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D85EX -15
Komatsu D85EX -15 User Manual
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OPERATION
TROUBLESHOOTING
OPERATION
TROUBLESHOOTING
If
the
machine
sinks
in
mud
and
cannot
get
out
under
its
own
power,
or
if
being
used
to
tow
a
heavy
object,
fit
the
wire
to
the
towing
hook
as
shown
in
the
diagram
on
the
right,
or
in
the
case
of
machines
with
a
drawbar,
fit
the
wire
to
the
drawbar
pin
when
towing.
3 - 143
189
191
Table of Contents
Safety Information
6
Signal Words
6
Other Signal Words
6
Example of Safety Message Using Signal Word
6
Safety Labels
7
Example of Safety Label Using Words
7
Safety Labels Using Pictogram
7
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
Positions of Safety Pictograms
17
General Precautions
22
Safety Rules
22
If Abnormalities Are Found
22
Clothing and Personal Protective Items
22
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
Fire Caused by Fuel or Oil
25
Fire Caused by Accumulation of Flammable Material
25
Window Washer Liquid
26
Precautions When Using Rops
26
Fire Coming from Electric Wiring
26
Fire Coming from Hydraulic Line
26
Precautions for Attachments
27
Unauthorized Modification
27
Safety at Worksite
27
Working on Loose Ground
27
Checking Signalman's Signals and Signs
29
Emergency Exit from Operator's Cab
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
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
Precautions When Using Hammer
43
Repair Welding
44
Removing Battery Terminal
44
Precautions When Using High-Pressure Grease to Adjust Track Tension
44
Precaution with High-Pressure Oil
45
Precaution for High Fuel Pressure
45
Precaution for High Voltage
45
Waste Material
46
Maintenance for Air Conditioner
46
Compressed Air
46
Periodic Replacement of Safety Critical Parts
46
General View
49
General View of Machine
49
General View of Controls and Gauges
50
Front Panel
51
Explanation of Components
52
Caution Monitor Group
53
Emergency Caution Items
53
Check Monitor Group
54
Radiator Coolant Level Caution Lamp
55
Maintenance Caution Lamp
57
Air Cleaner Clogging Caution Lamp
57
Engine Oil Pressure Caution Lamp
59
Engine Coolant Temperature Caution Lamp
59
Power Train Oil Temperature Caution Lamp
59
Hydraulic Oil Temperature Caution Lamp
59
Meter Group
60
Engine Coolant Temperature Gauge
61
Power Train Oil Temperature Gauge
61
Hydraulic Oil Temperature Gauge
62
Fuel Level Gauge
62
Engine Pre-Heating Pilot Lamp
63
Display Panel
63
Operating Mode
64
Maintenance Mode
65
Switches
66
Starting Switch
66
Off
66
Start
66
Buzzer Cancel Switch
67
Preset Mode Switch
67
Front Lamp Switch
67
Rear Lamp Switch
68
Fan Rotation Selector Switch
68
REV Position
68
CLN Position
68
Information Switch
69
Auto Shift down Switch
69
Lamps
70
Warning Lamp
70
Filter/Oil Change Interval Lamp
71
Fan Operation Confirmation Lamp
71
Method of Using Display Panel
72
Explanation of Modes and Controls
72
Method of Selecting Modes
73
Method of Using Maintenance Mode
74
Method of Using Pm Clinic Auxiliary Mode
76
Method of Using Fault Code Display Mode
77
Method of Using User Adjust Mode
78
Adjusting Backlighting of Liquid Crystal Display
78
Adjusting Backlighting of Display Panel B (Multi-Information)
79
Adjusting Contrast of Liquid Crystal Display Panel B
80
Mode to Rotate Cooling Fan at Maximum Speed
80
Fuel Control Dial
81
Horn Switch
81
Room Lamp Switch
82
Wiper Switch
82
Cigarette Lighter
84
Accessory Socket
84
Control Levers, Pedals
85
Work Equipment Lock Lever
85
Parking Brake Lever
86
Joystick (Steering, Directional and Gear Shift Lever)
86
Gear Shifting
87
Operating Counter-Rotation Turn
87
Brake Pedal
88
Decelerator Pedal
88
Blade Control Lever
89
For Power Tilt Dozer
89
Tilting Control
89
Single Tilt Dozer
90
Ripper Control Lever
90
Fixed Multi-Shank Ripper Specification
90
Variable Multi-Shank Ripper Specification
91
Lift Operation
91
Tilt Operation
91
Fuse
92
Chassis
92
Cab (Machines Equipped with Cab)
92
Fuse Capacity and Circuit Name
93
Main Power Circuit Breakers
94
Circuit Breaker
94
Power Source
95
Cap with Lock
96
Method of Opening Radiator Cap and Fuel Cap
96
Opening the Cap
96
Locking the Cap
96
Method of Opening Hydraulic Cap
97
Door Open Lock
98
Sash Glass Intermediate Lock
98
Door Pocket
99
Ashtray
99
Tool Box
99
Air Conditioner
100
General Locations and Function of Control Panel
100
Fan Switch
100
