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Komatsu D85Ex-15, D85Px-15 Bulldozer Operation & Maintenance Manual SN 10250, 1109 And Up – PDF DOWNLOAD
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Komatsu D85Ex-15, D85Px-15 Bulldozer Operation & Maintenance Manual
Book Code : TEN00027-02
SERIAL NUMBERS:
D85EX-10250 and up
D85PX- 1109 and up
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Description
Komatsu D85Ex-15, D85Px-15 Bulldozer Operation & Maintenance Manual
FILE DETAILS:
Komatsu D85Ex-15, D85Px-15 Bulldozer Operation & Maintenance Manual
Size : 9.30 MB
Format : PDF
Language : English
Number of Pages : 291 pages
Brand: Komatsu
Type of machine: Bulldozer
Type of document: Operation & Maintenance Manual
Model: D85EX-15 D85PX-15
Serial: 10250 1109 and up
KOMATSU D85EX-15, D85PX-15 BULLDOZER OPERATION & MAINTENANCE MANUAL SN 10250, 1109 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu D85Ex-15, D85Px-15 Bulldozer Operation & Maintenance Manual
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 forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
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
TABLE OF CONTENTS:
Komatsu D85Ex-15, D85Px-15 Bulldozer Operation & Maintenance Manual
COVER............................................................................................................... 1 FOREWORD............................................................................................................ 2 FOREWORD........................................................................................................ 3 SAFETY INFORMATION.............................................................................................. 6 INTRODUCTION.................................................................................................... 8 FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE................................................................ 8 BREAKING IN THE MACHINE..................................................................................... 8 NECESSARY INFORMATION........................................................................................... 9 PRODUCT IDENTIFICATION NUMBER (PIN), MACHINE SERIAL NO. PLATE............................................... 9 ENGINE SERIAL NO. PLATE..................................................................................... 9 POSITION OF SERVICE METER................................................................................... 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR................................................................... 10 CONTENTS............................................................................................................ 11 SAFETY.............................................................................................................. 14 SAFETY.......................................................................................................... 15 SAFETY LABELS................................................................................................... 17 POSITIONS OF SAFETY PICTOGRAMS.............................................................................. 17 SAFETY LABELS............................................................................................... 18 GENERAL PRECAUTIONS............................................................................................. 22 SAFETY RULES................................................................................................ 22 IF ABNORMALITIES ARE FOUND.................................................................................. 22 CLOTHING AND PERSONAL PROTECTIVE ITEMS...................................................................... 22 FIRE EXTINGUISHER AND FIRST AID KIT......................................................................... 22 SAFETY FEATURES............................................................................................. 22 KEEP MACHINE CLEAN.......................................................................................... 23 INSIDE OPERATOR'S COMPARTMENT............................................................................... 23 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT.............................................................. 23 HANDRAILS AND STEPS......................................................................................... 24 MOUNTING AND DISMOUNTING.................................................................................... 24 NO PEOPLE ON ATTACHMENTS.................................................................................... 24 CRUSHING OR CUTTING PREVENTION.............................................................................. 24 PREVENTION OF BURNS......................................................................................... 25 FIRE PREVENTION............................................................................................. 25 ACTION IF FIRE OCCURS....................................................................................... 26 WINDOW WASHER LIQUID........................................................................................ 26 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................................................ 26 PRECAUTIONS FOR ATTACHMENTS................................................................................. 27 UNAUTHORIZED MODIFICATION................................................................................... 27 SAFETY AT WORKSITE.......................................................................................... 27 WORKING ON LOOSE GROUND..................................................................................... 27 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...................................................................... 28 ENSURE GOOD VISIBILITY...................................................................................... 28 VENTILATION FOR ENCLOSED AREAS.............................................................................. 28 CHECKING SIGNALMAN'S SIGNALS AND SIGNS...................................................................... 29 EMERGENCY EXIT FROM OPERATOR'S CAB.......................................................................... 29 BE CAREFUL ABOUT ASBESTOS DUST.............................................................................. 29 PRECAUTIONS FOR OPERATION....................................................................................... 30 BEFORE STARTING ENGINE...................................................................................... 30 CHECKS BEFORE STARTING ENGINE........................................................................... 30 PRECAUTIONS WHEN STARTING............................................................................... 31 PRECAUTIONS IN COLD AREAS............................................................................... 31 OPERATION................................................................................................... 32 CHECKS BEFORE OPERATION................................................................................. 32 PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE.................................................... 32 PRECAUTIONS WHEN TRAVELING.............................................................................. 