Komatsu D85PX-15 - Maintenance

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Safety Information6
Signal Words6
Other Signal Words6
Example of Safety Message Using Signal Word6
Safety Labels7
Example of Safety Label Using Words7
Safety Labels Using Pictogram7
Front/Rear, Left/Right Directions of Machine8
Breaking in the Machine8
Necessary Information9
Product Identification Number (Pin), Machine Serial No. Plate9
Engine Serial No. Plate9
Position of Service Meter10
Table to Enter Serial No. and Distributor10
Contents11
Safety14
Positions of Safety Pictograms17
General Precautions22
Safety Rules22
If Abnormalities Are Found22
Clothing and Personal Protective Items22
Handrails and Steps24
Mounting and Dismounting24
No People on Attachments24
Crushing or Cutting Prevention24
Prevention of Burns25
Fire Prevention25
Fire Caused by Fuel or Oil25
Fire Caused by Accumulation of Flammable Material25
Window Washer Liquid26
Precautions When Using Rops26
Fire Coming from Electric Wiring26
Fire Coming from Hydraulic Line26
Precautions for Attachments27
Unauthorized Modification27
Safety at Worksite27
Working on Loose Ground27
Checking Signalman's Signals and Signs29
Emergency Exit from Operator's Cab29
Precautions for Operation30
Before Starting Engine30
Checks before Starting Engine30
Precautions When Starting31
Precautions in Cold Areas31
Operation32
Checks before Operation32
Precautions for Moving Machine Forward or in Reverse32
Precautions When Traveling33
Traveling on Slopes34
Using Brakes34
Operate Carefully on Snow34
Parking Machine35
Transportation36
Loading and Unloading36
Shipping36
Battery37
Battery Hazard Prevention37
Starting with Booster Cable38
Towing39
When Towing39
Precautions for Maintenance40
Warning Tag40
Stop Engine before Carrying out Inspection and Maintenance41
Two Workers for Maintenance When Engine Is Running42
Proper Tools42
Handling Accumulator42
Personnel43
Attachments43
Work under the Machine43
Precautions When Using Hammer43
Repair Welding44
Removing Battery Terminal44
Precautions When Using High-Pressure Grease to Adjust Track Tension44
Precaution with High-Pressure Oil45
Precaution for High Fuel Pressure45
Precaution for High Voltage45
Waste Material46
Maintenance for Air Conditioner46
Compressed Air46
Periodic Replacement of Safety Critical Parts46
General View49
General View of Machine49
General View of Controls and Gauges50
Front Panel51
Explanation of Components52
Caution Monitor Group53
Emergency Caution Items53
Check Monitor Group54
Radiator Coolant Level Caution Lamp55
Maintenance Caution Lamp57
Air Cleaner Clogging Caution Lamp57
Engine Oil Pressure Caution Lamp59
Engine Coolant Temperature Caution Lamp59
Power Train Oil Temperature Caution Lamp59
Hydraulic Oil Temperature Caution Lamp59
Meter Group60
Engine Coolant Temperature Gauge61
Power Train Oil Temperature Gauge61
Hydraulic Oil Temperature Gauge62
Fuel Level Gauge62
Engine Pre-Heating Pilot Lamp63
Display Panel63
Operating Mode64
Maintenance Mode65
Switches66
Starting Switch66
Off66
Start66
Buzzer Cancel Switch67
Preset Mode Switch67
Front Lamp Switch67
Rear Lamp Switch68
Fan Rotation Selector Switch68
REV Position68
CLN Position68
Information Switch69
Auto Shift down Switch69
Lamps70
Warning Lamp70
Filter/Oil Change Interval Lamp71
Fan Operation Confirmation Lamp71
Method of Using Display Panel72
Explanation of Modes and Controls72
Method of Selecting Modes73
Method of Using Maintenance Mode74
Method of Using Pm Clinic Auxiliary Mode76
Method of Using Fault Code Display Mode77
