL 3- 5
SWITCHES 3- 34
CONTROL LEVERS, PEDALS 3- 38
FUSE 3- 45
MAIN POWER CIRCUIT BREAKERS 3- 47
CIRCUIT BREAKER 3- 47
POWER SOURCE 3- 48
CAP WITH LOCK 3- 49
DOOR OPEN LOCK 3- 51
SASH GLASS INTERMEDIATE LOCK 3- 51
DOOR POCKET 3- 52
ASHTRAY 3- 52
TOOL BOX 3- 52
AIR CONDITIONER 3- 53
HEATER, HANDLING 3- 59
CAR STEREO, HANDLING 3- 60
EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER 3- 68
OPERATION 3- 76
CHECK BEFORE STARTING ENGINE, ADJUST 3- 76
STARTING ENGINE 3- 95
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FOREWORD CONTENTS
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3-100
STOPPING ENGINE 3-103
MACHINE OPERATION 3-104
SHIFTING GEAR 3-107
SHIFTING BETWEEN FORWARD AND REVERSE 3-111
STEERING MACHINE 3-113
PRECAUTIONS FOR OPERATION 3-115
WORK POSSIBLE USING BULLDOZER 3-118
ADJUSTING POSTURE OF WORK EQUIPMENT 3-120
PARKING MACHINE 3-124
CHECK AFTER FINISHING WORK 3-126
LOCKING 3-126
TIPS FOR LONGER UNDERCARRIAGE LIFE 3-127
TRANSPORTATION 3-130
TRANSPORTATION PROCEDURE 3-130
REMOVAL OF CAB 3-130
INSTALLATION OF CAB 3-131
INSTALLATION OF ROPS 3-131
LOADING, UNLOADING WORK 3-132
METHOD OF LIFTING MACHINE 3-135
PRECAUTIONS FOR TRANSPORTATION 3-136
TRAVELING ON ROADS 3-136
COLD WEATHER OPERATION 3-137
PRECAUTIONS FOR LOW TEMPERATURE 3-137
AFTER COMPLETION OF WORK 3-139
AFTER COLD WEATHER 3-139
LONG-TERM STORAGE 3-140
BEFORE STORAGE 3-140
DURING STORAGE 3-140
AFTER STORAGE 3-140
TROUBLESHOOTING 3-141
AFTER RUNNING OUT OF FUEL 3-141
METHOD OF TOWING MACHINE 3-142
IF BATTERY IS DISCHARGED 3-144
OTHER TROUBLE 3-148
MAINTENANCE 4- 1
GUIDES TO MAINTENANCE 4- 2
OUTLINES OF SERVICE 4- 5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 5
OUTLINE OF ELECTRIC SYSTEM 4- 8
WEAR PARTS 4- 9
WEAR PARTS LIST 4- 9
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 10
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 11
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 12
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- 14
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FOREWORD
CONTENTS
MAINTENANCE SCHEDULE CHART 4- 16
MAINTENANCE SCHEDULE CHART 4- 16
ADJUST INJECTOR 4- 18
SERVICE PROCEDURE 4- 19
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS) 4- 19
WHEN REQUIRED 4- 20
CHECK BEFORE STARTING 4- 44
EVERY 250 HOURS SERVICE 4- 45
EVERY 500 HOURS SERVICE 4- 52
EVERY 1000 HOURS SERVICE 4- 56
EVERY 2000 HOURS SERVICE 4- 63
EVERY 4000 HOURS SERVICE 4- 70
EVERY 8000 HOURS SERVICE 4- 74
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAUTIONS 6- 2
PRECAUTIONS RELATED TO SAFETY 6- 2
SELECTION OF TRACK SHOE 6- 3
METHOD OF SELECTING SHOES 6- 3
PROCEDURE FOR SELECTING RIPPER POINT 6- 4
HANDLING TRIMMING DOZER 6- 5
GENERAL VIEW 6- 5
EXPLANATION OF COMPONENTS 6- 6
MAINTENANCE 6- 7
SPECIFICATIONS 6- 11
HANDLING MACHINES EQUIPPED WITH KOMTRAX 6- 12
BASIC PRECAUTIONS 6- 12
INDEX 7- 1
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SAFETY
SAFETY
SAFETY
Safety Labels 2- 4
Positions of Safety Pictograms 2- 4
Safety Labels 2- 5
General Precautions
Safety Rules 2- 9
If Abnormalities are Found 2- 9
Clothing and Personal Protective Items 2- 9
Fire Extinguisher and First Aid Kit 2- 9
Safety Features 2- 9
Keep Machine Clean 2- 10
Inside Operator's Compartment 2- 10
Always Apply Lock when Leaving Operator's Seat 2- 10
Handrails and Steps 2- 11
Mounting and Dismounting 2- 11
No People on Attachments 2- 11
Crushing or cutting prevention 2- 11
Prevention of Burns 2- 12
Fire Prevention 2- 12
Action if Fire Occurs 2- 13
Window Washer Liquid 2- 13
Precautions when using ROPS 2- 13
Precautions for Attachments 2- 14
