D85ex15 Sen00060-02

SEN00060-02
BULLDOZER
D85EX-15E0
D85PX-15E0
D85EX- 11001
SERIAL NUMBERS and up
D85PX- 1201
SEN00069-02
BULLDOZER 1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model Serial number

D85EX-15E0 11001 and up
D85PX-15E0 1201 and up
00 Index and foreword 1

Index
Composition of shop manual................................................................................................................ 2

Table of contents .................................................................................................................................. 4
D85EX, PX-15E0 1
SEN00069-02 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00060-02
00 Index and foreword SEN00061-02

Index SEN00069-02 q
Foreword and general information SEN00070-00
01 Specification SEN00062-00
Specification and technical data SEN00071-00
10 Structure, function and maintenance standard SEN00063-00

Engine and cooling system SEN00293-00
Power train, Part 1 SEN00295-00
Undercarriage and frame SEN00298-00
Hydraulic system, Part 1 SEN00299-00
Work equipment SEN00305-00
Cab and its attachments SEN00306-00
Electrical system SEN00308-00
20 Standard value table SEN00064-00

Standard service value table SEN00629-00
30 Testing and adjusting SEN00065-00

Testing and adjusting, Part 1 SEN00630-00
40 Troubleshooting SEN00066-00
General information on troubleshooting SEN00633-00
Troubleshooting by failure code (Display of code), Part 1 SEN00634-00
Troubleshooting of electrical system (E-mode) SEN00638-00
2 D85EX, PX-15E0
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00639-00

Troubleshooting of engine (S-mode) SEN00640-00
50 Disassembly and assembly SEN00067-00

General information on disassembly and assembly SEN01263-00 Q
Engine and cooling system, Part 1 SEN01264-00 Q
Engine and cooling system, Part 2 SEN01265-00 Q
Power train, Part 1 SEN01266-00 Q
Power train, Part 2 SEN01267-00 Q
Undercarriage and frame, Part 1 SEN01268-00 Q
Undercarriage and frame, Part 2 SEN01269-00 Q
Hydraulic system SEN01270-00 Q
Work equipment SEN01271-00 Q
Cab and its attachments SEN01272-00 Q
Electrical system SEN01273-00 Q
90 Diagrams and drawings SEN00068-01

Hydraulic diagrams and drawings SEN00072-00
Electrical diagrams and drawings SEN00073-01
D85EX, PX-15E0 3
Table of contents 1
00 Index and foreword
Index SEN00069-02
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN00070-00

Foreword and general information .............................................................................................. 2
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 6
Explanation of terms for maintenance standard ...................................................................... 8
Handling electric equipment and hydraulic component ........................................................... 10
How to read electric wire code................................................................................................. 18
Method of disassembling and connecting push-pull type coupler ........................................... 21
Standard tightening torque table.............................................................................................. 24
Conversion table...................................................................................................................... 28
01 Specification
Specification and technical data SEN00071-00
Specification and technical data .................................................................................................. 2
Specification dimensions ......................................................................................................... 2
Specifications........................................................................................................................... 3
Weight table ............................................................................................................................. 11
Table of fuel, coolant and lubricants ........................................................................................ 16
10 Structure, function and maintenance standard

Engine and cooling system SEN00293-00
Engine and cooling system ......................................................................................................... 2
Engine mount........................................................................................................................... 2
Cooling system ........................................................................................................................ 4
Cooling fan pump..................................................................................................................... 6
Cooling fan motor .................................................................................................................... 14
Power train, Part 1....................................................................................................................... 2
Power train............................................................................................................................... 2
HSS system ............................................................................................................................. 4
General view of power train unit .............................................................................................. 6
Power train hydraulic piping drawing ....................................................................................... 8
Transmission control................................................................................................................ 9
Steering and brake control....................................................................................................... 10
Damper and universal joint ...................................................................................................... 12
Torque converter and PTO....................................................................................................... 14
Transmission............................................................................................................................ 20
Transmission clutch ECMV...................................................................................................... 32
Main relief valve and torque converter relief valve .................................................................. 37
Lubrication relief valve ............................................................................................................. 39
Power train, Part 2....................................................................................................................... 2
Bevel gear shaft, HSS and brake ............................................................................................ 2
Brake valve .............................................................................................................................. 16
Final drive ................................................................................................................................ 22
Undercarriage and frame SEN00298-00
Undercarriage and frame ............................................................................................................ 2
Main frame............................................................................................................................... 2
4 D85EX, PX-15E0
Suspension.............................................................................................................................. 4
Track frame.............................................................................................................................. 8
Idler cushion ............................................................................................................................ 10
Idler.......................................................................................................................................... 12
Track roller............................................................................................................................... 14
Carrier roller............................................................................................................................. 16
Sprocket................................................................................................................................... 18
Track shoe ............................................................................................................................... 20
Hydraulic system, Part 1 ............................................................................................................. 2
Work equipment hydraulic piping diagram .............................................................................. 2
PPC control piping diagram..................................................................................................... 5
Work equipment control........................................................................................................... 6
Hydraulic tank and filter ........................................................................................................... 8
Scavenging pump.................................................................................................................... 10
Power train and steering lubrication pump .............................................................................. 11
HSS pump ............................................................................................................................... 12
HSS motor ............................................................................................................................... 30
Control valve............................................................................................................................ 2
Self pressure reducing valve ................................................................................................... 36
Oil cooler bypass valve............................................................................................................ 2
PPC valve................................................................................................................................ 4
Electric lever (steering)............................................................................................................ 20
Quick drop valve...................................................................................................................... 23
PPC lock valve ........................................................................................................................ 24
Accumulator............................................................................................................................. 25
Work equipment .......................................................................................................................... 3
Cylinder stay ............................................................................................................................ 3
Blade ....................................................................................................................................... 4
Cutting edge and end bit ......................................................................................................... 6
Ripper ...................................................................................................................................... 8
Hydraulic cylinder .................................................................................................................... 10
Piston valve ............................................................................................................................. 12
Cab and its attachments.............................................................................................................. 2
Cab mount ............................................................................................................................... 2
Cab .......................................................................................................................................... 3
Air conditioner.......................................................................................................................... 5
Electrical system ......................................................................................................................... 2
Monitor system ........................................................................................................................ 2
Monitor panel ........................................................................................................................... 4
Engine control.......................................................................................................................... 8
Engine control system ............................................................................................................. 9
System components ................................................................................................................ 10
CRI engine control system ...................................................................................................... 20
Palm command control system ............................................................................................... 22
KOMTRAX terminal system..................................................................................................... 24
Sensor ..................................................................................................................................... 26
D85EX, PX-15E0 5
20 Standard value table

Standard service value table SEN00629-00
Standard service value table ....................................................................................................... 2
Standard service value table for engine................................................................................... 2
Standard service value table for chassis ................................................................................. 3
30 Testing and adjusting

Testing and adjusting, Part 1 ....................................................................................................... 3
Tools for testing, adjusting, and troubleshooting...................................................................... 3
Measuring engine speed ......................................................................................................... 5
Measuring intake air pressure (boost pressure) ...................................................................... 8
Measuring exhaust temperature .............................................................................................. 10
Measuring exhaust gas color................................................................................................... 12
Adjusting valve clearance ........................................................................................................ 13
Measuring compression pressure............................................................................................ 15
Measuring blow-by pressure.................................................................................................... 17
Measuring engine oil pressure................................................................................................. 18
Handling of fuel system devices .............................................................................................. 19
Releasing residual pressure from fuel system......................................................................... 19
Testing fuel pressure................................................................................................................ 20
Handling of reduced cylinder mode operation ......................................................................... 21
Handling of no injection cranking operation............................................................................. 21
Testing fuel return and leak amount......................................................................................... 22
Bleeding air from fuel circuit .................................................................................................... 25
Testing fuel circuit for leakage ................................................................................................. 27
Testing and adjusting alternator belt tension ........................................................................... 28
Testing and adjusting air conditioner compressor belt tension ................................................ 29
Adjusting fuel control dial and decelerator pedal ..................................................................... 30
Measuring power train oil pressure.......................................................................................... 32
Adjusting transmission speed sensor ...................................................................................... 37
Simple method to test brake performance............................................................................... 38
Adjusting brake pedal .............................................................................................................. 39
Adjusting parking brake lever .................................................................................................. 41
Emergency escape method when power train has trouble...................................................... 42
Adjusting clearance of idler...................................................................................................... 45
Inspecting wear of sprocket ..................................................................................................... 46
Testing and adjusting track shoe tension................................................................................. 46
Testing and adjusting work equipment and HSS oil pressure.................................................. 47
Testing control circuit basic pressure....................................................................................... 51
Measuring PPC valve output pressure .................................................................................... 52
Adjusting play of work equipment PPC valve .......................................................................... 54
Checking parts which caused hydraulic drift of blade and ripper............................................. 55
Measuring internal leakage of work equipment cylinder.......................................................... 56
Bleeding air from work equipment cylinder.............................................................................. 56
Releasing residual pressure in work equipment cylinder......................................................... 57
Adjusting work equipment lock lever ....................................................................................... 58
Measuring fan motor speed ..................................................................................................... 59
Measuring fan pump circuit pressure....................................................................................... 60
Bleeding air from fan pump...................................................................................................... 61
Adjusting blade ........................................................................................................................ 62
Testing and adjusting operator cab.......................................................................................... 64
Testing and adjusting, Part 2 ....................................................................................................... 2
Special functions of monitor panel (EMMS)............................................................................. 2
6 D85EX, PX-15E0

Testing and adjusting, Part3........................................................................................................ 2
Handling of voltage circuit of engine controller ........................................................................ 2
Adjustment method when controller has been replaced.......................................................... 2
Preparation work for troubleshooting for electrical system ...................................................... 4
Inspection procedure of diode ................................................................................................. 7
Pm Clinic service ..................................................................................................................... 8
How to start operation of KOMTRAX terminal ......................................................................... 18
Lamp display of KOMTRAX terminal....................................................................................... 21
40 Troubleshooting
General information on troubleshooting SEN00633-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
How to proceed troubleshooting.............................................................................................. 3
Checks before troubleshooting................................................................................................ 4
Classification and procedures of troubleshooting.................................................................... 5
How to distinguish wire code ................................................................................................... 8
Wiring table for connector pin numbers ................................................................................... 11
T-adapter box and T-adapter table .......................................................................................... 34
Troubleshooting by failure code (Display of code), Part 1........................................................... 3
Failure code table ............................................................................................................................ 3
Before troubleshooting by failure codes .......................................................................................... 10
Contents of troubleshooting table.................................................................................................... 12
Failure code [1500L0] Transmission clutch: Dual engagement....................................................... 14
Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF ............... 16
Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON .............. 18
Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF............... 20
Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON .............. 22
Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF ....................... 24
Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON....................... 26
Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF ...................... 28
Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON...................... 30
Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF....................... 32
Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON ...................... 34
Failure code [AA10NX] Air cleaner: Clogged .................................................................................. 36
Failure code [AB00MA] Abnormal battery charge: Malfunction....................................................... 38
Failure code [B@BAZG] Engine oil: Oil pressure too low ............................................................... 38
Failure code [B@BCNS] Radiator coolant: Overheat...................................................................... 39
Failure code [B@BCZK] Radiator coolant: Level too low................................................................ 39
Failure code [B@CENS] Power train oil: Overheat ......................................................................... 40
Failure code [B@HANS] Hydraulic oil: Overheat ............................................................................ 40
Failure code [CA111] Engine controller: Abnormality in controller................................................... 41
Failure code [CA115] Abnormal engine Ne and Bkup speed sensors:
Abnormal speed sensor signal................................................................................................. 42
Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected ......... 44
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected ............ 46
Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected........ 48
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected........... 50
Failure code [CA135] Oil pressure sensor too high: Excessively high voltage detected................. 52
Failure code [CA141] Oil pressure sensor too low: Excessively low voltage detected.................... 54
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ... 56
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected ...... 58
Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected .... 60
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected....... 62
Failure code [CA187] Sensor power source 2 too low: Low voltage detected ................................ 64
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected . 66
D85EX, PX-15E0 7
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected.... 68
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected........... 70
Failure code [CA234] Engine over speed: Excessively high speed ................................................ 72
Failure code [CA238] Abnormal power source for Ne speed sensor:
Excessively low voltage detected ............................................................................................ 74
Failure code [CA263] Fuel temperature sensor too high: Excessively high voltage detected ........ 76
Failure code [CA265] Fuel temperature sensor too low: Excessively low voltage detected ........... 78
Failure code [CA271] PCV1 short circuit: Short circuit.................................................................... 79
Failure code [CA272] PCV1 disconnection: Disconnection ............................................................ 80
Failure code [CA273] PCV2 short circuit: Short circuit.................................................................... 81
Failure code [CA274] PCV2 disconnection: Disconnection ............................................................ 82
Failure code [CA322] Injector No. 1 system disconnection or short circuit:
Disconnection, short circuit...................................................................................................... 3
Failure code [CA342] Engine controller data matching error: Matching error ................................. 9
Failure code [CA351] Abnormal injector drive circuit: Abnormal circuit .......................................... 10
Failure code [CA352] Sensor power source (1) too low: Excessively low voltage detected ........... 12
Failure code [CA386] Sensor power source (1) too high: Excessively high voltage detected ........ 14
Failure code [CA441] Power source voltage too low: Excessively low voltage detected................ 16
Failure code [CA442] Power source voltage too high: Excessively high voltage detected ............. 16
Failure code [CA449] Common rail pressure too high (2):
Excessively high pressure trouble occurred ............................................................................ 17
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected 18
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected ... 20
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected .... 20
Failure code [CA554] In-range error in common rail pressure sensor: In-range error .................... 21
Failure code [CA559] Loss of pressure feed from supply pump (1):
Loss of pressure feed detected ............................................................................................... 22
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal .................................. 26
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase ................... 28
Failure code [CA757] Loss of all engine controller data: Loss of all data ....................................... 29
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal ..................... 30
Failure code [CA1228] Abnormal EGR valve servo (1): EGR out of control ................................... 32
Failure code [CA1625] Abnormal EGR valve servo (2): EGR out of control ................................... 33
Failure code [CA1633] Abnormal KOMNET: Abnormal communication ......................................... 34
Failure code [CA2185] Decelerator pedal sensor power source too high:
Excessively high voltage detected........................................................................................... 36
Failure code [CA2186] Decelerator pedal sensor power source too low:
Excessively low voltage detected ............................................................................................ 37
Loss of pressure feed detected ............................................................................................... 38
Failure code [CA2271] EGR valve lift sensor too high: Excessively high voltage detected ............ 40
Failure code [CA2272] EGR valve lift sensor too low: Excessively low voltage detected............... 42
Failure code [CA2351] EGR valve solenoid drive short circuit: Short circuit................................... 44
Failure code [CA2352] EGR valve solenoid drive disconnection: Disconnection ........................... 46
Failure code [CA2555] Intake air heater relay disconnection: Disconnection ................................. 47
Failure code [CA2556] Intake air heater relay short circuit: Short circuit ........................................ 48
8 D85EX, PX-15E0

Failure code [D110KA] Battery relay: Disconnection....................................................................... 4
Failure code [D110KB] Battery relay: Short circuit .......................................................................... 6
Failure code [D130KA] Neutral safety relay: Disconnection............................................................ 8
Failure code [D130KB] Neutral safety relay: Short circuit ............................................................... 10
Failure code [D161KA] Back-up alarm relay: Disconnection........................................................... 12
Failure code [D161KB] Back-up alarm relay: Short circuit .............................................................. 14
Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection ......................... 16
Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit............................. 18
Failure code [D811KR] KOMTRAX controller CAN communication: Defective communication...... 20
Failure code [DAFRKR] Monitor panel CAN communication: Defective communication ................ 24
Failure codes [DAQ0KT] and [DB30KT] Steering and transmission controller:
Abnormal controller memory information ................................................................................. 27
Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller:
Power source voltage drop and input ...................................................................................... 28
Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller:
Failure codes [DAQ5KK] and [DB35KK] Steering and transmission controller sensor
5 V power source (1): Power source voltage drop and input ................................................... 32
Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor
24 V power source: Power source voltage drop and input ...................................................... 34
Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection:
Inconsistency in model select signal........................................................................................ 38
Failure codes [DAQRKR] and [DB3RKR] Steering and transmission controller
CAN communication: Defective communication ...................................................................... 40
Failure code [DB2RKR] Engine controller CAN communication: Defective communication ........... 44
Failure code [DB30KT] [DAQ0KT] Steering and transmission controller:
Abnormal controller memory information ................................................................................. 47
Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission controller:
Failure code [DB32KK] [DAQ2KK] Load power source of steering and transmission controller:
Failure codes [DB35KK] and [DAQ5KK] Steering and transmission controller sensor
Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor
24 V power source: Power source voltage drop and input ...................................................... 47
Failure codes [DB39KQ] and [DAQ9KQ] Steering and transmission controller model selection:
Inconsistent model selection signal ......................................................................................... 47
Failure codes [DB3RKR] and [DAQRKR] Steering and transmission controller
CAN communication: Defective communication ...................................................................... 47
Failure code [DD12KA] Shift up switch: Disconnection ................................................................... 48
Failure code [DD12KB] Shift up switch: Short circuit....................................................................... 50
Failure code [DD13KA] Shift down switch: Disconnection .............................................................. 52
Failure code [DD13KB] Shift down switch: Short circuit .................................................................. 54
Failure codes [DD14KA] and [DDQ2KA] Parking lock switch: Disconnection ................................. 56
Failure codes [DD14KB] and [DDQ2KB] Parking lock switch: Short circuit..................................... 58
Failure codes [DDQ2KA] and [DD14KA] Parking lock switch: Disconnection ................................. 60
Failure codes [DDQ2KB] and [DD14KB] Parking lock switch: Short circuit..................................... 60
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range ...... 62
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection ................................... 64
Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range ... 66
Failure code [DH22KA] HSS and work equipment pump oil pressure sensor: Disconnection ........ 68
Failure code [DH22KB] HSS and work equipment pump oil pressure sensor: Short circuit............ 70
D85EX, PX-15E0 9
Failure code [DK10KA] Fuel dial: Disconnection ............................................................................ 72

Failure code [DK10KB] Fuel dial: Short circuit ................................................................................ 74
Failure code [DK30KA] Steering potentiometer (1): Disconnection ................................................ 76
Failure code [DK30KB] Steering potentiometer (1): Short circuit .................................................... 78
Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range ...................... 80
Failure code [DK30KZ] Steering potentiometer: Disconnection or short circuit (Double failure)..... 80
Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal.................................... 81
Failure code [DK31KA] Steering potentiometer (2): Disconnection ................................................ 82
Failure code [DK31KB] Steering potentiometer (2): Short circuit .................................................... 84
Failure code [DK40KA] Brake potentiometer: Disconnection.......................................................... 86
Failure code [DK40KB] Brake potentiometer: Short circuit ............................................................. 87
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range ......... 88
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or
short circuit (Double failure)..................................................................................................... 88
Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal....................... 89
Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection ................................... 90
Failure code [DK56KB] Forward-reverse potentiometer (1): Short circuit....................................... 92
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection ................................... 94
Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit....................................... 96
Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit....................................... 3
Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection ................................... 4
Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor:
Input signal out of range ................................................................................................... 5
Failure code [DLT3KA] Transmission output speed sensor: Disconnection ............................ 6
Failure code [DLT3KB] Transmission output speed sensor: Short circuit................................ 7
Failure code [DV00KB] Alarm buzzer: Short circuit ................................................................. 8
Failure code [DW7BKA] Fan reverse solenoid: Disconnection................................................ 9
Failure code [DW7BKB] Fan reverse solenoid: Short circuit ................................................... 10
Failure code [DW7BKY] Fan reverse solenoid: Hot short circuit ............................................. 11
Failure code [DWN1KA] HSS EPC solenoid right: Disconnection........................................... 12
Failure code [DWN1KB] HSS EPC solenoid right: Short circuit .............................................. 13
Failure code [DWN1KY] HSS EPC solenoid right: Hot short circuit ........................................ 14
Failure code [DWN2KA] HSS EPC solenoid left: Disconnection ............................................. 15
Failure code [DWN2KB] HSS EPC solenoid left: Short circuit................................................. 16
Failure code [DWN2KY] HSS EPC solenoid left: Hot short circuit........................................... 17
Failure code [DWN5KA] Fan pump EPC solenoid: Disconnection .......................................... 18
Failure code [DWN5KB] Fan pump EPC solenoid: Short circuit.............................................. 19
Failure code [DWN5KY] Fan pump EPC solenoid: Hot short circuit........................................ 20
Failure code [DXA0KA] HSS and work equipment pump TVC solenoid: Disconnection......... 21
Failure code [DXA0KB] HSS and work equipment pump TVC solenoid: Short circuit ............ 22
Failure code [DXA0KY] HSS and work equipment pump TVC solenoid: Hot short circuit ...... 23
Failure code [DXH4KA] 1st clutch ECMV: Disconnection........................................................ 24
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ........................................................... 25
Failure code [DXH4KY] 1st clutch ECMV: Hot short circuit ..................................................... 26
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ...................................................... 27
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit .......................................................... 28
Failure code [DXH5KY] 2nd clutch ECMV: Hot short circuit .................................................... 29
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ....................................................... 30
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit........................................................... 31
Failure code [DXH6KY] 3rd clutch ECMV: Hot short circuit..................................................... 32
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection ............................................... 33
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit................................................... 34
Failure code [DXH7KY] Reverse clutch ECMV: Hot short circuit............................................. 35
Failure code [DXH8KA] Forward clutch ECMV: Disconnection ............................................... 36
Failure code [DXH8KB] Forward clutch ECMV: Short circuit................................................... 37
Failure code [DXH8KY] Forward clutch ECMV: Hot short circuit............................................. 38
10 D85EX, PX-15E0
Troubleshooting of electrical system (E-mode) SEN00638-00

Troubleshooting of electrical system (E-mode) ........................................................................... 3
Before troubleshooting of electrical system............................................................................. 3
Contents of troubleshooting table ............................................................................................ 5
E-1 Engine does not start. ............................................................................................................... 6
E-2 The preheater does not operate. .............................................................................................. 9
E-3 The monitor panel does not light up at all when the starting switch is turned ON. ................... 12
E-4 When the starting switch is turned ON, the monitor panel completely remains lighted and
does not go out. ....................................................................................................................... 14
E-5 When the starting switch is turned ON, the radiator coolant level caution lamp flashes........... 15
E-6 While the engine is running, the battery charge level caution lamp flashes. ............................ 16
E-7 While the engine is running, the emergency warning item flashes. .......................................... 18
E-8 While the preheater is operating, the preheating pilot lamp does not light up. ......................... 20
E-9 The coolant temperature gauge does not indicate correctly. .................................................... 22
E-10 Power train oil temperature gauge does not indicate correctly. .............................................. 24
E-11 Hydraulic oil temperature gauge does not indicate properly. .................................................. 26
E-12 Fuel gauge does not indicate properly. ................................................................................... 28
E-13 Gear speed and engine speed are not indicated properly. ..................................................... 29
E-14 The preset mode and service meter do not indicate properly. ................................................ 29
E-15 The warning lamp does not flash or does not go out. ............................................................. 30
E-16 The alarm buzzer does not sound or does not stop................................................................ 32
E-17 Auto shift down does not operate or does not release............................................................ 34
E-18 Buzzer cancel switch does not work. ...................................................................................... 36
E-19 The information switch does not work..................................................................................... 38
E-20 The manual mode does not operate or does not release. ...................................................... 40
E-21 The monitor panel cannot be set in the service mode or
cannot be set out of the service mode. .................................................................................... 42
E-22 The back-up alarm does not sound. ....................................................................................... 44
E-23 The head lamp and rear lamp do not light up. ........................................................................ 46
E-24 The horn does not sound or does not stop. ............................................................................ 49
E-25 Malfunction of wipers .............................................................................................................. 50
E-26 Washer does not spray water ................................................................................................. 66
E-27 The air conditioner does not operate ...................................................................................... 71
E-28 KOMTRAX system does not operate normally. ...................................................................... 76
Troubleshooting of hydraulic and mechanical system (H-mode) SEN00639-00
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................ 3
Contents of troubleshooting table ............................................................................................ 3
H-1 There is no travel power (no drawbar pull) ....................................................................... 4
H-2 Machine does not move (at 2nd or 3rd speed) ................................................................. 5
H-3 Machine does not move at any gear speed...................................................................... 6
H-4 Machine travels only in one direction, forward or reverse ................................................ 7
H-5 When gear is shifted or travel direction is changed, large time lag is made ..................... 8
H-6 Machine cannot be steered (Machine does not turn leftward or rightward) ...................... 9
H-7 Steering speed or power is low......................................................................................... 9
H-8 Brake does not work ......................................................................................................... 10
H-9 Overheat of power train oil................................................................................................ 11
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor 12
H-11 All work equipment speeds are slow............................................................................... 13
H-12 All work equipments do not move ................................................................................... 14
H-13 Blade lift speed is slow or lacks power ........................................................................... 14
H-14 Blade tilt speed is slow or lacks power ........................................................................... 15
H-15 Ripper lift speed is slow or lacks power .......................................................................... 15
H-16 Excessive hydraulic drift of blade lift ............................................................................... 16
H-17 Excessive hydraulic drift of blade tilt ............................................................................... 16
H-18 Excessive hydraulic drift of ripper lift............................................................................... 17
D85EX, PX-15E0 11
Troubleshooting of engine (S-mode) SEN00640-00

Troubleshooting of engine (S-mode) ........................................................................................... 3
Method of using troubleshooting charts................................................................................... 3
S-1 Starting performance is poor. ............................................................................................ 6
S-2 Engine does not start ........................................................................................................ 8
S-3 Engine does not pick up smoothly .................................................................................... 12
S-4 Engine stops during operations......................................................................................... 13
S-5 Engine does not rotate smoothly....................................................................................... 14
S-6 Engine lacks output (or lacks power) ................................................................................ 15
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 16
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 17
S-9 Oil becomes contaminated quickly.................................................................................... 18
S-10 Fuel consumption is excessive ....................................................................................... 19
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) ............................. 20
S-12 Oil pressure drops........................................................................................................... 21
S-13 Oil level rises (water, fuel in oil)....................................................................................... 22
S-14 Coolant temperature becomes too high (overheating).................................................... 24
S-15 Abnormal noise is made.................................................................................................. 25
S-16 Vibration is excessive...................................................................................................... 26
50 Disassembly and assembly

General information on disassembly and assembly SEN01263-00
General information on disassembly and assembly.................................................................... 2
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tool list ......................................................................................................................... 7
Sketch of special tool............................................................................................................... 11
Engine and cooling system, Part 1 SEN01264-00
Engine and cooling system, Part 1.............................................................................................. 2
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of cylinder head assembly ............................................................... 8
Removal and installation of fuel injector assembly .................................................................. 20
Removal and installation of engine front seal .......................................................................... 25
Removal and installation of engine rear seal........................................................................... 27
Removal and installation of engine oil pan .............................................................................. 31
Engine and cooling system, Part 2 SEN01265-00
Engine and cooling system, Part 2.............................................................................................. 2
Removal and installation of engine assembly.......................................................................... 2
Removal and installation of radiator assembly ........................................................................ 6
Removal and installation of fan drive assembly....................................................................... 9
Removal and installation of fan motor assembly ..................................................................... 11
Removal and installation of fuel tank assembly ....................................................................... 12
Removal and installation of damper assembly ........................................................................ 14
Removal and installation of engine hood assembly................................................................. 16
Power train, Part 1....................................................................................................................... 2
Removal and installation of power train unit assembly............................................................ 2
Disconnection and connection of power train unit assembly ................................................... 7
Disassembly and assembly of PTO assembly......................................................................... 11
Disassembly and assembly of torque converter assembly...................................................... 17
Disassembly and assembly of TORQFLOW transmission assembly ...................................... 21
Power train, Part 2....................................................................................................................... 2
Disassembly and assembly of HSS assembly......................................................................... 2
Removal and installation of final drive assembly ..................................................................... 21
Disassembly and assembly of final drive assembly................................................................. 23
12 D85EX, PX-15E0
Undercarriage and frame, Part 1 SEN01268-00

Undercarriage and frame, Part 1................................................................................................. 2
Removal and installation of track frame assembly .................................................................. 2
Removal and installation of idler assembly ............................................................................. 5
Disassembly and assembly of idler assembly ......................................................................... 7
Removal and installation of recoil spring assembly ................................................................. 11
Disassembly and assembly of recoil spring assembly ............................................................ 13
Removal and installation of track roller assembly ................................................................... 17
Disassembly and assembly of track roller assembly ............................................................... 18
Removal and installation of carrier roller assembly ................................................................. 21
Disassembly and assembly of carrier roller assembly............................................................. 22
Undercarriage and frame, Part 2 SEN01269-00
Undercarriage and frame, Part 2................................................................................................. 2
Expansion and installation of track shoe assembly ................................................................. 2
Whole disassembly and assembly of track shoe..................................................................... 6
Removal and installation of pivot shaft assembly .................................................................... 25
Removal and installation of equalizer bar assembly ............................................................... 26
Disassembly and assembly of equalizer bar assembly ........................................................... 28
Hydraulic system SEN01270-00
Hydraulic system......................................................................................................................... 2
Removal and installation of work equipment control valve assembly...................................... 2
Disassembly and assembly of work equipment control valve assembly ................................. 5
Removal and installation of HSS and work equipment pump assembly ................................. 6
Removal and installation of power train and lubricating oil pump assembly ........................... 8
Removal and installation of fan pump assembly ..................................................................... 9
Removal and installation of scavenging pump assembly ........................................................ 10
Removal and installation of HSS motor assembly................................................................... 11
Disassembly and assembly of hydraulic cylinder assembly .................................................... 12
Work equipment .......................................................................................................................... 2
Removal and installation of blade assembly ........................................................................... 2
Disassembly and assembly of ripper assembly....................................................................... 4
Cab and its attachments.............................................................................................................. 2
Removal and installation of ROPS guard assembly ................................................................ 2
Removal and installation of operator’s cab assembly ............................................................. 3
Removal and installation of operator’s cab glass (Stuck glass)............................................... 9
Removal and installation of floor frame assembly ................................................................... 18
Electrical system ......................................................................................................................... 2
Removal and installation of engine controller .......................................................................... 2
Removal and installation of steering and transmission controller............................................ 4
Removal and installation of KOMTRAX terminal ..................................................................... 5
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN00072-00
Hydraulic diagrams and drawings ............................................................................................... 2
Power train hydraulic circuit diagram....................................................................................... 2
Hydraulic circuit diagram ......................................................................................................... 3
Electrical diagrams and drawings ............................................................................................... 3
Electrical circuit diagram.......................................................................................................... 3
Connector arrangement diagram............................................................................................. 5
D85EX, PX-15E0 13
SEN00069-02
D85EX, PX-15E0 Bulldozer

Form No. SEN00069-02
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 06-06 (01)
14
SEN00070-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
00 Index and foreword 1

Foreword and general information
Foreword and general information .................................................................................................................. 2
Safety notice ........................................................................................................................................ 2
How to read the shop manual .............................................................................................................. 6
Explanation of terms for maintenance standard................................................................................... 8
Handling electric equipment and hydraulic component...................................................................... 10
How to read electric wire code ........................................................................................................... 18
Method of disassembling and connecting push-pull type coupler...................................................... 21
Standard tightening torque table ........................................................................................................ 24
Conversion table ................................................................................................................................ 28
D85EX, PX-15E0 1
Foreword and general information (Rev. 2005/09)
Safety notice 1
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w eld in g wo rk , alw ay s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to 1 Good arrangement
keep tools and removed parts. Always
2 Correct work clothes
keep the tools and parts in their correct
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water, 4 Making and checking signs
or oil on the floor. Smoke only in the areas Prohibition of operation and handling by
5
provided for smoking. Never smoke while unlicensed workers
working. 6 Safety check before starting work
3) When carrying out any operation, always Wearing protective goggles
wear safety shoes and helmet. Do not 7
(for cleaning or grinding work)
wear loose work clothes, or clothes with
Wearing shielding goggles and protectors
buttons missing. 8
(for welding work)
q Always wear safety glasses when hit-
ting parts with a hammer. 9 Good physical condition and preparation
q Always wear safety glasses when Precautions against work which you are
10
grinding parts with a grinder, etc. not used to or you are used to too much
4) When carrying out any operation with 2 or
more workers, always agree on the oper-
ating procedure before starting. Always 2. Preparations for work
inform your fellow workers before starting 1) Before adding oil or making any repairs,
any step of the operation. Before starting park the machine on hard and level
work, hang UNDER REPAIR signs in the ground, and apply the parking brake and
operator's compartment. block the wheels or tracks to prevent the
5) Only qualified workers must carry out work machine from moving.
and operation which require license or 2) Before starting work, lower the work
qualification. equipment (blade, ripper, bucket, etc.) to
6) Keep all tools in good condition, learn the the ground. If this is not possible, insert
correct way to use them, and use the the lock pin or use blocks to prevent the
proper ones of them. Before starting work, work equipment from falling. In addition,
thoroughly check the tools, machine, fork- be sure to lock all the control levers and
lift, service car, etc. hang warning signs on them.
2 D85EX, PX-15E0
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r l y c a r e fu l t o c he c k t h a t t h ey ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
D85EX, PX-15E0 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with one rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 D85EX, PX-15E0
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
D85EX, PX-15E0 5
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
6 D85EX, PX-15E0
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
D85EX, PX-15E0 7
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
8 D85EX, PX-15E0
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the size of a hole is smaller than the be replaced or repaired.
size of a shaft because of the standard
size and tolerance, the difference between
these sizes is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the shaft to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
D85EX, PX-15E0 9
Handling electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
10 D85EX, PX-15E0
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
splash water over the connector. The con-
nector is designed to prevent water from
entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the con-
nector, the pins will be short-circuited by
the water, so if any water gets in, immedi-
ately dry the connector or take other
appropriate action before passing electric-
ity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
D85EX, PX-15E0 11
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
12 D85EX, PX-15E0
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
1. Male connector
2. Female connector
q Normal locking state (Horizontal): a,
b, d
q Incomplete locking state (Diagonal): c
D85EX, PX-15E0 13
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om th e c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
14 D85EX, PX-15E0
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
D85EX, PX-15E0 15
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
16 D85EX, PX-15E0
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D85EX, PX-15E0 17
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
18 D85EX, PX-15E0
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
D85EX, PX-15E0 19
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
20 D85EX, PX-15E0
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
D85EX, PX-15E0 21
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
22 D85EX, PX-15E0
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
D85EX, PX-15E0 23
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80 – 100
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
24 D85EX, PX-15E0
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
D85EX, PX-15E0 25
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolt BANJO bolt
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8± 2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20
12 77 ± 12 7.85 ± 1.22 24 ± 4 2.45 ± 0.41
14 – – 36 ± 5 3.67 ± 0.51
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
26 D85EX, PX-15E0
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
D85EX, PX-15E0 27
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
28 D85EX, PX-15E0
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
D85EX, PX-15E0 29
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
30 D85EX, PX-15E0
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
D85EX, PX-15E0 31
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
32 D85EX, PX-15E0
SEN00070-00

© 2005 KOMATSU
All Rights Reserved
34
SEN00071-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
01 Specification 1
Specification and technical data
Specification and technical data...................................................................................................................... 2
Specification dimensions...................................................................................................................... 2
Specifications ....................................................................................................................................... 3
Weight table ........................................................................................................................................11
Table of fuel, coolant and lubricants ................................................................................................... 16
D85EX, PX-15E0 1
SEN00071-00 01 Specification
Specification and technical data 1

Specification dimensions 1
D85EX-15E0
Power tilt dozer Semi-U dozer
Item Unit
+ fixed multi-shank ripper + fixed multi-shank ripper
A Overall length mm 7,100 7,255
Overall height 3,330 3,330
B mm
(with ROPS) (3,324) (3,324)
C Overall width mm 3,715 3,635
Power tilt dozer Semi-U dozer

Item Unit
+ variable multi-shank ripper + variable multi-shank ripper
A Overall length mm 7,155 7,310
Overall height 3,330 3,330
B mm
(with ROPS) (3,324) (3,324)
C Overall width mm 3,715 3,635
D85PX-15E0
Item Unit Power tilt dozer + drawbar
A Overall length mm 6,065
Overall height 3,367
B mm
(with ROPS) (3,361)
C Overall width mm 4,365
2 D85EX, PX-15E0
Specifications 1
D85EX-15E0
Machine name and type D85EX-15E0

Serial number 11001 and up
Machine weight
• Bare tractor kg 21,140
• With semi-U dozer
+ fixed multi-shank ripper
kg 28,100
Weight
+ ROPS + cab + air conditioner

+ side cover
+ variable multi-shank ripper
kg 28,220
+ side cover
Min. turning radius (F1) m 2.0
Gradeability deg. 30
Stability (front, rear, left, right) deg. 35
1st speed 3.3
Travel speed
Forward 2nd speed km/h 6.1

3rd speed 10.1
1st speed 4.4
Reverse 2nd speed km/h 8.0
3rd speed 13.0
• Bare tractor kPa {kg/cm2} 60.7 {0.62}
• With power tilt dozer
Performance

kPa {kg/cm2} 79.9 {0.81}
+ side cover
Ground pressure

kPa {kg/cm2} 80.7 {0.82}
+ side cover
kPa {kg/cm2} 80.2 {0.82}
+ side cover
kPa {kg/cm2} 81.0 {0.83}
+ side cover
D85EX, PX-15E0 3