Method of Using User Adjust Mode78
Adjusting Backlighting of Liquid Crystal Display78
Adjusting Backlighting of Display Panel B (Multi-Information)79
Adjusting Contrast of Liquid Crystal Display Panel B80
Mode to Rotate Cooling Fan at Maximum Speed80
Fuel Control Dial81
Horn Switch81
Room Lamp Switch82
Wiper Switch82
Cigarette Lighter84
Accessory Socket84
Control Levers, Pedals85
Work Equipment Lock Lever85
Parking Brake Lever86
Joystick (Steering, Directional and Gear Shift Lever)86
Gear Shifting87
Operating Counter-Rotation Turn87
Brake Pedal88
Decelerator Pedal88
Blade Control Lever89
For Power Tilt Dozer89
Tilting Control89
Single Tilt Dozer90
Ripper Control Lever90
Fixed Multi-Shank Ripper Specification90
Variable Multi-Shank Ripper Specification91
Lift Operation91
Tilt Operation91
Fuse92
Chassis92
Cab (Machines Equipped with Cab)92
Fuse Capacity and Circuit Name93
Main Power Circuit Breakers94
Circuit Breaker94
Power Source95
Cap with Lock96
Method of Opening Radiator Cap and Fuel Cap96
Opening the Cap96
Locking the Cap96
Method of Opening Hydraulic Cap97
Door Open Lock98
Sash Glass Intermediate Lock98
Door Pocket99
Ashtray99
Tool Box99
Air Conditioner100
General Locations and Function of Control Panel100
Fan Switch100
Air Conditioner Switch101
Fresh/Recirc Selector Switch101
Recirculation of Air Inside Cab101
Intake of Fresh Air from Outside101
Temperature Control Switch102
Method of Operation102
When Not Using the Air Conditioner Regularly104
Cool Box104
Precautions When Using104
Precautions When Using the Cooling104
Checks During Off-Season105
Procedure for Replacing Receiver105
Precautions When Replacing Receiver105
Check Compressor Belt Tension and Refrigerant (Gas) Level105
Heater, Handling106
Cleaning Air Filter106
Car Stereo, Handling107
Power Switch/Volume108
Auto-Store/Preset Scan Button108
Bass Control Knob108
Preset Scan108
Treble Control Knob109
Loudness Button109
Time/Radio Display Selector Button109
Correcting the Time109
Tape Eject Button110
Cassette Door110
Fast Forward, Rewind Buttons110
Preset Buttons110
Metal Tape Button111
Manual Tuning Buttons111
Seek Tuning Buttons111
Band Selector Button111
Method of Setting Preset Buttons112
Method of Auto Preset112
Method of Manual Preset112
Listening to Radio113
Listening to Cassette Tape113
Reversing Tape114
Precaution When Using114
Handling Cassette Tape114
External Power Source Type Engine Preheating Heater115
Procedure for Setting up External Power Source115
Manufacturing External Power Source Input Cable116
Establishing Power Supply117
Specifications for Power Supply Equipment118
Overall Wiring Diagram for External Power Supply Type Engine Preheater119
Handling Procedure120
Method of Operating120
Check before Starting Engine, Adjust123
Walk-Around Check123
Check before Starting125
Check Oil Level in Engine Oil Pan, Add Oil125
Check Coolant Level, Add Coolant126
Check Dust Indicator127
Check Water Separator, Drain Water and Sediment128
Check Oil Level in Power Train Case, Add Oil129
Check Oil Level in Hydraulic Tank, Add Oil130
Check Electric Wiring131
Check Machine Monitor131
Check Fuel Level, Add Fuel132
Check Brake Pedal Travel133
Check that Lamps Light up133
Check Horn Sound134
Check Backup Alarm Sound135
Adjusting Operator's Seat136
Adjust Reclining Angle136
Using Seat Belt137
Fasten the Belt and Remove It137
Adjusting Direction of Seat137
Adjust Mirror138
Adjust Steering, Forward-Reverse, Gear Shift Lever138
Adjust Armrest139
Adjust Armrest (Right)139
Adjust Armrest (Left)139
Operations and Checks before Starting Engine140