33 TRAVELING ON SLOPES..................................................................................... 34 USING BRAKES............................................................................................ 34 OPERATE CAREFULLY ON SNOW............................................................................... 34 PARKING MACHINE......................................................................................... 35 TRANSPORTATION.............................................................................................. 36 LOADING AND UNLOADING................................................................................... 36 SHIPPING................................................................................................ 36 BATTERY..................................................................................................... 37 BATTERY HAZARD PREVENTION............................................................................... 37 STARTING WITH BOOSTER CABLE............................................................................. 38 TOWING...................................................................................................... 39 WHEN TOWING............................................................................................. 39 PRECAUTIONS FOR MAINTENANCE..................................................................................... 40 WARNING TAG................................................................................................. 40 KEEP WORK PLACE CLEAN AND TIDY.............................................................................. 40 APPOINT LEADER WHEN WORKING WITH OTHERS..................................................................... 40 STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE.................................................. 41 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.......................................................... 42 PROPER TOOLS................................................................................................ 42 HANDLING ACCUMULATOR........................................................................................ 42 PERSONNEL................................................................................................... 43 ATTACHMENTS................................................................................................. 43 WORK UNDER THE MACHINE...................................................................................... 43 NOISE....................................................................................................... 43 PRECAUTIONS WHEN USING HAMMER............................................................................... 43 REPAIR WELDING.............................................................................................. 44 REMOVING BATTERY TERMINAL................................................................................... 44 PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION......................................... 44 DO NOT DISASSEMBLE RECOIL SPRING............................................................................ 44 PRECAUTION WITH HIGH-PRESSURE OIL........................................................................... 45 PRECAUTION FOR HIGH FUEL PRESSURE........................................................................... 45 HANDLING HIGH-PRESSURE HOSES................................................................................ 45 PRECAUTION FOR HIGH VOLTAGE................................................................................. 45 WASTE MATERIAL.............................................................................................. 46 MAINTENANCE FOR AIR CONDITIONER............................................................................. 46 COMPRESSED AIR.............................................................................................. 46 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................................... 46 OPERATION........................................................................................................... 48 GENERAL VIEW.................................................................................................... 49 GENERAL VIEW OF MACHINE..................................................................................... 49 GENERAL VIEW OF CONTROLS AND GAUGES......................................................................... 50 EXPLANATION OF COMPONENTS....................................................................................... 52 FRONT PANEL................................................................................................. 52 SWITCHES.................................................................................................... 81 CONTROL LEVERS, PEDALS...................................................................................... 85 FUSE........................................................................................................ 92 MAIN POWER CIRCUIT BREAKERS................................................................................. 94 CIRCUIT BREAKER............................................................................................. 94 POWER SOURCE................................................................................................ 95 CAP WITH LOCK............................................................................................... 96 DOOR OPEN LOCK.............................................................................................. 98 SASH GLASS INTERMEDIATE LOCK................................................................................ 98 DOOR POCKET................................................................................................. 99 ASHTRAY..................................................................................................... 99 TOOL BOX.................................................................................................... 99 AIR CONDITIONER.............................................................................................100 HEATER, HANDLING............................................................................................106 CAR STEREO, HANDLING........................................................................................107 EXTERNAL POWER SOURCE TYPE ENGINE PREHEATING HEATER.........................................................115 OPERATION.......................................................................................................123 CHECK BEFORE STARTING ENGINE, ADJUST........................................................................123 STARTING ENGINE.............................................................................................142 OPERATIONS AND CHECKS AFTER STARTING ENGINE.................................................................147 STOPPING ENGINE.............................................................................................150 MACHINE OPERATION...........................................................................................151 SHIFTING GEAR...............................................................................................154 