• Bare tractor
mm 5,012
(to top of lift cylinder)
mm 7,100
Overall length

mm 7,155
mm 7,255
mm 7,310
• Bare tractor mm 2,560
Overall width
+ fixed/variable mm 3,715
Dimensions
multi-shank ripper
+ fixed/variable mm 3,635
multi-shank ripper
To top of exhaust pipe (incl. grouser) mm 3,330
To top of air intake duct
Overall height
mm 2,592
(incl. grouser, to top of control lever)
When cab is installed
mm 3,163
(incl. grouser, excluding exhaust pipe)
When ROPS canopy is installed
mm 3,324
(incl. grouser, excluding exhaust pipe)
Track gauge mm 2,000
Length of track on ground mm 3,050
Shoe width (standard) mm 560
Min. ground clearance
mm 450
(To bottom of undercover)
Name — SAA6D125E-5
4-cycle, water-cooled, in-line 6-cylinder, direct-injection,
Type —
with turbocharger and air-cooled aftercooler
No. of cylinders – bore x stroke mm 6 – 125 × 150
Total piston displacement l {cc} 11.04 {11,039}
Flywheel horsepower kW {HP}/rpm 197 {264}/1,900 (Net)
Performance
Max. torque Nm {kgm}/rpm 1,272 {130}/1,400 (Gross)

Engine
High idle speed under no load rpm 2,100

Low idle speed under no load rpm 750
Min. fuel consumption ratio g/kWh {g/HPh} 215 {160}
Starting motor 24 V, 7.5 kW
Alternator 24 V, 50 A
Battery 12 V, 150 Ah x 2
Type of radiator core Corrugated aluminum, 8.0/2
4 D85EX, PX-15E0

Torque converter 3-element, 1-stage, 1-phase type
Planetary gear, multiple disc,
hydraulic (electric),
Transmission gear pump pressure fed oil lubrication,
3 forward/reverse gear speeds,
electrically operated type
Variable swash plate type (HPV160)
MPa {kg/cm2}
HSS pump Max. discharge pressure: 40.2 {410}
Power train
l/min /rpm Theoretical discharge amount: 341/2,133

Fixed swash plate type (HMF112)
HSS motor MPa {kg/cm2}
Max. allowable working pressure: 40.2 {410}
Spiral bevel gear, gear pump pressure fed oil
Bevel gear shaft
lubrication type
Differential planetary gear, hydraulic motor drive,
HSS steering system
electric motorized, hydraulically actuated type
HSS
Wet multiple disc, spring-boosted,

Master brake
hydraulically actuated, pedal operated type
1-stage spur gear, 1-stage planetary gear,
Final drive
splash lubrication type
Type of suspension Rigid, balancing beam type
Undercarriage
Carrier roller 2 pieces on each side

Track roller 7 pieces on each side
Assembly type, single grouser,
Track shoe (560 mm)
41 pieces on each side, pitch: 216.3 mm
Power train + lubrication pump (tandem) Gear type (SAL(3)63 + (2)50)
Scavenging pump Gear type (SAR(3)80)
(common use with HSS)
Work equipment MPa {kg/cm2} Max. discharge pressure: 27.4 {280}
Work equipment pump
hydraulic system Work equipment relief pressure: 22.5 {230}
Variable swash plate type (LPV30)
MPa {kg/cm2}
Fan pump Max. discharge pressure: 20.6 {210}
Fan driving
system
Fixed swash plate type (LMF28)
Fan motor MPa {kg/cm2}
D85EX, PX-15E0 5

Machine with fixed multi-shank ripper
Type 3 + 1 spool type, hydraulic assist type
• For blade lift + blade lift
• For blade tilt + blade tilt
Main control valve
• For steering + steering

• For ripper lift + ripper lift
Machine with variable multi-shank ripper
Type 3 + 1 spool type, hydraulic assist type
• For ripper lift + ripper lift
• For ripper tilt + ripper tilt
Type Double acting piston
Cylinder bore mm 100
Lift cylinder
Piston rod outer diameter mm 65

Piston stroke (Max.) mm 1,350
Max. distance between pins mm 2,040
Work equipment hydraulic system
Min. distance between pins mm 690

Tilt cylinder

Piston stroke (Max.) mm 130
Min. distance between pins mm 1,221
Fixed multi-shank ripper

Lift cylinder

Lift cylinder

Variable multi-shank ripper

Tilt cylinder

Hydraulic tank Box type (external control valve type)
6 D85EX, PX-15E0

Hydraulic power tilt dozer
Type
Hydraulic semi-U dozer
Blade supporting method Left: brace, Right: tilt cylinder
Max. lift (above ground) mm 1,207
Dimensions Performance Dimensions Performance
Max. drop (below ground) mm 540

Power tilt dozer
Max. tilt mm 740

Blade capacity (SAE) m 3
5.2
Blade width mm 3,725
Blade height mm 1,450
Tip angle of blade cutting edge deg. 52

Semi-U dozer
Max. tilt mm 735

7.0
Work equipment
Tip angle of blade cutting edge deg. 52

Type Parallelogram
Weight kg 2,500
Beam length mm 2,246
Number of shanks piece 3
Digging angle deg. 54
Performance
Digging depth 2 levels switchable

Max. digging depth mm 653
Max. lift mm 564
Type Parallelogram
Weight kg 2,570
Beam length mm 2,246
Number of shanks piece 3
Digging angle (standard) deg. 42.4 – 63.6 (54)
Performance
Digging depth 2 levels switchable

Max. digging depth mm 736
Max. lift mm 720
D85EX, PX-15E0 7
D85PX-15
Machine name and type D85PX-15E0

Machine weight
• Bare tractor kg 23,420
Weight

+ drawbar + ROPS + cab kg 27,650
+ air conditioner + side cover
Min. turning radius (F1) m 2.7
Gradeability deg. 30
Stability (front, rear, left, right) deg. 35
1st speed 3.3
Travel speed
Forward 2nd speed km/h 6.0

3rd speed 10.0
Performance
1st speed 4.4

Reverse 2nd speed km/h 7.9
3rd speed 12.7
Overall width Overall length Ground pressure
• Bare tractor kPa {kg/cm2} 36.3 {0.37}

+ drawbar + ROPS + cab kPa {kg/cm2} 42.8 {0.44}
+ air conditioner + side cover
• Bare tractor (to top of lift cylinder) mm 4,720

mm 6,065
+ drawbar
• Bare tractor mm 3,160

mm 4,365
+ drawbar
Dimensions
To top of exhaust pipe (incl. grouser) mm 3,367

To top of air intake duct
Overall height
mm 2,629
(incl. grouser, to top of control lever)
When cab is installed
mm 3,200
(incl. grouser, not incl. exhaust pipe)
When ROPS canopy is installed
mm 3,361
(incl. grouser, not incl. exhaust pipe)
Track gauge mm 2,250
Length of track on ground mm 3,480
Shoe width (standard) mm 910
Min. ground clearance
mm 560
(To bottom of undercover)
8 D85EX, PX-15E0

Name SAA6D125E-5
4-cycle, water-cooled, in-line 6-cylinder, direct-injec-
Type
tion, with turbocharger and air-cooled aftercooler
No. of cylinders – bore x stroke mm 6 – 125 × 150
Total piston displacement l {cc} 11.04 {11,039}
Rated horsepower kW {HP}/rpm 197 {264}/1,900 (Net)
Performance
Max. torque Nm {kgm}/rpm 1,272 {130}/1,400 (Gross)

Engine
High idle speed under no load rpm 2,100

Low idle speed under no load rpm 750
Min. fuel consumption ratio g/kWh {g/HPh} 215 {160}
Starting motor 24 V, 7.5 kW
Alternator 24 V, 50 A
Battery 12 V, 150 Ah x 2
Type of radiator core Corrugated aluminum, 8.0/2
Torque converter 3-element, 1-stage, 1-phase type
Planetary gear, multiple disc, hydraulic (electric),
Transmission gear pump pressure fed oil lubrication, 3 forward/
reverse gear speeds, electrically operated type
MPa {kg/cm2}
HSS pump Max. discharge pressure: 40.2 {410}
Power train
Fixed swash plate type (HMF112)

HSS motor MPa {kg/cm2}
Spiral bevel gear, gear pump pressure fed oil
Bevel gear shaft
lubrication type
Differential planetary gear, hydraulic motor drive,
HSS steering system
electric motorized, hydraulically actuated type
HSS
Wet multiple disc, spring-boosted,

Master brake
hydraulically actuated, pedal operated type
1-stage spur gear, 1-stage planetary gear,
Final drive
splash lubrication type
Type of suspension Rigid, balancing beam type
Undercarriage
Carrier roller 2 pieces on each side

Track roller 8 pieces on each side
Assembly type, single grouser,
Track shoe (910 mm)
45 pieces on each side, pitch: 216.3 mm
Power train + lubrication pump (tandem) Gear type (SAL(3)63 + (2)50)
Scavenging pump Gear type (SAR(3)80)
hydraulic system
Work equipment
2 (common use with HSS)

MPa {kg/cm }
Max. discharge pressure: 27.4 {280}
Work equipment pump Work equipment relief pressure: 22.5 {230}
D85EX, PX-15E0 9

Variable swash plate type (LPV30)
MPa {kg/cm2}
Fan driving
Fan pump Max. discharge pressure: 20.6 {210}

system

Fixed swash plate type (LMF28)
Fan motor MPa {kg/cm2}
Main control valve
Type 3 spool type, hydraulic assist type

Work equipment hydraulic system
Type Double acting piston

Lift cylinder

Piston stroke (Max.) mm 1,225
Tilt cylinder

Min. distance between pins mm 1,221
Hydraulic tank Box type (external control valve type)
Type Hydraulic power tilt dozer
Blade supporting method Left: brace, Right: tilt cylinder
Work equipment

Performance
Power tilt dozer
Max. tilt mm 500

5.9
Dimensions
Tip angle of blade cutting
deg. 55
edge
10 D85EX, PX-15E0
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
D85EX-15E0
Unit: kg
Engine assembly (excluding coolant and oil) 1,483
• Engine assembly 1,330
• Damper assembly 131
• Universal joint 17
• Engine mounting parts (wiring) 5
Cooling assembly (excluding coolant and oil) 242
• Radiator 15
• Aftercooler 17
• Hydraulic oil cooler 4
Power train oil cooler assembly 47
Fuel tank assembly (when empty) 215
(when full) 618
Power train unit assembly (incl. HSS pump motor) 1,800
• Torque converter and PTO assembly 322
• Transmission assembly 443
• HSS assembly 748
• Brake valve assembly 5
• HSS cooler bypass valve assembly 11
• Power train filter assembly 17
• Scavenging pump 12
• Power train and lubrication pump 25
• HSS pump 106
• HSS motor 41
• Fan pump 25
• Fan motor 13
Final drive assembly 1,010 × 2
Sprocket teeth (10 x 9) × 2
Hull frame 3,262
Undercarriage assembly (each side) 2,168
• Track frame 800
• Idler assembly 290
• Recoil spring assembly 350
• Track roller assembly (single flange x 1) 72 × 5
(double flange x 1) 80 × 2
• Carrier roller assembly 39 × 2
• Roller guard etc. 130
Track shoe assembly (560 mm, wet type) 1,945 × 2
D85EX, PX-15E0 11
Unit: kg
Pivot shaft assembly 82 × 2
Equalizer bar 158
Hydraulic tank assembly 95
Main control valve
95
(blade lift + blade tilt + ripper lift + steering)
Engine underguard (front/rear) 80/89
Transmission underguard 160
Operator seat (excluding tilt and front-rear sliding device) 55
Power tilt dozer assembly 3,305
• Blade assembly (incl. edge etc.) 1,674
• Straight frame (left/right) 371/389
• Tilt brace 66
• Center brace 81 × 2
• Tilt cylinder assembly 130
Semi-U dozer assembly 3,575
• Semi-U blade assembly (incl. edge etc.) 1,860
Radiator mask assembly 117
Blade lift cylinder assembly 115 × 2
Fixed multi-shank ripper assembly 2,500
• Mount bracket 124 × 2
• Ripper arm 368
• Ripper beam 1,038
• Upper link 54 × 2
• Shank (incl. protector) 168 × 3
• Lift cylinder assembly 81 × 2
Variable multi-shank ripper assembly 2,570
• Mount bracket 162 × 2
• Ripper arm 464
• Ripper beam 898
• Shank (incl. protector) 168 × 3
• Lift cylinder assembly 78 × 2
• Tilt cylinder assembly 74 × 2
ROPS assembly 371
Cab assembly 410
ROPS canopy 437
Dashboard (for machine with cab and air conditioner) 76
Floor frame assembly 350
Air conditioner assembly (incl. air conditioner unit assembly) 76
Operator seat assembly 68
12 D85EX, PX-15E0
D85PX-15E0
Unit: kg
Engine assembly (excluding coolant and oil) 1,483
• Engine assembly 1,330
• Damper assembly 131
• Universal joint 17
• Engine mounting parts (wiring) 5
Cooling assembly (excluding coolant and oil) 242
• Radiator 15
• Aftercooler 17
• Hydraulic oil cooler 4
Power train oil cooler assembly 47
Fuel tank assembly (when empty) 215
(when full) 618
Power train unit assembly (incl. HSS pump motor) 1,800
• Torque converter and PTO assembly 322
• Transmission assembly 443
• HSS assembly 748
• Brake valve assembly 5
• HSS cooler bypass valve assembly 11
• Power train filter assembly 17
• Scavenging pump 12
• Power train and lubrication pump 25
• HSS pump 106
• HSS motor 41
• Fan pump 25
• Fan motor 13
Final drive assembly 1,063 × 2
Sprocket teeth (10 × 9) × 2
Hull frame 3,262
Undercarriage assembly (each side) 2,278
• Track frame 860
• Idler assembly 290
• Recoil spring assembly 350
• Track roller assembly (single flange x 1) 72 × 6
(double flange x 1) 80 × 2
• Carrier roller assembly 39 × 2
• Roller guard etc. 108
Track shoe assembly (910 mm, wet type) 2,795 × 2
Pivot shaft assembly 106 × 2
Equalizer bar 204
D85EX, PX-15E0 13
Unit: kg
Hydraulic tank assembly 95
Main control valve (blade lift + blade tilt + steering) 84
Engine underguard (front/rear) 80/89
Transmission underguard 160
Operator seat (excluding tilt and front-rear sliding device) 55
Power tilt dozer assembly 3,343
• Blade assembly (incl. edge etc.) 1,779
• Tilt brace 66
Radiator mask assembly 117
Blade lift cylinder assembly 110 × 2
ROPS assembly 371
Cab assembly 410
ROPS canopy 437
Dashboard (for machine with cab and air conditioner) 76
Floor frame assembly 350
Air conditioner assembly (incl. air conditioner unit assembly) 76
Operator seat assembly 68
14 D85EX, PX-15E0
Table of fuel, coolant and lubricants 1

a For details of notes (Notes 1 and 2...) in the table, see Operation and Maintenance Manual.
a Although SAE10W30DH and SAE15W40DH are specified to be used as engine oil for engine oil pan,
SAE10W30 (API CH4, CI-4) and SAE15W40 (API CH4, CI-4) can be used instead respectively.
16 D85EX, PX-15E0
Unit: l
D85EX-15E0 D85PX-15E0
Supply point
Specified capacity Refill capacity Specified capacity Refill capacity
Engine oil pan 44 38 44 38
Damper case 1.6 1.6 1.6 1.6
Idler (each of right and left) 0.35 0.35 0.35 0.35
Power train case 90 60 90 60
Hydraulic oil system 120 67 106 67
Final drive case (each of right and left) 26 26 36 36
Fuel tank 490 — 490 —
Cooling system (including sub-tank) 58 — 58 —
D85EX, PX-15E0 17
SEN00071-00

© 2005 KOMATSU
All Rights Reserved
18
SEN00293-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
Engine and cooling system ............................................................................................................................. 2
Engine mount ....................................................................................................................................... 2
Cooling system..................................................................................................................................... 4
Cooling fan pump ................................................................................................................................. 6
Cooling fan motor............................................................................................................................... 14
D85EX, PX-15E0 1
SEN00293-00 10 Structure, function and maintenance standard
Engine and cooling system 1

Engine mount 1
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bracket and size Shaft Hole clearance limit
1
cushion –0.100 +0.046 0.100 –
60 0.4 Replace
–0.300 +0.046 0.346
Standard size Repair limit
2 Free height of mount rubber
90 88
2 D85EX, PX-15E0
Cooling system 1
4 D85EX, PX-15E0
A: Power train oil cooler inlet

B: Power train oil cooler outlet
C: Hydraulic oil cooler inlet
D: Hydraulic oil cooler outlet
1. Cooling fan motor

2. Aftercooler inlet hose
3. Radiator inlet hose
4. Reservoir tank
5. Aftercooler outlet hose
6. Radiator outlet hose
7. Power train oil cooler
8. Aftercooler
9. Radiator cap
10. Radiator
11. Hydraulic oil cooler
12. Drain plug
13. Cooling fan
Specifications
Power train
Radiator Hydraulic oil cooler Aftercooler
oil cooler
Corrugated Corrugated
Core type PTO-OL 3A-CS
aluminum aluminum
Fin pitch (mm) 8.0/2 — 3.5 8.0/2
Total heat dissipation sur-
34.81 × 2 2.259 1.86 33.0
face (m2)
Cracking pressure of pres- 88.3 ± 14.7
— — —
sure valve (kPa{kg/cm2}) {0.9 ± 0.15}
Cracking pressure of vac- 0 – 4.9
— — —
uum valve (kPa {kg/cm2}) {0 – 0.05}
D85EX, PX-15E0 5
Cooling fan pump 1

Type: LPV30
P1: Pump discharge

PS: Pump suction
T0: Drain
T1: Drain plug
PEPC: EPC valve basic pressure input
PCEPC: EPC output pressure detection plug
6 D85EX, PX-15E0
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
D85EX, PX-15E0 7
Function Structure
q The pump converts the engine rotation trans- q Cylinder block (7) is supported to shaft (1) by
mitted to its shaft to oil pressure and delivers spline (a), and shaft (1) is supported by the
pressurized oil corresponding to the load. front and rear bearings.
q It is possible to change the discharge amount q The tip of piston (6) is a concave ball, and shoe
by changing the swash plate angle. (5) is caulked to it to form one unit. Piston (6)
and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface as it
slides in a circle. Rocker cam (4) also slides
around ball (11) using it as fulcrum.
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q Cylinder block (7) carries out rotation relative
to valve plate (8) while sealing the pressurized
oil, and this surface ensures that the hydraulic
balance is maintained correctly.
q The oil inside each cylinder chamber of cylin-
der block (7) is sucked in and discharged
through valve plate (8).
8 D85EX, PX-15E0
Operation
Operation of pump
q Cylinder block (7) rotates together with shaft q When center line (X) of rocker cam (4) is the
(1), and shoe (5) slides on flat surface (A). At same as the axial direction of cylinder block (7)
this point, since rocker cam (4) inclines with [s was h pl ate an gl e = 0], the d iffer e nc e
ball (11) as fulcrum, inclination (a) between the between volumes (E) and (F) inside cylinder
center line of rocker cam (4) and the shaft block (7) is 0, so pump does not suck and dis-
direction of cylinder block (7) changes. (a) is charge, and no pumping is carried out. [The
called swash plate angle. swash plate angle is not set to 0 actually, how-
q With the condition of center line (X) of rocker ever.]
cam (4) has swash plate angle (a) to axial q In other word, swash plate angle (a) and the
direction of cylinder block (7), flat surface (A) pump discharge amount is in relation of pro-
functions as cam against shoe (5). portion.
q Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
result, each piston (6) sucks and discharges oil
by (F) – (E).
q In other words, cylinder block (7) rotates, and
the volume of chamber (E) becomes smaller,
so pressurized oil is discharged during this
process. At the same time, the volume of
chamber (F) becomes larger and the oil is
sucked in this process. [In the figure, chamber
(F) is at the end of the suction stroke and
chamber (E) is at the end of the discharge
stroke.]
D85EX, PX-15E0 9
Control of discharge amount

q The discharge amount is increased by the
increase of capacity difference of (E) and (F)
as swash plate angle (a) is increased. Swash
plate angle (a) is changed by servo piston (10).
q Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the servo valve.
This straight line motion is transmitted to
rocker cam (4). Then, rocker cam (4) sup-
ported on ball (11) sways around ball (11).
10 D85EX, PX-15E0
Servo valve
P: EPC valve basic pressure 1. Plug

T: Drain 2. Lever
PE: Control piston pressure 3. Retainer
PH: Pump discharge pressure 4. Seat
5. Spool
6. Piston
7. Sleeve
D85EX, PX-15E0 11
A: Drain side
B: Pump discharge pressure input side
C: EPC output pressure received
D: EPC output pressure
12 D85EX, PX-15E0
Function Operation
q The servo valve controls the current input to q The output pressure of EPC valve is applied to
the EPC valve and the swash plate angle of piston chamber (C) to push piston (6). Piston
the pump so that they will be related as shown (6) pushes spool (5) until it is balanced with the
in the diagram. spring.
q Then, land (PE) of the servo piston pressure
passage is connected to the pump discharge
passages by the notch of spool (5) and the dis-
charge pressure is led to the servo piston.
q The servo piston is raised by the rocker com.
Then, the position feedback is applied and the
lever moves to compress the spring.
q If spool (5) is pushed back, the pump dis-
charge circuit and the servo piston circuit are
shut off. The pressure in the servo piston
chamber lowers and the rocker cam returns
toward the maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
q The relationship between input current (i) to put is balanced with the spring force.
the EPC valve and output pressure (F) of EPC q Accordingly, as the EPC output pressure is
valve is as follows. heightened, the swash plate angle is
decreased. As the EPC output pressure is low-
ered, the swash plate angle is increased.
D85EX, PX-15E0 13
Cooling fan motor 1

Type: LMF28
P: From fan pump Specifications

T: From cooler to tank Type : LMF28
TC: To tank Capacity : 28.0 cc/rev
Rated speed : 1,650 rpm
Rated flow : 46 l/min
Check valve
cracking pressure : 0.044 MPa {0.45 kg/cm2}
14 D85EX, PX-15E0
1. Output shaft 8. Center spring

2. Case 9. Check valve spring
3. Thrust plate 10. Check valve
4. Piston assembly 11. Pilot valve
5. Cylinder block 12. Spool for reversible valve
6. Valve plate 13. Spring for reversible valve
7. End cover 14. Safety valve
Unit: mm
Free length
Installation Installation Installation Replace spring if
× outer Free length
9 Check valve spring length load load damaged or
diameter
deformed.
3.43 N 2.55 N
13.0 × 6.5 7.0 —
{0.35 kg} {0.26 kg}
D85EX, PX-15E0 15
Hydraulic motor unit
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses piston (4) [2 or 3 pieces], and gener-
ates force (F1)[F1 = P x xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°) to
output shaft (1), the force is divided into com-
ponents (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 x ri] against the (Y-Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = Σ(F3 x ri)] rotates
cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
16 D85EX, PX-15E0
Suction valve
Function When stopping

q If the fan pump stops, the pressurized oil does
not flow into the motor. Since the motor contin-
ues revolution because of the force of inertia,
however, the pressure on the outlet side of the
motor rises.
q When the oil stops flowing in from inlet port (P),
the suction valve sucks in the oil on the outlet
side and supplies it to port (MA) where there is
not sufficient oil to prevent cavitation.
Operation
When starting
q If the engine is stopped and the input revolu-

tion of the fan pump lowers to 0 rpm, the pres-
surized oil from the pump is not supplied to
port (P) any more. As the pressurized oil is not
supplied to (MA) side of the motor, the motor
speed lowers gradually to stop.
q If the motor shaft is revolved by the force of
inertia while the oil flow in port (P) is reducing,
the oil in port (T) on the outlet side is sent by
suction valve (1) to (MA) side to prevent cavita-
tion.
q If the pressurized oil from the pump is supplied

to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor,
the motor starts revolution. The oil on motor
outlet (MB) side of the motor returns through
port (T) to the tank.
D85EX, PX-15E0 17
Reversible valve
When the ON-OFF solenoid for the reversible When the ON-OFF solenoid for the reversible
valve is “demagnetized” valve is “energized”
q If ON-OFF solenoid (1) for the reversible valve q If ON-OFF solenoid (1) for reversible valve is
is “demagnetized”, the pressurized oil from the “energized”, ON-OFF selector valve (2) changes
pump is blocked by ON-OFF selector valve (2), to let the pressurized oil from the pump flow
and port (C) opens for the tank circuit. through port (C) into spool chamber (D).
q Accordingly, reversible valve spool spring (3) is q The pressurized oil in chamber (D) pushes
pushed by reversible valve spool spring (4) to reversible valve spool (3) to the left against
the right to open motor port (MA) and then the reversible valve spring (4). As a result, motor
pressurized oil flows in to revolve the motor port (MB) opens and pressurized oil flows in to
forward (clockwise). revolve the motor in reverse (counterclock-
wise).
18 D85EX, PX-15E0
Safety valve
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
D85EX, PX-15E0 19
SEN00293-00

© 2005 KOMATSU
All Rights Reserved
20
SEN00295-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Power train, Part 1
Power train, Part 1 .......................................................................................................................................... 2
Power train ........................................................................................................................................... 2
HSS system ......................................................................................................................................... 4
General view of power train unit........................................................................................................... 6
Power train hydraulic piping drawing ................................................................................................... 8
Transmission control ............................................................................................................................ 9
Steering and brake control ................................................................................................................. 10
Damper and universal joint ................................................................................................................ 12
Torque converter and PTO ................................................................................................................. 14
Transmission ...................................................................................................................................... 20
Transmission clutch ECMV ................................................................................................................ 32
Main relief valve and torque converter relief valve............................................................................. 37
Lubrication relief valve ....................................................................................................................... 39
D85EX, PX-15E0 1
Power train, Part 1 1

Power train 1
Outline
q The power generated by engine (1) has its tor- q The power transmitted to bevel gear shaft is
sional vibration dampened by damper (2), and transferred to HSS (Hydrostatic Steering Sys-
then passes through universal joint (3) and is tem) (11).
transmitted to torque converter (8). HSS pump (5) is driven by PTO (6), and dis-
q The power generated by engine (1) has its tor- charged oil from the HSS pump drives HSS
sional vibration dampened by damper (2), and motor (12).
then passes through universal joint (3) and is The rotation of the pair of the HSS gears on
transmitted to torque converter (8). the right and left is controlled by HSS motor
q The power from the engine is transmitted to (12). The turning direction is controlled by gen-
the transmission input shaft (turbine shaft) via erating a difference in speed on the right and
the oil by torque converter (8) corresponding to left.
load change. It is also possible to use the HSS mechanism
q Transmission (9) uses a combination of a plane- to rotate the right and left sides in opposite
tary gear system and hydraulic clutches to directions to carry out counter-rotation.
reduce the speed and shift the gears (3 forward q Brake (13) of HSS is used for braking the
speeds and 3 reverse speeds). It connects 2 sets machine. Brake (13) is a wet, multiple disc
of clutches selected corresponding to the change clutch and spring boosted type.
of the load, and transmits the power to bevel The power from brake (13) is transmitted to
gear (10) from the bevel pinion at the rear end of final drive (14).
the transmission. q Final drive (14) consists of a single-stage spur
gear and a single-stage planetary gear system.
It reduces the speed and rotates sprocket (15)
to drive track shoe (16) and move the machine.
Also, fan pump (7) is driven by PTO (6), and
discharged oil from the fan pump drives fan
motor (19).
2 D85EX, PX-15E0
1. Engine 11. HSS unit

2. Damper 12. HSS motor
3. Universal joint 13. Brake
4. Scavenging pump 14. Final drive
5. HSS pump 15. Sprocket
6. PTO 16. Track shoe
7. Cooling fan pump 17. Power train pump
8. Torque converter 18. Lubrication pump
9. Transmission 19. Cooling fan motor
10. Bevel gear
D85EX, PX-15E0 3
HSS system 1
a HSS: Abbreviation for Hydrostatic Steering System
4 D85EX, PX-15E0
1. Steering/directional/gear shift lever (PCCS lever) Outline

2. Transmission and steering controller q HSS system stands for Hydrostatic Steering
3. Control valve System.
4. HSS pump The hydrostatic is equal to fluid statics.
5. Engine q The HSS system consists of control valve,
6. EPC valve HSS pump and HSS motor as shown in the fig-
7. Hydraulic tank ure. It turns the machine continuously without
8. Sprocket lowering the traveling speed by making a dif-
9. Final drive ference in speed between both track shoes.
10. HSS motor q Transmission and steering controller uses the
11. HSS circuit EPC valve of the control valve to control the
12. Servo valve rotating direction and speed of the HSS motor
13. Engine controller according to the tilting direction and angle of
the PCCS lever.
Input and output signals The HSS motor acts on the planetary gear
A. Forward and reverse signals mechanism of the bevel gear shaft making a
B. Steering signal difference in speed between right and left
C. Engine control information sprockets to turn the machine.
D. Work equipment oil pressure signal q Transmission and steering controller detects
E. CAN communication network the engine speed and the oil pressure of each
portion, and controls the HSS pump and the
control valve to drive the HSS pump so that the
engine will not stall.
q The engine control information including engine
rotation signal etc. is exchanged via the CAN
communication network connecting engine con-
troller and transmission and steering controller.
D85EX, PX-15E0 5
General view of power train unit 1
6 D85EX, PX-15E0
1. Transmission Outline
2. Torque converter and PTO q The power train unit broadly consists of torque
3. HSS pump converter and PTO (2), transmission (1), and
4. Power train pump HSS unit (9). Therefore, after the power train
5. Lubrication pump unit is removed, it can be divided into torque
6. Fan pump converter and PTO (2), transmission (1), and
7. HSS motor HSS unit (9).
8. Brake valve q HSS unit consists of the bevel pinion unit,
9. HSS unit bevel gear shaft, HSS motor, planetary gear
10. Main relief valve mechanism and brake.
11. Scavenging pump
12. Power train oil strainer
D85EX, PX-15E0 7
Power train hydraulic piping drawing 1
A: Brake oil pressure detection port 1. HSS pump

B: Transmission 3rd clutch oil pressure detection 2. Lubrication pump
port (3RD) 3. Power train pump
C: Transmission 2nd clutch oil pressure detection 4. Brake control valve
port (2ND) 5. HSS motor
D: Transmission 1st clutch oil detection port (1ST) 6. Main relief valve
E: Transmission R clutch oil pressure detection 7. Centralized pressure pick-up port
port (R) 8. Scavenging pump
F: Transmission F clutch oil pressure detection 9. Power train oil filter
port (FWD) 10. Power train oil cooler
G: Torque converter inlet pressure detection port 11. Transmission clutch ECMV
(IN)
H: Transmission main relief pressure detection
port (TM)
J: Torque converter outlet pressure detection port
(OUT)
8 D85EX, PX-15E0
Transmission control 1
a For the operation of PCCS lever relating to the operation of the steering, see “Steering and brake control”.
a PCCS: Abbreviation for Palm Command Control System
1. Brake pedal Lever positions

2. Parking brake lever A: Neutral
3. Steering/directional/gear shift lever (PCCS lever) B: Forward
3A. Up switch C: Reverse
(Gear is shifted up each time this switch is D: OFF
pressed.) E: Shift up
3B. Down switch F: Shift down
(Gear is shifted down each time this G: Free
switch is pressed.) H: Lock
4. Transmission neutral safety switch
5. Cable Outline
6. Transmission clutch ECMV q The transmission is controlled with PCCS lever
(3).
PCCS lever is used to select the forward-reverse
direction, shift the gear and steering.
q If parking brake lever (2) is not set in the “lock”
position, transmission neutral safety switch
does not work, thus the engine does not start.
D85EX, PX-15E0 9
Steering and brake control 1

a For the operation of PCCS lever relating to the operation of the transmission, see “Transmission control”.
a PCCS: Abbreviation for Palm Command Control System
10 D85EX, PX-15E0
Positions of lever and pedal Outline

A: Neutral q PCCS lever (4) sends electric signals to trans-
B: Forward straight mission and steering controller (6). Upon
C: Reverse straight receiving these electric signals, the transmis-
D: Left turn sion and steering controller (6) sends signals
E: Right turn to the EPC valve of the control valve to change
F: Brake “released” the discharge of the pump and operate the
G: Brake “operated” steering motor.
H: Free q Brake pedal (1) operates brake valve (3)
J: Lock through rod (8) to control the brake.
q Parking brake lever (2) is connected to brake
1. Brake pedal valve (3) and is also used as the parking
2. Parking brake lever brake.
3. Brake valve
4. Steering/directional/gear shift lever
(PCCS lever)
5. Limit switch
6. Transmission and steering controller
7. Cable
8. Rod (from brake pedal)
9. Potentiometer
D85EX, PX-15E0 11
Damper and universal joint 1
12 D85EX, PX-15E0
1. Breather
2. Oil level gauge
3. Drain plug
4. Output shaft
5. Flywheel
6. Outer body
7. Coupling
8. Universal joint
9. Cover
10. Rubber coupling
11. Inner body
Unit: mm
Clearance between flywheel size Shaft Hole clearance limit
12
housing and cover –0.022 +0.070 0.022 –
511.18 0.2
–0.092 +0.070 0.162
Clearance between flywheel –0.020 +0.063 0.020 – Replace
13 466.72 0.2
and damper –0.083 +0.063 0.146
Standard size Tolerance Repair limit
Outer diameter of oil seal
14 –0.087
contact surface of coupling 90 89.8
–0.087
Outline
q The damper dampens the torsional vibration
caused by the change in engine torque and the
impact torque generated when accelerating
suddenly or carrying out heavy-duty operation
mode. In this way it acts to protect the torque
converter, transmission, and other parts of the
power train.
q The damper has few component parts: it uses
a rubber coupling, so the vibration is absorbed
by the damping effect of the rubber material.
Operation
q The power from the engine transmitted through
flywheel (5) to outer body (6). The torsional
vibration of the engine is absorbed by rubber
coupling (10), and the power is transmitted to
inner body (11). It passes through universal
joint (8), and is then transmitted to the torque
converter and transmission.
D85EX, PX-15E0 13
Torque converter and PTO 1

a PTO: Abbreviation for Power Take Off
14 D85EX, PX-15E0
D85EX, PX-15E0 15
A: Torque converter oil inlet port Outline

B: To oil cooler q The torque converter is a 3-element, 1-stage,
C: From transmission case and 1-phase type, which is integral with the
(to scavenging pump) transmission.
D: From transmission case q Pump (14) is integrated with input coupling (7),
(to power train and lubrication pump) PTO drive gear (8) and drive case (12), and
E: To transmission case (passage) rotates by the power from the engine.
q Turbine (13) is integrated with transmission
1. HSS and work equipment pump mounting port input shaft (17), and rotates by the oil from
2. Scavenging pump mounting port pump (14) as medium.
3. Power train and lubrication pump mounting port q Stator (15) is integrated with stator shaft (16),
4. Power train oil strainer and fixed to PTO case (11).
5. PTO lubrication tube q Each pump installed to PTO case is driven with
6. Cooling fan pump mounting port the power transmitted through PTO drive gear
7. Input coupling (8) to PTO idler gear (10), and pump drive
8. PTO idler gear (number of teeth: 55) gears (18), (19) and (20).
9. PTO idler gear shaft
10. PTO idler gear (number of teeth: 74)
11. PTO case
12. Drive case
13. Turbine
14. Pump
15. Stator
16. Stator shaft
17. Transmission input shaft
18. Power train and lubrication pump drive gear
(number of teeth: 47)
19. HSS, work equipment pump and fan pump drive
gear (number of teeth: 49)
20. Scavenging pump drive gear
(number of teeth: 48)
21. Scavenging pump strainer
22. Sleeve
16 D85EX, PX-15E0
D85EX, PX-15E0 17
18 D85EX, PX-15E0
Unit: mm
Outer diameter of oil seal con-
1 –0.054 Repair by hard
tact surface of input coupling 100 99.8
–0.054 chrome plating
Inner diameter of seal ring +0.040 or replace
2 120 120.3
contact surface of retainer +0.040
–0.1
Wear of stator shaft Width 3.95
–0.1
3.5
3
seal ring
Thickness 4.6 ±0.1 4.1
Backlash between PTO drive
4 0.192 – 0.485
gear and PTO idler gear
Backlash between PTO idler
5 gear and power train and lubri- 0.192 – 0.485 Replace
cation pump drive gear
Backlash between PTO idler
6 gear and HSS pump and fan 0.192 – 0.485
pump drive gear
Backlash between PTO drive
7 gear and scavenging pump 0.192 – 0.485
drive gear
D85EX, PX-15E0 19
Transmission 1
20 D85EX, PX-15E0
A: To forward clutch L: To steering valve

B: To reverse clutch M: From steering case
C: To 3rd clutch N: Transmission lubrication oil inlet port
D: To 2nd clutch P: Transmission 1st clutch oil pressure pick-up
E: To 1st clutch port
F: To torque converter case Q: Transmission 3rd clutch oil pressure pick-up
(to power train and lubrication pump) port
G: From torque converter case R: Transmission R clutch oil pressure pick-up port
H: To scavenging pump S: Transmission 2nd clutch oil pressure pick-up
J: To torque converter case port
K: From power train and lubrication pump T: Transmission F clutch oil pressure pick-up port
D85EX, PX-15E0 21
22 D85EX, PX-15E0
1. Main relief valve Outline