Unauthorized Modification 2- 14
Safety at Worksite 2- 14
Working on Loose Ground 2- 14
Do not Go Close to High-Voltage Cables 2- 15
Ensure Good Visibility 2- 15
Ventilation for Enclosed Areas 2- 15
Checking Signalman's Signals and Signs 2- 16
Emergency exit from operator's cab 2- 16
Be Careful About Asbestos Dust 2- 16
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SAFETY SAFETY
Precautions for Operation 2- 17
Before Starting Engine 2- 17
Checks Before Starting Engine 2- 17
Precautions when Starting 2- 18
Precautions in Cold Areas 2- 18
Operation 2- 19
Checks Before Operation 2- 19
Precautions for Moving Machine Forward or in Reverse 2- 19
Precautions when Traveling 2- 20
Traveling on Slopes 2- 21
Using Brakes 2- 21
Operate Carefully on Snow 2- 21
Parking Machine 2- 22
Transportation 2- 23
Shipping 2- 23
Battery 2- 24
Battery Hazard Prevention 2- 24
Starting with Booster Cable 2- 25
Towing 2- 26
When Towing 2- 26
Precautions for Maintenance 2- 27
Warning Tag 2- 27
Keep Work Place Clean and Tidy 2- 27
Appoint Leader when Working with Others 2- 27
Stop Engine Before Carrying Out Inspection and Maintenance 2- 28
Two Workers for Maintenance when Engine is Running 2- 29
Proper Tools 2- 29
Handling Accumulator 2- 29
Personnel 2- 30
Attachments 2- 30
Work Under the Machine 2- 30
Noise 2- 30
Precautions when Using Hammer 2- 30
Repair Welding 2- 31
Removing Battery Terminal 2- 31
Precautions when Using High-Pressure Grease to Adjust Track Tension 2- 31
Do not Disassemble Recoil Spring 2- 31
Precaution with High-Pressure Oil 2- 32
Precaution for High Fuel Pressure 2- 32
Handing High-Pressure Hoses 2- 32
Precaution for High Voltage 2- 32
Waste Material 2- 33
Maintenance for Air Conditioner 2- 33
Compressed Air 2- 33
Periodic Replacement of Safety Critical Parts 2- 33
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SAFETY
SAFETY LABELS
SAFETY LABELS
The following warning signs and safety labels are used on this machine.
Be sure that you fully understand the correct position and content of labels.
To ensure that the content of labels can be read properly, be sure that they are in the correct place and always
keep them clean. When cleaning them, do not use organic solvents or gasoline. These may cause the labels to
peel off.
There are also other labels in addition to the warning signs and safety labels. Handle those labels in the same
way.
If the labels are damaged, lost, or cannot be read properly, replace them with new ones. For details of the part
numbers for the labels, see this manual or the actual label, and place an order with Komatsu distributor.
POSITIONS OF SAFETY PICTOGRAMS
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SAFETY SAFETY LABELS
SAFETY LABELS
(1) Caution for operation, inspection, and maintenance
(09651-A0641)
(2) Caution when traveling in reverse (09802-13000)
(3) Warning for leaving operator's seat (09654-B0641)
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SAFETY
SAFETY LABELS SAFETY SAFETY LABELS
(4) Warning for hot water hazard (09653-A0481)
(5) Caution when adjusting track tension (09657-A0881)
Safety label is attached to the back side of the inspection cover
of the track frame.
(6) Precautions for handling electric wires (09808-A0881)
(7) Caution for engine running (09667-A0481)
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SAFETY SAFETY LABELS SAFETY SAFETY LABELS
(8) Caution for handling accumulator (09659-A057B)
(9) Caution for approach when machine moving (09806-B1683)
(10) ROPS (09620-B2000)
(11) FOPS (09620-C2000)
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