SHIFTING BETWEEN FORWARD AND REVERSE........................................................................158 STEERING MACHINE............................................................................................160 PRECAUTIONS FOR OPERATION...................................................................................162 WORK POSSIBLE USING BULLDOZER...............................................................................165 ADJUSTING POSTURE OF WORK EQUIPMENT.........................................................................167 PARKING MACHINE.............................................................................................171 CHECK AFTER FINISHING WORK..................................................................................173 LOCKING.....................................................................................................173 TIPS FOR LONGER UNDERCARRIAGE LIFE..........................................................................174 TRANSPORTATION..................................................................................................177 TRANSPORTATION PROCEDURE....................................................................................177 REMOVAL OF CAB..............................................................................................177 INSTALLATION OF CAB.........................................................................................178 INSTALLATION OF ROPS........................................................................................178 LOADING, UNLOADING WORK.....................................................................................179 METHOD OF LIFTING MACHINE...................................................................................182 PRECAUTIONS FOR TRANSPORTATION..............................................................................183 TRAVELING ON ROADS..........................................................................................183 COLD WEATHER OPERATION..........................................................................................184 PRECAUTIONS FOR LOW TEMPERATURE.............................................................................184 AFTER COMPLETION OF WORK....................................................................................186 AFTER COLD WEATHER..........................................................................................186 LONG-TERM STORAGE...............................................................................................187 BEFORE STORAGE..............................................................................................187 DURING STORAGE..............................................................................................187 AFTER STORAGE...............................................................................................187 TROUBLESHOOTING.................................................................................................188 AFTER RUNNING OUT OF FUEL...................................................................................188 METHOD OF TOWING MACHINE....................................................................................189 IF BATTERY IS DISCHARGED....................................................................................191 OTHER TROUBLE...............................................................................................195 MAINTENANCE.........................................................................................................200 GUIDES TO MAINTENANCE...........................................................................................201 OUTLINES OF SERVICE.............................................................................................204 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC......................................................204 OUTLINE OF ELECTRIC SYSTEM..................................................................................207 WEAR PARTS......................................................................................................208 WEAR PARTS LIST.............................................................................................208 RECOMMENDED FUEL, COOLANT, AND LUBRICANT........................................................................209 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE........................................210 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL.........................211 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS..................................................................212 TORQUE LIST.................................................................................................212 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...................................................................213 SAFETY CRITICAL PARTS.......................................................................................213 MAINTENANCE SCHEDULE CHART......................................................................................215 MAINTENANCE SCHEDULE CHART..................................................................................215 ADJUST INJECTOR.............................................................................................217 SERVICE PROCEDURE...............................................................................................218 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)..................................................218 WHEN REQUIRED...............................................................................................219 CLEAN INSIDE OF COOLING SYSTEM..........................................................................219 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT............................................................223 CHECK AND ADJUST TRACK TENSION..........................................................................227 CHECK AND TIGHTEN TRACK SHOE BOLTS......................................................................229 ADJUST IDLER CLEARANCE..................................................................................230 REVERSE AND REPLACE THE END BITS AND CUTTING EDGES......................................................232 CLEAN, CHECK RADIATOR FINS AND OIL COOLER FINS..........................................................233 CLEAN FUEL TANK STRAINER................................................................................235 DRAIN WATER AND SEDIMENT IN FUEL TANK...................................................................235 CLEAN STEERING CLUTCH CASE BREATHER.....................................................................235 CHECK UNDERCARRIAGE OIL.................................................................................236 CLEAN AIR CONDITIONER AIR FILTER (FRESH/RECIRC FILTER)..................................................237 CHECK AND ADJUST AIR CONDITIONER........................................................................237 LUBRICATE DOOR HINGE....................................................................................239 CHECK DOOR LATCH........................................................................................239 CHECK