2. Transmission case q The transmission adopted is a “forward 3-gear
3. Transmission control valve and valve cover speed and reverse 3-gear speed” transmission
4. Lubrication relief valve which consists of the planetary gear mecha-
5. Input shaft nisms and the disc clutches.
6. Reverse sun gear (number of teeth: 30) q Among the 5 sets of planetary gear system
7. Pinion shaft and disc clutches of the transmission, 2
8. Reverse ring gear (number of teeth: 70) clutches are fixed hydraulically with the control
9. Reverse planetary pinion (number of teeth: 20) valve to select 1 rotating direction and rotating
10. Disc speed.
11. Plate q Clutches No.1, No.2, No.3, No.4, and No.5 are
12. Piston fixed respectively when the reverse, forward,
13. Forward planetary pinion (number of teeth: 20) 3rd, 2nd, and 1st gears are selected.
14. 3rd planetary pinion (number of teeth: 30)
15. 3rd ring gear (number of internal teeth: 76,
number of external teeth: 90) Number of plates and discs used
16. 2nd sun gear (number of teeth: 35)
17. 1st planetary pinion (number of teeth: 18) Clutch No. Number of plates Number of discs
18. 1st sun gear (number of teeth: 39) No.1 clutch 5 5
19. Output shaft (number of 3rd sun gear teeth: 17) No.2 clutch 5 6
20. 1st ring gear (number of internal teeth: 75,
No.3 clutch 4 3
number of external teeth: 90)
21. 1st carrier (number of teeth: 76) No.4 clutch 4 3
22. 1st clutch housing No.5 clutch 4 3
23. 2nd clutch housing
24. 2nd planetary pinion (number of teeth: 21)
25. 2nd ring gear (number of internal teeth: 76, Gear speeds and operated clutches
number of external teeth: 90)
26. 3rd clutch housing Gear speed Operated clutches
27. 2nd, 3rd carrier Forward 1st No.2 × No.5
28. Forward 3rd clutch housing Forward 2nd No.2 × No.4
29. Forward sun gear (number of teeth: 35)
Forward 3rd No.2 × No.3
30. Forward ring gear (number of internal teeth:
75, number of external teeth: 90) Neutral *1
31. Forward carrier (number of teeth: 70) Reverse 1st No.1 × No.5
32. Reverse and forward clutch housing Reverse 2nd No.1 × No.4
33. Return spring
Reverse 3rd No.1 × No.3
34. Reverse ring gear (hub)
(number of internal teeth: 75, *1: Speed clutch No. 5, No. 4, or No. 3 is simply
number of external teeth: 90) filled with low-pressure oil.
35. Pin
36. Reverse carrier (number of teeth: 75)
D85EX, PX-15E0 23
24 D85EX, PX-15E0
Unit: mm
Installation Installation Installation
Free length Free length
1 No.1 clutch spring (10 pcs.) length load load
120.6 N 114.5 N
77 60 74.7
{12.3 kg} {11.6 kg}
99.5 N 94.5 N
2 No.2 clutch spring (10 pcs.) 77 63 74.7
{10.2 kg} {9.6 kg}
206.8 N 196.4 N
3 No.3 clutch spring (10 pcs.) 55.7 37.5 57.2
{21.1 kg} {20.0 kg}
206.8 N 196.4 N
4 No.4 clutch spring (10 pcs.) 55.7 37.5 57.2
{21.1 kg} {20.0 kg}
137.3 N 130.4 N
5 No.5 clutch spring (10 pcs.) 59 45 57.2
{14.0 kg} {13.3 kg}
Thickness of clutch disc Standard size Tolerance Repair limit
6
(No.1, 2 clutches) 5.0 ±0.1 4.4
Thickness of clutch disc
7 5.0 ±0.1 4.3
(No.3, 4, 5 clutches)
Thickness of clutch plate
8 3.2 ±0.1 2.9
(No.1, 2, 3, 4, 5 clutches)
Total thickness of No.1 clutch assem-
9 41.0 ±0.3 38.9
bly consisting of 5 discs and 5 plates
10 46.0 ±0.4 43.7
Replace
11 29.6 ±0.3 20.2
12 29.6 ±0.3 20.2
13 29.6 ±0.3 20.2
Backlash between each sun gear and
14 planetary pinion (forward, reverse, 0.13 – 0.32
2nd and 3rd)
Backlash between reverse planetary
15 0.13 – 0.37
pinion and internal teeth of ring gear
Backlash between each planetary
16 pinion and internal teeth of ring gear 0.14 – 0.37
(forward, 1st and 3rd)
Backlash between reverse carrier
17 0.17 – 0.47
and internal teeth of ring gear
Backlash between forward carrier
18 0.17 – 0.53
and internal teeth of ring gear
Backlash between 1st carrier and
19 0.30 – 0.64
internal teeth of ring gear
Backlash between1st sun gear and
20 0.14 – 0.35
planetary pinion
Backlash between 2nd planetary pin-
21 0.14 – 0.43
ion and internal teeth of ring gear
D85EX, PX-15E0 25
Operation
Operation of disc clutch Clutch “disengaged” (released)

q The disc clutch consists of piston (12), plate q When the supply of pressure oil from the con-
(11), disc (10), pin (35), return spring (33), etc. trol valve is shut off, piston (12) is returned to
to secure ring gear (hub) (34). the right direction by the force of piston return
q The internal teeth of discs (10) are meshed spring (33). This releases the frictional force
with the external teeth of ring gear (hub) (34). between plates (11) and discs (10), making the
q The teeth on the outer diameter of plate (11) ring gear (hub) (34) release.
engage with pin (35) fixed to clutch housing
(32).
Clutch “engaged” (fixed)

q Oil from the control valve flows under pressure
through the port in housing (32) to the back of
piston (12) and the piston moves to the left.
q Piston compresses plates (11) and discs (10)
and the resulting frictional force stops the rota-
tion of discs so ring gear (hub) (34) meshing
with the internal teeth of the disc is locked.
26 D85EX, PX-15E0
Oil passage in speed clutch

The 1st, 2nd, or 3rd gear speed is set, even if the
steering/directional/gear shift lever is in the neutral
position. The oil circuit is so controlled electroni-
cally that the piston chamber of the speed clutch
corresponding to the set gear speed will be kept
filled with the oil.
Accordingly, when the steering/directional/gear shift

lever is shifted from the “neutral” position to the “for-
ward” or “reverse” position, the pump is required to
supply oil of only quantity to fill the piston chamber
of the forward or reverse clutch.
When the gear speed is changed from the “F1” to

“F2”, the pump is required to supply oil of only
quantity to fill the 2nd clutch since the forward
clutch has been filled with the oil.
The time lag in the gear shifting operation is

reduced by using the oil as explained above.
D85EX, PX-15E0 27
Power transmitting route

Forward 1st speed
q When the transmission is set to forward 1st, q Carrier (31) and carrier (27) are joined by a
the No. 2 clutch and No. 5 clutch are engaged. spline, and rotate as one unit, so the rotation of
The motive force from the torque converter carrier (31) passes through planetary pinion
transmitted to input shaft (5) is then transmit- (24) and is transmitted to ring gear (25).
ted to output shaft (19). q Carrier (21) is meshed with ring gear (25), and
q No. 2 clutch is actuated by the hydraulic pres- rotates as one unit, so the rotation is transmit-
sure applied to the clutch piston, and holds ring ted to planetary pinion (17).
gear (30) in position. No. 5 clutch is actuated q Ring gear (20) is being held in position by No.
by the hydraulic pressure applied to the clutch 5 clutch, so the rotation of planetary pinion (17)
piston, and holds ring gear (20) in position. rotates sun gear (18), and this rotates output
q The motive force from the torque converter is shaft (19).
transmitted to input shaft (5), and the rotation
of the input shaft passes through sun gear (29)
and is transmitted to planetary pinion (13).
q Ring gear (30) is held in position by No. 2
clutch, so the rotation of planetary pinion (13)
rotates carrier (31), which is on the inside of
ring gear (30).
28 D85EX, PX-15E0
Forward 2nd speed
q When the transmission is set to forward 2nd, q Ring gear (25) is being held in position by No.
the No. 2 clutch and No. 4 clutch are engaged. 4 clutch, so the rotation of planetary pinion (24)
The motive force from the torque converter rotates sun gear (16), and this rotates output
transmitted to input shaft (5) is then transmit- shaft (19).
ted to output shaft (19).
q No. 2 clutch is actuated by the hydraulic pres-
sure applied to the clutch piston, and holds ring
gear (30) in position. No. 4 clutch is actuated
by the hydraulic pressure applied to the clutch
piston, and holds ring gear (25) in position.
q The motive force from the torque converter is
ring gear (30).
q Carrier (31) is meshed with ring gear (27), and
rotates as one unit, so the rotation is transmit-
ted to planetary pinion (24).
D85EX, PX-15E0 29
Forward 3rd speed
q When the transmission is set to forward 3rd, q Ring gear (15) is being held in position by No.
the No. 2 clutch and No. 3 clutch are engaged. 3 clutch, so the rotation of planetary pinion (14)
The motive force from the torque converter rotates output shaft (19).
transmitted to input shaft (5) is then transmit-
ted to output shaft (19).
q No. 2 clutch is actuated by the hydraulic pres-
sure applied to the clutch piston, and holds ring
gear (30) in position. No. 3 clutch is actuated
by the hydraulic pressure applied to the clutch
piston, and holds ring gear (15) in position.
q The motive force from the torque converter is
ring gear (30).
q Carrier (31) is meshed with ring gear (27), and
rotates as one unit, so the rotation is transmit-
ted to planetary pinion (14).
30 D85EX, PX-15E0
Reverse 1st speed
q When the transmission is set to reverse 1st, q Carrier (31) and carrier (27) are joined by a
the No. 1 clutch and No. 5 clutch are engaged. spline, and rotate as one unit, so the rotation of
The motive force from the torque converter carrier (31) passes through planetary pinion
transmitted to input shaft (5) is then transmit- (24) and is transmitted to ring gear (25).
ted to output shaft (19). q Carrier (21) is meshed with ring gear (25), and
q No. 1 clutch is actuated by the hydraulic pres- rotates as one unit, so the rotation is transmit-
sure applied to the clutch piston, and holds ted to planetary pinion (17).
carrier (36) in position. No. 5 clutch is actuated q Ring gear (20) is being held in position by No.
by the hydraulic pressure applied to the clutch 5 clutch, so the rotation of planetary pinion (17)
piston, and holds ring gear (20) in position. rotates sun gear (18), and this rotates output
q The motive force from the torque converter is shaft (19).
q Carrier (36) is being held in position by No. 1
rotates ring gear (8). Ring gear (8) rotates in
the opposite direction from the input shaft, and
rotates carrier (31).
D85EX, PX-15E0 31
Transmission clutch ECMV 1

a ECMV: Abbreviation for Electronic Control Modulation Valve
32 D85EX, PX-15E0
A: 1st clutch oil pressure pick-up port

B: 3rd clutch oil pressure pick-up port
C: R clutch oil pressure pick-up port
D: 2nd clutch oil pressure pick-up port
E: F clutch oil pressure pick-up port
F: To clutch
P: From pump
T: Drain
1. Proportional solenoid valve (for 3rd clutch)

2. Proportional solenoid valve (for 1st clutch)
3. Proportional solenoid valve (for R clutch)
4. Proportional solenoid valve (for 2nd clutch)
5. Proportional solenoid valve (for F clutch)
6. Fill switch (for 3rd clutch)
7. Fill switch (for 2nd clutch)
8. Fill switch (for 1st clutch)
9. Fill switch (for R clutch)
10. Fill switch (for F clutch)
11. Connector for proportional solenoid valve (for 1st clutch)
12. Connector for proportional solenoid valve (for 3rd clutch)
13. Connector for proportional solenoid valve (for R clutch)
14. Connector for proportional solenoid valve (for 2nd clutch)
15. Connector for proportional solenoid valve (for F clutch)
16. Connector for fill switch (for 3rd clutch)
17. Connector for fill switch (for 2nd clutch)
18. Connector for fill switch (for 1st clutch)
19. Connector for fill switch (for R clutch)
20. Connector for fill switch (for F clutch)
21. Filter
22. Pressure control valve
23. Pressure detection valve
24. Pressure control valve spring
D85EX, PX-15E0 33
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
This valve receives the current from the trans- shown below according to the command cur-
mission controller with the proportional sole- rent from the controller.
noid, and then converts it into oil pressure. The thrust generated by the proportional sole-
q Fill switch noid is applied to the pressure control valve
This switch detects that the clutch is filled with spool to generate oil pressure as shown in the
oil and has the following functions. figure below. Accordingly, the thrust is changed
1. Outputs a signal (a fill signal) to the controller by controlling the command current to operate
to notify that filling is completed when the the pressure control valve to control the flow
clutch is filled with oil. and pressure of the oil.
2. Keeps outputting signals (fill signals) to the
controller to notify presence or absence of oil Current of propulsion solenoid – thrust charac-
pressure while oil pressure is applied to the teristics
clutch.
Thrust of proportional solenoid – oil pressure

characteristics
Region A: Before shifting gear (when draining)

Area B: During filling ECMV and fill switch
Range C: Pressure regulation q For each ECMV, 1 fill switch is installed.
Range D: During filling (During triggering) As the clutch complete filling, the fill switch is
Point E: Start of filling turned “ON” by the pressure of the clutch. This
Point F: End of filling signal starts increasing the oil pressure.
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
34 D85EX, PX-15E0
Operation of ECMV Before shifting gear (when draining) (Range A

q ECMV is controlled with the command current in chart)
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current of ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q Under the condition where any current is not

sent to proportional solenoid (1), pressure con-
trol valve (2) drains the oil from clutch port (A)
through drain port (dr).
Since oil pressure is not applied to pressure
detection valve (3) at this time, fill switch (4) is
Region A: Before shifting gear (when draining) turned“off”.
Area B: During filling
Range C: Pressure regulation
Range D: During filling (During triggering)
Point E: Start of filling
Point F: End of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned “ON” during triggering (Range
D).
D85EX, PX-15E0 35
During filling (Range B in chart) Pressure regulation (Range C in chart)
q If current is supplied to proportional solenoid q If current is applied to proportional solenoid

(1) with no oil in the clutch, the oil pressure (1), the solenoid generates propulsion force
force balanced with the solenoid force is that is proportionate to the current. The pres-
applied to chamber (B) and pushes pressure sure is adjusted by balancing the propulsion
control valve (2) to the right. As a result, pump force of the solenoid, the propulsion force of
port (P) and clutch port (A) open and oil starts clutch port (A), and reaction force of pressure
filling the clutch. If the clutch is filled with oil, control spring (5).
pressure detection valve (3) is actuated and fill
switch (4) is turned“on”.
36 D85EX, PX-15E0
Main relief valve and torque converter relief valve 1
A: Drain (Torque converter relief) 1. Body

B: Drain 2. Piston
C: From pump 3. Torque converter relief valve
D: Drain 4. Piston
E: To torque converter 5. Main relief valve
P1: Main relief oil pressure pick-up port
P2: Torque converter relief oil pressure pick-up port
Unit: mm
Clearance between main relief size Shaft Hole clearance limit
6
valve and valve body –0.035 +0.013 0.035 –
28 0.078
–0.045 +0.013 0.058
Clearance between torque con-
–0.035 +0.013 0.035 –
7 verter relief valve and valve 22 0.078
–0.045 +0.013 0.058
body
Replace
Main relief valve spring Free length Free length
8 length load load
(outside)
508.6 N 483.2 N
128 75.3 124.2
{51.9 kg} {49.3 kg}
Main relief valve spring 401.8 N 381.7 N
9 108 75.3 104.8
(inside) {41.0 kg} {39.0 kg}
Torque converter relief valve 182.1 N 173 N
10 50 40.5 48.5
spring {18.6 kg} {17.7 kg}
D85EX, PX-15E0 37
Outline
Main relief valve

q The main relief valve is keeping each oil pres-
sure circuit of the transmission and the brake
below the set pressure.
Set pressure: 3.40 MPa {34.7 kg/cm2}
(Engine at rated speed)
Torque converter relief valve

q The torque converter relief valve is keeping the
oil pressure of the torque converter inlet circuit
below the set pressure to protect the torque
converter from the abnormal high pressure.
Set pressure: 1.00 MPa {10.2 kg/cm2} Operation of torque converter relief valve
(Cracking pressure) q The oil relieved by the main relief valve flows
from port (C) into the torque converter and the
same time, passes through orifice (b) of spool
Operation (2) and enters chamber (D).
When the circuit leading to the torque con-
Operation of main relief valve verter becomes filled with oil, the oil pressure
q The oil from the hydraulic pump passes starts to rise.
through the filter and enters port (A) of the q As the oil pressure going to the torque con-
relief valve. It then passes through orifice (a) of verter rises, the oil entering chamber (D)
spool (6) and enters chamber (B). pushes piston (9). The reaction force moves
When the oil from the pump fills the circuit, the spool (2) to the right to open the circuit
oil pressure starts to rise. between port (C) and port (E).
When this happens, the oil at port (C) is
relieved to port (E) and drains to the oil tank.
The oil pressure at port (C) at this point is 1.00
MPa {10.2 kg/cm2} (cracking pressure).
q As the oil pressure in the circuit rises, the oil

entering chamber (B) pushes piston (4). The
reaction force compresses valve spring (7) and
moves spool (6) to the left to open the circuit
between port (A) and port (C).
When this happens, the oil at port (A) is
relieved to port (C) and flows from port (C) to
the torque converter.
The oil pressure at port (A) at this point is 3.40
MPa {34.7 kg/cm2} (engine at rated speed).
38 D85EX, PX-15E0
Lubrication relief valve 1
Unit: mm
1 Lubrication relief valve spring length load load Replace
12.0 N 11.4 N
26 23.7 25.2
{1.22 kg} {1.16 kg}
2. Piston Outline
3. Spring q The oil leaving the torque converter passes
4. Forward clutch housing through the oil cooler built in the radiator lower
tank. It then goes through the lubrication relief
A: From oil cooler valve and lubricates the transmission and
B: Drain PTO.
C: Drain q The lubrication relief valve is installed to the
left side face of the forward clutch housing.
And prevents any abnormal pressure in the
lubrication oil.
At this time, the oil pressure (cracking pres-
sure) is 0.34 MPa {3.5 kg/cm2}.
The normal oil pressure is 0.08 – 0.20 MPa
{0.8 – 2.0 kg/cm2}.
D85EX, PX-15E0 39
SEN00295-00

© 2005 KOMATSU
All Rights Reserved
40
SEN00297-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Power train, Part 2
Power train, Part 2 .......................................................................................................................................... 2
Bevel gear shaft, HSS and brake......................................................................................................... 2
Brake valve ........................................................................................................................................ 16
Final drive........................................................................................................................................... 22
D85EX, PX-15E0 1

Bevel gear shaft, HSS and brake 1
2 D85EX, PX-15E0
D85EX, PX-15E0 3
4 D85EX, PX-15E0
1. Output shaft
2. Brake spring (large)
3. Brake spring (small)
4. Stopper
5. Hub
6. Cage
7. Piston (number of teeth: 109)
8. Cover
9. Plate (one side: 5 pcs.)
10. Disc (one side: 6 pcs.)
11. Brake drum (number of teeth: 109)
12. Brake hub (number of teeth: 72)
13. Gear A (number of teeth: 55)
14. Cage
15. Gear B (number of teeth: 32)
16. Bevel gear shaft
17. Bevel gear (number of teeth: 35)
18. Bearing
19. Shaft
20. Gear C (number of teeth: 32)
21. Planetary pinion (number of teeth: 26)
22. Ring gear (number of teeth: 91)
23. Planetary shaft
24. Hub (number of teeth: 91)
25. Carrier
26. Gear D (number of teeth: 48)
27. HSS motor drive gear (number of teeth: 25)
28. HSS motor
D85EX, PX-15E0 5
6 D85EX, PX-15E0
Unit: mm
Thickness of bake plate Replace
3.0 2.7
1
Tolerance Repair limit
Brake plate distortion Repair or replace
Max 0.15 0.3
Thickness of bake disc Replace
5.2 4.9
2
Tolerance Repair limit
Brake disc distortion Repair or replace
Max 0.25 0.4
Total assembled thickness of brake Standard size Repair limit

3
plates and discs 46.2 43.3
Backlash between gear A and Standard clearance Clearance limit

4
gear B 0.06 – 0.65 — Replace
Backlash between sun gear and
5 0.14 – 0.35 —
planetary pinion
Backlash between planetary pinion
6 0.15 – 0.38 —
and ring gear
Backlash between bevel gear and
7 0.20 – 0.28 0.45
pinion
Adjust
Preload of taper roller bearing for
8 Starting torque 10.3 – 14.7 Nm {1.05 – 1.50 kgm}
bevel gear shaft
D85EX, PX-15E0 7
Unit: mm
Backlash between gear A and Standard clearance Clearance limit
1
gear D 0.09 – 0.64 —
Backlash between gear C and Replace
2 0.15 – 0.49 —
gear D
Backlash between gear D and
3 0.10 – 0.40 —
HSS motor drive gear
8 D85EX, PX-15E0
Outline
Bevel gear shaft Brake

q The engine power is transmitted through the q The brake is established only to control the
torque converter to the transmission. Then, movement of the machine, and is attached to
the bevel gear shaft system engages the bevel brake inner drum (12).
pinion with bevel gear (17) to turn the engine q The brake adopts the wet multiple disc clutch
power at a right angles into the lateral direction type and the spring-boosted type, and it is the
and reduce the rotation speed. hydraulic actuated type by the brake valve
q The bevel gear shaft system adopts the spiral which is activated with the operation of the
bevel gear at the bevel pinion and bevel gear brake pedal.
(17), and it adopts the splash lubrication with In addition, lubrication adopts the forced lubri-
the oil from the lubrication pump and the scav- cation type which sends the oil from the power
enging pump for lubrication. train lubrication pump and the scavenging
q The bevel gear shaft system consists of bevel pump to the housing and the cage through the
gear (17) which meshes with the bevel pinion, passage inside the steering case, and eventu-
bevel gear shaft (16), bevel gear shaft bearing ally to the disc plate.
(18) which supports the bevel gear shaft and When the engine is stopped, the back pres-
cage (14). sure of the brake piston descends even if the
brake pedal is not depressed, which initiates
HSS the brake to “operate”. However, the parking
q The HSS (Hydrostatic Steering System) is con- brake must be in the “lock” position, because
structed from the transfer area which transmits the brake is “released” as the oil pressure
the rotation of HSS motor (28) by turning it in within the circuit rises when the engine is
the reverse direction, and the planetary area restarted.
which adjusts the inputs to ring gear (22) and The brake is constructed from; carrier (25),
gear A (13) and then outputs to carrier (25). inner drum (12) attached to brake hub (5), disc
The tur nin g dir ec tion o f the m achi ne is (10) meshed with the inner drum, plate (9)
changed by stopping or reversing the revolu- whose outside perimeter is connected to brake
tion of the HSS motor (28). drum (11) by the gear, brake drum (11), piston
q The transfer unit employs a spur gear speed (7) and springs (2) and (3) which compress the
reduction mechanism and is lubricated with oil disc and the plate, and cage (6), brake cover
splashed by the scavenging pump and lubrica- (8) and output shaft (1) which support all of
tion pump. them.
q Planetary area adopts forced lubrication with Brake drum (11) and brake cover (8) are fixed
oil from scavenging pump and lubrication to the steering case.
pump for lubrication. Output shaft (1) is connected to brake hub (5)
q The transfer unit consists of HSS motor drive by the spline and fixed in the axial direction
gear (27) connected to HSS motor (28) by the with stopper (4).
spline, gear D (26) meshed with the HSS
motor drive gear, gear C (20) meshed with
gear D, gear B (15) connected to shaft (19),
gear A (13) supported by the bearing on the
bevel gear shaft and meshed with gear D (26),
and case to support these parts.
q The planetary gear unit consists of gear A (13),
planetary pinion (21), planetary shaft (23), hub
(24) connected to bevel gear shaft (16) and
ring gear (22) by the gear, and carrier (25) con-
nected to brake inner drum (12).
D85EX, PX-15E0 9
HSS operation
When steering operation is at “neutral” (straight travel)
When the steering lever is at the “neutral” position,

Rotation direction of HSS motor
the rotation of the gear in the transfer section and
PCCS lever Neu-
the left and right gears A (13) in the planet section steering operation tral
Right turn Left turn
is also stopped.
Free,
Under this condition, the power from bevel gear PCCS lever * *
not For- Reve For- Reve
forward/reverse Neu- Neu-
shaft (16) is input to ring gear (22), is transmitted to spec- ward rse ward rse
switching operation tral tral
ified
carrier (25) through planetary pinion (21) and plan-
Rotation direction
etary pinion shaft (23), and then to output shaft (1) of HSS motor
Does
not Left Left Right Right Right Left
through brake inner drum (12) and brake hub (5). viewed from left side
rotate
of machine
Therefore, the number of the output rotation of left
*: Counter-rotation
and right is the same and the machine travels
straight.
10 D85EX, PX-15E0
When steering operation is at “right turn” (forward travel)
*A: Transmission power If the steering lever is operated to the“right” when

*B: HSS motor power traveling forward; HSS motor (28) rotates counter-
*C: Combined power clockwise, gear A (13) on the left side of the
machine rotates clockwise, and gear A (13) on the
*1. Transmission output speed right side of the machine rotates counterclockwise,
*2. Increase in speed from HSS motor viewing from the left side of the machine.
*3. Left bevel gear shaft output speed (*1. + *2.) When traveling forward, bevel gear shaft (16) and
*4. Transmission output speed ring gear (22) linked to the shaft, rotate clockwise,
*5. Decrease in speed from HSS motor viewing from the left side of the machine.
*6. Right bevel gear shaft output speed (*4. – *5.) Accordingly, considering the rotation speed at each
element in pair of planetary gears, that of left side
carrier (25) increases its speed with the power of
HSS motor, and that of right side carrier (25) slows
down, compared to that of straight travel. There-
fore, the machine travels forward turning to the right
whose output rotation speed is lower.
D85EX, PX-15E0 11
When steering operation is at “right turn” (reverse travel)
*A: Transmission power machine rotates clockwise viewing from the left
*B: HSS motor power side of the machine.
*C: Combined power When the machine is traveling in reverse, bevel
gear shaft (16) and ring gear (22) which are inter-
*1. Transmission output speed connected, rotate counterclockwise viewing from
*2. Increase in speed from HSS motor the left side of the machine.
*3. Left bevel gear shaft output speed (*1. + *2.) Accordingly, considering the rotation speed at each
*4. Transmission output speed element in pair of planetary gears, that of left side car-
*5. Decrease in speed from HSS motor rier (25) increases its speed (in the reverse direction)
*6. Right bevel gear shaft output speed (*4. – *5.) with the power of HSS motor, and that of right side
carrier (25) slows down, compared to that of straight
If the steering lever is operated to the “right” when forward. Therefore, the machine travels backward
the machine is traveling in reverse, the action of the turning to the right side whose output rotation speed is
selector valve makes HSS motor (28) rotate in the lower.
opposite direction when traveling forward. That is,
the HSS motor rotates clockwise and gear A (13)
on the left side of the machine rotates counterclock-
wise while gear A (13) on the right side of the
12 D85EX, PX-15E0
When steering operation is at “left turn” (forward travel)
*A: Transmission power If the steering lever is operated to the “left”, when
*B: HSS motor power traveling forward; HSS motor (28) rotates clock-
*C: Combined power wise, gear A (13) on the left side of the machine
rotates counterclockwise, and gear A (13) on the
*1. Transmission output speed right side of the machine rotates clockwise, viewing
*2. Decrease in speed from HSS motor from the left side of the machine.
*3. Left bevel gear shaft output speed (*1 – *2)
On the other hand, when traveling forward, bevel
*4. Transmission output speed
gear shaft (16) and ring gear (22) linked to the
*5. Increase in speed from HSS motor
shaft, rotate clockwise, viewing from the left side of
*6. Right bevel gear shaft output speed (*4. + *5.)
the machine.
Accordingly, considering the rotation speed at each
element in pair of planetary gears, that of right side
carrier (25) increases its speed with the power of
HSS motor, and that of left side carrier (25) slows
down, compared to that of straight forward. There-
fore, the machine travels forward turning to the left
whose output rotation speed is lower.
D85EX, PX-15E0 13
When steering operation is at “left turn” (reverse travel)
*A: Transmission power machine rotates counterclockwise viewing from the

*B: HSS motor power left side of the machine.
*C: Combined power When the machine is traveling in reverse, bevel
gear shaft (16) and ring gear (22) which is intercon-
*1. Transmission output speed nected, rotate counterclockwise viewing from the
*2. Decrease in speed from HSS motor left side of the machine.
*3. Left bevel gear shaft output speed (*1 – *2) Accordingly, considering the rotation speed at each
*4. Transmission output speed element in pair of planetary gears, that of right side
*5. Increase in speed from HSS motor carrier (25) increases its speed (in the reverse
*6. Right bevel gear shaft output speed (*4. + *5.) direction) with the power of HSS motor, and that of
left side carrier (25) slows down, compared to that
If the steering lever is operated to the “left” when of straight forward. Therefore, the machine travels
the machine is traveling in reverse, the action of the backward turning to the left side whose output rota-
selector valve makes HSS motor (28) rotate in the tion speed is lower.
opposite direction when traveling forward. That is,
the HSS motor rotates counterclockwise and gear
A (13) on the left side of the machine rotates clock-
wise while gear A (13) on the right side of the
14 D85EX, PX-15E0
Brake operation
When brake is “released” When brake is “operated” (when brake pedal

When the brake pedal is at the “released” position, “depressed”)
the brake valve is at the “neutral” position and the When the brake pedal is depressed, the brake
back pressure port of brake piston (7) is filled with valve is switched and the oil which applies the back
the oil. pressure to piston (7) is connected to the drain cir-
Rising of the oil pressure makes the piston move cuit.
towards the left direction and compress springs (2) In this condition, piston (7) moves to the right direc-
and (3), and release disc (10) and plate (9). Then, tion using tension of springs (2) and (3), and com-
the power transmitted from bevel gear shaft (16) via presses disc (10) and plate (9) against the stopper
HSS steering to brake inner drum (12), is transmit- portion of brake outer drum (11). The brake outer
ted from hub (5) to output shaft (1) and then to the drum is connected and fixed to the steering case.
final drive. Therefore, the rotation of brake inner drum (12),
that is, the rotation of output shaft (1) is controlled
by compressing the disc and the plate.
By adjusting the depression power of the brake
pedal and controlling the oil pressure given to pis-
ton (7), the brake pedal can adjust the braking
power.
D85EX, PX-15E0 15
Brake valve 1
P: From power train pump Outline

T1: To steering case q The brake valve is located in the circuit
T2: To steering case between the power train pump through the
Br (R): To right brake main relief valve and the piston of the brake
Br (L): To left brake inside HSS unit. It consists of the main brake
valve and the parking brake valve.
1. Parking brake valve q When the brake pedal is depressed, the oil
2. Main brake valve flow to the brake piston is interrupted, the
3. Body brake piston compresses the disc and the
4. Return spring plate by the force of the spring and the brake is
5. Plug “operated”.
6. Return spring In case of HSS, since the brake is for braking
7. Brake valve power control [not involved in steering opera-
8. Piston tion], both left and right brake operates concur-
9. Shaft rently.
10. Modulating spring
11. Guide
16 D85EX, PX-15E0
Unit: mm
Clearance between brake valve size Shaft Hole clearance limit
1
and body –0.020 +0.013 0.020 –
19 0.07
–0.030 +0.013 0.043
Clearance between brake valve –0.030 +0.015 0.030 –
2 9 0.08
and piston –0.040 +0.015 0.055
Clearance between parking brake –0.034 +0.013 0.034 –
3 19 0.08
valve and body –0.043 +0.013 0.056
Standard size Repair limit Replace

4 Brake modulating spring length load load
75.3 N 71.6 N
48 36 46.6
{7.68 kg} {7.3 kg}
169 N 162 N
5 Brake valve return spring 52 37 50.4
{17.3 kg} {16.5 kg}
16.7 N 15.7 N
6 Parking brake valve return spring 36.5 28.5 35.4
{1.7 kg} {1.6 kg}
D85EX, PX-15E0 17
Operation
When the brake is “released” (brake pedal “released”, parking brake lever “free”)
q When the brake pedal is “released” [not

depressed], parking brake valve (1) opens port
(A) and chamber (B) by the tension of return
spring (4). Brake valve (7) opens chamber (C)
and port (D) by the tension of return spring (6).
The oil pressure from the power train pump is

regulated at the main relief valve, flows from
port (A) through chamber (B) and (C) to the
brake piston back pressure port through port
(D). It moves the piston to the left direction and
compresses the brake spring to “release” the
brake. At this time, the oil pressure is balanced
at 3.02 MPa {30.8 kg/cm2}, which can be mea-
sured at pressure pick-up port (Q).
18 D85EX, PX-15E0
When the brake is “engaged” (when brake pedal “depressed”, parking brake lever “free”)
q When starting to depress the brake pedal, q As the brake pedal is depressed further, the
guide (11) and shaft (9) are pushed to the right operation as described above is repeated until
direction and compress modulating spring brake valve (7) reaches to the stroke end, at
(10), and its reaction force moves brake valve which the brake is fully “engaged”.
(7) to the right direction. When this happens, q The oil pressure behind port (D) is determined
chamber (C) and port (D) close and port (D) by the tension of return spring (6) of which load
and port (E) open. The oil from the power train varies in accordance with the brake pedal
pump enters chamber (B) through port (A) and travel.
blocked by chamber (C).
When the brake pedal travel is short, the oil
A portion of oil which had flown into the brake pressure behind port (D) is high, meaning that
piston back pressure port is drained from port the brake is “half way engaged”, and when the
(D) to port (E). The other portion of oil flows travel is long, the oil pressure is low, meaning
through port (D) and orifice (a) to chamber (H). that the brake is “engaged”.
The oil behind port (D) is drained to port (E)
and the oil pressure is reduced, it enters port
(H) to push piston (8). Then the force pushing
brake valve (7) to the right is reduced, and
brake valve (7) moves to left by the tension of
return spring (6). This closes ports (D) and (E)
and the oil pressure behind port (D) is main-
tained not to be reduced.
D85EX, PX-15E0 19
When the brake is “parked” (brake pedal “released”, parking brake lever “locked”)
q When the parking brake lever is in the “locked”

position, parking brake valve (1) is pulled to the
left. When this happens, port (A) and port (B)
close and chamber (B) and chamber (G) open.
The oil from the power train pump is blocked
by port (A).
q The oil which had flown into the brake piston
back pressure port flows from port (D) through
chambers (C), (B) and (G) and is drained
through port (F). The oil pressure at the brake
piston back pressure port continues to be
reduced because parking brake valve (1) is
he ld to th e left . Th en the b ra ke i s ful l y
“engaged” and remains in that condition.
This condition is maintained while engine is

restarted.
20 D85EX, PX-15E0
D85EX, PX-15E0 21
Final drive 1
Outline
q The final drive is a single-stage spur gear, sin-
gle-stage planetary gear reduction type. The
lubrication is the splash type utilizing the gear
rotation.
And, the final drive can be removed and
installed as a single unit.
q Floating seal (1) is installed to the rotating and
sliding portion of the sprocket to prevent entry
of dirt or sand from the outside and the lubrica-
tion oil leakage.
22 D85EX, PX-15E0
D85EX-15E0
D85EX, PX-15E0 23
D85PX-15E0
24 D85EX, PX-15E0
1. Floating seal 10. No.1 pinion

2. Sun gear 11. Final drive case
3. Carrier 12. Bearing cage
4. Sprocket boss 13. No.1 gear
5. Sprocket teeth 14. No.1 gear hub
6. Cover 15. Shaft
7. Planetary gear 16. Wear guard
8. Ring gear 17. Pivot shaft
9. Cover
Unit: mm
Backlash between No.1 pinion and Standard clearance Clearance limit
18
No.1 gear 0.23 – 0.79 0.79
Backlash between sun gear and Replace
19 0.20 – 0.74 0.74
planetary gear
Backlash between planetary gear
20 0.24 – 0.83 0.83
and ring gear
Outer diameter of oil seal contact
21 –0.074
surface of No.1 pinion 70 69.9 Replace or
–0.074
repair
Thickness of thrust collar of inner
22 23 22.95
body roller bearing
Standard Tolerance Standard Interference

Interference between outer diame-
ter of planetary gear shaft and inner size Shaft Hole interference limit
23
diameter of carrier hole (small +0.021 –0.03 0.002 –
diameter) 70 0.002
+0.002 –0.03 0.051 Replace
Interference between outer diame-
ter of planetary gear shaft and inner +0.059 +0.035 0.002 –
24 84 0.002
diameter of carrier hole (large +0.037 +0.035 0.059
diameter)
Standard shim thickness for No.1
25 2 Adjust
pinion bearing cage
26 Wear of wear guard Replace or repair
52 21
D85EX, PX-15E0 25
Power transmitting route
26 D85EX, PX-15E0
q The power from the bevel gear and the steer-

ing clutch is transmitted to No.1 pinion (10) and
to No.1 gear (13) which meshes with No.1 pin-
ion (10), then the rotation of No.1 gear (13) is
transmitted to sun gear (2).
The rotation of sun gear (2) is transmitted to
planetary gear (7). Since ring gear (8) which
meshes with planetary gear (7), is fixed to
cover (6), planetary gear (7) rotates along ring
gear (8) and revolves around sun gear (2).
Then, the rotation torque of sun gear (2) forms
the rotation torque of carrier (3) which supports
planetary gear (7), and is transmitted to
sprocket boss (4) via shaft (15).
The rotating direction of carrier (3) is the same
with sun gear (2).
The torque transmitted to sprocket boss (4), is
transmitted to sprocket teeth (5).
D85EX, PX-15E0 27
SEN00297-00

© 2005 KOMATSU
All Rights Reserved
28
SEN00298-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Undercarriage and frame
Undercarriage and frame ................................................................................................................................ 2
Main frame ........................................................................................................................................... 2
Suspension .......................................................................................................................................... 4
Track frame .......................................................................................................................................... 8
Idler cushion....................................................................................................................................... 10
Idler .................................................................................................................................................... 12
Track roller ......................................................................................................................................... 14
Carrier roller ....................................................................................................................................... 16
Sprocket ............................................................................................................................................. 18
Track shoe.......................................................................................................................................... 20
D85EX, PX-15E0 1
Undercarriage and frame 1