Starting Engine142
Normal Starting142
Starting in Cold Weather144
Operations and Checks after Starting Engine147
Warming up Operations147
In Cold Areas149
Stopping Engine150
Machine Operation151
Moving Machine151
Stopping Machine153
Shifting Gear154
Gearshifting Operation Using Preset Mode Function155
Shift Operation When [F1-R1] Mode Is Set156
Shift Operation When [F1-R2] Mode Is Set156
Shift Operation When [F2-R2] Mode Is Set156
Auto Shift down Function157
Shifting between Forward and Reverse158
Steering Machine160
Normal Turning160
Turning Gradually to Left While Traveling Forward160
Counterrotation Turns to Left When Traveling Forward161
Turning While Descending a Slope161
Permissible Water Depth162
Precautions When Traveling for a Long Time162
Precautions When Traveling up or down Hills162
Method of Using Decelerator Pedal162
Precautions When Operating Blade163
Method of Using Blade Lift Cylinder163
Precautions on Slope163
Precautions When Engine Stops on Slope163
Method of Using Brakes164
Precautions for Blind Spots Caused by Cab Stay and Rops Stay164
Work Possible Using Bulldozer165
Dozing165
Cutting into Hard or Frozen Ground or Ditching165
Felling Trees, Removing Stumps165
Pusher Operations166
Smoothing166
Adjusting Posture of Work Equipment167
Blade Adjustment167
Tilting the Tiltdozer167
Adjusting Shim in Blade Cylinder Cap167
Adjusting Digging Angle168
Adjusting Brace169
Shim Adjustment169
Adjusting Ripper170
Adjusting Digging Depth170
Replacing Point and Protector170
Check after Finishing Work173
Before Stopping Engine173
After Stopping Engine173
Tips for Longer Undercarriage Life174
Inspection and Adjusting174
Inspection and Repair175
Measuring Link Pitch175
Measuring Height of Grouser175
Measuring Outside Diameter of Track Roller176
Transportation Procedure177
Removal of Cab177
Installation of Cab178
Installation of Rops178
Loading, Unloading Work179
Securing Machine180
Method of Lifting Machine182
Precautions for Transportation183
Traveling on Roads183
Cold Weather Operation184
Precautions for Low Temperature184
After Completion of Work186
After Cold Weather186
Long-Term Storage187
Before Storage187
During Storage187
After Storage187
Troubleshooting188
After Running out of Fuel188
Procedure for Bleeding Air188
Method of Towing Machine189
If Battery Is Discharged191
Removal and Installation of Battery191
Removal, Installation of Battery Cable191
Precautions When Charging Battery192
Starting Engine with Booster Cable193
Precautions When Connecting and Disconnecting Booster Cable193
Connecting the Booster Cables193
Starting the Engine194
Disconnecting the Booster Cables194
Other Trouble195
Electrical System195
Monitor Panel196
Maintenance200
Guides to Maintenance201
Check Service Meter201
Clean Oil and Grease201
Check Foreign Material in Drained Oil201
Dusty Worksites202
Avoid Mixing Oils202
Locking Inspection Covers202
Bleeding Air202
Checks after Inspection and Maintenance:203
Outlines of Service204
Handling Oil, Fuel, Coolant, and Performing Oil Clinic204
Coolant and Water for Dilution205
Grease205
Carrying out Kowa205
Kowa Analysis Items206
Measurement of Density of Metal Wear Particles206
Measurement of Quantity of Particles206
Oil Sampling206
Filters207
Outline of Electric System207
Wear Parts208
Wear Parts List208
Recommended Fuel, Coolant, and Lubricant209
Use of Fuel, Coolant and Lubricants According to Ambient Temperature210
Supercoolant (AF-NAC)211
Standard Tightening Torques for Bolts and Nuts212
Torque List212
Safety Critical Parts213
Maintenance Schedule Chart215