DOOR LOCK STRIKER.................................................................................239 REPLACE DOOR DAMPER.....................................................................................240 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID..............................................................240 REPLACE WIPER BLADE.....................................................................................241 BLEEDING AIR IN HYDRAULIC SYSTEM........................................................................242 CHECK ELECTRICAL INTAKE AIR HEATER......................................................................242 LUBRICATING.............................................................................................242 CHECK BEFORE STARTING.......................................................................................243 EVERY 250 HOURS SERVICE.....................................................................................244 LUBRICATING.............................................................................................244 CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST.............................................................246 CHECK LEVEL OF BATTERY ELECTROLYTE......................................................................247 CHECK BRAKE PERFORMANCE.................................................................................249 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.................................................................250 EVERY 500 HOURS SERVICE.....................................................................................251 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.......................................251 REPLACE PRE-FUEL FILTER CARTRIDGE.......................................................................252 REPLACE POWER TRAIN OIL FILTER ELEMENT..................................................................254 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL............................................................254 EVERY 1000 HOURS SERVICE....................................................................................255 CHANGE OIL IN POWER TRAIN CASE, WASH STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER)....255 REPLACE HYDRAULIC TANK BREATHER ELEMENT.................................................................257 CHANGE OIL IN FINAL DRIVE CASE..........................................................................258 CHECK, CLEAN FUEL STRAINER..............................................................................258 REPLACE FUEL MAIN FILTER CARTRIDGE......................................................................259 CHECK TIGHTENING PARTS OF TURBOCHARGER..................................................................260 REPLACE CORROSION RESISTOR CARTRIDGE....................................................................261 EVERY 2000 HOURS SERVICE....................................................................................262 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC OIL FILTER ELEMENT, CLEAN HYDRAULIC TANK STRAINER.......262 CHANGE OIL IN DAMPER CASE, CLEAN DAMPER BREATHER........................................................263 CHECK PIVOT BEARING OIL LEVEL, ADD OIL..................................................................264 CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)...........................265 CLEAN ENGINE BREATHER ELEMENT...........................................................................268 CHECK ALTERNATOR, STARTING MOTOR........................................................................268 CHECK VIBRATION DAMPER..................................................................................268 CLEAN AND CHECK TURBOCHARGER............................................................................268 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................268 CHECK ENGINE VALVE CLEARANCE, ADJUST....................................................................268 CHECK INJECTOR (EPA EXHAUST GAS REGULATION AREAS ONLY)..................................................268 EVERY 4000 HOURS SERVICE....................................................................................269 REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)...............................................................269 CHECK WATER PUMP........................................................................................269 CHECK INJECTOR (ALL AREAS EXCEPT EPA EXHAUST GAS REGULATION AREAS)......................................269 REPLACE INJECTOR ASSEMBLY (EPA EXHAUST GAS REGULATION AREAS ONLY).......................................269 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER......................................270 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER.....................................271 CHECK MAIN FRAME, WORK EQUIPMENT (BLADE, RIPPER)........................................................272 EVERY 8000 HOURS SERVICE....................................................................................273 REPLACE INJECTOR NOZZLE TIP (ALL AREAS EXCEPT EPA EXHAUST GAS REGULATION AREAS).........................273 REPLACE HIGH-PRESSURE PIPING CLAMPS.....................................................................273 REPLACE FUEL SPLAY PREVENTION CAPS......................................................................273 SPECIFICATIONS......................................................................................................274 SPECIFICATIONS..................................................................................................275 ATTACHMENTS, OPTIONS................................................................................................276 GENERAL PRECAUTIONS.............................................................................................277 PRECAUTIONS RELATED TO SAFETY...............................................................................277 SELECTION OF TRACK SHOE.........................................................................................278 METHOD OF SELECTING SHOES...................................................................................278 PROCEDURE FOR SELECTING RIPPER POINT............................................................................279 HANDLING TRIMMING DOZER.........................................................................................280 GENERAL VIEW................................................................................................280 EXPLANATION OF COMPONENTS...................................................................................281 MAINTENANCE.................................................................................................282 SPECIFICATIONS..............................................................................................286 HANDLING MACHINES EQUIPPED WITH KOMTRAX.........................................................................287 BASIC PRECAUTIONS...........................................................................................287 INDEX...............................................................................................................288
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