Main frame 1
2 D85EX, PX-15E0
1. Main frame
2. Cage
3. Clamp
4. Cover
5. Seal
6. Clamp
7. Cap
8. Plate
Unit: mm
Clearance between equalizer bar size Shaft Hole clearance limit
9 Replace
shaft and bushing –0.030 +0.179 0.130 –
80 1.5
–0.076 +0.100 0.255
Press fit force of equalizer bar shaft
10 21.6 – 71.6 kN {2.2 – 7.3 ton} Adjust
mounting bushing
D85EX, PX-15E0 3
Suspension 1
1. Equalizer bar Outline

2. Pivot shaft assembly q The front of the track frame rocks up and down
3. Cover using rear pivot shaft (6) as a fulcrum. Equal-
4. Thrust plate izer bar (1) is connected to the right and left
5. Thrust plate track frames by side pin (10) and sways using
6. Pivot shaft center pin (11) as a fulcrum.
7. Seal cage
4 D85EX, PX-15E0
8. Seal
9. Bushing
10. Side pin
11. Center pin
12. Bushing
Unit: mm
Press-fitting force of side pin bush-
9 15.7 – 35.3 kN {1.6 – 3.6 ton}
ing
—
Press-fitting force of center pin
12 57.9 – 161.8 kN {5.9 – 16.5 ton}
bushing

Clearance between center pin and size Shaft Hole clearance limit
13
bushing
–0.030 +0.234 0.199 –
80 1.0
–0.076 –0.169 0.310
Clearance between side pin and –0.030 +0.046 0.030 –
14 60 1.0 Replace bushing
bushing –0.060 +0.046 0.106

Interference between side pin boss size Shaft Hole interference limit
15
and bushing +0.035 –0.024 0.041 –
110 —
+0.017 –0.059 0.094
D85EX, PX-15E0 5
Unit: mm
Interference between pivot shaft size Shaft Hole interference limit
16 Replace
and seal stopper ring +0.083 –0.050 0.093 –
157 —
+0.043 –0.090 0.173

Clearance between pivot shaft and size Shaft Hole clearance limit
17
bushing
–0.145 +0.099 0.180 – Replace bushing
148 1.0
–0.208 +0.035 0.307
Clearance between pivot shaft and –0.145 +0.132 0.204 –
18 155 1.0
bushing –0.208 +0.059 0.340
6 D85EX, PX-15E0
Track frame 1
a The figure shows D85EX-15E0.
1. Equalizer bar Track roller

2. Idler Quantity for
3. Carrier roller Flange type and arrangement
one side
4. Track frame D85EX-15E0 7 pieces S, D, S, S, S, D, S
5. Sprocket
S: Single flange
6. Track roller guard D: Double flange
7. Track roller
8. Pivot shaft
Quantity for
Flange type and arrangement
one side
D85PX-15E0 8 pieces S, S, D, S, S, S, D, S
S: Single flange
D: Double flange
8 D85EX, PX-15E0
Unit: mm
Item Repair limit
Bending 7 (for level length of 3,000)
4 Deformation of track frame Repair or replace
Twisting 3 (for level length of 300)
Dent (pipe portion) 12
D85EX, PX-15E0 9
Idler cushion 1
1. Yoke Outline
2. Dust seal q The idler cushion moves rod (3) back and forth
3. Rod by filling or draining grease from lubricator (6)
4. Recoil spring and adjusts the track shoe tension. The idler
5. Wear ring cushion also dampenes any sudden shock to
6. Lubricator the idler.
7. Nut
8. Housing
9. Cylinder
10. Holder
10 D85EX, PX-15E0
Unit: mm
1 Press-fitting force of idler yoke 392 kN {40 ton} Adjust

Clearance between rod and size Shaft Hole clearance limit
3
bushing –0.120 +0.270 0.181 –
90 1.0
–0.207 +0.061 0.477

4 Recoil spring length load load
227.5 kN 208.9 kN
787.4 651 855
{23,200 kg} {21,300 kg}
D85EX, PX-15E0 11
Idler 1
12 D85EX, PX-15E0
Unit: mm
1 Outer diameter of projection
686 —
2 Outer diameter of tread 650 625
Build-up welding or
3 Depth of tread 18 30.5
replace
4 Thickness of tread 23 10.5
5 Width of tread 49.5 53.5
6 Overall width 204.0 —
Standard Tolerance
Standard clearance
Clearance between shaft and size Shaft Hole
7
bushing –0.250 +0.188
68 0.226 – 0.538
–0.350 –0.024 Replace
Clearance between shaft and –0.250 -0.110
8 68 0.030 – 0.180
support –0.290 –0.220
9 Axial play of shaft 0.26 – 0.66
Clearance between guide plate and Build-up welding or
10 2.0
support replace
Clearance between guide plate and Adjust shim or
11 0.5 – 1.0
side plate replace plate
Standard shim thickness for guide
12 4
plate
13 8 Adjust
plate
14 6
plate
D85EX, PX-15E0 13
Track roller 1
14 D85EX, PX-15E0
Unit: mm
1 Outer diameter of flange (outside)
254 —
2 Outer diameter of flange (inside) 246 —
3 Outer diameter of track roller tread 222.0 182
4 Thickness of tread 53.5 33.5 Build-up welding or
5 Width of flange (outside) 21.0 — replace
6 Width of flange (inside) 21.0 —

7 Width of tread (single flange) 55.6 —
8 Width of tread (double flange) 51.6 —
9 Overall width 251.2 —
Standard Tolerance
Standard clearance
10
bushing –0.210 +0.134
70 0.270 – 0.394
–0.260 +0.060
Standard Tolerance
Standard interference
Interference between outside size Shaft Hole
11 Replace
bushing and roller
+0.094 +0.027
115 0.013 – 0.141
+0.040 –0.047
Standard clearance
12 Axial play of shaft
0.50 – 0.75
Standard size Allowable size
13 Width of collar on shaft
20.0 —
D85EX, PX-15E0 15
Carrier roller 1
16 D85EX, PX-15E0
Unit: mm
1 Outer diameter of flange
217 —
Outer diameter of carrier roller
2 185 162 Build-up welding or
tread
replace
3 Thickness of tread 37.5 26
4 Width of carrier roller tread 57 —
5 Width of flange 19 —
Standard Tolerance
Standard clearance
6 Replace bushing
support
–0.2 +0.300
58 0 – 0.5
–0.2 +0.300
Standard Tolerance
Interference between shaft and size Shaft Hole
7
seal guard
+0.046 –0.12
59 0.120 – 0.216 Replace
+0.046 –0.17
Standard clearance
8 Axial play of roller
0 – 0.22
D85EX, PX-15E0 17
Sprocket 1
Unit: mm
1 Wear of tooth tip
229 217 Replace or repair
2 Thickness of tooth root 22 17
18 D85EX, PX-15E0
Full-size drawing of sprocket tooth shape

a Set the rule to the full-scale size, and then copy the whole drawing to an OHP sheet.
D85EX, PX-15E0 19
Track shoe 1
*1. Single shoe

*2. Swamp shoe
a P portion shows the link of bushing press fitting end.
20 D85EX, PX-15E0
Unit: mm
1 Link pitch
216.3 219.3
Reverse
Standard size Reverse or replace
2 Outer diameter of bushing Light load Heavy load
79.5 69.3 71.9
3 Thickness of bushing 15.9 5.7 8.3
4 Height of link
140 127.5
Repair or replace
Thickness of link (Press-fitting
5 43.5 31
portion of bushing)
Retightening angle (angle)
Tightening torque
a. Regu- (Nm {kgm}) Standard tightening Allowable
Shoe bolt lar link angle tightening angle
(single shoe)
(heavy duty shoe) 343 ± 39 {35 ± 4} 120 ±10
6 b. Master –00 Retighten

343 ± 39 {35 ± 4} 180
link –20
a. Regu-
539 ± 49 {55 ± 5} 120 ±10
Shoe bolt lar link
(swamp shoe) b. Master –00
343 ± 39 {35 ± 4} 180
link –20
Standard Allowable size

Interference between bushing and size Shaft Hole
7
link +0.344 +0.074
74 0.230 – 0.344
+0.304 +0.074
Interference between regular pin +0.190 –0.138 Adjust or replace
8 47 0.268 – 0.390
and link +0.130 –0.200
Standard clearance
9 Clearance between link and link Each side Both sides
1.4 2.8
D85EX, PX-15E0 21
Single shoe, Heavy duty shoe
Unit: mm
Single
71.4 25
1 Height of grouser shoe
Heavy
71.4 25 Build-up welding or
duty shoe
replace
Single
86.4 40
shoe
2 Thickness of grouser
Heavy
88 41.6
duty shoe
Swamp shoe
Unit: mm
1 Height of grouser Build-up welding or
120 98
replace
2 Thickness of grouser 27 5
22 D85EX, PX-15E0
SEN00298-00

© 2005 KOMATSU
All Rights Reserved
24
SEN00299-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Hydraulic system, Part 1
Hydraulic system, Part 1 ................................................................................................................................. 2
Work equipment hydraulic piping diagram ........................................................................................... 2
PPC control piping diagram ................................................................................................................. 5
Work equipment control ....................................................................................................................... 6
Hydraulic tank and filter........................................................................................................................ 8
Scavenging pump .............................................................................................................................. 10
Power train and steering lubrication pump..........................................................................................11
HSS pump.......................................................................................................................................... 12
HSS motor.......................................................................................................................................... 30
D85EX, PX-15E0 1
Hydraulic system, Part 1 1

Work equipment hydraulic piping diagram 1
Semi-U dozer
1. 1. Blade tilt cylinder 5. Hydraulic tank

2. R.H. blade lift cylinder 6. HSS pump
3. Control valve 7. L.H. blade lift cylinder
4. Accumulator 8. Oil cooler
2 D85EX, PX-15E0
1. Control valve
2. Divider block
3. Ripper lift cylinder
D85EX, PX-15E0 3
1. Control valve
2. Divider block
3. Ripper lift cylinder
4. Ripper tilt cylinder
4 D85EX, PX-15E0
PPC control piping diagram 1

a PPC: Abbreviation for Proportional Pressure Control
Blade, ripper control
1. Accumulator 5. Ripper PPC valve

2. Control valve 6. PPC lock valve
3. Work equipment lock lever 7. HSS pump
4. Blade PPC valve 8. Self pressure reducing valve
D85EX, PX-15E0 5
Work equipment control 1
6 D85EX, PX-15E0
1. Work equipment lock lever

2. Blade control lever
3. Ripper control lever
4. PPC lock valve
Lever positions
A: Blade “hold”
B: Blade “lower”
C: Blade “float”
D: Blade “raise”
E: Blade “left tilt”
F: Blade “right tilt”
G: Ripper “hold”
H: Ripper “raise”
J: Ripper “lower”
K: Ripper “tilt in”
(for variable multi-shank ripper)
L: Ripper “tilt back”
(for variable multi-shank ripper)
M: Free
N: Lock
Outline
q The work equipment control employs a PPC
method which uses a PPC valve to move each
control valve spool.
q Work employment lock lever (1) is interlocked
with PPC lock valve (4) and shuts off the oil in
the PPC circuit at “lock” (N) position.
D85EX, PX-15E0 7
Hydraulic tank and filter 1
1. Pressure valve 7. Strainer

2. Drain valve 8. Suction valve
3. Drain plug 9. Spring
4. Cover 10. Hydraulic oil filter element
5. Cover 11. Oil filler cap
6. Hydraulic tank 12. Sight gauge
8 D85EX, PX-15E0
Specified value
Tank total capacity (l) 95
Hydraulic Hi 74
tank Tank capacity (l) Middle 67
Lo 64
Cracking pressure 38.2 ± 14.7
(kPa {kg/cm2}) {0.39 ± 0.15}
Oil filler
cap Actuating pressure of
0 – 4.5
vacuum valve
{0 – 0.046}
(kPa {kg/cm2})
Specified value
Cracking pressure 147 ± 29.4
(kPa {kg/cm2}) {1.5 ± 0.3}
Filter mesh size
Hydraulic oil (mm) 20/10/5
filter
Filtering area (cm2) 13,600
Filtering oil flow
195
(l/min)
Filter mesh size
105
Strainer (mm)
Filtering area (cm2) 1,850
D85EX, PX-15E0 9
Scavenging pump 1
SAR(3)80
A: Suction port
B: Discharge port
Unit: mm
1 Spline shaft rotating torque 7.85 – 11.8 Nm {0.8 – 1.2 kgm}
Standard
Discharge Discharge
Delivery Speed discharge
Type pressure amount limit —
— Oil: SAE10W (rpm) amount
(MPa {kg/cm2}) (l)
Oil temperature: 45 – 55°C (l)
SAR(3)80 2,500 0.29 {3.0} — —
Specifications Outline
Type: SAR(3)80 q The scavenging pump is installed to the lower
Theoretical discharge capacity: 80.0 cc/rev part of the torque converter and the PTO case
Max. discharge pressure: 20.6 MPa {210 kg/cm2} and driven with the power from the engine.
Max. revolving speed: 2,500 rpm q The scavenging pump sucks the oil collected
in the bottom of the transmission case through
the strainer and returns it to the steering case.
10 D85EX, PX-15E0
Power train and steering lubrication pump 1

SAL(3)63+(2)50
Unit: mm
Type Standard clearance Clearance limit
1 Side clearance SAL(3)63 0.10 – 0.15 —
SAL(2)50 0.10 – 0.15 —
Clearance between plain bearing
SAL(3)63
2 inner diameter and gear shaft outer 0.060 – 0.149 —
SAL(2)50
diameter
Standard size Tolerance
Build-up welding
3 Pin driving depth –0.5
14
–0.5
–0.5
4 Pin driving depth 13
–0.5
–0.5
5 Pin driving depth 12
–0.5
6 Spline shaft rotating torque 9.8 – 18.6 Nm {1.0 – 1.9 kgm}
Discharge
Standard Discharge
Speed pressure
Type delivery amount limit
(rpm) (MPa {kg/
(l/min) (l/min)
Delivery cm2})
— Oil: SAE10W —
3.3
Oil temperature: 45 – 55°C SAL(3)63 63.1 —
{34}
2,500
0.29
SAL(2)50 50.1 —
{3.0}
D85EX, PX-15E0 11
HSS pump 1
Type: HPV160
PA: Pump discharge Outline

PS: Pump suction q This pump consists of a variable displacement
PD1: Pump drain swash plate type piston pump and a servo
PD2: Pump drain plug valve.
PEN: Control pressure pick-up plug
PLS1: Load pressure input Specifications
Type HPV160
1. Piston pump
2. Servo valve Theoretical delivery (cm3/rev) 160 ± 1
Rated speed (rpm) 2,133
Max. cut off pressure
38.2 {390}
(MPa {kg/cm2})
12 D85EX, PX-15E0
Piston pump
PA: Pump discharge

PS: Pump suction
PA1: Pump pressure signal
PEN: Control pressure
D85EX, PX-15E0 13
1. Shaft 8. Piston
2. Case 9. Cylinder block
3. Cradle 10. Valve plate
4. Rocker cam 11. End cap
5. Shoe 12. Impeller
6. Servo piston 13. Spline
7. Rod
14 D85EX, PX-15E0
Function Structure
q The pump converts the engine rotation trans- q Cylinder block (9) is supported to shaft (1) by
mitted to its shaft to oil pressure and delivers spline (13), and shaft (1) is supported by the
pressurized oil corresponding to the load. front and rear bearings.
q It is possible to change the discharge amount q The end of piston (8) has a concave ball
by changing the swash plate angle. shape, and shoe (5) is caulked to it to form one
unit. Piston (8) and shoe (5) form a spherical
bearing.
q Rocker cam (4) holds flat surface (A), and
shoe (5) is always pressed against this surface
as it slides in a circle.
q Rocker cam (4) forms a static bearing sending
high pressure oil at cylinder surface (B) of cra-
dle (3), which is fixed to case (2), and carries
out a sliding movement.
q Piston (8) carries out motion relative to the
cylinder block (9).
to valve plate (10) while sealing the pressur-
ized oil, and this surface ensures that the
hydraulic balance is maintained correctly. The
oil inside each cylinder chamber of cylinder
block (9) is sucked in and discharged through
valve plate (10).
q Impeller (12) is fixed to shaft (1), and rotates
together with the shaft. This makes it easier
for the oil, which is sucked in from the suction
port, to be sucked in and sends it into the cylin-
der chamber by centrifugal force.
D85EX, PX-15E0 15
Operation
Operation of pump
q Cylinder block (9) rotates together with shaft q When center line (X) of rocker cam (4) is the
(1), and shoe (5) slides on flat surface (A). same as the axial direction of cylinder block (9)
When this happens, angle (a) of center line (X) [s was h pl ate an gl e = 0], the d iffer e nc e
of rocker cam (4) to the axial direction of cylin- between volumes (E') and (F') inside cylinder
der block (9) changes. (a) is called swash plate block (9) is 0, so pump does not suck and dis-
angle. charge, and no pumping is carried out. [The
swash plate angle is not set to 0 actually, how-
ever.]
q In other word, swash plate angle (a) and the
pump discharge amount is in relation of pro-
portion.
q With the condition of center line (X) of rocker

cam (4) has swash plate angle (a) to axial
direction of cylinder block (9), flat surface (A)
functions as cam against shoe (5).
q In this way, piston (8) slides inside cylinder
block (9), and as a result, a difference is gener-
ated between volumes (E) and (F) inside cylin-
der block (9). The amount of suction and
discharge is equal to difference (F) – (E).
q In other words, cylinder block (9) rotates, and
the volume of chamber (F) becomes smaller,
so pressurized oil is discharged during this
process. At the same time, the volume of
chamber (E) becomes larger and the pressur-
ized oil is sucked in this process.
16 D85EX, PX-15E0
Control of delivery
q The discharge amount is increased by the
increase of capacity difference of (E) and (F)
as swash plate angle (a) is increased. Swash
plate angle (a) is changed by servo piston (6).
q Servo piston (6) reciprocates straight accord-
ing to the signal pressure of the servo valve.
This straight line movement is transmitted to
rocker cam (4) through rod (7), and rocker cam
(4) which is supported on the cylindrical sur-
face by cradle (3) rotates with sliding motion.
q The area receiving the pressure is different at
the left and right sides of servo piston (6), and
the receiving pressure at the small diameter
piston end is always connected with the main
pump discharge pressure [self pressure (PP)].
q Output pressure (PNC) of the servo valve is
applied to the pressure chamber at the large
diameter piston end.
q The movement of servo piston (6) is controlled
by the relationship of the size of the pressure
at the large diameter piston end and self pres-
sure (PP), and the comparative size of the ratio
of the area receiving the pressure at the large
diameter piston end and small diameter piston
end.
D85EX, PX-15E0 17
Servo valve
PA1: Pump self pressure

PEN11: Control pressure
PEN12: Control pressure pick-up plug
PLS1: Load pressure input
PT: Drain
18 D85EX, PX-15E0
LS valve TVC valve Variable throttle valve

1. Locknut 8. Solenoid 16. Screw
2. Plug 9. Piston 17. Locknut
3. Spring 10. Sleeve 18. Spring
4. Spool 11. Spring 19. Seat
5. Sleeve 12. Spring 20. Spool
6. Piston 13. Piston 21. Block
7. Plug 14. Lever 22. Plug
15. Valve body
D85EX, PX-15E0 19
Function
LS valve
q LS valve detects the load and controls the dis-
charge amount.
q This valve controls main pump delivery (Q)
according to differential pressure (dPLS) [ =
PP – PLS], called the LS differential pressure
(the difference between main pump pressure
(PP) and control valve outlet port pressure
(PLS)).
q Main pump pressure (PP), pressure (PLS)
[called LS pressure] coming from the control
valve output enter this valve.
q The relationship between the differential pres-
sure (dPLS) [ = PP – PLS], the difference q During the high load operation, or when the engine
between main pump pressure (PP) and LS speed slowed down etc., the current is supplied to
pressure (PLS), and discharge amount (Q) TVC valve solenoid by the controller command.
changes as shown in the diagram. q It reduces the pump discharge amount [pump
absorption torque], and reduces the load of engine.
Variable throttle valve

q Because the main pump controls its own pres-
sure, there is a tendency for the response
speed of the swash plate to be quick at high
pressure and slow at low pressure.
q The variable throttle valve has been installed
for the following reasons.
1) To reduce the swash plate speed between
minimum and maximum at high pressure; to
reduce the impact force on the rod and other
parts of the main pump; and to prevent exces-
sive response.
TVC valve 2) To prevent cavitation at the suction port
q When the pump discharge pressure (PP) is caused by the sudden increase in the suction
high, the TVC valve controls the pump so that volume when changing from minimum to maxi-
no more oil than the constant flow (in accor- mum.
dance with the discharge pressure) flows even q The characteristics of the variable throttle
if the stroke of the control valve becomes valve are as shown in the diagram. It has the
larger. It carries out equal horsepower control function and property of maintaining the
so that the horsepower absorbed by the pump response during operations at low pressure by
does not exceed the engine horsepower. making the area of the opening smaller at high
q If the load during the operation becomes larger pressure and the area of the opening larger at
and the pump discharge pressure rises, it low pressure, and by preventing the above
reduces the discharge amount from the pump; problems 1) and 2) at high pressure.
and if the pump discharge pressure drops, it
increases the discharge amount from the pump.
q The relationship between pump discharge pres-
sure (PP) and pump discharge amount (Q) with
the electric current value given to TVC valve
solenoid as the parameter is shown in the dia-
gram.
20 D85EX, PX-15E0
Operation
LS valve
(1) When control valve is at “neutral” position
q LS valve is a 3-way selector valve, with pres- q Pump pressure (PP) enters the large diameter
sure [LS pressure] (PLS) from the outlet port of end of the piston from port (h). The same
the control valve brought to spring chamber (i), pump pressure (PP) also enters the small
and main pump discharge pressure (PP) diameter end of the piston, so the swash plate
brought to chamber (j) of plug (6). is moved to the minimum angle by the differ-
q The size of LS pressure (PLS) + force (F) of ence in area of piston (1).
spring (3) and the main pump pressure [self
pressure] (PP) determines the position of spool
(4).
q Before the engine is started, servo piston (1) is
pushed to the right by spring (7) installed to rod
(2). [See right figure: section (A – A)]
q If the control lever is at the neutral position
when the engine is started, LS pressure (PLS)
will be set to 0 MPa {0 kg/cm2}. (It is intercon-
nected to the drain circuit via the control valve
spool)
q Spool (4) is pushed to the left, and port (d) and
port (c) are connected.
D85EX, PX-15E0 21
(2) Operation in direction for “maximum” pump discharge amount
q When the difference between main pump pres-

sure (PP) and LS pressure (PLS), in other
wo r ds , L S d iff er e nti a l p re s s ur e (dP L S)
becomes smaller [for example, when the area
of opening of the control valve becomes larger
and pump pressure (PP) drops], spool (4) is
pushed to the right by the combined force of
LS pressure (PLS) and the force of spring (3).
q When spool (4) moves, port (b) and port (c) are
joined and connected to the TVC valve.
q TVC valve is connected to the drain port, so
the pressure of circuit (c) – (h) becomes drain
pressure (PT). [The operation of TVC valve is
explained later.]
q The pressure at the large piston diameter end
of servo piston (1) becomes drain pressure
(PT), and pump pressure (PP) enters the small
diameter end, so servo piston (1) is pushed to
the right.
q Rod (2) moves to the right and moves the
swash plate in the direction to make the dis-
charge amount larger.
22 D85EX, PX-15E0
(3) Operation in the direction for “minimum” pump discharge amount
q The following explains the situation if servo

piston (1) moves to the left [the discharge
amount becomes smaller].
q When LS differential pressure (dPLS) becomes
larger [for example, when the area of opening of
the control valve becomes smaller and pump
pressure (PP) rises], pump pressure (PP)
pushes spool (4) to the left.
q When spool (4) moves, main pump pressure
(PP) flows from port (d) to port (c), and from
port (h), it enters the large piston diameter end.
q Main pump pressure (PP) also enters the small
piston diameter end, but because of the differ-
ence in area between the large and the small
piston diameter ends of servo piston (1), servo
piston (1) is pushed to the left.
q Rod (2) moves in the direction to make the
swash plate angle smaller.
D85EX, PX-15E0 23
(4) When servo piston is balanced
q Let us take the area receiving the pressure at q The position where spool (4) is balanced and
the large diameter end of the piston as (A1), stopped is the standard center, and the force of
the area receiving the pressure at the small spring (3) is adjusted so that it is determined
diameter end as (A0), and the pressure flowing when (PP) – (PLS) = 1.96 MPa {20 kg/cm2}.
into the large diameter end of the piston as
(PEN).
q If main pump pressure (PP) of the LS valve
and the combined force of force (F) of spring
(3) and LS pressure (PLS) are balanced, the
relationship is (A0) × (PP) = (A1) × (PEN).
q Servo piston (1) stops in that position, and the
swash plate is kept at an intermediate position.
[It stops at the position where the opening from
port (b) to port (c) and from port (d) to port (c)
of spool (4) is approximately the same.]
q The relationship between the area receiving
the pressure at both ends of piston (1) is (A0) :
(A1) = 1 : 2, so the pressure applied to both
e n d s o f th e p i s to n w h e n i t i s b a l a n c e d
becomes (PP) : (PEN) C 2 : 1.
24 D85EX, PX-15E0
TVC valve
(1) When the transmission and steering controller is normal

1) When the load on the actuator is small and pump discharge pressure (PP) is low
a. Operation of solenoid (1)

q Command current (X) from the transmission
and steering controller flows to solenoid (1).
This command current (X) changes the internal
force pushing solenoid push pin (11).
q On the opposite side to the force pushing this
solenoid push pin (11) is the spring set pres-
sure of springs (3) and (4) and pump pressure
(PP). Piston (2) stops at a position where the
combined force pushing piston (2) is balanced.
q The pressure output from TVC valve [pressure
of port (c)] changes according to this position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
D85EX, PX-15E0 25
b. Operation of springs (3) and (4)

q The spring load of springs (3) and (4) in the
TVC valve is determined by the swash plate
position.
q When servo piston (9) moves, cam (7), which
is connected to rod (8), also moves. When this
happens, lever (6) is rotated by the angle of
cam (7), and piston (5) moves to the right and
left.
q If piston (5) moves to the right, spring (3) is
compressed, and if it moves further to the right,
spring (4) contacts seat (10), so both spring (3)
and spring (4) function.
q The spring load is changed by piston (5)
expanding or contracting springs (3) and (4).
q If command current (X) input to solenoid (1)
changes, the force pushing solenoid push pin
(11) changes, and the spring load of spring (3)
and spring (4) also changes according to the
command current (X) of the solenoid.
q Port (c) of the TVC valve is connected to port
(e) of the LS valve [see “LS valve”]. Self pres-
sure (PP) enters port (b), the small piston
diameter end of servo piston (9), and port (g).
q When pump pressure (PP) is small, piston (2)
is on the right.
q Port (c) and port (d) are connected, and the
pressure entering the LS valve becomes drain
pressure (PT).
q If port (h) and port (e) of LS valve are con-
nected [see “LS valve”], the pressure entering
the large piston diameter end from port (f)
becomes drain pressure (PT), and servo piston
(9) moves to the right.
q The pump delivery will be set to the increasing
trend.
q As servo piston (9) moves further, piston (5) is
moved to the left by rod (8), cam (7) and lever
(6). Springs (3) and (4) expand and the spring
force becomes smaller.
q When the spring force becomes smaller, piston
(2) moves to the left, so the connection
between port (c) and port (d) is cut, and port (c)
is connected to port (b) of pump discharge
pressure.
q The pressure at port (c) rises, and the pressure
at the large piston diameter end also rises, so
the movement of piston (9) to the right is
stopped.
q The stop position for piston (9) [ = pump dis-
charge amount] is decided at the point where
for the force of springs (3) and (4), and the
pushing force by solenoid and the pushing
force created by pressure (PP) acting on pis-
ton (2) are in balance.
26 D85EX, PX-15E0
2) When the load on the actuator is small and pump discharge pressure (PP) is high
q When the load is large and pump discharge q Springs (3) and (4) are compressed and push
pressure (PP) is high, the force pushing piston back piston (2). Because of this force, piston
(2) to the left becomes larger and piston (2) (2) cuts of the connection from port (b) to port
moves to the position shown in the diagram (c), and port (c) and port (d) are connected.
above. q As a result, the pressure at port (c) [= (f)]
q As shown in the diagram above, part of the drops, and piston (9) stops moving to the left.
pressurized oil from port (b) flows out to port q The position in which piston (9) stops when
(d) and the pressure oil flowing from port (c) to this happens is further to the left than the posi-
the LS valve becomes approximately half of tion when pump pressure (PP) is low.
main pump pressure (PP).
q When port (h) and port (e) of LS valve are con-
nected [see “LS valve”], the pressure from port
(f) enters the large piston diameter end of
servo piston (9), and servo piston (9) stops.
q If main pump pressure (PP) increases further
and piston (2) moves further to the left, main
pump pressure (PP) flows to port (c) and acts
to make the discharge amount the minimum.
q When piston (9) moves to the left, piston (5) is
moved to the right by cam (7) and lever (6).
D85EX, PX-15E0 27
q The relation of pump pressure (PP) and the

position of servo piston (9) forms a bent line
because of the double-spring effect of springs
(3) and (4). The relationship between pump
pressure (PP) and pump discharge amount (Q)
is shown in the figure.
28 D85EX, PX-15E0
Variable throttle valve
(1) Operation in direction for maximum pump q The opening area of part (A) increases and the
delivery oil flowing from the large diameter end of servo
q Pump discharge pressure (PP) enters the vari- piston (1) through port (c) to port (b) is not lim-
able throttle valve through port (a). ited and the moving speed of servo piston (1)
is heightened.
1) When main pump pressure (PP) is high
(2) Operation in the direction for smaller pump
q If the pressure becomes higher than the force
of spring (3) because of the difference in sec- delivery
tional area of spool (4) in chamber (e), spool q The hydraulic oil flows from port (b) through
(4) moves to the right. port (c) to the large diameter side of servo pis-
q If spool (4) moves to the right, the opening ton (1).
area between ports (c) and (b) is reduced by q Spool (4) operates according to main pump
the notch at part (A). Accordingly, less oil flows pressure (PP) as explained in the above sec-
from the large diameter end of servo piston (1) tion.
and the moving speed of servo piston (1) is
lowered.
2) When main pump pressure (PP) is low

q Even if main pump pressure (PP) enters cham-
ber (e) through port (a), spool (4) pushes
spring (3) less strongly and moves to the right
for shorter distance.
D85EX, PX-15E0 29
HSS motor 1
Type: HMF112
PA: From control valve Outline

PB: From control valve
q This motor is composed of the fixed capacity
T2: To hydraulic tank
swash plate type piston motor, flashing shuttle
valve, bypass valve and charge relief valve.
1. HSS motor
2. Counterbalance valve
Specifications
3. Safety valve
4. Check valve Type HMF112
Theoretical displacement
112.7
(cc/rev)
Rated output pressure
38.2 {390}
(MPa {kg/cm2})
Rated speed (rpm) 2,241
30 D85EX, PX-15E0
1. Output shaft 10. Counterbalance valve

2. Motor case 11. Safety valve
3. Thrust plate 12. Check valve
4. Piston 13. Check valve spring
5. Cylinder block 14. Sub bearing
6. Valve plate 15. Spline
7. End cover 16. Shoe
8. Brake valve assembly 17. Main bearing
9. Spool return spring
Unit: mm
Free length
18 Spool return spring length load load Replace spring if
diameter
damaged or
192 N 154 N deformed.
42.7 × 30.0 40.5 —
{19.6 kg} {15.7 kg}
1.27 N 0.98 N
19 Check valve spring 43 × 13.8 32.9 —
{0.13 kg} {0.10 kg}
D85EX, PX-15E0 31
Outline
q Pressurized oil sent from pump is converted to
rotating torque and is transmitted to output
shaft.
Structure
q Cylinder block (5) is supported to output shaft
(1) by spline (15), and output shaft (1) is sup-
ported by main and sub bearings (17) and (14).
q The end of piston (4) has a concave ball
shape, and shoe (16) is caulked to it to form
one unit. Piston (4) and shoe (16) form a
spherical bearing.
q Piston (4) carries out motion relative to the
cylinder block (5).
to valve plate (6) while sealing the pressurized
oil.
q This surface ensures that the hydraulic bal-
ance is maintained correctly.
q The oil inside each cylinder chamber of the
rotating section [cylinder block] is sucked in
and discharged through the port of the station-
ary section [valve plate].
32 D85EX, PX-15E0
Operation
Operation of motor Rotation speed and torque control

q The pressurized oil sent from the pump enters q As flow (Q) from the HSS pump is increased,
cylinder block (5) and pushes piston (4) from motor speed (N) is heightened.
the back face. q Since the swash plate angle of the HSS motor
q In the case of the motor, the center line of plate is fixed [(a) is constant], rotating torque (T) is
(3) is always at an angle [swash plate angle proportional to pressure (P).
(a)] to the axial direction of cylinder block (5). q Swash plate angle (a) is approx. 19°.
q As a result, if we take the example of one of
pistons (4), the oil pressure is applied to the Q = qN
back face of the piston, and the piston axial (q = E – F)
force (FO) is generated.
q With shoe (16), which is joined to piston (4) by
T = Pq/2x
the spherical surface, reaction force (FR) in a
direction at right angles to flat surface (A) is
generated. The combined force of (FO) and Q: Total flow
(FR) is (FP) and this becomes the force to q: Flow per 1 turn
rotate cylinder block (5). N: Rotation speed
P: Pressure
T: Rotating torque
q Shaft (1), which is meshed to cylinder block (5)

by spline (15) transfers this rotating torque to
the output side.
q Cylinder block (5) rotates, and while the condi-
tion changes from volume (E) to volume (F),
pressurized oil from the pump flows into the
cylinder chamber, and pressure (P) is gener-
ated according to the load.
q On the other hand, when the condition goes
beyond volume (F) and changes to volume (E),
the oil is pushed out and returned to the pump.
D85EX, PX-15E0 33
Brake valve operation Operation when oil is supplied

q The brake valve consists of check valve (12), q When the steering lever is operated, the pres-
counterbalance valve (10), and safety valve surized oil from the control valve is supplied to
(11), and forms the circuit as shown below. port (PA). It pushes open check valve (12a),
q The function and the operation of each compo- and flows from HSS motor inlet port (MA) to
nent is as given below. HSS motor outlet port (MB).
q However, the outlet port side of the HSS motor
is closed by check valve (12b) and spool (10),
so the pressure at the side where the oil is
being supplied rises.
Counterbalance valve, check valve

Function
q When the steering is operated on a downhill
slopes, the weight on the machine produces a
force in the downward direction which makes
the machine try to turn faster than the speed of
the HSS motor.
q Because of this, if the engine is run at low
speed and the steering is operated, the HSS
motor will overrun, and this will create an
extremely dangerous condition.
q To prevent this, this valve is installed to carry
out the steering in accordance with the engine
speed [pump discharge amount].
34 D85EX, PX-15E0
q The pressurized oil at the side where the oil is Action of brakes when operating steering on
being supplied flows from orifice (E1) of spool downhill slopes
(10) into chamber (S1). And when the pres- q When the steering is operated on a downhill
sure in chamber (S1) becomes greater than slopes, if the machine attempts to run away,
the spool switching pressure, spool (10) is the HSS motor will rotate under no load, and
pushed to the right. the oil pressure at the inlet port of the HSS
q In this way, port (MB) and port (PB) are con- motor will drop. This drop in the pressure will
nected, so the outlet port side of the HSS pass through orifice (E1), so the pressure in
motor is opened and the HSS motor starts to chamber (S1) will also drop.
turn. q If the pressure in chamber (S1) drops below
the spool switching pressure, spool (10) is
pushed to the left by spring (9), and outlet port
(MB) is throttled.
q As a result, the pressure at the outlet port
rises, and this creates a resistance to the rota-
tion of the HSS motor which prevents the
motor from overrunning.
q In other words, the spool moves to a position
where it balances the pressure at outlet port
(MB) with the force resulting from the weight of
the machine and the pressure at the inlet port.
In this way, it throttles the outlet port circuit and
controls the motor to a speed that matches the
amount of oil discharged from the pump.
D85EX, PX-15E0 35
Safety valve
Function q If the pressure in chamber (E) [or chamber (F)]
q When the operation of the steering stops, goes above the set pressure, the force of x/4
counterbalance valve (10) closes the circuit at (D12 – D22) × pressure resulting from the dif-
the inlet and outlet ports of the HSS motor. ference in area of (D1) and (D2) [or the force
q But the HSS motor continues to turn because of x/4 (D3 2 – D12 ) × pressure resulting from
of inertia. As a result, the pressure at the out- the difference in area of (D3) and (D1)]
let port of the HSS motor becomes extremely becomes greater than the force of the spring
high, and this will damage the HSS motor and and moves the poppet to the right. The oil then
the piping. flows to chamber (F) [or chamber (E)] in the
q The safety valve acts to release this abnormal circuit on the opposite side.
pressure to the inlet port of the HSS motor to
protect the equipment from damage.
Operation
q When the operation of the steering is stopped,
the check valve of the counterbalance valve
closes chamber (E) (or chamber (F)) in the out-
let port circuit, but the pressure at the outlet
port side continues to rise because of inertia.
36 D85EX, PX-15E0
SEN00299-00

© 2005 KOMATSU
All Rights Reserved
38
SEN00300-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Control valve ........................................................................................................................................ 2
Self pressure reducing valve.............................................................................................................. 36
D85EX, PX-15E0 1