Air Conditioner Switch
101
Fresh/Recirc Selector Switch
101
Recirculation of Air Inside Cab
101
Intake of Fresh Air from Outside
101
Temperature Control Switch
102
Method of Operation
102
When Not Using the Air Conditioner Regularly
104
Cool Box
104
Precautions When Using
104
Precautions When Using the Cooling
104
Checks During Off-Season
105
Procedure for Replacing Receiver
105
Precautions When Replacing Receiver
105
Check Compressor Belt Tension and Refrigerant (Gas) Level
105
Heater, Handling
106
Cleaning Air Filter
106
Car Stereo, Handling
107
Power Switch/Volume
108
Auto-Store/Preset Scan Button
108
Bass Control Knob
108
Preset Scan
108
Treble Control Knob
109
Loudness Button
109
Time/Radio Display Selector Button
109
Correcting the Time
109
Tape Eject Button
110
Cassette Door
110
Fast Forward, Rewind Buttons
110
Preset Buttons
110
Metal Tape Button
111
Manual Tuning Buttons
111
Seek Tuning Buttons
111
Band Selector Button
111
Method of Setting Preset Buttons
112
Method of Auto Preset
112
Method of Manual Preset
112
Listening to Radio
113
Listening to Cassette Tape
113
Reversing Tape
114
Precaution When Using
114
Handling Cassette Tape
114
External Power Source Type Engine Preheating Heater
115
Procedure for Setting up External Power Source
115
Manufacturing External Power Source Input Cable
116
Establishing Power Supply
117
Specifications for Power Supply Equipment
118
Overall Wiring Diagram for External Power Supply Type Engine Preheater
119
Handling Procedure
120
Method of Operating
120
Check before Starting Engine, Adjust
123
Walk-Around Check
123
Check before Starting
125
Check Oil Level in Engine Oil Pan, Add Oil
125
Check Coolant Level, Add Coolant
126
Check Dust Indicator
127
Check Water Separator, Drain Water and Sediment
128
Check Oil Level in Power Train Case, Add Oil
129
Check Oil Level in Hydraulic Tank, Add Oil
130
Check Electric Wiring
131
Check Machine Monitor
131
Check Fuel Level, Add Fuel
132
Check Brake Pedal Travel
133
Check that Lamps Light up
133
Check Horn Sound
134
Check Backup Alarm Sound
135
Adjusting Operator's Seat
136
Adjust Reclining Angle
136
Using Seat Belt
137
Fasten the Belt and Remove It
137
Adjusting Direction of Seat
137
Adjust Mirror
138
Adjust Steering, Forward-Reverse, Gear Shift Lever
138
Adjust Armrest
139
Adjust Armrest (Right)
139
Adjust Armrest (Left)
139
Operations and Checks before Starting Engine
140
Starting Engine
142
Normal Starting
142
Starting in Cold Weather
144
Operations and Checks after Starting Engine
147
Warming up Operations
147
In Cold Areas
149
Stopping Engine
150
Machine Operation
151
Moving Machine
151
Stopping Machine
153
Shifting Gear
154
Gearshifting Operation Using Preset Mode Function
155
Shift Operation When [F1-R1] Mode Is Set
156
Shift Operation When [F1-R2] Mode Is Set
156
Shift Operation When [F2-R2] Mode Is Set
156
Auto Shift down Function
157
Shifting between Forward and Reverse
158
Steering Machine
160
Normal Turning
160
Turning Gradually to Left While Traveling Forward
160
Counterrotation Turns to Left When Traveling Forward
161
Turning While Descending a Slope
161
Permissible Water Depth
162
Precautions When Traveling for a Long Time
162
Precautions When Traveling up or down Hills
162
Method of Using Decelerator Pedal
162
Precautions When Operating Blade
163
Method of Using Blade Lift Cylinder
163
Precautions on Slope
163
Precautions When Engine Stops on Slope
163
Method of Using Brakes
164
Precautions for Blind Spots Caused by Cab Stay and Rops Stay
164
Work Possible Using Bulldozer
165
Dozing
165
Cutting into Hard or Frozen Ground or Ditching
165
Felling Trees, Removing Stumps
165
Pusher Operations
166
Smoothing
166
Adjusting Posture of Work Equipment
167
Blade Adjustment
167
Tilting the Tiltdozer
167
Adjusting Shim in Blade Cylinder Cap
167
Adjusting Digging Angle
168
Adjusting Brace
169
Shim Adjustment
169
Adjusting Ripper
170
Adjusting Digging Depth
170
Replacing Point and Protector
170
Check after Finishing Work
173
Before Stopping Engine
173
After Stopping Engine
173
Tips for Longer Undercarriage Life
174
Inspection and Adjusting
174
Inspection and Repair
175
Measuring Link Pitch
175
Measuring Height of Grouser
175
Measuring Outside Diameter of Track Roller
176
Transportation Procedure
177
Removal of Cab
177
Installation of Cab
178
Installation of Rops
178
Loading, Unloading Work
179
Securing Machine
180