Adjust Injector217
A Regulation Area217
Every 2000 Hours Service217
Every 4000 Hours Service217
Service Procedure218
Initial 250 Hours Service (Only after the First 250 Hours)218
Replace Power Train Oil Filter Element218
Change Oil in Final Drive Case218
Clean Inside of Cooling System219
Mixing Rate of Water and Antifreeze220
Check, Clean and Replace Air Cleaner Element223
Cleaning or Replacing Outer Element224
Replacing Element226
Check and Adjust Track Tension227
When Increasing Tension227
When Loosening Tension228
Check and Tighten Track Shoe Bolts229
Method of Tightening Shoe Bolt229
Method of Tightening Master Link Connecting Bolt229
Order for Tightening229
Adjust Idler Clearance230
Adjusting in Sideways Direction230
Adjusting in Vertical Direction231
Reverse and Replace the End Bits and Cutting Edges232
Clean, Check Radiator Fins and Oil Cooler Fins233
Cleaning by Rotating Cooling Fan in Reverse Direction233
Cleaning with Compressed Air234
Clean Fuel Tank Strainer235
Drain Water and Sediment in Fuel Tank235
Clean Steering Clutch Case Breather235
Check Undercarriage Oil236
Clean Air Conditioner Air Filter (Fresh/Recirc Filter)237
Check and Adjust Air Conditioner237
Check Tension of Compressor Belt237
Replace Belt238
Check Level of Refrigerant(Gas)238
Operating Air Conditioner Off-Season238
Lubricate Door Hinge239
Check Door Latch239
Check Door Lock Striker239
Replace Door Damper240
Check Window Washer Fluid Level, Add Fluid240
Proportion for Mixing Fluid with Water240
Replace Wiper Blade241
Front, Rear Wiper241
Rear Wiper241
Door Wiper241
Bleeding Air in Hydraulic System242
Bleeding Air from Cylinders242
Check Electrical Intake Air Heater242
Lubricating242
Every 250 Hours Service244
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, Adjust246
Check Level of Battery Electrolyte247
When Checking Electrolyte Level from Side of Battery247
When It Is Impossible to Check Electrolyte Level from Side of Battery248
When It Is Possible to Use Indicator to Check Electrolyte Level248
Check Brake Performance249
Check Oil Level in Damper Case, Add Oil250
Every 500 Hours Service251
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge251
Replace Pre-Fuel Filter Cartridge252
Check Oil Level in Final Drive Case, Add Oil254
Every 1000 Hours Service255
Change Oil in Power Train Case, Wash Strainers255
Replace Hydraulic Tank Breather Element257
Refill Capacity258
Check, Clean Fuel Strainer258
Replace Fuel Main Filter Cartridge259
Check Tightening Parts of Turbocharger260
Replace Corrosion Resistor Cartridge261
Change Oil in Damper Case, Clean Damper Breather263
Check Pivot Bearing Oil Level, Add Oil264
Checking Charge Pressure of Nitrogen Gas in Accumulator265
Function of Accumulator265
Checking Function of Accumulator265
Method of Releasing Pressure in Hydraulic Circuit267
Clean Engine Breather Element268
Check Alternator, Starting Motor268
Check Vibration Damper268
Clean and Check Turbocharger268
Replace Accumulator (for Control Circuit)269
Check Water Pump269
Checking for Looseness of High-Pressure Clamp, Hardening of Rubber270
Checking for Missing Fuel Spray Prevention Cap, Hardening of Rubber271
Check Main Frame, Work Equipment (Blade, Ripper)272
Specifications275
Attachments, Options276
Precautions Related to Safety277
Selection of Track Shoe278
Method of Selecting Shoes278
Procedure for Selecting Ripper Point279
Handling Trimming Dozer280
Handling Machines Equipped with Komtrax287
Index288

Komatsu D85PX-15 - Maintenance

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