Control valve 1
Outline
q This manual explains the 3-spool valve (Blade
lift + Tilt + Steering) and 4-spool valve (Ripper
+ Blade lift + Tilt + Steering).
3-spool valve
P: From pump
T: To tank
A1: To HSS motor
A2: To tilt cylinder bottom
A3: To lift cylinder head
B1: To HSS motor
B2: To tilt cylinder head
B3: To lift cylinder bottom
LS: To pump LS valve
PC: Pump pressure plug
PI: From self pressure reducing valve
TS: To tank
PA1: Connector (from controller)
PA2: From PPC valve
PA3: From PPC valve
PB1: Connector (from controller)
PB2: From PPC valve
PB3: From PPC valve
PLSC: LS pressure plug
1. EPC valve
2 D85EX, PX-15E0
D85EX, PX-15E0 3
1. Cover
2. Lift spool
3. Tilt spool
4. Steering spool
5. Valve body
6. Steering priority valve
7. Load check valve
8. Pressure compensation valve
9. Main relief valve
10. LS relief valve (for steering valve)
11. Unload valve
12. LS relief valve (for work equipment valve)
13. LS check valve (for work equipment valve)
14. LS check valve (for steering valve)
4 D85EX, PX-15E0
Unit: mm
Free length
15 Spool return spring (for lift) length load load
diameter
224 N 178 N
73.4 × 31 68.5 —
{22.8 kg} {18.2 kg}
Spool return spring 140 N 112 N
16 51.7 × 31.3 50 —
(for tilt, steering) {14.3 kg} {11.4 kg}
17 65.3 × 36.5 33.5 — Replace spring if
(for lift “float”) {34.2 kg} {27.4 kg}
damaged or
12.7 N 9.81 N deformed.
18 Load check valve spring 20.8 × 10.2 13.5 —
{1.3 kg} {1.0 kg}
Pressure compensation valve 563 N 450 N
19 109.4 × 29.5 81 —
spring (steering valve) {57.4 kg} {45.9 kg}
20 70 × 6.5 62.5 —
spring (tilt valve) {20.1 kg} {16.1 kg}
21 97.7 × 29.5 81 —
spring (lift valve) {46.2 kg} {37.0 kg}
192 N 154 N
22 Unload valve spring 86.7 × 30 66 —
{19.6 kg} {15.7 kg}
D85EX, PX-15E0 5
1. Suction valve
2. Preset check valve
3. LS bypass valve
Unit: mm
Free length
Installation Installation Installation Replace spring if
4 Suction valve spring length load load damaged or
diameter
deformed.
6.4 N 5.1 N
64.9 × 12.5 56 —
{0.65 kg} {0.52 kg}
6 D85EX, PX-15E0
4-spool valve
P: From pump
T: To tank
A1: To HSS motor
A2: To tilt cylinder bottom
A3: To lift cylinder head
A4: To ripper cylinder bottom
B1: To HSS motor
B2: To tilt cylinder head
B3: To lift cylinder bottom
B4: To ripper cylinder head
LS: To pump LS valve
PC: Pump pressure plug
PI: From self pressure reducing valve
TS: To tank
PA1: Connector (from controller)
PA2: From PPC valve
PA3: From PPC valve
PA4: From PPC valve
PB1: Connector (from controller)
PB2: From PPC valve
PB3: From PPC valve
PB4: From PPC valve
PLSC: LS pressure plug
1. EPC valve
8 D85EX, PX-15E0
D85EX, PX-15E0 9
1. Valve block
2. Ripper spool
3. Lift spool
4. Tilt spool
5. Steering spool
6. Valve body
7. Steering priority valve
8. Load check valve
9. Pressure compensation valve
10. Main relief valve
11. LS relief valve (for steering valve)
12. Unload valve
13. LS relief valve (for work equipment valve)
14. LS check valve (for work equipment valve)
15. LS check valve (for steering valve)
10 D85EX, PX-15E0
Unit: mm
Free length
Spool return spring × outer Free length
16 length load load
(for lift) diameter
224 N 178 N
73.4 × 31 68.5 —
{22.8 kg} {18.2 kg}
17 51.7 × 31.3 50 —
(for tilt, steering) {14.3 kg} {11.4 kg}
18 65.3 × 36.5 33.5 —
(for lift “float”) {34.2 kg} {27.4 kg}
12.7 N 9.81 N Replace spring if
19 Load check valve spring 20.8 × 10.2 13.5 —
{1.3 kg} {1.0 kg} damaged or
deformed.
20 109.4 × 29.5 81 —
spring (steering valve) {57.4 kg} {45.9 kg}
21 70 × 26.5 62.5 —
spring (tilt valve) {20.1 kg} {16.1 kg}
22 97.7 × 29.5 81 —
spring (lift valve) {46.2 kg} {37.0 kg}
Pressure compensation valve
51.3 N 41 N
23 spring 64.5 × 26.5 62.5 —
{5.23 kg} {4.18 kg}
(ripper valve)
192 N 154 N
24 Unload valve spring 86.7 × 30 66 —
{19.6 kg} {15.7 kg}
D85EX, PX-15E0 11
1. Suction valve 3. LS bypass valve

2. Preset check valve 4. Suction valve
Unit: mm
Free length
5 Suction valve spring length load load Replace spring if
diameter
damaged or
6.4 N 5.1 N deformed.
64.9 × 12.5 56 —
{0.65 kg} {0.52 kg}
5.49 N 4.41 N
6 Suction valve spring 46.8 × 7.5 40.6 —
{0.56 kg} {0.45 kg}
12 D85EX, PX-15E0
Operation of control valve
At “hold” (operation of unload valve)
Function Operation
q When the main spool is at the “hold” position, it q When the main spool is at the “hold” position,
drains the excess oil discharged by the pump, the pump pressure passes from chamber (A)
and prevents the pressure from being formed through throttle (4) to chamber (D). Chambers
in the circuit from rising. (C) and (C') are connected to the drain circuit.
q When the oil is supplied from the pump, the
pressure in chamber (D) rises, and spool (1) is
pushed to the right by pressure which is deter-
mined by the cross-sectional area of piston (3)
receiving the pressure.
q When the received pressure becomes larger
than set load of spring (2), the spool moves to
the right and connects the passage between
chamber (A) and chamber (B), so the oil from
the pump is drained.
q Therefore, spool (1) is balanced at a position
that matches the supply of oil from the pump.
Actually, the amount of oil supplied from the
pump is small, so the pressure in the circuit is
almost the same as the set load of spring (2).
14 D85EX, PX-15E0
Control of oil flow
Function
q Use of the CLSS circuit (Closed center Load Sensing System) makes it possible to control the oil flow by
adjusting the area of opening of the spool driven by the EPC valve regardless of the load.
1. Steering valve
1) At “hold”
Operation q Chamber (G) is drained through chamber (H)

q When the spool is at the “hold” position, the to chamber (F). When this happens, the pump
pump pressure is sent from chamber (A) pressure is acting on the left end of spool (3) of
through the notch in spool (3) of the steering the steering priority valve, so it pushes against
priority valve, and passes through chamber (B) the load of spring (4) and moves to the right to
to chamber (C). the maximum stroke position.
q In this condition, the area of the opening to
spool (1) of the steering valve is at its mini-
mum.
D85EX, PX-15E0 15
2) When turning to the left
q dPLS = Differential pressure between ports (K) q Chamber (C) and chamber (D) are connected,
and (J) = 2.0 MPa {20 kg/cm2} and the oil from the pump flows through ports
q dPLS' = Differential pressure between ports (I) (A), (B), (C) and (D) to HSS motor (6).
and (D) q At the same time, the load pressure in cham-
q dPLS C dPLS' ber (D) passes through LS orifice (5) and
chamber (H), and is sent to chamber (G). It is
Operation also sent from LS circuit (O) to pump servo
q When the steering lever is operated to turn the valve (7).
machine to the “left”, pilot pressure (PI) acts on q The condition of the pressure of spool (3) is
the right end of spool (1) through the EPC chamber (B) pressure C chamber (C) pressure,
valve. and chamber (G) pressure C chamber (D)
q When the pressure becomes greater than the pressure, so spool (3) is controlled by the dif-
set load of spring (2), spool (1) moves to the ferential pressure of spool (1) (chamber (C)
left. It becomes balanced at a position that pressure – chamber (D) pressure), and bal-
matches pilot pressure (PI). ances with spring (4).
16 D85EX, PX-15E0
q In other words, if the oil flow is too large, the

differential pressure of spool (1) becomes
larger, so spool (3) moves in the direction to
throttle the oil flow.
q On the other hand, if the oil flow is too small,
spool (3) moves in the direction to increase the
oil flow.
q In addition, pump servo valve (7) is controlled
so that the differential pressure between pump
pressure (P) and LS pressure (LS) (LS differ-
ential pressure: dPLS) remains constant, so a
suitable amount of oil flows to ensure that the
loss of pressure at the control valve (dPLS') is
equal to (dPLS).
q The loss of pressure in the control valve is
determined by the area of the opening of the
main spool, so the oil flow matches the open-
ing of the spool.
q The return oil flow from HSS motor (6) passes
through chamber (E) and chamber (F), and is
drained.
D85EX, PX-15E0 17
2. Work equipment valve (tilt valve, lift valve, ripper valve)

a The diagram shows the blade lift valve.
18 D85EX, PX-15E0
Operation
q When spool (1) of the work equipment valve is at
the “hold” position, the pump pressure (unload
pressure) is sent to chambers (D) and (D').
q The pressure is not formed in chambers (H)
and (H'), so pressure compensation valve
spool (3) and steering priority valve spool (4)
are pushed completely to the right.
q The pump pressure passes through chambers
(A) and (B) of steering priority valve (4), and is
sent to chamber (C) of the work equipment
valve. From here it goes through chamber (D)
and chamber (E) to chamber (F).
q In the same way as described in topic “1. Steer-
ing valve”, the position of pressure compensation
valve spool (3) is determined to match the open-
ing of work equipment valve spool (1), and the oil
flow is determined so that the pressure loss of
the control valve becomes equal to the control
differential pressure (dLS) of pump LS valve (7).
D85EX, PX-15E0 19
3. Meter-out control when blade moves down under its own weight
20 D85EX, PX-15E0
Function
q If the blade moves down under its own weight,
the oil flow of return oil from cylinder is con-
trolled by the area of the opening of main spool
(1).
Operation
q When the spool port is opened by pilot pres-
sure (PI), because of the weight of the blade,
the oil from the cylinder head side passes
through ports (A), (B), (C) and (D), and is
drained to the tank.
q When this happens, the flow of return oil from
the lift cylinder is throttled by the area of open-
ing between ports (A) and (B), so the down-
ward speed is controlled.
q The oil flowing from the cylinder head end
passes from the drain circuit through suction
valve (2) and is supplied to the bottom end of
the cylinder.
q The oil discharged from the pump passes
through ports (A'), (B'), (C'), (D') and (E'), and
is supplied to the cylinder bottom.
D85EX, PX-15E0 21
4. Meter-out control when blade moves down under its own weight (work equipment lever at “float”)
22 D85EX, PX-15E0
Function
q When the lift valve is at “float”, the cylinder port
and drain port are connected to put the circuit
in a no-load condition.
q When the lift valve is in the “float” condition,
the pump passage and cylinder ports (A3) and
(B3) are separated so that the other control
valves can be operated.
Operation
q When the work equipment control lever is at
the “float” position, if pressure (PA3) becomes
3.4 MPa {35 kg/cm2} or more, lift spool (1) is
moved to the maximum stroke position.
q In this condition, ports (A3) and (B3) and LS
passage (O) are all connected to the drain cir-
cuit, so there is no load on the lift cylinder.
q If the cylinder is driven by the weight of the
blade, the oil entering from port (A3) flows to
ports (A), (B), (B') and (A'), while the rest of the
pressurized oil flows through ports (C) and (D),
and is drained.
q When this happens, the oil flow is throttled by
the area of opening between ports (A) and (B)
of spool (1), and the cylinder speed is con-
trolled.
q The pump circuit chamber (E) and ports (A3)
and (B3) are separated, and pump pressure
(P) is formed, so it is possible to carry out com-
pound operations with other control valves.
D85EX, PX-15E0 23
At relief
1. Steering valve
a The diagram shows the condition at relief for steering LS relief valve (5).
24 D85EX, PX-15E0
q dP1 = dP3 + dP4 = Differential pressure between ports (M) and (E)
q dP2 = Differential pressure between ports (E) and (N)
q dP3 = Differential pressure between ports (M) and (B)
q dP4 = Differential pressure between ports (B) and (E)
q dLS = dP1 + dP2 = Differential pressure between ports (M) and (N) = 2.0 MPa {20 kg/cm2}
Function
q It sets the maximum pressure when the HSS
motor is operated.
Operation
q If steering spool (1) is moved and the pressure
of HSS motor (7) becomes higher, the poppet
of steering LS relief valve (5) will start to open
and oil will be drained from LS circuit (O).
[Ports (E), (F), (G), (J), (K) and (L)]
q As a result, there will be a drop in pressure in
LS passage (O) starting from LS sensing hole
(F), and (dP2) will become larger.
q For the same reason, if the pressure in cham-
bers (H) and (I) drops, spool (2) will push
against spring (3) and move to the right, and
will make the opening between chambers (B)
and (C) smaller, so the flow to chambers (B)
and (C) will be throttled and (dP4) will become
larger.
q Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by
the flow at steering LS relief valve (5). (dP1) +
(dP2) equal to LS differential pressure (dLS).
q When this happens, pump LS valve (6) detects
the differential pressure generated by steering
LS relief valve (5), and moves the pump swash
plate angle from the maximum to the minimum
position. The pump swash plate is balanced at
a position where the LS differential pressure is
2.0 MPa {20 kg/cm2}.
q When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil
flow is greater than the LS relief oil flow + leak-
age at any part, the pressure is confined in the
pump circuit (between the pump and chambers
(A) and (B)), so the LS differential pressure
rises.
q If this differential pressure goes above the set
pressure for unload valve (4), the unload valve
is actuated to relieve the excess oil flow and
balance the circuit.
D85EX, PX-15E0 25
2. Blade lift, tilt and ripper valve

a The diagram shows the relief condition of work equipment LS relief valve (5) with the blade tilt at the
end of its stroke.
26 D85EX, PX-15E0
q dP1 = dP3 + dP4 = Differential pressure between ports (M) and (P)
q dP2 = Differential pressure between ports (P) and (N)
q dP3 = Differential pressure between ports (M) and (B)
q dP4 = Differential pressure between ports (B) and (P)
q dLS = dP1 + dP2 = Differential pressure between ports (M) and (N) = 2.0 MPa {20 kg/cm2}
Operation
q If blade tilt spool (1) is moved and the pressure
of tilt cylinder (8) becomes higher, the poppet
of work equipment LS relief valve (5) will start
to open and oil will be drained from LS circuit
(O). [Ports (E), (F), (G), (J), (K) and (L)]
q As a result, there will be a drop in pressure in
LS passage (O) starting from LS sensing hole
(F), and (dP2) will become larger.
q For the same reason, if the pressure in cham-
bers (H) and (I) drops, spool (2) will push
against spring (3) and move to the right, and
will make the opening between chambers (B)
and (C) smaller, so the flow to chambers (B)
and (C) will be throttled and (dP4) will become
larger.
q Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by
the flow at work equipment LS relief valve (5).
(dP1) + (dP2) equal to LS differential pressure
(dLS).
q When this happens, pump LS valve (6) detects
the differential pressure generated by work
equipment LS relief valve (5), and moves the
pump swash plate angle from the maximum to
the minimum position. The pump swash plate
is balanced at a position where the LS differen-
tial pressure is 2.0 MPa {20 kg/cm2}.
q When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil
flow is greater than the LS relief oil flow + leak-
age at any part, the pressure is confined in the
pump circuit (between the pump and chambers
(A) and (B)), so the LS differential pressure
rises.
q If this differential pressure goes above the set
pressure for unload valve (4), the unload valve
is actuated to relieve the excess oil flow and
balance the circuit.
D85EX, PX-15E0 27
3. Compound operation of work equipment valve

a The diagram shows the relief condition of LS relief valves (4) and (5) at steering stall with the blade
tilt at the end of its stroke.
28 D85EX, PX-15E0
q d = P – P2
q dPO = Differential pressure between ports (H) and (K)
q Pressure P2 = LSO + dPO
Function
q When steering valve (1) and work equipment
valve (2) are relieved at the same time, the
pump pressure is separated by pressure com-
pensation valve (3) in the work equipment
valve, and the port pressure is maintained at a
constant value.
Operation
q If HSS motor (6) reaches the stall condition,
the load pressure increases and LS relief valve
(4) for the steering valve is actuated, so the
system is cut off.
q For details, see topic “1. Steering valve”.
q When this happens, the pump pressure is
maintained at 38.2 MPa {390 kg/cm2}, and this
is sent to chamber (G) of the work equipment
valve.
q When work equipment valve (2) is operated
and the load on the work equipment valve is
greater, work equipment LS relief valve (5) is
actuated, and drain oil flow (Q1) flows to LS
circuit (O).
q As a result, a differential pressure is generated
on the left and right sides of pressure compen-
sation valve (3) by LS throttle (M) of spool (2),
and it moves the full stroke to the right.
q When this happens, the opening between
chambers (D) and (E) is throttled to the mini-
mum size (pump pressure separated).
q Oil flow (Q1) is determined by pump pressure
(P) and the total pressure loss d (P – LSO) of
ports (C), (D), (E), (F), (G), (I), (J) and (K).
q Furthermore, pressure (P2) (the pressure in
chamber (H)) becomes the total (LSO + dPO)
of the circuit pressure loss of ports (H), (I), (J)
and (K), and the set pressure of work equip-
ment LS relief valve (5).
D85EX, PX-15E0 29
Compound operations
1. Steering + work equipment valve
a The diagram shows the condition when the steering and blade lift valve are operated at the same
time.
30 D85EX, PX-15E0
Function When pump swash plate does not reach maxi-

q The steering valve is equipped with steering mum angle
priority valve (3), so if the steering valve and q When the maximum oil flow from the pump is
the downstream work equipment valve are greater than the sum of the flow demanded by
operated at the same time, priority is given to the steering valve and work equipment valve,
the flow of oil to the steering valve, and the rest an amount of oil that matches the opening of
of the oil discharged from the pump goes to the steering spool (1) flows to the steering valve.
work equipment valve. q An amount of oil decided by the pump pres-
sure, the load pressure and the area of the
Operation spool opening flows to the work equipment
q When steering spool (1) is operated by pilot valve.
pressure (P1) and the oil flows, a differential
pressure is created between chambers (C) and When pump swash plate is at maximum angle
(D). q When the maximum flow of oil from the pump
q Steering priority valve (3) is controlled by this is smaller than the sum of the oil flow
differential pressure, and at the same time, the demanded by the steering valve and work
pump swash plate angle is controlled at equipment valve.
(dPLS) = 2.0 MPa {20 kg/cm2}, and the flow of
oil to the steering valve is fixed. 1) When steering valve load Z work equipment
q For details, see topic “1. Steering valve” of valve load.
“Control of oil flow.” q An amount of oil that matches the opening of
q In this condition, if downstream work equip- steering spool (1) flows to the steering valve,
ment lift spool (2) is operated, the pump pres- and the remaining oil flows to work equipment
sure momentarily drops. valve.
q At this point, the differential pressure between
chambers (C) and (D) becomes smaller, and 2) When steering valve load > work equipment
steering priority valve (3) is moved to the left by valve load.
the pressure in chamber (E) in the direction to q Pump pressure (P) is determined by the steer-
throttle the opening to the work equipment ing valve load, but in this condition, if the
valve. downstream work equipment valve where the
q At the same time, (dPLS) becomes smaller, so load is smaller is operated, the difference in
the pump swash plate angle moves in the max- pressure will cause the oil to try to flow to the
imum direction to supply an oil flow to make up work equipment valve, so the pump pressure
the amount that the pressures drops. will drop.
q When this happens, steering priority valve (3)
increases the size of the opening to the steer-
ing system, while at the same time reducing
the size of the opening to the work equipment
in order to ensure the flow of oil to the steering
system.
q In this condition, the flow of oil is divided in pro-
portion to the difference in pressure between
differential pressure (P) – (P1) and differential
pressure (P) – (P2).
q The bigger (P1) – (P2) is, the smaller the flow
of oil to the steering system becomes.
D85EX, PX-15E0 31
2. Compound operation of work equipment valve

a The diagram shows the condition when the blade lift and tilt valves are operated at the same time.
32 D85EX, PX-15E0
Function
q It consists of a parallel circuit, so when com-
pound operations are carried out, the oil flow is
divided according to the size of each spool
opening.
Operation
q When tilt spool (1) and lift spool (2) are at the
“hold” position or are “operated”, steering prior-
ity valve (3) is pushed completely to the right,
and the size of the opening to the downstream
area is at its maximum.
q Tilt spool (1) and lift spool (2) are actuated by
PPC valve output pressure (PA2) and (PB3),
and each is balanc ed at a position that
matches its own pilot pressure.
When pressure (P2) Z (P3)

q Lift valve load pressure (P3) is sent to pump
LS valve (4) through LS passage (O).
1) When pump swash plate does not reach maxi-

mum angle
q When the maximum flow of oil from the pump
i s g r e a te r th a n t h e t o ta l o f t h e o i l f l o w
demanded by the tilt valve and lift valve, an oil
flow that matches the opening of the spool
flows to both the tilt valve and lift valve.
2) When pump swash plate is at maximum angle

q When the maximum flow of oil from the pump
i s s m a l l e r t ha n t h e t o ta l o f t h e o i l fl o w
demanded by the tilt valve and lift valve, the
flow of oil to the tilt valve and lift valve is
divided according to differential pressure (PO)
– (P2) and differential pressure (PO) – (P3).
q In other words, more oil flows to (P2) where
the load is small.
a In cases where the blade is raised above

ground and the tilt valve and lift valve for
“raise” are operated at the same time, the tilt
valve load pressure is smaller than the lift
valve load pressure, so the flow of oil to the tilt
valve is given priority. In addition, the oil flow
demanded by the tilt valve is smaller, so the
condition is just as if priority was given to the
oil flow for the tilt valve.
When pressure (P2) = (P3)

q (P) – (P2) C (P) – (P3), so an oil flow propor-
tional to the size of the spool opening is distrib-
uted to each spool.
D85EX, PX-15E0 33
Unload valve preset system

a The diagram shows the condition with preset check valve (3) open immediately after blade lift valve is
operated.
34 D85EX, PX-15E0
Function
q This improves the response of the system
including the pump swash plate and pressure
compensation valve by sending the pilot pres-
sure (basic pressure of PPC valve) to the LS
circuit, and compensating the rise of the LS cir-
cuit pressure.
Operation
q When lift valve spool (1) is at the “hold” posi-
tion, pilot pressure (P1) (basic pressure of
PPC valve) is sent through preset check valve
(3) to chamber (F) of the pressure compensa-
tion valve. This pressure is called preset pres-
sure (P2).
q At the same time, unload pressure (P) is being
sent to chamber (B), but (P1) + (F0) > (P) (F0:
load of spring (4)), so pressure compensation
spool (2) moves to the left and the size of the
opening between chambers (A) and (B)
becomes the maximum.
q When spool (1) is switched, unload pressure
(P) flows immediately through chambers (A),
(B), (C), (D) and (E) to lift cylinder (8), so the
pressure at the port starts to rise and the time
lag becomes smaller.
q At the same time, preset pressure (P2) is sup-
plied to LS circuit (O) by the timing of the
spool, and the pressure in the LS circuit rises.
q Because of this, unload valve (7) closes, and
oil is sent further to pump LS valve (6) to
improve the response of the pump swash plate
angle. This makes it possible to reduce the
response time for giving the necessary oil flow.
D85EX, PX-15E0 35
Self pressure reducing valve 1
T: To tank
P1: From pump
P2: To fan motor
PR: Supply to PPC valve and EPC valve
36 D85EX, PX-15E0
1. Valve (sequence valve)

2. Spring
3. Screw
4. Poppet
5. Spring (pressure reducing valve pilot)
6. Spring (pressure reducing valve main)
7. Valve (pressure reducing valve)
8. Spring (safety valve)
9. Ball
10. Filter
D85EX, PX-15E0 37
Unit: mm
Free length
Spring × outer Free length
11 length load load
(pressure reducing valve main) diameter
19.6 N 17.7 N
19.2 × 7.20 16.1 — Replace spring if
{2.0 kg} {1.80 kg}
damaged or
Spring 28 N 25.6 N deformed.
12 17.8 × 7.20 12.7 —
(pressure reducing valve pilot) {2.90 kg} {2.60 kg}
200 N 186 N
13 Spring 71.0 × 18.0 59.0 —
{20.4 kg} {19.0 kg}
61.7 N 58.8 N
14 Spring (safety valve) 16.1 × 7.80 13.4 —
{6.30 kg} {6.0 kg}
Function
q The self pressure reducing valve reduces the
discharge pressure of the fan pump and sup-
plies it to the PPC valve, EPC valve, etc. as the
control pressure.
38 D85EX, PX-15E0
Operation
At engine stop (total low pressure)
q Spring (6) pushes poppet (5) to the seat, and

the circuit between ports (PR) and (T) is
closed.
q Spring (7) pushes valve (8) to the left side, and
the circuit between ports (P1) and (PR) is
open.
q Spring (3) pushes valve (2) to the upper side,
and the circuit between ports (P1) and (P2) is
closed.
D85EX, PX-15E0 39
When load pressure (P2) is lower than output pressure (PR) of the self pressure reducing valve
q Spring (3) and pressure (PR) [0 MPa {0 kg/

cm2} at the time of engine stop] pushes valve
(2) in the direction to close the circuit between
ports (P1) and (P2). When the hydraulic oil
enters port (P1), the expression [pressure (P1)
C Spring (3) force + (area (d) × pressure (PR))]
holds, and the self pressure reducing valve will
adjust the openings of ports (P1) and (P2) so
that pressure (P1) can be maintained higher
than pressure (PR).
q When pressure (PR) rises above set pressure,
poppet (5) opens and hydraulic oil flows
through the route, from port (PR), through hole
(a) in spool (8), through poppet (5) opening to
tank port (T).
q Therefore, differential pressure occurs around
hole (a) in spool (8) and spool (8) moves from
port (P1) in the direction to close opening (PR).
Then pressure (P1) is reduced and adjusted to
a certain pressure [set pressure] with the
opening and is supplied as pressure (PR).
40 D85EX, PX-15E0
At raise of load pressure (P2)
q When load pressure (P2) rises due to digging

or other operations, pump delivery increases
and pressure (P1) rises. Then the expression
{pressure (P1) > Spring (3) force + [area (d) ×
pressure (PR)]} will hold, and valve (2) will
move to the below side till the stroke end. As a
result, the opening between ports (P1) and
(P 2) inc reases and passage resi stanc e
becomes smaller, reducing engine horsepower
loss.
q When pressure (PR) rises above set pressure,
poppet (5) opens and hydraulic oil flows
through the route, from port (PR), through hole
(a) in spool (8), through poppet (5) opening to
tank port (T).
q Therefore, differential pressure occurs around
hole (a) in spool (8) and spool (8) moves from
port (P1) in the direction to close opening (PR).
Then pressure (P1) is reduced and adjusted to
a certain pressure [set pressure] with the
opening and is supplied as pressure (PR).
D85EX, PX-15E0 41
In the case of abnormal high pressure
q When pressure (PR) of the self pressure

reducing valve rises abnormally high, ball (10)
will separate from the seat against spring (9)
force to flow the hydraulic oil to output ports
(PR) o (T) so as to reduce pressure (PR). As
a result, the equipment [PPC valve, EPC
valve, etc.], to which the oil pressure is sup-
plied, is protected from the abnormal high
pressure.
42 D85EX, PX-15E0
SEN00300-00

© 2005 KOMATSU
All Rights Reserved
44
SEN00302-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Oil cooler bypass valve ........................................................................................................................ 2
PPC valve ............................................................................................................................................ 4
Electric lever (steering) ...................................................................................................................... 20
Quick drop valve ................................................................................................................................ 23
PPC lock valve ................................................................................................................................... 24
Accumulator ....................................................................................................................................... 25
D85EX, PX-15E0 1

Oil cooler bypass valve 1
C : From hydraulic oil cooler Outline

M: From fan motor q This valve is installed in the circuit between the
T : To hydraulic tank fan motor oil return circuit and the oil cooler. If
any abnormal pressure is generated in the oil
1. Plug flowing to the oil cooler, this valve acts to
2. Poppet return the oil directly to the hydraulic tank.
3. Spring
4. Body
Specified pressure
Cracking pressure
0.78 {8.0}
(MPa {kg/cm2})
2 D85EX, PX-15E0
Unit: mm
5 Spring length load load
61.5 N 58.4 N
30.4 24.5 29.5
{6.28 kg} {5.96 kg} Replace
Clearance between oil cooler size Shaft Hole clearance limit
6
bypass valve and valve body.
–0.032 +0.027 0.032 –
14 0.11
–0.059 +0.027 0.086
D85EX, PX-15E0 3
PPC valve 1
For blade lift and blade tilt
4 D85EX, PX-15E0
P: From self pressure reducing valve 1. Disc

T: To hydraulic tank 2. Plate
P1: To blade lift valve (port PA3) 3. Body
P2: To blade lift valve (port PB3)
P3: To blade tilt valve (port PA2)
P4: To blade tilt valve (port PB2)
D85EX, PX-15E0 5
Operation
At neutral
For blade lift For blade tilt
q Ports (PA3) and (PB3) of the blade lift control q Ports (PA2) and (PB2) of the blade tilt control
valve and ports (P1) and (P2) of the PPC valve valve and ports (P3) and (P4) of the PPC valve
are connected to drain chamber (D) through are connected to drain chamber (D) through
fine control hole (f) of spool (1). fine control hole (f) of spool (1).
6 D85EX, PX-15E0
During fine control
1. Control lever “neutral“ o fine control

q When piston (4) is pushed by disc (5),
retainer (9) is pushed, spool (1) is also
pushed by metering spring (2), and moves
down.
q By this move, fine control hole (f) is shut
off from drain chamber (D) and almost
simultaneously it is connected to pump
pressure chamber (PP). The pilot pres-
sure oil passes through fine control hole
(f) and is conducted from port (P1) to port
(PA3).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine
control hole (f) is shut off from pump pres-
sure chamber (PP). At almost the same
time, it is connected to drain chamber (D)
to release the pressure at port (P1).
q As a result, spool (1) moves up and down so
that the force of metering spring (2) is bal-
anced with the pressure at port (P1). The
relation between the positions of spool (1)
and body (10) [fine control hole (f) is at the
midpoint between drain chamber (D) and
pump pressure chamber (PP) ] does not
change until retainer (9) contacts spool (1).
q Therefore, metering spring (2) is com-
pressed in proportion to the strokes of the
control lever. Thus, the pressure at port
(P1) increases in proportion to the strokes
of the control lever.
q The control valve spool moves to a posi-
tion where the pressure in chamber (PA3)
[same as pressure at port (P1)] is bal-
anced with the force of the return spring.
D85EX, PX-15E0 7
During full stroke

2. When control lever is returned q When disc (5) pushes down piston (4) and
q When disc (5) starts to be returned, spool retainer (9) pushes down spool (1), fine control
(1) is pushed up by the force of centering hole (f) is shut off from drain chamber (D) and
spring (3) and the pressure at port (P1). is connected to pump pressure chamber (PP).
q Because of this, fine control hole (f) is con- q Therefore, the pilot pressure oil passes
nected to drain chamber (D), and the through fine control hole (f), is taken from port
pressurized oil at port (P1) is released. (P1) to chamber (PA3), and pushes the control
q If the pressure at port (P1) goes down too valve spool.
far, spool (1) is pushed down by metering q The return oil from chamber (PB3) passes from
spring (2). Fine control hole (f) is shut off port (P2) through fine control hole (f'), and then
from drain chamber (D), and almost simul- flows to drain chamber (D).
taneously, it is connected to pump pres-
sure chamber (PP). Pump pressure is
supplied until the pressure at port (P1)
recovers to a pressure equivalent to the
position of the lever.
q When the control valve spool returns, the
oil at drain chamber (D) flows in from fine
control hole (f') in the valve on the side
that is not moving. Oil passes through port
(P2), is taken to chamber (PB3), and fills
the chamber.
8 D85EX, PX-15E0
When blade is operated to “float“ When blade is released from “float“

q When piston (4) at port (P1) “lower“ side is q When disc (5) is returned from the “float“ posi-
pushed by disc (5) and moves down, ball (11) tion, it is pushed down by a force greater than
contacts protrusion (a) of the piston during the the hydraulic force in chamber (E).
stroke. [Detent starts to act] q As a result, chamber (E) is shut off from pas-
q When piston (4) is pushed in further, ball (11) sage (d) and is connected to the drain cham-
pushes up collar (12), which is being held by ber. Therefore, the oil pressure inside chamber
detent spring (13). While pushing up collar (E) is lost, and the “float“ position is canceled.
(12), it escapes to the outside and passes over
protrusion (a) of the piston.
q When this happens, piston (4') on the opposite
side is pushed up by spring (14).
q As a result, the oil inside chamber (F) passes
through (b) and (c), and flows to chamber (E),
and piston (4') follows disc (5). Passage (d) is
connected to port (P1), so more or less the
same pressure is applied as is applied to port
(P1).
q Chamber (E) is normally connected to drain
chamber (D), but if ball (11) passes over pro-
trusion (a) of the piston, passage (d) and
chamber (E) which were shut off, are con-
nected and the pressure oil flows.
q At the same time, the control valve also moves
to “float“ position and the circuit is set to the
“float“ condition.
q Piston (4') is being pushed up by the oil pres-
sure inside chamber (E), so even if the lever is
released, it is held at the “float“ position.
D85EX, PX-15E0 9
For fixed multi-shank ripper
T: To tank 1. Spool
P: From self pressure reducing valve 2. Metering spring
P1: To ripper valve (port PB4) 3. Centering spring
P2: To ripper valve (port PA4) 4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
10 D85EX, PX-15E0
Unit: mm
Free length
9 Centering spring length load load Replace spring if
diameter
damaged or
125 N 100 N deformed.
33.9 × 15.3 28.4 —
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
10 Metering spring 22.7 × 8.10 22.0 —
{1.70 kg} {1.36 kg}
D85EX, PX-15E0 11
Operation q As a result, spool (1) moves up and down

until the force of metering spool (2) is bal-
At neutral anced with the pressure at port (P1).
q Ports (A) and (B) of the control valve and ports q The relation between the positions of
(P1) and (P2) of the PPC valve are connected spool (1) and body (8) [fine control hole (f)
to drain chamber (D) via fine control hole (f) in is at the midpoint between drain chamber
spool (1). (D) and pump pressure chamber (PP)]
does not change until retainer (7) contacts
spool (1).
q In this way, the control valve spool moves
to a position where the pressure of cham-
ber (A) [same as pressure at port (P1)]
and the force of the return spring of the
control valve spool are balanced.
During fine control

q As piston (4) is pushed by lever (5),
retainer (7) is pushed too. At the same
time, spool (1) is also pushed down via
metering spring (2).
simultaneously, it is connected to pump
(A).
12 D85EX, PX-15E0
During full stroke

2. When control lever is returned q When lever (5) pushes down piston (4) and
q When lever (5) starts to be returned, spool retainer (7) pushes down spool (1), fine control
Because of this, fine control hole (f) is con- q Therefore, the pilot pressure oil passes
pressurized oil at port (P1) is released. (P1) to chamber (A), and pushes the control
far, spool (1) is pushed down by metering q The oil returning from chamber (B) passes
spring (2). Fine control hole (f) is shut off from port (P2) through fine control hole (f') and
q When the spool of the control valve
returns, the oil in drain chamber (D) flows
in from fine control hole (f') in the valve on
the side that is not working. The oil passes
through port (P2) and enters chamber (B)
to replenish the chamber with pressurized
oil.
D85EX, PX-15E0 13
For scraper and variable multi-shank ripper
P: From PPC lock valve

T: To tank
P1: To scraper ball or ripper tilt spool (port PA5)
P2: To scraper ball or ripper tilt spool (port PB5)
P3: To scraper apron or ripper lift spool (port PA4)
P4: To scraper apron or ripper lift spool (port PB4)
D85EX, PX-15E0 15
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for lever connection)
16 D85EX, PX-15E0
Unit: mm
Free length
Centering spring × outer Free length
12 length load load
(For ports P3 and P4) diameter
Replace spring if
55.9 N 44.7 N
50.4 × 15.5 34.0 — damaged or
{5.7 kg} {4.56 kg}
deformed.
Centering spring 71.4 N 56.9 N
13 50.1 × 15.5 34.0 —
(For ports P1 and P2) {7.28 kg} {5.8 kg}
16.7 N 13.3 N
14 Metering spring 26.5 × 8.20 24.9 —
{1.70 kg} {1.36 kg}
D85EX, PX-15E0 17
Operation q As a result, spool (1) moves up and down

so that the force of metering spring (2) is
At neutral balanced with the pressure at port (P1).
q Ports (A) and (B) of the control valve and ports The relation between the positions of
(P1), (P2), (P3) and (P4) of the PPC valve are spool (1) and body (10) [fine control hole
connected to drain chamber (D) through fine (f) is at the midpoint between drain cham-
control hole (f) of spool (1). ber (D) and pump pressure chamber (PP)]
does not change until retainer (9) contacts
spool (1).
q In this way, the control valve spool moves
to a position where the pressure of cham-
ber (A) [same as pressure at port (P1)]
and the force of the return spring of the
control valve spool are balanced.
During fine control

q When piston (4) is pushed by disc (5),
retainer (9) is pushed, spool (1) is also
pushed by metering spring (2), and moves
down.
simultaneously, it is connected to pump
(A).
18 D85EX, PX-15E0
During full stroke