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
Procedure for Bleeding Air
188
Method of Towing Machine
189
If Battery Is Discharged
191
Removal and Installation of Battery
191
Removal, Installation of Battery Cable
191
Precautions When Charging Battery
192
Starting Engine with Booster Cable
193
Precautions When Connecting and Disconnecting Booster Cable
193
Connecting the Booster Cables
193
Starting the Engine
194
Disconnecting the Booster Cables
194
Other Trouble
195
Electrical System
195
Monitor Panel
196
Maintenance
200
Guides to Maintenance
201
Check Service Meter
201
Clean Oil and Grease
201
Check Foreign Material in Drained Oil
201
Dusty Worksites
202
Avoid Mixing Oils
202
Locking Inspection Covers
202
Bleeding Air
202
Checks after Inspection and Maintenance:
203
Outlines of Service
204
Handling Oil, Fuel, Coolant, and Performing Oil Clinic
204
Coolant and Water for Dilution
205
Grease
205
Carrying out Kowa
205
Kowa Analysis Items
206
Measurement of Density of Metal Wear Particles
206
Measurement of Quantity of Particles
206
Oil Sampling
206
Filters
207
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
Supercoolant (AF-NAC)
211
Standard Tightening Torques for Bolts and Nuts
212
Torque List
212
Safety Critical Parts
213
Maintenance Schedule Chart
215
Adjust Injector
217
A Regulation Area
217
Every 2000 Hours Service
217
Every 4000 Hours Service
217
Service Procedure
218
Initial 250 Hours Service (Only after the First 250 Hours)
218
Replace Power Train Oil Filter Element
218
Change Oil in Final Drive Case
218
Clean Inside of Cooling System
219
Mixing Rate of Water and Antifreeze
220
Check, Clean and Replace Air Cleaner Element
223
Cleaning or Replacing Outer Element
224
Replacing Element
226
Check and Adjust Track Tension
227
When Increasing Tension
227
When Loosening Tension
228
Check and Tighten Track Shoe Bolts
229
Method of Tightening Shoe Bolt
229
Method of Tightening Master Link Connecting Bolt
229
Order for Tightening
229
Adjust Idler Clearance
230
Adjusting in Sideways Direction
230
Adjusting in Vertical Direction
231
Reverse and Replace the End Bits and Cutting Edges
232
Clean, Check Radiator Fins and Oil Cooler Fins
233
Cleaning by Rotating Cooling Fan in Reverse Direction
233
Cleaning with Compressed Air
234
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
Check Tension of Compressor Belt
237
Replace Belt
238
Check Level of Refrigerant(Gas)
238
Operating Air Conditioner Off-Season
238
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
Proportion for Mixing Fluid with Water
240
Replace Wiper Blade
241
Front, Rear Wiper
241
Rear Wiper
241
Door Wiper
241
Bleeding Air in Hydraulic System
242
Bleeding Air from Cylinders
242
Check Electrical Intake Air Heater
242
Lubricating
242
Every 250 Hours Service
244
Blade Lift Cylinder Support Yoke (4 Places)
244
Blade Lift Cylinder Support Shaft (2 Places)
244
Blade Arm Ball Joint (4 Places)
244
Check Alternator Drive Belt Tension, Adjust
246
Check Level of Battery Electrolyte
247
When Checking Electrolyte Level from Side of Battery
247
When It Is Impossible to Check Electrolyte Level from Side of Battery
248
When It Is Possible to Use Indicator to Check Electrolyte Level
248
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
Check Oil Level in Final Drive Case, Add Oil
254
Every 1000 Hours Service
255
Change Oil in Power Train Case, Wash Strainers
255
Replace Hydraulic Tank Breather Element
257
Refill Capacity
258
Check, Clean Fuel Strainer
258
Replace Fuel Main Filter Cartridge
259
Check Tightening Parts of Turbocharger
260
Replace Corrosion Resistor Cartridge
261
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
265
Function of Accumulator
265
Checking Function of Accumulator
265
Method of Releasing Pressure in Hydraulic Circuit
267
Clean Engine Breather Element
268
Check Alternator, Starting Motor
268
Check Vibration Damper
268
Clean and Check Turbocharger
268
Replace Accumulator (for Control Circuit)
269
Check Water Pump
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
Specifications
275
Attachments, Options
276
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
Handling Machines Equipped with Komtrax
287
Index
288
4
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Komatsu D85EX -15 Specifications
General
Brand
Komatsu
Model
D85EX -15
Category
Tractor
Language
English
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