2. When control lever is returned q When disc (5) pushes down piston (4) and
q When disc (5) starts to be returned, spool retainer (9) pushes down spool (1), fine control
q Because of this, fine control hole (f) is con- q Therefore, the pilot pressure oil passes
pressurized oil at port (P1) is released. (P1) to chamber (A), and pushes the control
far, spool (1) is pushed down by metering q The oil returning from chamber (B) passes
spring (2). Fine control hole (f) is shut off from port (P2) through fine control hole (f') and
q When the spool of the control valve
returns, the oil in drain chamber (D) flows
in from fine control hole (f') in the valve on
the side that is not working. The oil passes
through port (P2) and enters chamber (B)
to replenish the chamber with pressurized
oil.
D85EX, PX-15E0 19
Electric lever (steering) 1
a Do not disassemble.
Otherwise, adjustments will be required for the characteristics of voltage output and operating efforts.
1. Boot 5. Screw
2. Bracket 6. Lever
3. Plate 7. Connector
4. Bolt
20 D85EX, PX-15E0
Function
Operating effort characteristics

1. Operation for forward and reverse travel 2. Operation for left and right steering
q The control lever is held at 3 positions: q Free return
“forward“, “neutral“ and “reverse“.
D85EX, PX-15E0 21
Output voltage characteristics

q The control unit is installed to the left control
stand and the control lever is installed directly
onto it.
q The operating angle (stroke) of the control
levers sensed with potentiometers and signal
voltages are output to the transmission, steer-
ing controller.
q A potentiometer is installed in each of longitu-
dinal direction and lateral direction. Each
potentiometer outputs 2 signal voltages which
are opposite to each other as shown in the fig-
ure at right.
22 D85EX, PX-15E0
Quick drop valve 1

(lift cylinder)
Unit: mm
Clearance between spool and size Shaft Hole clearance limit
1
valve body –0.011 +0.010 0.011 –
38.0 0.03
–0.016 +0.010 0.026

2 Valve spring length load load
136.3 N 122.6 N
75.2 55.9 67.7
{13.9 kg} {12.5 kg}
D85EX, PX-15E0 23
PPC lock valve 1

1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
q The PPC lock valve is installed in the PPC cir-
cuit between the PPC charge valve and PPC
valve. When the work equipment lock lever is
placed at the “lock“ position, the PPC lock
valve is actuated together with the work equip-
ment lock lever. This stops the oil in the PPC
circuit and makes it impossible to operate the
work equipment.
24 D85EX, PX-15E0
Accumulator 1
For PPC circuit
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Outline
q The accumulator is installed between the cool-
ing fan pump and blade PPC valve. Even if the
engine is stopped with the work equipment
raised, the operator can send pilot oil pressure
to the control valve the have the work equip-
ment lower with its own weight by using nitro-
gen gas pressure in the accumulator.
Specifications
Gas used: Nitrogen gas
Quantity of gas: 300 cc
Charged gas pressure: 1.18 MPa {12 kg/cm2}
(at 80 °C)
Max. allowable working
pressure: 6.86 MPa {70 kg/cm2}
D85EX, PX-15E0 25
SEN00302-00

© 2005 KOMATSU
All Rights Reserved
26
SEN00305-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Work equipment
Work equipment .............................................................................................................................................. 3
Cylinder stay ........................................................................................................................................ 3
Blade .................................................................................................................................................... 4
Cutting edge and end bit ...................................................................................................................... 6
Ripper................................................................................................................................................... 8
Hydraulic cylinder............................................................................................................................... 10
Piston valve........................................................................................................................................ 12
D85EX, PX-15E0 1
Work equipment 1
Cylinder stay 1
1. Yoke
2. Oil seal
3. Bushing
4. Bushing
5. Air breather plug
Unit: mm
Clearance between cylinder yoke size Shaft Hole clearance limit
6
and bushing –0.144 +0.054 0.144 –
115 —
–0.198 +0.054 0.252
Replace
Clearance between cylinder yoke –0.147 +0.046 0.147 –
7 76 —
and bushing –0.193 +0.046 0.239
Clearance between lift cylinder –0.100 +0.075 0.100 –
8 75 0.5
support shaft and bushing –0.174 +0.075 0.249
D85EX, PX-15E0 3
Blade 1
Semi-U dozer
4 D85EX, PX-15E0
Unit: mm
size Shaft Hole clearance limit
1 Clearance between brace and pin
–0.3 +0.5 Replace
60 0.6 – 1.0 2
–0.5 +0.3
Clearance between brace pin and –0.3 +0.5
2 60 0.5 – 1.0 2
bracket –0.5 +0.2
Clearance between brace spherical –0.1 +0.5
3 100 0.2 – 0.6 1
surface and cap –0.1 +0.2 Adjust shim
Clearance between center brace –0.1 +0.5 or replace
4 100 0.2 – 0.6 1
spherical surface and cap –0.1 +0.2
Clearance between joint and blade –0.2 +0.5
5 120 0.5 – 1.2 2
bracket –0.7 +0.3
Clearance between frame pin and –0.3 +0.3
6 60 0.3 – 0.8 3
joint –0.5 +0.3
Replace
Clearance between blade bracket –0.3 +0.3
7 60 0.3 – 0.8 3
pin and blade bracket –0.5 +0.3
Clearance between blade bracket –0.3 +0.3
8 60 0.3 – 0.8 3
pin and joint –0.5 +0.3
Clearance between center brace –0.1 +0.5 Adjust shim
9 100 0.2 – 0.6 1
spherical surface and cap –0.1 +0.2 or replace
Clearance between center link pin –0.3 +0.1
10 85 0.2 – 0.6 2
and center link –0.5 –0.1
Clearance between center link pin –0.3 +0.3
11 85 0.3 – 0.8 2
and blade bracket –0.5 +0.3
Replace
Clearance between center link and –0.1 +0.5
12 196 0.3 – 0.6 2
blade bracket –0.1 +0.3
Clearance between trunnion spher- –0.5 +0.5
13 160 0.5 – 1.5 8
ical surface and cap –1.0 +0.5
D85EX, PX-15E0 5
Cutting edge and end bit 1
Unit: mm
Standard size Repair limit Replace or reverse
1 Height of cutting edge (after reversing
254 213 max. 172 mm)
2 Height of end bit (outside) 302 211
3 Height of end bit (inside) 254 211 Replace
4 Width of end bit 447 360
6 D85EX, PX-15E0
Ripper 1
Unit: mm
Clearance between link pin and size Shaft Hole clearance limit
1
bushing –0.030 +0.396 0.229 –
75 1.5
–0.076 +0.199 0.472
Clearance between link pin and –0.030 +0.165 0.145 –
2 75 1.5
bushing –0.076 +0.115 0.241
Clearance between shank holder Shaft: 60 +0.300 +0.300 1.400 – Replace
3 10.0
and shank pin Hole: 62 –0.300 –0.300 2.600
Clearance between shank pin and Shaft: 60 +0.300 +1.000 3.700 –
4 15.0
shank hole Hole: 65 –0.300 –1.000 6.300
5 Wear of point
335 225
6 Wear of protector 113 93
8 D85EX, PX-15E0
Unit: mm
Clearance between link pin and size Shaft Hole clearance limit
1
bushing –0.036 +0.207 0.156 –
85 1.5
–0.090 +0.120 0.297
Clearance between shank holder Shaft: 60 +0.300 +0.300 1.400 –
2 10.0
and shank pin Hole: 62 –0.300 –0.300 2.600 Replace
Clearance between shank pin and Shaft: 60 +0.300 +1.000 3.700 –
3 15.0
shank hole Hole: 65 –0.300 –1.000 6.300
4 Wear of point
335 225
5 Wear of protector 113 93
D85EX, PX-15E0 9
Hydraulic cylinder 1
For power tilt dozer
Lift cylinder
Tilt cylinder
Ripper lift cylinder

Ripper tilt cylinder (for variable multi-shank ripper)
a The above figure shows lift cylinder for fixed multi-shank ripper. Lift cylinder and tilt cylinder for variable
multi-shank ripper are different in form of piping.
10 D85EX, PX-15E0
Unit: mm
size Shaft Hole clearance limit
–0.030 +0.250 0.085 –

Lift 65 0.626
Clearance between –0.076 +0.055 0.326
1
piston rod and bushing –0.030 +0.279 0.095 –
Tilt 75 0.655
–0.076 +0.065 0.355
Ripper –0.030 +0.271 0.105 –
70 0.675
lift/tilt –0.104 +0.075 0.375
Clearance between pis-
ton rod spherical sur- +0.3
2 Lift S85 — — 1.0
face and blade ball +0.3
portion
Replace
Clearance between cyl-
–0.100
3 inder support shaft Lift 75 — — 0.5
–0.174
bushing and yoke
Clearance between pis-
–0.200
4 ton rod spherical sur- Tilt S100 — — —
–0.300
face and cap
+0.174
Clearance between Tilt 60 — — 1.0
+0.100
5 cylinder bottom support
shaft and bushing Ripper +0.286
75 — — 1.0
lift/tilt +0.184
Clearance between
Ripper +0.286
6 piston rod support shaft 75 — — 1.0
lift/tilt +0.184
and bushing
D85EX, PX-15E0 11
Piston valve 1
(lift cylinder)
Outline
q The piston valve is installed on the piston in
the blade lift cylinder. When the piston reaches
its stroke end, the valve releases the oil from
the HSS pump to reduce the oil pressure being
exerted on the piston.
In addition, the piston valve relieves the shock
which occurs when the piston comes into con-
tact with the cylinder head or the bottom, and
serves to reduce the subsequent surge pres-
sure in the cylinder by letting the oil escape
from the cylinder before the piston reaches its
stroke end.
Operation
Piston valve “closed” Piston valve “open”
Just before piston rod (1) reaches its stroke end,

The oil from the work equipment pump acts on pis- the tip of valve (6) contacts the cylinder bottom, so
ton (2) and piston valve (3). valve (6) and piston valve (3) stop at the position
Piton valve (3) is pushed to the right and it seals the and do not move further. Only piston (2) moves fur-
tapered section of piston valve seat (4). This ther.
causes the pressure in the cylinder to rise and the At this moment, the oil at the cylinder head, which
piston (2) moves to the right. was sealed by piston valve (3), escapes from piston
valve seats (4) and (5), and the pressure inside the
cylinder stops rising.
12 D85EX, PX-15E0
SEN00305-00

© 2005 KOMATSU
All Rights Reserved
14
SEN00306-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Cab and its attachments
Cab and its attachments ................................................................................................................................. 2
Cab mount............................................................................................................................................ 2
Cab....................................................................................................................................................... 3
Air conditioner ...................................................................................................................................... 5
D85EX, PX-15E0 1
Cab and its attachments 1

Cab mount 1
1. Support Outline
2. Damper mount (front) q Mounts are installed at two places in the front
3. Damper mount (rear) and two places in the rear to secure the floor
frame and cab.
q An oil-filled damper mount is used to absorb
the vibration.
2 D85EX, PX-15E0
Cab 1
1. Front wiper
2. Front window
3. Rear wiper
4. Door
D85EX, PX-15E0 3
a ROPS: Abbreviation for RollOver Protective Structure
1. ROPS guard
4 D85EX, PX-15E0
Air conditioner 1
1. Condenser A: Fresh air inlet

2. Hot water outlet B: Recirculated air
3. Hot water pickup piping C: Hot air/cold air
4. Refrigerant piping
5. Receiver tank
6. Hot water return piping
7. Compressor
8. Hot water inlet
9. Front window defroster
10. Air conditioner unit
11. Vent
12. Blower motor
13. Side window defroster
D85EX, PX-15E0 5
SEN00306-00

© 2005 KOMATSU
All Rights Reserved
6
SEN00308-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Electrical system
Electrical system ............................................................................................................................................. 2
Monitor system..................................................................................................................................... 2
Monitor panel ....................................................................................................................................... 4
Engine control ...................................................................................................................................... 8
Engine control system.......................................................................................................................... 9
System components........................................................................................................................... 10
CRI engine control system ................................................................................................................. 20
Palm command control system .......................................................................................................... 22
KOMTRAX terminal system ............................................................................................................... 24
Sensor................................................................................................................................................ 26
D85EX, PX-15E0 1
Electrical system 1
Monitor system 1
q The monitor system notifies the operator of the q The CPU (Central Processing Unit) in the mon-
machine condition. It monitors the machine itor panel displays and outputs various infor-
condition with the sensors installed to various mation items processed by the transmission
parts of the machine and processes and dis- steering controller. The display unit is LCD
plays the obtained information on the panel (Liquid Crystal Display).
immediately.
The contents displayed on the panel are
roughly classified as shown bellow.
1. Machine trouble alarm (Monitor section)

2. Coolant temperature, torque converter oil
temperature, and fuel level (gauge sec-
tion)
3. Error code
4. Current and voltage of each sensor and
solenoid
2 D85EX, PX-15E0
Processing in monitor panel (Common to all specifications)
Display of monitor panel

Contents and conditions of processing Method Flow of signals
1. Display of travel direction and gear speed
F1, R3, etc. are notified by CAN signal according to information of CAN signal
transmission and steering controller.
2. Display of gauges of engine speed, engine coolant temperature, etc.
Controller converts the sensor signals into gauge numbers and sends CAN signal
them to the monitor panel by CAN signal.
3. Display of trouble
When the machine has a trouble, the corresponding failure code is Each sensor/solenoid
notified to the monitor panel by CAN signal. O
Which one should be turned on, the buzzer or the caution lamp, is Controller
notified, too. O
1) In normal state Monitor panel
User code
CAN signal
2) In trouble history display mode
The service code (6-digit code) and the following items are dis-
played
q Time after first occurrence
q Time after latest occurrence
q Number of past occurrences
The monitor panel displays the code on the multi information section.
Display of monitoring condition

1. The communication conditions of each sensor, each solenoid, and
CAN signal are displayed.
The item Nos. and device conditions are notified to the monitor panel Each sensor
CAN signal O
by CAN signal.
The monitor panel displays the items and each value on its multi-infor- Controller
mation section. O
Monitor panel
2. Each items is selected by using the cursor switches, selector switches,
CAN signal
buzzer cancel switch, and shift UP/DOWN switches.
a For details of the operating method, see “Testing and adjusting, Special functions of monitor panel
(EMMS)”.
Other items
1. Maintenance mode
2. Pm clinic auxiliary mode
3. Adjustment mode
4. Failure code display mode Each sensor
5. Maintenance interval change mode O
6. Electric system failure code display mode CAN signal Controller
7. Mechanical system failure code display mode O
8. Adjustment mode Monitor panel
9. Load saving display mode
10. Real-time monitoring mode
11. Dual display monitoring mode
a For details of the operating method, see “Testing and adjusting, Special functions of monitor panel
(EMMS)”.
D85EX, PX-15E0 3
Monitor panel 1
1. Display panel A (gear speed display and 8. Power train oil temperature caution lamp
engine speed) 9. Coolant temperature caution lamp
2. Charge level caution lamp 10. Engine oil pressure caution lamp
3. Power train oil temperature gauge 11. Maintenance caution lamp
4. Coolant temperature gauge 12. Preheating pilot lamp
5. Fuel gauge 13. Coolant level caution lamp
6. Hydraulic oil temperature gauge 14. Display panel B (Multi-information)
7. Hydraulic oil temperature caution lamp
Outline Check before starting

q The monitor panel consists of the monitor sec- 1) After all the lighting described above is termi-
tion which issues an alarm when the machine nated, if there is any error in the check-before-
has any trouble, the gauge section which dis- starting items, the corresponding item flashes
plays the machine condition constantly, and and the contents of the error are displayed on
the service meter display section. the display panel B (14).
A microcomputer is installed in the monitor 2) If the engine is started, the light of the check-
panel and the signals from each sensor and before-starting items turns off. (Whether the
controller are processed and displayed. engine is running is judged by the signal (CAN)
The items displayed on the monitor section from the engine controller.)
and the gauge section are listed in the table on
the next page. Caution items
q The caution items are checked constantly
Operation while the engine is running.
When power is turned ON (When starting switch If an error occurs, the error is displayed by
is turned to “on” position) flashing and the warning lamp synchronously
1) All items of the gauge section and the monitor flashes.
section light up for 3 seconds. Further, if an emergency item flashes, the
2) The warning lamp lights up for 2 seconds. alarm buzzer also sounds at the same time.
a The monitor and the alarm lamp light up and
go off repeatedly at the intervals of about 0.8
seconds.
a The flashing frequency of the monitor may
slightly change when outside temperature is
low (below about –10°C), however, this does
not indicate any abnormality.
4 D85EX, PX-15E0
Display of monitor panel
D85EX, PX-15E0 5
6 D85EX, PX-15E0
Engine control 1
1. Decelerator pedal Outline

2. Decelerator potentiometer q The throttle signals of fuel dial (4) and deceler-
3. Starting switch ator pedal (1) enter transmission and steering
4. Fuel dial controller (7) and are processed together with
5. Battery the 3rd throttle signal, then are sent to engine
6. Battery relay controller (8) as throttle commands. Engine
7. Transmission and steering controller controller (8) controls the engine according to
8. Engine controller the commands.
9. Starting motor
10. Fuel supply pump
8 D85EX, PX-15E0
Engine control system 1
Outline q The information from the engine controller is

q The engine controller receives the fuel control possessed jointly by the other controllers
dial signal of the 1st throttle, the decelerator through the network and used for the optimum
pedal signal of the 2nd throttle, and the 3rd control of the relationship between the engine
throttle signal which is a control signal from the and the machine body.
transmission and steering controller, and then q The automatic deceleration is a function of lower-
selects the command signal indicating the lowing the engine speed temporarily when the travel
est engine speed and controls the fuel supply direction is changed from F3, R3, F2 or R2 (for
pump. protection of the transmission clutch).
The control signals of the 3rd throttle are as q The neutral deceleration is a function of limit-
follows. ing the high idle speed when the transmission
1) Automatic-deceleration (F3, R3, F2, R2) is set in neutral.
2) Neutral deceleration
q The transmission and steering controller calcu-
lates a proper engine speed from the informa-
tion such as 1) and 2) and sends it as the 3rd
throttle signal to the engine controller.
D85EX, PX-15E0 9
System components 1
Fuel control dial
1. Knob Function
2. Dial q The fuel control dial is installed to the left side
3. Spring of the operator's seat.
4. Ball q If knob (1) is turned, the shaft of potentiometer
5. Potentiometer (5) is turned to change the resistance of the
6. Connector variable resistor and send a throttle signal to
the engine controller.
q The hatched areas in the following graph is the
abnormality detection areas. In those areas,
the engine speed is reduced to a half.
10 D85EX, PX-15E0
Deceleration potentiometer
1. Connector Outline
2. Lever q The deceleration potentiometer is installed to
3. Body the front lower part of the operator's cab and
4. Potentiometer connected to the decelerator pedal by linkage.
5. Coupling q If the decelerator pedal is pressed, the throttle
6. Shaft potentiometer shaft rotates by the linkage and
7. Stopper the potentiometer resistance changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and an electric
signal is sent through pin (B) to the engine
controller according to the position of the
decelerator pedal.
D85EX, PX-15E0 11
Engine controller
q The signal classification used in the following CN-CE01

terminal table is as follows: Input/
A: Power source Pin No. Signal name
Output
B: Input 11 EGR valve (–) C
C: Ground/shield/return 12 NC (*) —
D: Output 13 Engine oil pressure sensor D
E: Communication 14 NC (*) —
CN-CE01 15 Water temperature sensor D
Input/ 16 Sensor power source (5V) A
Pin No. Signal name
Output 17 NC (*) —
1 NC (*) — 18 NC (*) —
2 NC (*) — 19 EGR valve position sensor D
3 Atmospheric pressure sensor D 20 NC (*) —
4 Supply pump #1 (+) B 21 NC (*) —
5 Supply pump #1 (–) C 22 EGR valve (+) B
6 CAN (–) C 23 Boost temperature sensor D
7 NC (*) — 24 NC (*) —
8 CAN (+) B 25 Common rail pressure sensor D
9 Supply pump #2 (+) B 26 Bkup sensor (+) D
10 Supply pump #2 (–) C 27 NE sensor (+) D
*: Do not connect to NC since it will cause malfunction and trouble. *: Do not connect to NC since it will cause malfunction and trouble.
12 D85EX, PX-15E0
CN-CE01 CN-CE02
Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
28 NC (*) — 13 NC (*) B
29 NC (*) — 14 NC (*) B
30 Fuel temperature sensor D 15 NC (*) B
31 NC (*) — 16 NC (*) B
32 NC (*) — 17 NC (*) B
33 Sensor power source (5V) A 18 NC (*) B
34 NC (*) — 19 NC (*) B
35 NC (*) — 20 NC (*) E
36 NC (*) — 21 NC (*) A
37 Sensor power source (5V) A 22 Fuel dial (+5V) A
38 GND C 23 Fuel dial (–) C
39 NC (*) — 24 NC (*) B
40 NC (*) — 25 NC (*) B
41 NC (*) — 26 NC (*) B
42 NC (*) — 27 NC (*) B
43 NC (*) — 28 NC (*) B
44 Boost pressure sensor D 29 NC (*) C
45 Injector #1 (+) B 30 NC (*) B
46 Injector #5 (+) B 31 NC (*) B
47 Sensor GND C 32 NC (*) C
48 Ne sensor (–) C 33 NC (*) C
49 NC (*) — 34 NC (*) C
50 NC (*) — 35 NC (*) B
51 Injector #2 (–) C 36 NC (*) B
52 Injector #3 (–) C 37 CAN (shield) C
53 Injector #1 (–) C 38 NC (*) D
54 Injector #2 (+) B 39 Key switch (ACC) B
55 Injector #3 (+) B 40 Intake air heater relay activate D
56 Injector #4 (+) B 41 NC (*) D
57 Injector #6 (+) B 42 GND C
58 Injector #4 (–) C 43 NC (*) D
59 Injector #6 (–) C 44 NC (*) D
60 Injector #5 (–) C 45 NC (*) —
*: Do not connect to NC since it will cause malfunction and trouble. 46 CAN(+) E
47 CAN(–) E
CN-CE02 48 NC (*) D
Input/ 49 NC (*) D
Pin No. Signal name
output 50 NC (*) D
1 NC (*) B *: Do not connect to NC since it will cause malfunction and trouble.
2 NC (*) B
3 NC (*) B CN-CE03
4 NC (*) B Input/
Pin No. Signal name
5 NC (*) B Output
6 NC (*) B 1 GND C
7 NC (*) B 2 GND C
8 NC (*) B 3 Power source (+24V constant) A
9 Fuel control dial (+) B 4 Power source (+24V constant) A
10 NC (*) E *: Do not connect to NC since it will cause malfunction and trouble.
11 NC (*) B
12 NC (*) B
*: Never connect to NC or malfunctions or failures will occur.
D85EX, PX-15E0 13
Transmission and steering controller
14 D85EX, PX-15E0
Input and output signals
DEUTSCH-24P [CN-PTC1]
Input/Output Input/Output
signal signal
1 Work equipment oil pressure sensor Input 13 Travel lever position 3 Input
2 Steering lever potentiometer 1 Input 14 NC —
3 Brake pedal potentiometer Input 15 Alternator (R) Input
4 GND (signal) — 16 Sensor power source (+24 V) Output
5 NC — 17 Key C signal Input
6 Service SW Input 18 Shift down SW (NO) Input
7 Travel lever position 4 Input 19 Travel lever position 2 Input
8 Pitch angle sensor Input 20 Fuel dial Input
9 Hydraulic oil temperature sensor Input 21 GND (analog) —
10 NC — 22 Sensor power source (+5 V) Output
11 NC — 23 NC —
12 Shift up SW (NC) Input 24 Shift down SW (NC) Input
DEUTSCH-40P(1) [CN-PTC2]
signal signal
1 NC — 21 NC —
2 NC — 22 CAN0 (L) Input/Output
3 NC — 23 NC —
4 Flash ROM write (Rx) Input 24 Flash ROM write permission signal Input
5 Parking SW (NC) Input 25 T/M reverse fill SW Input
6 Cursor SW2 Input 26 Select SW Input
7 Fan reverse SW Input 27 NC —
8 Neutral safety relay Output 28 NC —
9 Engine controller activating command Output 29 GND (Pulse) —
10 Manual mode SW Input 30 Bevel speed Input
11 NC — 31 NC —
12 CAN shield — 32 CAN0 (H) Input/Output
13 NC — 33 NC —
14 Flash ROM write (Tx) Output 34 GND (Flash ROM write) —
15 Parking SW (NO) Input 35 T/M forward fill SW Input
16 Cursor SW1 Input 36 Alarm buzzer cancel SW Input
17 Fan forward SW Input 37 Automatic shift-down SW Input
18 Backup alarm relay Output 38 NC —
19 Engine controller shutoff relay Output 39 NC —
20 Relay input Input 40 NC —
DEUTSCH-40P(2) [CN-PTC3]
signal signal
1 Power source (Controller) Input 21 GND (Power source) Input
2 Power source (Solenoid) Input 22 Power source (Solenoid) Input
3 GND (Solenoid, common) Input 23 GND (Solenoid, common) Input
4 For activating battery relay Output 24 Starting switch (ACC) Input
5 NC — 25 HSS spool (Left) Output
6 1st gear speed ECMV Output 26 3rd gear speed ECMV Output
7 NC — 27 Forward ECMV Output
8 NC — 28 NC —
9 Shift up SW (NO) Input 29 T/M 2nd gear fill SW Input
10 NC — 30 HSS specification selection Input
11 Power source (Controller) Input 31 GND (Power source) Input
12 Power source (Solenoid) Input 32 GND (Power source) Input
13 GND (Solenoid, common) Input 33 GND (Power source) Input
14 Starting switch (ACC) Input 34 Sensor power source (+5V) Output
15 NC — 35 HSS spool (Right) Output
16 2nd gear speed ECMV Output 36 Fan control SOL Output
17 HSS pump TVC SOL Output 37 Reverse ECMV Output
18 Fan reverse SOL Output 38 NC —
19 T/M 1st gear fill SW Input 39 T/M 3rd gear fill SW Input
20 NC — 40 C/B specification selection Input
D85EX, PX-15E0 15
Engine oil pressure switch
1. Connector
2. Sensor
3. O-ring
Coolant temperature sensor

Fuel temperature sensor
1. Connector
2. Sensor
3. O-ring
16 D85EX, PX-15E0
Engine speed sensor
1. Connector
2. Sensor
3. O-ring
Atmospheric pressure sensor
1. Connector
2. Pressure induction hole
D85EX, PX-15E0 17
Boost pressure sensor
1. O-ring
2. Sensor
3. Connector
Boost temperature sensor
1. Connector
2. Sensor
3. O-ring
18 D85EX, PX-15E0
EGR valve stroke sensor
1. Core
2. O-ring
3. Sensor
4. Connector
D85EX, PX-15E0 19
CRI engine control system 1

a CRI: Abbreviation for Common Rail Injection.
System diagram
1. Fuel tank 5. Common rail

2. Fuel supply pump assembly 6. Pressure limiter
2A. PCV 7. Flow damper
2B. High pressure pump 8. Injector assembly
2C. Priming pump 9. Fuel cooler
2D. Feed pump 10. Engine controller
2E. Bypass valve 11. NE speed sensor
2F. G speed sensor 12. Large-capacity priming pump
3. Fuel filter 13. Check valve
4. Overflow valve 14. Additional fuel filter
20 D85EX, PX-15E0
Outline
q The signals detected by various sensors are
input to the engine controller.
q The input signals are processed by the control-
ler and output to each actuator to control the
fuel injection rate and fuel injection timing.
System configuration
q The CRI system consists of the fuel supply q The fuel pressure in the common rail is applied
pump, common rail, injector, engine controller to the nozzle side of the injector and to the
to control them, and sensors. control chamber through the fuel injection pipe
q The fuel supply pump generates fuel pressure of each cylinder.
in the common rail. The fuel pressure is con- q The injector controls the fuel injection rate and
trolled by the fuel discharge rate of the supply fuel injection timing by turning on and off the
pump. TWV (2-way solenoid valve).
q The discharge rate is controlled by turning on q If the TWV is turned on (energized), the fuel
and off the PCV (pressure control valve) of the circuit is so changed that the high-pressure
fuel supply pump according to the electric sig- fuel in the control chamber will flow through the
nals from the engine controller. orifice. As a result, the needle valve is raised
q The common rail receives the pressurized fuel to start fuel injection by the nozzle cracking
from the fuel supply pump and distributes it to pressure of the high-pressure fuel on the noz-
the cylinders. zle side.
q The fuel pressure is sensed by the common q If the TWV is turned off (de-energized), the fuel
rail fuel pressure sensor installed to the com- circuit is so changed that the high-pressure
mon rail. fuel will be applied to the control chamber
q A feedback control is applied so that the actual through the orifice. As a result, the needle
fuel pressure will match to the command pres- valve lowers and finishes fuel injection.
sure set according to the engine speed and the q Accordingly, the fuel injection timing and fuel
load on the engine. injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.
D85EX, PX-15E0 21
Palm command control system 1
1. Monitor panel (Multi-information)

2. Preset mode switch
3. Auto shift-down switch
4. Engine controller
5. Transmission and steering controller
6. Engine speed sensor
7. Transmission clutch ECMV
8. Steering control valve
9. Transmission output shaft speed sensor
22 D85EX, PX-15E0
Shift mode function Auto shift-down function

1. Function 1. Function
When you shift the PCCS lever to the forward This function automatically shifts the gear
or reverse, the gear speed selected from the speed down if load is increased while the
shift mode is applied. machine is traveling at 2nd or 3rd speed or
q Shift mode 1: F1/R1 while the machine is in operation.
q Shift mode 2: F1/R2
q Shift mode 3: F2/R1 1) This function turns on the shift-down auto-
q Shift mode 4: F2/R2 matically by calculating the drawbar pull
(load to the machine body) based the
2. Type of modes engine speed, transmission speed and
1) F1-R1 throttle information from the transmission
2) F1-R2 and steering controller.
3) F2-R1 2) Once the transmission gear is shifted
4) F2-R2 down automatically, it is not shifted up
again to the former gear speed automati-
3. How to use cally.
Turn the preset mode switch “on”. (It can be shifted up with the shift switch,
Shift the PCCS lever to “N”. however)
Select a mode with the shift up switch and shift 3) This function is applicable to both forward
down switch. and reverse travels.
4. Display 2. How to use

The selected mode is displayed on the monitor Turn auto shift-down switch (1) “on”.
panel.
D85EX, PX-15E0 23
KOMTRAX terminal system 1

(if equipped)
q The KOMTRAX terminal sends various information on the machine by a wireless communication. The
KOMTRAX operator refers to this information in the office, and various services can be provided for the
customer.
a To be provided with the KOMTRAX terminal service, it is necessary to sign up separately.
Information that can be sent from the KOMTRAX terminal is as follows:

1. Traveling history
2. Service meter
3. Location information
4. Error history
24 D85EX, PX-15E0
KOMTRAX terminal 1
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)
Input and output signals

DEUTSCH-40P [CN-G01]
signal signal
1 NC — 21 Operation mode selection 1 Input
2 NC — 22 Operation mode selection 2 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 CAN shield GND — 26 NC —
7 CAN signal (L) Input/Output 27 Starting switch (C) Input
8 CAN signal (H) Input/Output 28 Alternator (R) Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch (ACC) Input
17 NC — 37 Power source GND —
18 NC — 38 Power source GND —
19 NC — 39 Constant power source (24V) Input
20 Immobilizing signal Output 40 Constant power source (24V) Input
Outline
q The KOMTRAX controller can send informa-
tion via wireless communication antenna,
acquiring various information of the machine
from the network signal in the machine and the
input signal. Also, the controller incorporates
CPU (Central Processing Unit) and provide the
wireless communication function and the GPS
function.
q There are the LED lamp and the 7-segment
indicator lamp in the display area, and these
lamps are used for the testing and the trouble-
shooting.
q The information of the LED lamp and the 7-
segment indicator lamp can be checked on the
monitor panel by EMMS.
D85EX, PX-15E0 25
Sensor 1
q The signals from the sensors are input through the controller to the monitor panel.
q The sensors are classified into 4 types of contact, resistance, electromagnetic, and capacitor.
q Either side of each sensor of contact type is always connected to the chassis ground.
Type of sensor Sensor method When normal When abnormal
Power train oil temperature Resistance — —
Hydraulic oil temperature Resistance — —
Radiator coolant level Contact ON OFF
Fuel level Resistance — —
Bevel speed Electromagnetic — —
Pitch angle Capacitor — —
Pump pressure Resistance — —
Power train oil temperature sensor

Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
Radiator coolant level sensor
1. Float 4. Wire
2. Sensor 5. Connector
3. Tube
26 D85EX, PX-15E0
Fuel level sensor
1. Connector Function
2. Float q The fuel level sensor is installed to the side of
3. Arm the fuel tank. Its float moves up and down
4. Body according to the fuel level.
5. Spring The movement of the float operates the vari-
6. Contact able resistor through the arm. As a result, sig-
7. Spacer nals of change in resistance are generated.
D85EX, PX-15E0 27
Bevel speed sensor
1. Magnet 4. Boot
2. Terminal 5. Connector
3. Case
Pitch angle sensor
1. Body 3. Wire
2. Tube 4. Connector
28 D85EX, PX-15E0
Pump pressure sensor
1. Plug Function
2. Sensor q The pump pressure sensor is installed to the
3. Connector HSS pump outlet circuit. It converts pump dis-
charge pressure into voltage signals and sends
them to transmission and steering controller.
D85EX, PX-15E0 29
SEN00308-00

© 2005 KOMATSU
All Rights Reserved
30
SEN00629-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard service value table for engine ............................................................................................... 2
Standard service value table for chassis .............................................................................................. 3
D85EX, PX-15E0 1
SEN00629-00 20 Standard value table
Standard service value table 1

Standard service value table for engine 1
Machine model D85EX,PX-15E0

Engine SAA6D125E-5
Standard value for
Check item Measurement conditions Unit Permissible value
new machine
High idle 2,100 ± 50 2,100 ± 50
Rotation speed Low idle rpm 750 (+50/0) 750 (+50/0)
Rated speed 1,900 —
Air boost pressure kPa Min. 93 73
At rated horsepower
(Boost pressure) {mmHg} {Min. 700} {550}
At sudden acceleration Bosch Max. 2.5 —
Exhaust gas color
At high idle index Max. 1.0 —
Whole speed range
Exhaust temperature °C Max. 650 700
(Ambient temperature 20°C)
Valve clearance Intake valve 0.33 —
mm
(Normal temperature) Exhaust valve 0.71 —
MPa Min. 2.9 2.0
Oil temperature: 40 – 60°C
Compression pressure {kg/cm2} {Min. 30} {20}
(Engine speed)
(rpm) (200 – 250)
At rated horsepower kPa Max. 0.98 1.96
Blow-by pressure
Coolant temperature: Min. 70°C {mmH2O} {Max. 100} {200}
At rated horsepower
0.29 – 0.69 0.18
Engine oil temperature: SAE0W30EOS
{3.0 – 7.0} {1.8}
Min. 80°C SAE5W40EOS MPa
Oil pressure SAE10W30DH
At low idle {kg/cm2}
SAE15W40DH Min. 0.05 0.03
Engine oil temperature: SAE30DH
{Min. 0.5} {0.3}
Min. 80°C
Oil temperature Whole speed range (Inside oil pan) °C 90 – 110 Min. 120
Deflection when
Alternator –
pressed with finger
Crankshaft 13 – 16 —
force of approx. 58.5 N
pulley
{approx. 6 kg}
Belt tension mm
Deflection when Air conditioner
pressed with finger compressor –
16 – 20 —
force of approx. 98 N Crankshaft
{approx. 10 kg} pulley
2 D85EX, PX-15E0
Standard service value table for chassis 1

Standard
Classifi-
cation
Permissible
Check item Measurement condition Unit value for new
value
machine
Decelerator pedal • Coolant temperature: Within operating range
1,025 ± 25 1,025 ± 25
speed • Torque converter oil temperature:
Auto-deceleration Within operating range
Engine speed
• Hydraulic oil temperature: 1,875 ± 25 1,875 ± 25

speed
Within operating range
Torque converter stall • Decelerator pedal speed: Press pedal. rpm
1,760 ± 50 1,760 ± 50
speed • Auto-deceleration speed: Full neutral
Torque converter stall + • Torque converter stall speed: F3
Work equipment relief • Torque converter + Work equipment speed: 1,710 ± 50 1,710 ± 50
speed F3 + Ripper RAISE
Neutral o
Forward 30 ± 10 30 ± 10
Forward
and
reverse Neutral o
30 ± 10 30 ± 10
PCCS • Engine stopped Reverse
lever • Center of lever knob 40 ± 10 40 ± 10
Neutral o Left
(Play: Max. 3) (Play: Max. 3)
Stroke of control lever and pedal
Steering
40 ± 10 40 ± 10
Neutral o Right
(Play: Max. 3) (Play: Max. 3)
• Engine stopped
Decelerator pedal 45 ± 15 45 ± 15
• Center of pedal
All stroke mm 77 ± 8 77 ± 8
• Engine low idle
Brake pedal Stroke to 0 of oil
• Center of pedal 64 ± 10 64 ± 10
pressure
• Engine low idle Neutral – Raise
72 ± 10 72 ± 10
• Hydraulic oil temperature: or Float
Blade control lever
Within operating range Neutral – Left or
• Center of lever knob 53 ± 10 53 ± 10
Right tilt
• Engine low idle
Ripper control lever • Hydraulic oil temperature: Neutral – Raise
55 ± 10 55 ± 10
(for EX) Within operating range or Lower
• Center of lever knob
Neutral o
56.9 ± 6.9 56.9 ± 6.9
Forward or
Forward {5.8 ± 0.7} {5.8 ± 0.7}
Reverse
and
Operating effort of control
reverse Forward or
51 ± 6.9 51 ± 6.9
PCCS • Engine stopped Reverse o
{5.2 ± 0.7} {5.2 ± 0.7}
lever and pedal
lever • Center of lever knob Neutral

N 24.5 ± 4.9 24.5 ± 4.9
Neutral o Left
{kg} {2.5 ± 0.5} {2.5 ± 0.5}
Steering
27.4 ± 4.9 27.4 ± 4.9
Neutral o Right
{2.8 ± 0.5} {2.8 ± 0.5}
• Engine stopped 49.0 ± 9.8 49.0 ± 9.8
Decelerator pedal
• Center of pedal {5.0 ± 1.0} {5.0 ± 1.0}
• Engine low idle 460.6 ± 49.0 460.6 ± 49.0
Brake pedal
• Center of pedal {47 ± 5.0} {47 ± 5.0}
D85EX, PX-15E0 3

Standard
Classifi-
cation
Permissible
value
machine
39.2 ± 9.8 39.2 ± 9.8
Neutral o Raise
{4.0 ± 1.0} {4.0 ± 1.0}
Operating effort of control
• Engine low idle

• Hydraulic oil temperature: 82.3 ± 9.8 82.3 ± 9.8
Blade control lever Neutral o Float
lever and pedal
Within operating range {8.4 ± 1.0} {8.4 ± 1.0}

• Center of lever knob Neutral – Left or N 28.4 ± 9.8 28.4 ± 9.8
Right tilt {kg} {2.6 ± 1.0} {2.6 ± 1.0}
• Engine low idle Neutral o Raise 25.5 ± 9.8 25.5 ± 9.8
Ripper control lever • Hydraulic oil temperature: or Lower {2.6 ± 1.0} {2.6 ± 1.0}
(for EX) Within operating range Neutral – Tilt in 25.5 ± 9.8 25.5 ± 9.8
• Center of lever knob or out {2.6 ± 1.0} {2.6 ± 1.0}
0.1 – 0.5 0.1 – 0.5
Engine low idle
Torque converter inlet {1 – 5} {1 – 5}
pressure Max. 1.02 Max. 1.02
Engine high idle
{Max. 10} {Max. 10}
0.1 – 0.31 0.1 – 0.31
Engine low idle
Torque converter outlet {1 – 3} {1 – 3}
pressure 0.61 – 0.81 0.61 – 0.81
Engine high idle
{6 – 8} {6 – 8}
2.82 – 3.02 Min. 2.65
Engine low idle
Transmission main {28.8 – 30.8} {Min. 26.8}
relief pressure 3.24 – 3.53 Min. 3.04
Engine high idle
{33 – 36} {Min. 31}
2.16 – 2.45 Min. 1.96
Engine low idle
Transmission F clutch {22 – 25} {Min. 20}
pressure 2.16 – 2.45 Min. 1.96
Engine high idle
{22 – 25} {Min. 20}
Power train oil pressure
2.75 – 3.02 Min. 2.55

Engine low idle
Transmission R clutch {28 – 30.8} {Min. 26}
pressure • Torque converter oil 2.75 – 3.04 Min. 2.55
Engine high idle MPa
temperature: {28 – 31} {Min. 26}
{kg/cm2}
Within operating range 2.35 – 2.65 Min. 2.16
Engine low idle
Transmission 1st clutch {24 – 27} {Min. 22}
pressure 2.35 – 2.65 Min. 2.16
Engine high idle
{24 – 27} {Min. 22}
2.55 – 2.84 Min. 2.35
Engine low idle
Transmission 2nd {26 – 29} {Min. 24}
clutch pressure 2.55 – 2.84 Min. 2.35
Engine high idle
{26 – 29} {Min. 24}
2.75 – 3.02 Min. 2.55
Engine low idle
Transmission 3rd {28 – 30.8} {Min. 26}
clutch pressure 2.75 – 3.04 Min. 2.55
Engine high idle
{28 – 31} {Min. 26}
Transmission
0.1 – 0.25 0.1 – 0.25
lubricating oil pressure Engine high idle
{1.0 – 2.5} {1.0 – 2.5}
(For reference)
2.75 – 2.94 Min. 2.26
Engine low idle
Steering brake {28 – 30} {Min. 23}
pressure 2.75 – 2.94 Min. 2.45
Engine high idle
{28 – 30} {Min. 25}
4 D85EX, PX-15E0

Standard
Classifi-
cation
Permissible
value
machine
38.2 – 41.7 38.2 – 41.7
Relief pressure
pressure
• Hydraulic oil temperature: Within operating {390 – 425} {390 – 425}

MPa
HSS
range
LS pressure (Load {kg/cm2} 36.2 – 38.1 36.2 – 38.1
• Engine at high idle
sensing pressure) {369 – 389} {369 – 389}
3.3 ± 0.2/ 3.3 ± 0.2/
F1
3.3 ± 0.2 3.3 ± 0.2
• Flat road
Performance of power train
6.1 ± 0.3/ 6.1 ± 0.3/

• Coolant temperature: F2
6.0 ± 0.3 6.0 ± 0.3
• Torque converter oil 10.1 ± 0.5/ 10.1 ± 0.5/
F3
temperature: EX/ 10.0 ± 0.5 10.0 ± 0.5
Travel speed km/h
Within operating range PX 4.4 ± 0.2/ 4.4 ± 0.2/
• Engine at high idle R1
4.4 ± 0.2 4.4 ± 0.2
• Before measuring, run machine
8.0 ± 0.4/ 8.0 ± 0.4/
10 – 30 m. R2
7.9 ± 0.4 7.9 ± 0.4
• Measuring distance: 20 m
13.0 ± 0.7/ 13.0 ± 0.7/
R3
12.7 ± 0.7 12.7 ± 0.7
Engine low idle — —
Unload pressure 2.45(+1.37/0) 2.45(+1.37/0)
Engine high idle
{25(+14/0)} {25(+14/0)}
21.6 ± 1.18 21.6 ± 1.18
Engine low idle
{220 ± 12} {220 ± 12}
Blade lift relief pressure
22.54 ± 1.18 22.54 ± 1.18
Engine high idle
• Hydraulic oil temperature: {230 ± 12} {230 ± 12}
Within operating range 21.6 ± 1.18 21.6 ± 1.18
Work equipment oil pressure
• Unload pressure: Set all Engine low idle

{220 ± 12} {220 ± 12}
Blade tilt relief pressure equipment in neutral.
• Relief pressure: 22.54 ± 1.18 22.54 ± 1.18
Engine high idle
Set cylinder to stroke end. {230 ± 12} {230 ± 12}
• LS pressure: MPa 21.6 ± 1.18 21.6 ± 1.18
Engine low idle {kg/cm2}
Ripper lift relief Set cylinder to stroke end. {220 ± 12} {220 ± 12}
pressure (for EX) 22.54 ± 1.18 22.54 ± 1.18
Engine high idle
{230 ± 12} {230 ± 12}
20.2 ± 0.98 20.2 ± 0.98
Engine low idle
LS pressure (Load {206 ± 10} {206 ± 10}
sensing pressure) 20.2 ± 0.98 20.2 ± 0.98
Engine high idle
{206 ± 10} {206 ± 10}
Control circuit main
3.97(+0.49/0) 3.97(+0.49/0)
pressure • Hydraulic oil temperature: Within operating {40.5 (+5/0)} {40.5 (+5/0)}
(HSS, PPC, fan) range
PPC valve output • Engine at high idle 3.82 – 4.12 3.82 – 4.12
pressure {39 – 42} {39 – 42}
a See figure A Low idle 8 – 15 20
Work equipment
Work equipment
Raise
• Hydraulic oil tempera- EX: 2.5 – 4.5 5.5

speed
ture: 45 – 55°C High idle

Blade lift Second PX: 2.2 – 4.2 5.2
• Apply no load to blade.
Low idle 1.0 – 1.7 2.2
Lower
• Between ground level

and rising end of blade High idle 1.0 – 1.7 2.2
D85EX, PX-15E0 5

Standard
Classifi-
cation
Permissible
value
machine
a See figure B Low idle 3–5 7
Left tilt
• Hydraulic oil tempera-
ture: 45 – 55°C High idle 2.7 ± 0.5 3.5
Work equipment speed
Blade tilt • Apply no load to blade.
Right tilt
• Between left tilt end Low idle 3–5 7
and right tilt end
High idle 2.2 ± 0.5 3.5
a See figure C Low idle 7 – 10 13
Raise
• Hydraulic oil tempera-
ture: 45 – 55°C High idle 2.5 ± 0.5 4.0
Ripper lift (EX) • Apply no load to ripper.
• Between ground level Low idle 2–3 4.0
Lower
and rising end of ripper.
High idle 1.5 ± 0.5 4.0
• Hydraulic oil temperature:
45 – 55°C Second
Low idle Max. 8 11
• Move lever to stroke end.
• Lower blade from max. ris-
Blade
ing position and measure
time after blade comes in
contact with ground until High idle Max. 1.8 2.5
Time lag
idler is lifted.
• Hydraulic oil temperature:
45 – 55°C
Low idle Max. 6 8
• Move lever to stroke end.
• Lower ripper from max. ris-
Work equipment
Ripper (for EX)

ing position and measure
time after ripper comes in
contact with ground until High idle Max. 1.5 2.5
sprocket is lifted.
a See figure D
• Hydraulic oil temperature: 45 – 55°C
Hydraulic drift Max. 200/ 300/
• Stop engine.
of lifted blade 15 minutes 15 minutes
• Measure reduction of blade bottom height h
(for 15 minutes).
a See figure E
Hydraulic drift • Hydraulic oil temperature: 45 – 55°C
Max. 50/ 100/
of machine • Stop engine.
5 minutes 15 minutes
lifted by blade • Measure reduction of idler center height h
(for 5 minutes).
a See figure F
Hydraulic drift

mm/ Max. 50/ 100/
of machine • Stop engine.
min. 5 minutes 15 minutes
tilted by blade • Measure reduction of idler center height h
(for 5 minutes).
a See figure G
Max. 80/ 160/
of lifted ripper • Stop engine.
15 minutes 15 minutes
(for EX) • Measure reduction of shank bottom height h
(for 15 minutes).
a See figure H
Hydraulic drift
• Hydraulic oil temperature: 45 – 55°C
of machine Max. 50/ 100/
• Stop engine.
lifted by ripper 5 minutes 5 minutes
• Measure reduction of sprocket center height
(for EX)
h (for 5 minutes).
6 D85EX, PX-15E0

Standard
Classifi-
cation
Permissible
value
machine
Blade tilt
Leakage from cylinder
4 16
cylinder
Work equipment
Ripper lift • Engine at high idle

cylinder • Hydraulic oil temperature: 45 – 55°C 4 16
cc/min
(for EX) • Relieve cylinder and measure leakage for 1
Ripper tilt minute.
cylinder 4 16
(for EX)
• Fan 100% speed mode
Min. speed 800 ± 50 400
• Engine: Low idle
Cooling fan
Fan speed rpm

• Fan 100% speed mode
Max. speed 1,650 ± 50 1,550
• Engine at high idle
• Fan 100% speed mode MPa 14.7 – 17.6 14.7 – 17.6
Fan pump pressure
• Engine at high idle {kg/cm2} {150 – 180} {150 – 180}
D85EX, PX-15E0 7
Illustrations related to standard value table
Figure A Figure D
Figure B Figure E
Figure C Figure F
8 D85EX, PX-15E0
Figure G
Figure H
D85EX, PX-15E0 9
SEN00629-00

© 2006 KOMATSU
All Rights Reserved
10
SEN00630-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Testing and adjusting, Part 1........................................................................................................................... 3
Tools for testing, adjusting, and troubleshooting .................................................................................. 3
Measuring engine speed...................................................................................................................... 5
Measuring intake air pressure (boost pressure)................................................................................... 8
Measuring exhaust temperature ........................................................................................................ 10
Measuring exhaust gas color ............................................................................................................. 12
Adjusting valve clearance .................................................................................................................. 13
Measuring compression pressure ...................................................................................................... 15
Measuring blow-by pressure .............................................................................................................. 17
Measuring engine oil pressure ........................................................................................................... 18
Handling of fuel system devices......................................................................................................... 19
Releasing residual pressure from fuel system ................................................................................... 19
Testing fuel pressure .......................................................................................................................... 20
Handling of reduced cylinder mode operation.................................................................................... 21
Handling of no injection cranking operation ....................................................................................... 21
Testing fuel return and leak amount ................................................................................................... 22
D85EX, PX-15E0 1
SEN00630-00 30 Testing and adjusting
Bleeding air from fuel circuit ............................................................................................................... 25

Testing fuel circuit for leakage ............................................................................................................ 27
Testing and adjusting alternator belt tension ...................................................................................... 28
Testing and adjusting air conditioner compressor belt tension........................................................... 29
Adjusting fuel control dial and decelerator pedal................................................................................ 30
Measuring power train oil pressure .................................................................................................... 32
Adjusting transmission speed sensor................................................................................................. 37
Simple method to test brake performance ......................................................................................... 38
Adjusting brake pedal......................................................................................................................... 39
Adjusting parking brake lever ............................................................................................................. 41
Emergency escape method when power train has trouble ................................................................ 42
Adjusting clearance of idler ................................................................................................................ 45
Inspecting wear of sprocket................................................................................................................ 46
Testing and adjusting track shoe tension ........................................................................................... 46
Testing and adjusting work equipment and HSS oil pressure ............................................................ 47
Testing control circuit basic pressure ................................................................................................. 51
Measuring PPC valve output pressure............................................................................................... 52
Adjusting play of work equipment PPC valve..................................................................................... 54
Checking parts which caused hydraulic drift of blade and ripper ....................................................... 55
Measuring internal leakage of work equipment cylinder .................................................................... 56
Bleeding air from work equipment cylinder ........................................................................................ 56
Releasing residual pressure in work equipment cylinder ................................................................... 57
Adjusting work equipment lock lever .................................................................................................. 58
Measuring fan motor speed................................................................................................................ 59
Measuring fan pump circuit pressure ................................................................................................. 60
Bleeding air from fan pump ................................................................................................................ 61
Adjusting blade................................................................................................................................... 62
Testing and adjusting operator cab .................................................................................................... 64
2 D85EX, PX-15E0
Testing and adjusting, Part 1 1

Tools for testing, adjusting, and troubleshooting 1
Quantity
Symbol
Testing or adjusting
Part No. Part name Remarks
item
Air boost pressure

A 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
(boost pressure)
Water temperature, oil
temperature and B 799-101-1502 Digital temperature gauge 1 –99.9 – 1,299°C
exhaust temperature
1 799-201-9001 Handy smoke checker 1
Exhaust gas color C Commercial Bosch index: 0 – 9
2 Smoke meter 1
item
Commercial
Valve clearance D Clearance gauge 1
item
0 – 6.9 MPa {0 – 70 kg/cm2}
1 795-502-1590 Compression gauge 1
KIT Part No.: 795-502-1205
Compression pressure E
2 795-471-1420 Adapter 1 For 125E-5
3 6217-71-6112 Gasket 1
Blow-by pressure F 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm2}
Engine oil pressure G
Pressure gauge:
790-261-1204 Digital hydraulic tester 1
58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester 1
1 *As common as G1
Testing fuel pressure H 790-261-1204 Digital hydraulic tester 1
2 799-401-2320 Hydraulic tester 1 *As common as G2
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
Commercial
3 Hose 1
item
Testing fuel return and Commercial
J 4 Hose 1
leak amount item
Commercial
5 Measuring cylinder 1
item
Commercial
6 Stopwatch 1
item
1 *As common as G1
Power train oil pressure K 790-261-1204 Digital hydraulic tester 1
2 799-401-2320 Hydraulic tester 1 *As common as G2
19M-06-32820 Switch assembly 1
1
Emergency escape 17M-06-41530 Wiring harness 1
method when power L 799-101-5220 Nipple (10 x 1.25 mm) 1
train has trouble 2
07002-11023 O-ring 1
3 790-190-1601 Pump assembly 1
D85EX, PX-15E0 3
Quantity
Symbol
Testing or adjusting
Part No. Part name Remarks
item

Testing and adjusting 1 *As common as G1
work equipment and M
HSS oil pressure 799-101-5220 Nipple (10 x 1.25 mm) 2
2 *As common as L2
07002-11023 O-ring 2
Testing control circuit 1 *As common as G1
N 790-261-1204 Digital hydraulic tester 1
basic pressure
2 799-401-3200 Adapter (size 03) 1
1 *As common as G1
Measuring PPC valve 790-261-1204 Digital hydraulic tester 1
P
output pressure 2 799-401-3100 Adapter (size 02) 1
3 799-401-3200 Adapter (size 03) 1
Measuring internal
Commercial
leakage of work Q Measuring cylinder 1
item
equipment cylinder
Measuring fan motor
R 799-205-1100 Tachometer KIT 1
speed
1 *As common as G1
Measuring fan pump
S 2 799-401-3400 Adapter (size 05) 1
circuit pressure
799-101-5220 Nipple (10 x 1.25 mm) 1
3 *As common as L2
07002-11023 O-ring 1
79A-264-0021 0 – 294 N {0 – 30 kg} 1
Operating effort T
79A-264-0091 0 – 490 N {0 – 50 kg} 1
Stroke and hydraulic Commercial
U Scale 1
drift item
Commercial
Work equipment speed V Stopwatch 1
item
Commercial
Voltage and resistance W Tester 1
item
a For the types and part numbers of T-adapter and T-adapter box which are used for troubleshooting of
machine monitor, controller, sensor, actuator and harnesses, see “T-adapter box and T-adapter table” in
troubleshooting.
4 D85EX, PX-15E0
Measuring engine speed 1

a Measure the engine speed under the following 3. Measuring high idle speed
condition. 1) Start the engine and set the fuel control
q Coolant temperature: dial in the high idle position.
Within operating range 2) Set the PCCS lever and work equipment
q Hydraulic oil temperature: control lever in neutral and measure the
Within operating range engine speed.
q Power train oil temperature: a The high idle speed measured in the
Within operating range “Monitoring mode” or in the “Pm Clinic
auxiliary mode” is the auto-deceleration
1. Preparatory work speed.
Turn the starting switch ON and set the monitor a When measuring the high idle speed of
panel in the “Monitoring mode” to prepare for the engine, use the “Adjustment mode”.
measurement of the engine speed. Adjustment code:
a For the operating method, see “Special 0007 (Engine decelerator cut mode)
functions of monitor panel (EMMS)”.
q Monitoring code: 01000 (Engine speed)
4. Measuring decelerator pedal speed

1) Start the engine and set the fuel control
2. Measuring low idle speed dial in the high idle position.
1) Start the engine and set the fuel control 2) Set the PCCS lever and work equipment
dial in the low idle position. control lever in neutral, and measure the
2) Set the PCCS lever and work equipment engine speed with the decelerator pedal
control lever in neutral and measure the depressed.
engine speed.
D85EX, PX-15E0 5
5. Measuring torque converter stall speed q Adjustment code: 0530 (stall speed
1) Start the engine and set the fuel control check mode)
dial in the low idle position.
2) With the brake pedal depressed securely
and the parking brake lever in the “free”
position, set the PCCS lever in the “for-
ward” and 3rd gear speed position.
a Before going to the next step, check
that the upper display unit of the mon-
itor panel is set in the normal display
state and it displays [F3].
a Keep the steering unit in neutral.
3) Press the decelerator pedal and set the
fuel control dial in the high idle position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at
high idle.
k Keep pressing the brake pedal
securely and keep your right foot
on the decelerator pedal for safety
until the work is finished.
5) Just after the power train oil temperature
gauge reads the top line of the green
range, return the direction of the PCCS
lever into neutral.
8) Perform steps 2) – 4) again and measure

the engine speed about 5 seconds after
the power train oil temperature gauge
reads the top line of the green range.
a After finishing measurement, return
the direction of the PCCS lever into
neutral and lower the power train oil
temperature with the engine at high
idle.
6. Measuring torque converter stall + work

equipment relief speed (full stall speed)
6) Repeat above steps 2) – 5) 3 times.
1) Start the engine and set the fuel control
7) Change the monitor panel to [Adjustment
dial in the low idle position. Operate the
mode] display and prepare to measure the
ripper lever and raise up the ripper lift cyl-
torque converter stall speed.
inder to the stroke end.
a Refer to “Special functions of monitor
2) With the brake pedal depressed securely
panel (EMMS)” for the operating
and the parking brake lever in the “free”
method.
position, set the PCCS lever in the “for-
ward” and 3rd gear speed position.
a Before going to the next step, check
that the upper display unit of the mon-
itor panel is set in the normal display
state and it displays [F3].
a Keep the steering unit in neutral.
3) Press the decelerator pedal and set the
fuel control dial in the high idle position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at
high idle.
6 D85EX, PX-15E0
k Keep pressing the brake pedal 8) Perform steps 2) – 4) and also operate rip-
securely and keep your right foot per RAISE relief using ripper lever and
on the decelerator pedal for safety measure the engine speed about 5 sec-
until the work is finished. onds after the power train oil temperature
5) Just after the power train oil temperature gauge reads the top line of the green
gauge reads the top line of the green range.
range, return the direction of the PCCS a After finishing measurement, return
lever into neutral. the direction of the PCCS lever into
neutral and lower the power train oil
temperature with the engine at high
idle.
a The engine speed can be measured
by the following operation:
q “Pm clinic auxiliary mode” of the
monitor panel
q Each time the information switch
is set to the right or left when the
monitor panel is in the normal
display state, the display in the
multi information section turns to
the display of service meter or
engine speed. (However, mea-
sure the high idle speed of the
6) Repeat above steps 2) – 5) 3 times.
engine in the “Adjustment
7) Change the monitor panel to [Adjustment
mode“).
mode] display and prepare to measure the
torque converter stall speed.
method.
q Adjustment code: 0530 (stall speed
check mode)
D85EX, PX-15E0 7
Measuring intake air pressure 4. Run the engine at medium or higher speed and
(boost pressure) 1 drain the oil from the hose.
a Insert the joint of the gauge and hose half-
a Measuring instruments for intake air pressure way and open the self-seal on the hose
(boost pressure) side repeatedly, and the oil is drained.
a If Pm kit (A) is available, the air bleeding
Symbol Part No. Part name
coupling (790-261-1130) in it may be
A 799-201-2202 Boost gauge kit used.
a If any oil is left in the hose, the gauge does
k When installing and removing the measur- not move. Accordingly, be sure to drain
ing instrument, take care not to touch a hot the oil.
part of the engine.
a Measure the intake air pressure (boost pres- 5. Measure the intake air pressure (boost pres-
sure) under the following condition. sure) while the engine is running at high idle
q Coolant temperature: and the torque converter is stalling.
Within operating range a For the procedure for stalling the torque
q Hydraulic oil temperature: converter, see “Measuring engine speed”.
Within operating range a Normally, the intake air pressure (boost
q Power train oil temperature: pressure) should be measured while the
Within operating range engine is running at the rated output. In
the field, however, an approximate value
1. Open the left side cover of the engine. can be obtained by stalling the torque con-
verter.
2. Remove air intake connector boost pressure
pickup plug (1) (R1/8).
6. After finishing measurement, remove the mea-

suring instrument and reinstall the removed
3. Install nipple [1] of boost gauge kit A and con- parts.
nect gauge [2].
8 D85EX, PX-15E0
a The boost pressure can be measured in the

“Pm Clinic auxiliary mode” of the monitor
panel.
D85EX, PX-15E0 9
Measuring exhaust temperature 1 4. Procedure for measuring the maximum value

for troubleshooting
a Measuring instrument for exhaust temperature Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the digital temper-
B 799-101-1502 Digital temperature gauge ature gauge.
a The exhaust temperature largely depends
k Install and remove the measuring instru- on the ambient temperature (intake air
ment after the exhaust manifold is cooled. temperature of the engine). Accordingly, if
a Measure the exhaust temperature under the any abnormal value is obtained, compen-
following condition. sate it by the following calculation.
q Coolant temperature: Within operating q Corrected value [°C] = Measured value
range + 2 x (20 – Ambient temperature)
q Hydraulic oil temperature: Within operat-
ing range
q Power train oil temperature: Within operat-
ing range
1. Open the right inspection cover of the engine

and remove turbocharger heat insulation cover
(1).
5. Procedure for measuring periodically for pre-

ventive maintenance
a If the torque converter is stalled simply,
the torque converter oil temperature is
overheated before the exhaust tempera-
ture is stabilized. Accordingly, measure
according to the following procedure.
1) Stall the torque converter fully to raise the
2. Remove exhaust temperature measurement exhaust temperature to about 650°C
plug (2). according to the following procedure (con-
dition (a) in the figure).
3. Install sensor [1] and connect them to digital 1] Start the engine and set the fuel con-
temperature gauge B. trol dial to the low idle position, and
a Clamp the wiring harness of the digital then operate the ripper lever to raise
temperature gauge so that it will not touch the ripper lift cylinder to the stroke end.
a hot part during measurement. 2] With the brake pedal depressed
securely, set the PCCS lever in the
“forward” and 3rd gear speed position.
3] Press the decelerator pedal and set
the fuel control dial in the high idle
position.
4] Return the decelerator pedal slowly to
allow the torque converter to stall at
high idle and relieve the ripper raise
circuit.
k Keep pressing the brake pedal
securely and keep your right
foot on the decelerator pedal
for safety until the work is fin-
ished.
10 D85EX, PX-15E0
2) Stop only relieving the blade tilt and lower

the exhaust temperature by only stalling
the torque converter (condition (b) in the
figure).
a If the temperature does not lower but
it rises, set the higher temperature in
step 1).
3) After the temperature lowers and is stabi-
lized, measure it (condition (c) in the fig-
ure).
k Just after the power train oil tem-
p e r a t u r e g a u g e r e a d s t he r e d
range, return the direction of the
PCCS lever into neutral and lower
the power train oil temperature.

parts.
D85EX, PX-15E0 11
Measuring exhaust gas color 1

a Measuring instrument for exhaust gas color

1 799-201-9001 Handy smoke checker
C Commercial
2 Smoke meter
item
k When installing and removing the measur-

ing instrument, take care not to touch a hot
part.
a If an air source and a electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, etc.,
use smoke meter C2. 2) Connect the probe hose, receptacle of the
a Measure the exhaust gas color under the fol- accelerator switch, and air hose to smoke
lowing condition. meter C2.
q Coolant temperature: a Restrict the supplied air pressure
Within operating range below 1.5 MPa {15 kg/cm2}.
3) Connect the power cable to a receptacle
1. Measuring with handy smoke checker C1 of AC100V power source.
1) Stock a sheet of filter paper to smoke a Before connecting the cable, check
checker C1. that the power switch of the smoke
2) Insert the exhaust gas intake pipe in the meter is turned off.
exhaust pipe. 4) Loosen the cap nut of the suction pump
3) Start the engine. and fit the filter paper.
4) As increasing the engine speed rapidly or a Fit the filter paper securely so that the
running it at high idle, operate the handle exhaust gas will not leak.
of smoke checker C1 so that the filter 5) Turn on the power switch of smoke meter
paper will absorb the exhaust gas. C2.
5) Remove the filter paper and compare it 6) Start the engine.

with the attached scale to make a judge- 7) As increasing the engine speed rapidly or
ment. running it at high idle, press the accelera-
6) After finishing measurement, remove the tor pedal of smoke meter C2 and collect
measuring instrument and reinstall the the exhaust gas with the filter paper.
removed parts. 8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
2. Measuring with smoke meter C2 filter paper holder and read the indicated
1) Insert probe [1] of smoke meter C2 in the value.
outlet of the exhaust pipe and fix it to the 9) After finishing measurement, remove the
exhaust pipe with a clip. measuring instrument and reinstall the
removed parts.
12 D85EX, PX-15E0
Adjusting valve clearance 1 4. Rotate the crankshaft forward, align of damper

“1.6TOP” stamp line (a) to pointer (8), and then
a Adjusting instrument for valve clearance set the No.1 cylinder to the compression top
dead center.
a Always crank forward using damper
Commercial mounting bolt (width across flats: 24 mm)
D Clearance gauge
item
to prevent loosening the bolt.
a When No. 1 cylinder is at the compression
1. Open the left upper side cover of the engine.
top dead center, the rocker arms on both
intake side and exhaust side can be
2. Remove air cleaner (1) and bracket (2).
moved by the valve clearance with the
hand. If the rocker arms cannot be moved,
rotate the crankshaft one more turn.
3. Remove all cylinder head cover (3).
5. While the No.1 cylinder is at the compression

top dead center, adjust the clearance of valve
marked with q in the valve arrangement figure.
D85EX, PX-15E0 13
6. To adjust the valve clearance, insert clearance

gauge D into clearance (b) between rocker
arm (4) and crosshead (5), and adjust the
valve clearance with adjustment screw (6).
a With the clearance gauge inserted, turn
the adjustment screw so that clearance
gauge can move with a light force.
7. While holding adjustment screw (6), tighten

locknut (7).
3 Locknut:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
q After finishing the adjustment of all the

valves marked with q, rotate the crank-
shaft 360° forward and align “1.6TOP”
stamp line (a) of the damper to pointer (8)
in order to set the No.6 cylinder to the
compression top dead center.
8. While the No. 6 cylinder is at the compression

top dead center location, adjust the clearance
of valve marked with Q in the valve arrange-
ment figure.
a Procedure for the adjustment is as same
as 6) and 7).
9. It also can be done by rotating the crankshaft

forward by 120° at one time and adjusting the
va lve cl eara nce of eac h c yli nder in the
sequence of the firing order.
a Firing order: 1 – 5 – 3 – 6 – 2 – 4
10. After finishing adjustment, set to the original

condition.
3 Cylinder head cover mounting bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
3 Air intake connector hose clamp bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Air cleaner intake hose clamp bolt:
8.8 ± 0.5 Nm {0.9 – 0.05 kgm}
3 Air cleaner mounting band bolt:
9.8 – 11.76 Nm {1.0 – 1.2 kgm}
14 D85EX, PX-15E0
Measuring compression 4. Set cylinder to be tested at compression top

pressure 1 dead center and remove rocker arm assembly
(4).
a Measuring instruments for compression pres- a Refer to “Adjusting valve clearance”.
sure
5. Disconnect the fuel high-pressure tube (5) and
injector harness (6), and remove injector (7).
1 795-502-1590 Compression gauge a Before disconnecting the fuel high-pres-
E 2 795-471-1420 Adapter sure tube, loosen all the intermediate
3 6217-71-6112 Gasket clamps on the tube.
a To remove injector harness from injector,
k When measuring the compression pres- disconnect the terminal in the injector side
sure, take care not to burn yourself on the and the bracket in the rocker housing side
exhaust manifold, muffler, etc. or get and pull them out of the rocker arm hous-
caught in a rotating part. ing. (Loosen 2 terminal nuts alternately.)
a Measure the compression pressure after the a Lead a wire under the fuel pipe which
engine is warmed up. comes out sideways from the injector and
(Engine oil temperature: 40 – 60°C) pull up the wire to remove injector (do not
ply the upper part of the injector to remove
1. Open the left upper side cover of the engine. it).
2. Remove air cleaner (1) and bracket (2).
3. Remove all 6 cylinder head covers (3).
D85EX, PX-15E0 15
6. Install gasket E3 and install adapter E2 to the 9. Crank the engine with the starting motor and
mounting hole of the injector and connect com- check the compression pressure.
pression gauge E1. a Measure the pressure when the pointer of
a Fix the adapter with the holder for injector. the gauge is stabilized.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm} 10. When the checking is completed, remove the
a Leakage can be prevented by applying a instruments and reinstall the removed parts.
little amount of engine oil to the fitting a Install the injector, injector harness and
faces of the adapter and gauge. fuel high-pressure tube according to fol-
lowing procedure.
7. Install rocker arm assembly (4) and adjust 1) Install O-ring and gasket to injector (7).
valve clearance. 2) Set holder (8) to injector (7) and install it
3 Rocker arm assembly mounting bolts: temporarily to the cylinder head integrally.
58.8 – 73.5 Nm {6.0 – 7.5 kgm} 3) Tighten mounting bolt (9) with spherical
a Refer to “Adjusting valve clearance”. washer (10) to install injector to cylinder
head.
2 Spherical surface section of spheri-
cal washer: Engine oil (SAE30DH)
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
4) Insert harness (6) into rocker arm housing
and fix with mounting bolt (11).
5) Insert harness (6) into holder (12).
6) Tighten 2 nuts at the end of harness (6)
onto injector (7) alternately.
3 Nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
7) Tighten tube (5) to injector (7).
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
8) Tighten the clamping bolt of the fuel pip-
8. Disconnect connector EGC3 of engine control-
ing.
3 Clamping bolt:
ler.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
k Be sure to disconnect the connector.

Otherwise, engine may start during the 3 Rocker arm assembly mounting
measurement and this may create a bolts:
dangerous condition. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
k Since connector (EGC3) includes the a Adjust valve clearance referring to
power source circuit of engine control- “Adjusting valve clearance”.
ler, cover the connector on the harness 3 Cylinder head cover mounting bolt:
side with a vinyl sheet, etc. to prevent 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
electric leakage and ground fault.
a Adjust mode of the monitor panel “no
injection cranking mode” can be set.
16 D85EX, PX-15E0
Measuring blow-by pressure 1 4. Measure the blow-by pressure while the

engine is running at high idle and the torque
a Measuring instrument for blow-by pressure converter is stalling.
a For the procedure for stalling the torque
converter, see “Measuring engine speed”.
F 799-201-1504 Blow-by checker a Normally, the blow-by pressure should be
measured while the engine is operated at
a Measure the blow-by pressure under the fol- the rated output. In the field, however, an
lowing condition. approximate value can be obtained by
q Coolant temperature: Within operating stalling the torque converter.
range a If it is impossible to run the engine at the
q Hydraulic oil temperature: Within operat- rated output or stall the torque converter,
ing range measure while the engine is running at
q Power train oil temperature: Within operat- high idle.
ing range The value obtained in this case is about
80% of the blow-by pressure at the rated
1. Open the left upper side cover of the engine. output.
a The blow-by pressure may vary largely
2. Remove the mounting clamp of blow-by hose with the engine condition. If the measured
(1) on the engine side which is mounted on No. value is judged abnormal, check for
6 cylinder head cover and pull out the hose to increase of oil consumption, bad exhaust
the left outer side of the engine. gas color, premature deterioration or con-
tamination of oil, etc. which are related to
the abnormal blow-by pressure.
q It also can be done by loosening clamp (2)

and di sconnect hose (1) and install
another hose (KES07287-01914 or equiv-
alent). 5. After completing the measurement, remove
the measuring instrument and set to the origi-
3. Install nozzle [1] of blow-by checker F to blow- nal condition.
by hose (1) and connect to gauge [2].
D85EX, PX-15E0 17
Measuring engine oil pressure 1 4. Start the engine and measure the engine oil
pressure when the engine is running at low idle
a Measuring instruments for engine oil pressure and at high idle.
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
a Measure the engine oil pressure under the fol-

lowing condition.
q Coolant temperature: Within operating
range
1. Open the left upper side cover of the engine.
2. Remove oil pressure inspection plug (1).

parts.
3. Install nipple [1] of hydraulic tester G1 to the

plug installation portion and connect to hydrau-
lic tester G2.
18 D85EX, PX-15E0
Handling of fuel system devices 1 Releasing residual pressure from

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low pressure cir-
The common rail fuel injection system (CRI) cuit and high pressure circuit of the fuel system
consists of more precise parts than the con- while the engine is running.
ventional fuel injection pump and nozzle. If for- Low pressure circuit: Feed pump – Fuel main
eign matter enters this system, it can cause a filter – Fuel supply pump
trouble. High-pressure circuit: Fuel supply pump –
When testing and maintaining the fuel system, Common rail – Fuel injector
take care more than the past. If dust, etc. a The pressure in both low pressure circuit and
sticks to any part, wash that part thoroughly high pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use Komatsu genuine fuel filter car- a Before the fuel circuit is tested and its parts are
tridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. ping the engine until the residual pressure
If a filter other than the genuine one is used, in the fuel circuit is released. (Do not start
the fuel system may have a trouble. Accord- the work just after stopping the engine
ingly, never use such a filter. since there is residual pressure.)
D85EX, PX-15E0 19
Testing fuel pressure 1 3. Start the engine and inspect the fuel pressure
with the engine running at high idle or at the
a Measuring tools for fuel pressure equivalent of rated output speed (stall load).
a If the fuel pressure is in the following
range, it is normal.
1 Engine speed Fuel pressure
H 790-261-1204 Digital hydraulic tester
At high idle or
2 799-401-2320 Hydraulic tester 0.15 – 0.3 MPa
at the equivalent of rated
{1.5 – 3 kg/cm2}
output speed
a Measure the fuel pressure only for the low
pressure circuit between the feed pump – fuel
filter – fuel supply pump.
k Since the pressure in the high pressure cir-
cuit from the fuel supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Open the left upper side cover of the engine

and remove fuel pressure inspection plug (1)
(R1/8) of fuel filter head.
4. After finishing testing, remove the testing tools

and return the removed parts.
2. Install elbow [1] and nipple [2] of hydraulic

tester H1, and connect to hydraulic tester H2.
20 D85EX, PX-15E0
Handling of reduced cylinder Handling of no injection cranking

mode operation 1 operation 1
a Reduced cylinder mode operation means to a No injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. engine unit has been stored for a long period,
1. This operation is used to find out a cylinder the no injection cranking is performed to lubri-
which does not output power normally (or, cate the engine parts and protect them from
combustion in it is abnormal). seizure.
2. When engine speed and output do not change a To implement no injection cranking operation,
from the normal operation (all cylinder operat- see “Special functions of monitor panel”.
ing mode) even though the fuel injection has
been cut out for any cylinder, the cylinder is
suspected to be defective.
The following problems can be considered:
q Leaking of cylinder head gasket
q Defective injection of injector
q Defective piston, piston ring or cylinder
liner
q Defective valve mechanism (valve sys-
tem)
q Defective electrical system
3. Since the injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, the reduced cylinder mode
operation can be obtained by easier operations
of the switches when compared with the
mechanical fuel injection system. This allows
to narrow down the causes of the incident eas-
ily.
a To implement reduced cylinder mode
operation, see “Special functions of moni-
tor panel”.
D85EX, PX-15E0 21
Testing fuel return and leak amount 1
a Testing tools for fuel return and leak amount 1. Preparation work
1) Remove tube (3) between common rail (1)
Symbol Part No. Part name and return block (2).
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
J Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
2) Insert spacer J1 to return block (2) side
and retighten it with the currently removed
joint bolt.
a Be sure to fit the gaskets to both ends
of the spacer.
22 D85EX, PX-15E0
3) Insert joint J2 to common rail (1) side and a If the leakage from the pressure lim-
retighten it with the currently removed joint iter is in the following range, it is nor-
bolt. mal.
a Be sure to fit the gaskets to both ends Engine speed Leaking amount
of the joint. (rpm) (cc/min)
4) Connect inspection hose J3 to the tip of
Equivalent to rated
joint J2. Max. 10
operation
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
3. Testing return rate from injector

a During testing injector return amount,
keep the end of hose J3 connected to
2. Testing leakage from pressure limiter pressure limiter and insert the other end to
1) Adjust routing to prevent its slacking of oil pan (receiver).
inspection hose J3 and insert the hose 1) Disconnect fuel return hose (4) of return
end to the oil pan (saucer). block (2).
2) Referencing “Measuring engine speed”, a Block the fuel hose side with plugs,
set up the condition necessary for check- etc. and fix it to the frame.
ing the engine speed. Plug: 07376-70315
3) Start the engine and operate at the equiv-
alent to rated operation (torque converter
stall load).
4) After making sure that the engine speed is
stabilized, measure leakage volume per
minute by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
D85EX, PX-15E0 23
2) Connect inspection hose J4 to return

block (2) side.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
3) Adjust routing to prevent its slacking of
inspection hose J4 and insert the hose
end to the oil pan (container).
7) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
4) Referencing “Measuring engine speed”,

set up the condition necessary for check-
ing the engine speed.
5) Start the engine and operate at the equiv-
alent to rated operation (torque converter
stall load).
6) After making sure that the engine speed is
stabilized, measure return rate per minute
by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
24 D85EX, PX-15E0
Bleeding air from fuel circuit 1
a Bleed the air as follows if the engine has run 2. Remove air bleeding plug (3) of fuel main filter
out of fuel or the fuel circuit equipment has (2) and operate priming pump (4).
been removed and installed. a Operate until fuel flows through plug hole
and when fuel is confirmed, install the
1. Remove fuel pre-filter (1), fill up fuel inside and plug.
reinstall. 3 Air bleeding plug:
a When filling, use clean fuel and be careful 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
not to let dirt get in.
a Add fuel through inlet port (a) areas (8 3. There can be following two cases concerning
places) of the filter. Area (b) is the outlet the reason why the engine does not start up
port after the fuel has been filtered (clean easily after bleeding air from the common rail
side), so never add fuel from here. fuel injection system (CRI) even after carrying
a If clean fuel is not available, do not out the items 1 and 2 above.
remove the filter. Operate the priming a If the air has not been bled completely and
pump to fill the filter with fuel. remained in the circuit, cranking the
engine with the starting motor cannot
bleed air in a short period of time. Thus
the engine start-up becomes difficult.
1) In the cases that the fuel has run out, that
the fuel filter has been replaced or that
some fuel device has been removed and
installed.
q Most of the fuel is left in the fuel cir-
cuit, so the engine may be started
after bleeding air with the air bleeding
procedure introduced in the item 1
and 2 above.
D85EX, PX-15E0 25
2) In the case that a number of fuel devices q Still continue to operate the prim-
have been removed and installed in ing pump until it becomes harder
course of engine overhauling. to operate and a relief noise (a
q Since little fuel is left in the fuel circuit, high pitch noise) of overflow
so air cannot be eliminated com- valve (7) in the supply pump is
pletely by the air bleeding methods heard. It requires approx. 50
introduced in the item 1 and 2 above times of operation to reach that
(ordinary method). In that case, stage.
bleed air in the following procedure. 4] Tighten bolt of priming pump (4) to fix.
5] Crank the engine with the starting
motor and start the engine.
a Do not operate the starting motor
continuously for more than 20
seconds. Moreover try to start up
the engine only after 2 minutes
pause.
a If the engine does not start up
even after repeating to crank for
20 seconds 4 times, insufficient
air bleeding is suspected. In that
case, start the air bleeding steps
once again from step 1].
4. Loosen air bleeder (6) of the fuel supply pump

1] Remove air bleeding plug (3) of fuel
and operate priming pump (4) 90 to 100 times.
main filter (2) and operate priming
a Operate priming pump until fuel flows
pump (4).
through air bleeder and when fuel is con-
q Bleed air
firmed, tighten air bleeder and operate
Operate the priming pump until
several times more until priming pump
fuel flows through plug hole and
becomes stiff.
3 Air bleeder:
when fuel is confirmed, tighten
the plug.
3 Air bleeding plug:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
5. Crank the engine with the starting motor and
2] Remove fuel pressure measuring
start the engine.
plug (5) for the fuel filter and operate
a The air in the high-pressure circuit is bled
priming pump (4).
automatically if the engine is cranked.
q Operate the priming pump until
a If the engine does not start, there still may
fuel flows through plug hole and
be air in the low-pressure circuit. In this
when fuel is confirmed, tighten
case, repeat the above procedure from
the plug.
3 Fuel measuring plug:
step 2.
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
3] Loosen air bleeder (6) of fuel supply
pump (after loosening locknut) and
operate priming pump (4) from 90 to
100 times.
q Operate the priming pump until
fuel flows through air bleeder (6)
and when fuel i s confir med,
tighten the plug.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
26 D85EX, PX-15E0
Testing fuel circuit for leakage 1 9. Inspect the fuel piping and the devices for fuel
leakage.
k Very high pressure is generated in the high- a Inspect the high-pressure circuit parts
pressure circuit of the fuel system. If fuel concentration on the areas coated with the
leaks while the engine is running, it is dan- color checker, for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
and installing its components, check for a If any fuel leakage is not detected, inspec-
fuel leakage according to the following pro- tion is completed.
cedure.
a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at a speed less than 1,000 rpm

and stop it after its rotation is stabilized.
3. Inspect the fuel piping and the devices for fuel

leakage.
a Inspect the high-pressure circuit parts
concentration on the areas coated with the
color checker, for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

leakage.
6. Run the engine at high idle.

leakage.
8. Run the engine at high idle to apply load to the

engine.
a Relieve by tilting the blade or raising the
ripper.
D85EX, PX-15E0 27
Testing and adjusting alternator 2. Loosen locknut (4), turn adjustment nut (5) to
belt tension 1 move alternator (6) and adjust the belt tension.
Testing 3. After the adjustment, tighten nut (3) and bolt

q Press the intermediate point between alterna- (2) to fix alternator (6) and install cap (1).
tor pulley and drive pulley with a finger and 3 Nut (3): 107.8 – 147 Nm {11 – 15 kgm}
measure deflection (a). 3 Bolt (2): 28.4 – 32.4 Nm {2.9 – 3.3 kgm}
a Pressing force: Approx. 59 N {Approx. 6 kg}
a Deflection (a): 13 – 16 mm
Adjusting
a If the deflection is out of range, adjust it
1. Remove cap (1) and loosen bolt (2) and nut

(3).
28 D85EX, PX-15E0
Testing and adjusting air

conditioner compressor belt
tension 1
Testing
Press the intermediate point between air condi-
tioner compressor pulley and drive pulley with a fin-
ger and measure deflection (a).
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Deflection (a): 16 – 20 mm
Adjusting
a If the deflection is out of range, adjust it
1. Loosen 4 compressor bracket mounting bolts

(1).
2. Loosen locknut (2), turn adjustment nut (3) and

adjust the belt tension.
3. After adjusting the belt tension to the standard

value, tighten locknut (2), then tighten 4 com-
pressor bracket mounting bolts (1).
D85EX, PX-15E0 29
Adjusting fuel control dial and 2. Preparatory work

decelerator pedal 1 1) Start the engine, set the monitor panel in
the “Adjustment mode”, and prepare to
1. Outline of fuel control system measure the engine speed.
q The following signals are inputted as rota- a For the operation method, see “Spe-
tion command signals to the engine con- cial functions of monitor panel
troller. (EMMS)”.
q Decelerator pedal potentiometer signal q Adjustment code: 0007
q 3rd throttle signal (Engine deceleration cut mode)
The engine controller controls the fuel a The engine speed is displayed by 1 rpm.
control system of the engine (CRI system)
according to the lowest engine speed sig-
nal among those input signals.
q Adjust the deceleration slow speed by
adjusting the decelerator pedal linkage.
[1] Fuel control dial

[2] Engine controller
[3] Steering and transmission controller
[4] Decelerator pedal
[5] Decelerator potentiometer
[6] Engine (CRI system)
[7] 3rd throttle signal
[8] Rod
30 D85EX, PX-15E0
3. Adjusting decelerator pedal engine speed

With the fuel control dial in the high idle posi-
tion, press decelerator pedal (1) to stopper bolt
(2) and check that the decelerator pedal
engine speed is normal.
q Decelerator pedal engine speed: 1,000 –
1,050 rpm
a If the decelerator pedal engine speed is
out of range, adjust installation dimension
(a) of stopper bolt (2).
q Standard installation dimension (a) of
stopper bolt: 19 mm
4. Engine speed at high idle

Set the fuel control dial in the high idle position
and check that the engine speed at high idle is
normal.
q Engine speed at high idle: 2,050 – 2,150
rpm
q Standard installation dimension (b) of
stopper bolt: 6 mm
q Monitoring mode 31701 decelerator open-
ing 100%
(Exit from the engine deceleration cut
mode and carry out in real time monitoring
mode.)
a If the engine speed is out of range, per-
form the following.
q When the engine speed is 2,050 rpm or
less:
Adjust the engine speed to the high idle
speed with stopper bolt (3).
q When the decelerator opening is less than
100%:
Adjust the decelerator opening to 100%
with stopper bolt (3).
D85EX, PX-15E0 31
Measuring power train oil

pressure 1
a Measuring tools for power train oil pressure

1
K 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
k Stop the machine on a level place, lower

the work equipment to the ground, and set
the parking brake lever and work equip-
ment lock lever in the lock position.
a Measure the power train oil pressure under the
following condition. 1. Measuring torque converter outlet pressure
q Power train oil temperature: (OUT)
Within operating range 1) Connect hydraulic tester K2 to oil pres-
a The centralized power train oil pressure pickup sure measurement nipple (1).
ports are installed inside the inspection cover a Use an oil pressure gauge of 0.98
on the left outside of the operator cab. MPa {10 kg/cm2}.
a A nipple for measuring oil pressure is not
installed as standard.
a List of oil pressure measuring points and

gauges to be used.
Gauge
No. Mark Oil pressure reading
(MPa {kg/cm2})
Torque converter outlet
1 OUT 0.98 {10}
pressure
Torque converter main
2 TM 5.9 {60}
relief pressure
Torque converter inlet
3 IN 2.5 {25}
pressure
Transmission forward
2) Run the engine and set the PCCS lever in
4 FWD 5.9 {60} the full neutral position.
clutch pressure
3) Measure the oil pressure while the engine
Transmission reverse
5 R 5.9 {60} is running at low idle and high idle.
clutch pressure
Transmission 1st clutch
6 1ST 5.9 {60}
pressure
Transmission 2nd clutch
7 2ND 5.9 {60}
pressure
Transmission 3rd clutch
8 3RD 5.9 {60}
pressure
9 BR Steering brake pressure 5.9 {60}
4) After finishing measurement, remove the

measuring instrument and reinstall the
removed parts.
32 D85EX, PX-15E0
2. Measuring transmission main relief pressure 3. Measuring torque converter inlet pressure
(TM) (IN)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester K1 to oil pressure measurement lic tester K1 to oil pressure measurement
nipple (2). nipple (3).
a Use an oil pressure gauge of 5.9 MPa a Use an oil pressure gauge of 2.5 MPa
{60 kg/cm2}. {25 kg/cm2}.
2) Run the engine and set the PCCS lever in 2) Run the engine and set the PCCS lever in
the full neutral position. the full neutral position.
3) Measure the oil pressure while the engine 3) Measure the oil pressure while the engine
is running at low idle and high idle. is running at low idle and high idle.
removed parts.
a For the oil pressure gauge, see
BPD11546.

removed parts.
D85EX, PX-15E0 33
4. Measuring transmission forward clutch 5. Measuring transmission reverse clutch

pressure (FWD) pressure (R)
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the parking brake 2) Start the engine and set the parking brake
lever in free position. lever in the free position.
3) With the brake pedal depressed, set the 3) With the brake pedal depressed, set the
PCCS lever in the “forward” and 3rd gear PCCS lever in the “reverse” and 3rd gear
speed position. speed position.
is running at high idle. is running at high idle.
k Since the torque converter is k Since the torque converter is
stalled, press th e b rake pedal stalled, press the brake pedal
securely and keep your right foot securely and keep your right foot
on the decelerator pedal for safety on the decelerator pedal for safety
until the work is finished. until the work is finished.
a For the oil pressure gauge, see a For the oil pressure gauge, see
BPD11546. BPD11546.
5) After completing the measurement, 5) After completing the measurement,
remove the measuring instrument and set remove the measuring instrument and set
to the original condition. to the original condition.
34 D85EX, PX-15E0
6. Measuring transmission 1st clutch pres- 7. Measuring transmission 2nd clutch pres-
sure (1ST) sure (2ND)
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the parking brake 2) Run the engine and set the parking brake
lever in free position. lever in free position.
3) With the brake pedal depressed, set the 3) With the brake pedal depressed, set the
PCCS lever in the “forward” and 1st gear PCCS lever in the “forward” and 2nd gear
speed position. speed position.
is running at low idle. is running at low idle.
k Since the torque converter is k Since the torque converter is
stalled, keep pressing the brake stalled, keep pressing the brake
pedal securely. pedal securely.
k Do not run the engine at high idle k Do not run the engine at high idle
while measuring. while measuring.
a For the oil pressure gauge, see a For the oil pressure gauge, see
BPD11546. BPD11546.
5) After completing the measurement, 5) After completing the measurement,
remove the measuring instrument and set remove the measuring instrument and set
to the original condition. to the original condition.
D85EX, PX-15E0 35
8. Measuring transmission 3rd clutch pres- 9. Measuring steering brake pressure (BR)
sure (3RD) 1) Connect oil pressure gauge [1] of hydrau-
1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure measurement
lic tester K1 to oil pressure measurement nipple (9).
nipple (8). a Use an oil pressure gauge of 5.9 MPa
a Use an oil pressure gauge of 5.9 MPa {60 kg/cm2}.
{60 kg/cm2}.
2) Run the engine and set the parking brake

2) Run the engine and set the parking brake lever in free position.
lever in free position. 3) Measure the oil pressure while the engine
3) With the brake pedal depressed, set the is running at low idle and high idle.
PCCS lever in the “forward” and 3rd gear a Check that the oil pressure lowers to
speed position. 0 when the brake pedal is depressed
4) Measure the oil pressure while the engine or the parking brake lever is set in the
is running at low idle. lock position.
k Since the torque converter is a For the oil pressure gauge, see
stalled, keep pressing the brake BPD11546.
pedal securely. 4) After completing the measurement,
k Do not run the engine at high idle remove the measuring instrument and set
while measuring. to the original condition.
a For the oil pressure gauge, see
BPD11546.
5) After completing the measurement,
remove the measuring instrument and set
to the original condition.
36 D85EX, PX-15E0
Adjusting transmission speed 6. Taking care of the mounting direction of cover

sensor 1 (2), install cover (2) and sensor (1) as a unit
again to HSS case (4).
1. Remove the undercover of the fuel tank, then 3 Surfaces of cover and case:
remove transmission speed sensor assembly Gasket sealant (LG-5)
(1) and cover (2) as a unit.
a Before adjusting transmission speed sen-
sor (1), remove it temporarily and check
that its tip is free from a steel chip and a
flaw.
a Before installing, separate sensor (1),
cover (2) and locknut (3).
7. After completing adjustment, set the monitor

panel in “Monitoring display mode” and check
that it displays the transmission speed nor-
mally.
a For the operating method, see “Special
a Monitoring code:
2. Install cover (2) to HSS case (4) temporarily. 31400 (Transmission speed)
a Take care of the mounting direction of
cover (2).
3. Screw in sensor (1) until its tip touches the

tooth tip of gear (5).
3 Threads of sensor:
Gasket sealant (LG-5)
4. Return sensor (1) from the above position by

the specified angle.
a Returning angle of sensor: 1/2 – 1 turn
a Adjust clearance (a) between sensor tooth
tip and gear tooth tip to 0.75 – 1.50 mm.
5. Remove sensor (1) and cover (2) as a unit and

secure them with locknut (3).
a Take care that the adjustment angle of the
sensor will not change.
3 Nut: 49.0 – 68.6 Nm {5 – 7 kgm}
D85EX, PX-15E0 37
Simple method to test brake

performance 1
a Implement simple method to test brake perfor-
mance under the following condition.
q Power train oil temperature:
1. Set the blade and ripper in the travel posture

on a level place.
2. Run the engine and set the parking brake lever

in free position.
3. While the engine is running at low idle and the

brake pedal is depressed securely, set PCCS
lever in the forward and 2nd gear speed posi-
tion.
k If this test is carried out in the 1st gear
position, the brake is overloaded.
Therefore, be sure to carry it out in 2nd
gear speed.
a Set the steering unit in neutral.
4. Press the decelerator pedal and set the fuel

control dial in the high idle position.
5. Return the decelerator pedal slowly and check

that the machine does not start when the
engine speed reaches the high idle level.
k Since the torque converter is stalled,
press the brake pedal securely and
keep your right foot on the decelerator
pedal for safety until the work is fin-
ished.
38 D85EX, PX-15E0
Adjusting brake pedal 1
k Tighten the locknuts of the rods and cables

securely, and bend the cotter pins securely.
1. Adjust the stroke (a) of brake pedal (1) with the

installation dimension (b) of damper (2).
q Pedal stroke (a): 77 mm
q Installation dimension (b) of damper: 24 mm
2. Adjust installation dimension (c) of rod (3) on

the valve side, then connect to brake valve
lever (4).
q Rod installation dimension (c): 954 mm
a Fully screw in joint (5) to the valve side.
3. Adjust installation dimension (d) of rod (6) on

the pedal side, then connect to brake pedal (1).
q Rod installation dimension (d): 195 mm
4. Lightly push rod (3) on the valve side toward

the rear of the machine, and turn only joint (7)
to connect rods (3) and (6).
a Push rod (3) with a force of about 9.8 –
19.6 N {1 – 2 kg}.
3 Joint: 34.3 – 58.8 Nm {3.5 – 6.0 kgm}
D85EX, PX-15E0 39
5. With brake pedal (1) released, adjust its play

with dimension (e) between the pins of rod
assembly (8).
q Play of pedal: 1 – 5 mm (center of pedal)
q Dimension (e) between pins of rod assem-
bly: 1,125 mm
a Adjust by turning joints (5) and (7) in the
same direction at the same time.
6. With brake pedal (1) released, check that

brake pedal (1) is in contact with damper (2).
7. Checking brake oil pressure
Oil pressure (MPa {kg/cm2})

Brake
2.84 ± 0.10 {29 ± 1}
released
Brake applied 0
8. After adjusting the pedal, adjust the zero point

of the brake potentiometer (Adjustment mode:
0005).
a For the operating method, see “Special
40 D85EX, PX-15E0
Adjusting parking brake lever 1
1. Assembling and installing lever assembly 3. Checking brake oil pressure

1) Assemble lever assembly (9) and adjust Check that the brake oil pressure is as follows
the operation of limit switch (10). when the parking brake lever is set in free and
a When assembling the lever assembly, lock positions.
disconnect the parking brake cable a For the method of measuring the brake oil
from the lever. pressure, see “Measuring power train oil
q When lever is pulled up: OFF, pressure”.
lowered: ON q Lock position: 0,
q Operation stroke of limit switch: 3 mm Free position: Specified pressure
2) Install lever assembly (9).
4. Checking limit switch
2. Adjusting installation length of parking Change the monitor panel to the monitoring
brake cable display mode and set the parking brake lever
1) Connect parking brake cable (11) to the in free and lock positions. Check that the limit
lever side and valve side, and adjust switch signal is normal at this time.
installation dimensions (f) and (g). a For the operation method of the monitor-
q Cable installation dimension (f): 88 mm ing display mode, see “Special functions
q Cable installation dimension (g): 90 mm of monitor panel (EMMS)”.
2) Operate parking brake lever (12) between q Monitoring code:
the free and lock positions, and adjust rod 40910 (Steering related controller switch
end (14) so that spool stroke (h) of brake input 1)
valve (13) is normal.
q Spool stroke (h): 13 mm
D85EX, PX-15E0 41
Emergency escape method when a Put switch assembly [1] in the cab
power train has trouble 1 through the cab window.
a Devices used for emergency escape

19M-06-32820 Switch assembly
1
17M-06-41530 Wiring harness
L 799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
3 790-190-1601 Pump assembly
1. Emergency escape method by the switch

box (Use L1)
a If the machine cannot be moved because
of a trouble in the electrical system of the
power train control unit (travel direction, 3) Disconnect neutral safety relay (NSF) in
gear speed, steering), carry out the emer- the rear of the control box and connect
gency escape according to the following pins [3] and [5] of the connector on the
procedure. wiring harness side.
a The engine must be able to start during a When PL2 connector is discon-
implementing this procedure. nected, a model selection error is trig-
If the engine cannot be started, see gered and the neutral safety relay will
“Emergency escape method with brake not be actuated. Above procedure is
releasing device”. implemented to avoid this condition.
1) Connect switch assembly [1] to wiring har- k If the engine is started by this
ness [2] of emergency escape device L1. method, the neutral safety function
k To prevent the machine from start- does not work. Accordingly, before
ing suddenly, set all the gear speed starting the engine, set the parking
switches of switch assembly [1] to brake lever in lock position and set
OFF position and the direction the PCCS lever in full neutral posi-
switch in P position. tion.
k Start the engine by this method
only in an emergency. If the engine
does not start in other cases, be
sure to carry out troubleshooting
and repair the trouble.
2) Open the left fender inspection cover and

connect wiring harness [2] to PL1 connec-
tor (1) and PL2 connector (2).
q PL1 connector (1): Connect to male
side and female side.
q PL2 connector (2): Connect to female 4) Run the engine and set the parking brake
side. lever in free position.
a PL2 connector on the male side is
kept disconnected, mask it with a
vinyl sheet, etc.
42 D85EX, PX-15E0
5) Operate switch assembly [1] and move 2. Emergency escape method with brake
the machine to a safe place. releasing device (Use L3)
a The electrical circuit of the gear a If the engine cannot be started and the
speed switches is configured so that parking brake cannot be released, carry
the switch on the lower gear speed is out the emergency escape according to
operated first. the following procedure.
k Take care that the L.H. and R.H. 1) Assemble pump assembly L3.
steering directions are opposite
when reverse.
2) Install volume pump [1] of pump assembly

L3 to the outside of the operator cab.
D85EX, PX-15E0 43
3) Remove inspection plug for measuring oil

pressure which is located within the
inspection cover on the left outer side of
the operator cab.
4) Install nipple L2 and connect hose [2] of
pump assembly L3.
5) Turn the starting switch on and set the

parking brake lever in free position.
6) Operate the volume pump to raise the
brake releasing oil pressure to the initial
pressure.
q Initial pressure: Approx. 2.74 MPa
{Approx. 28 kg/cm2}
a Since an accumulator is installed in
the circuit, the handle must be oper-
ated 30 – 50 times to raise the oil
pressure.
a If the oil pressure does not rise above
a certain level, the relief valve may be
set to low pressure. In this case,
adjust the set pressure of the relief
valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure low-
ers gradually because of internal
leakage and the brake is applied
again about 1 minute after. Therefore,
work immediately.
a If the brake releasing pressure lowers
to about 1.57 MPa {16 kg/cm 2}, the
brake is applied. In this case, operate
the volume pump again to raise the
brake releasing pressure to the initial
pressure.
8) When disconnecting the hose after finish-
ing the work, loosen the screw slowly and
do not stand in the spouting direction of
the oil.
44 D85EX, PX-15E0
Adjusting clearance of idler 1
a If the lateral guide and vertical guide plates of 4) Pull up vertical guide (4) with a bar, etc.
the idler have worn excessively and the idler and pull out shim (5) by the quantity of
ran out slants, adjust the clearance of the idler adjustment obtained in 1).
according to the following procedure. 5) Add shim (5) pulled out onto shim (6).
(8 places in total on both sides, inside, and
1. Lateral adjustment outside)
1) Drive the machine 1 – 2 m on flat ground, a The total number of shims (5) and (6)
then measure clearance (a) between the before adjustment must be the same
track frame and guide plate (4 places; left, as that after adjustment.
right, inner and outer sides). q Sorts of shim thickness: 1 mm, 2 mm
2) If clearance (a) is larger than 4 mm,
loosen bolt (1) and reduce shim (2).
q Standard clearance (a) on each side:
0.5 – 1.0 mm
q Shim thickness: 0.5 mm, 1.0 mm
2. Vertical adjustment
1) Measure clearance (b), subtract 2 mm
from it, and record the result (quantity of
adjustment).
Example: When clearance (b) = 5 mm
The quantity of adjustment is
5 – 2 = 3 mm.
2) Loosen bolts (3) (4 pieces on inside and
outside) until the reaction force of the
spring is lost.
3) Loosen bolt (1). However, do not loosen it
more than 3 turns.
D85EX, PX-15E0 45
Inspecting wear of sprocket 1 Testing and adjusting track shoe

a Use the “Full-scale dimensions drawing of tension 1
sprocket profile” in the topic “Sprocket” in the Testing
chapter “Structure, function and maintenance 1. Move the machine slowly on a level place, then
standard” as a gauge for measuring wear of stop it.
the sprocket. a Do not apply the brake when stopping.
a Make a copy of the “Full-scale dimensions
drawing of sprocket profile” on a transparent 2. Place straight steel bar (1) between the idler
paper or sheet and apply it directly to the and front carrier roller and measure clearance
sprocket to see if the sprocket can be used. (a) between the bottom of the steel bar and
shoe grouser.
q Standard clearance (a):
EX: 20 – 30 mm
PX: 10 – 15 mm
Adjusting
a If the track shoe tension is abnormal, adjust it
1. Remove cover (2).

2. When the tension is too high
Loosen plug (3) to discharge the grease.
k Since the high-pressure grease may
spout out, do not loosen the plug more
than 1 turn.
3 Plug: 59 – 88 Nm {6 – 9 kgm}
3. When tension is low

Add grease through grease fitting (4).
a If the track shoe is not tensed well, move
the machine forward and in reverse slowly.
46 D85EX, PX-15E0
Testing and adjusting work 3) Install nipple M2 and connect it to oil pres-
equipment and HSS oil pressure 1 sure gauge [1] of hydraulic tester M1.
a Use an oil pressure gauge of 39.2
a Equipments for testing and adjusting work MPa {400 kg/cm2}.
equipment and HSS oil pressure

1
790-261-1204 Digital hydraulic tester
M
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring
Measuring
a Measure the work equipment and HSS oil
pressure under the following condition. 4) Run the engine at high idle and set the
q Hydraulic oil temperature: Within operat- blade lever and ripper lever in neutral and
ing range measure the oil pressure.
1. Measuring unload pressure

1) Remove main control valve cover (1) on
the right side of operator seat.

removed parts.
2) Remove measurement plug (2).
D85EX, PX-15E0 47
2. Measuring work equipment and HSS oil Work equipment oil pressure
pressure 1] Run the engine and set the work equip-
1) Remove main control valve cover on the ment lock lever in the free position.
right side of operator seat. 2] Run the engine at high idle and operate
2) Remove pump discharge oil pressure the blade lever and ripper lever. When
measurement plug (1) and LS oil pressure each cylinder is relieved at the stroke end,
(load sensing pressure) measurement measure the oil pressure.
plug (2). a Block the return hose of the blade lift
cylinder.
3] After finishing measurement, remove the
removed parts.
HSS oil pressure

1] Start the engine, set the parking brake
lever in the free position, and depress the
brake pedal.
k Since the steering circuit will be
relieved, keep pressing the brake
pedal securely and keep your right
foot on the decelerator pedal for
safety until the work is finished.
2] Run the engine at high idle and steer to
3) Install nipples M2 and connect it to oil the right or left with the PCCS lever. When
pressure gauge [1] of hydraulic tester M1. the steering circuit is relieved, measure
a Use the following oil pressure gauges the oil pressure.
Work equipment oil pressure: 3] After finishing measurement, remove the
39.2 MPa {400 kg/cm2} measuring instrument and set to the origi-
HSS oil pressure: nal condition.
58.8 MPa {600 kg/cm2}
48 D85EX, PX-15E0
a The unload pressure and relief pressure

also can be measured in the “Pm clinic
auxiliary mode” of the monitor panel.
D85EX, PX-15E0 49
3. Adjusting
1) LS pressure (Load sensing pressure) of 2) LS pressure (Load sensing pressure) of
work equipment HSS
Loosen locknut (4) of work equipment LS Loosen locknut (7) of HSS LS valve (6)
valve (3) and rotate adjustment screw (5) and rotate adjustment screw (8) to adjust
to adjust the LS pressure. the LS pressure.
a If the adjustment screw is a If the adjustment screw is
q rotated to the right, the oil pres- q rotated to the right, the oil pres-
sure is heightened. sure is heightened.
q rotated to the left, the oil pres- q rotated to the left, the oil pres-
sure is lowered. sure is lowered.
a If the adjustment screw is rotated 1 a If the adjustment screw is rotated 1
turn, the pressure is heightened or turn, the pressure is heightened or
lowered by 17.6 MPa {179 kg/cm2}. lowered by 15.1 MPa {154 kg/cm2}.
3 Locknut: 3 Locknut:
29.4 – 39.2 Nm {3 – 4 kgm} 68.6 – 78.5 Nm {7 – 8 kgm}
q After adjusting, check the relief pres- q After adjusting, check the relief pres-
sure and LS pressure of work equip- sure and LS pressure of work equip-
ment again. ment again.
50 D85EX, PX-15E0
Testing control circuit basic 3. Install oil pressure pickup adapter N2 and con-
pressure 1 nect the disconnected hose again.
a Instruments for testing and adjusting control 4. Install nipple [1] of hydraulic tester N1 and con-
circuit basic pressure nect oil pressure gauge [2].
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
1
N 790-261-1204 Digital type hydraulic tester
2 799-401-3200 Adapter (size 03)
a The control circuit main pressure is the pres-

sure lowered by the self pressure reducing
valve. It is used commonly for blade PPC, fan
pump control, steering EPC and ripper PPC.
Measuring
a Measure the control circuit basic pressure
5. Run the engine at high idle and set the blade
under the following condition.
lever and ripper lever in neutral and measure
q Hydraulic oil temperature:
the oil pressure.
1. Remove main control valve cover on the right

side of operator seat.
2. Disconnect hose (1).

parts.
Adjusting
a The self pressure reducing valve cannot be
adjusted.
D85EX, PX-15E0 51
Measuring PPC valve output 5. Run the engine at high idle and operate the
pressure 1 control lever of the circuit to be measured and
measure the oil pressure.
a Measuring instruments for PPC valve output a Measure the oil pressure with the lever at
pressure full stroke.
a For the blade lower side, operate the lever
to the float position.
1
790-261-1204 Digital type hydraulic tester
P
2 799-401-3100 Adapter (size 02)
3 799-401-3200 Adapter (size 03)

a Before measuring the PPC valve output pres-

sure, check that the control circuit basic pres-
sure is normal.
a Measure the PPC valve output pressure under
the following condition. 6. After finishing measurement, remove the mea-
q Hydraulic oil temperature: suring instrument and reinstall the removed
Within operating range parts.
1. Remove main control valve cover on the right
side of operator seat.
2. Disconnect PPC valve output pressure hose

(1). Install adapters P2 and P3 and connect
the disconnected hose again.
a For the circuits to be measured, see the
drawing on the next page.
3. Install nipple [1] of hydraulic tester P1 and con-

nect oil pressure gauge [2].
4. Run the engine and set the work equipment

lock lever in the free position.
52 D85EX, PX-15E0
1. Main valve A. Blade LEFT TILT

2. Self pressure reducing valve B. Blade LOWER
3. PPC lock valve C. Ripper RAISE
4. Blade PPC valve D. Ripper LOWER
5. Ripper PPC valve E. Blade RAISE
F. Blade RIGHT TILT
D85EX, PX-15E0 53
Adjusting play of work equipment

PPC valve 1
a The ripper valve is not adjustable.
a If the end play of the blade lever is excessive,
adjust it with their PPC valves according to the
following procedure.
q Standard play (a):

0.5 – 3.0 mm at 200 mm from revolution center
of lever
(in both longitudinal and lateral directions)
1. Remove boot (1).
2. Loosen locknut (2) and turn disc (3) to adjust

the play.
a Do not move the piston at this time.
3. Fix disc (3) and tighten locknut (2).

3 Locknut: 98 – 127 Nm {10 – 13 kgm}
4. Install boot (1).
54 D85EX, PX-15E0
Checking parts which caused 3) Ripper lift cylinder

hydraulic drift of blade and ripper1 Tens e r ipp er to pus h u p the re ar of
machine.
a When a hydraulic drift of blade or ripper
occurred, check if the parts causing the drift is
located in cylinder packing side or in control
valve side according to the following proce-
dure.
1. Stop the engine with the cylinder at the follow-

ing positions.
1) Blade lift cylinder
Tense blade to push up the fr ont of
machine.
a Do not extend the blade lift cylinder to
the stroke end since it is equipped
with the piston valve.
2. Move the control lever of cylinder to be

checked to the direction of extending cylinder
and validate the movement of cylinder.
q If the drift speed becomes faster, a cylin-
der packing is defective.
q If the speed does not change, a control
valve is defective.
a If the pressure of the accumulator is lost,
run the engine for approx. 10 seconds to
build up the pressure.
[Reference] In case of the hydraulic drift is caused

by defective cylinder packing, the rea-
son why the drift speed becomes
2) Blade tilt cylinder faster by above mentioned operation
Retract the tilt cylinder to the stroke end is as follows:
and tense blade further to push up the 1) When work equipment is set in the above
right side of the machine. mentioned position, where the holding
pressure is applied to the bottom side, the
oil leaks from bottom side to head side.
Since the volume of head side is smaller
than that of bottom side by the volume of
the rod, the inner pressure of head side
rises by the oil leak from bottom side.
2) If the inner pressure of head side rises,
cylinder is balanced at certain pressure
(depending on the amount of leakage)
which is in proportion to the inner pres-
s ure. Therefore, the dr ifting s peed
becomes slower.
3) At this time, if the circuit in the head side is
opened (bottom side is closed by check
valve) to drain circuit by above mentioned
lever operation, the oil in the head side
flows into the drain circuit causing the lost
of the pressure balance. Then the drift
speed becomes faster.
D85EX, PX-15E0 55
Measuring internal leakage of Bleeding air from work equipment

work equipment cylinder 1 cylinder 1
a Measuring instruments for leakage of work a If the work equipment cylinder was removed
equipment cylinder and installed or its piping was disconnected
and connected, bleed air from its circuit
Symbol Part No. Part name according to the following procedure.
Commercial
Q Measuring cylinder
item 1. Run the engine at low idle for about 5 minutes.
a Measure the internal leakage of work equip- 2. Running the engine at low idle, extend and
ment cylinder under the following condition. retract the cylinder to be bled 4 – 5 times.
q Hydraulic oil temperature: 45 – 55°C a Move the piston rod to about 100 mm
a Since the blade lift cylinder is equipped with a before the stroke end and never relieve
piston valve, its internal leakage cannot be the oil.
measured.
3. Running the engine at high idle, carry out the
1. Retract the cylinder to be measured to the operation in 2.
stroke end and set the machine in the measur-
ing position. 4. Running the engine at low idle, move the cylin-
1) Blade tilt cylinder der to the stroke end to relieve the oil.
Tilt the blade to the right end.
2) Ripper lift cylinder
Pull out the shank pin and lower the ripper
to the end.
2. Disconnect hose on the cylinder bottom side

and block the hose side with a plug.
a Remove the hose cover of the blade tilt
cylinder.
k Take care not to disconnect the hose
on the head side.
3. Run the engine at high idle and apply the relief

pressure to the cylinder bottom side.
q Blade tilt cylinder: Operate to tilt blade to
right.
q Ripper lift cylinder: Operate to lower rip-
per.
4. After 30 seconds, measure leakage for 1 minute.
5. After finishing measurement, return the

removed parts.
56 D85EX, PX-15E0
Releasing residual pressure in

work equipment cylinder 1
a When disconnecting the piping between the
control valve and work equipment cylinder,
release the residual pressure in the circuit
1. Loosen the hydraulic tank cap gradually to

release the residual pressure in the tank.
2. Set the work equipment lock lever in the free

position and operate the blade lever and ripper
lever forward, backward, to the right, and to the
left.
a After the levers are operated 2 – 3 times,
the residual pressure in the accumulator is
fully released.
3. Run the engine at low idle for about 5 seconds,

and then stop it.
4. Repeat above steps 2 and 3 by 2 – 3 times.
D85EX, PX-15E0 57
Adjusting work equipment lock lever 1
1. Adjust dimension (a) between pins of rod (1).

q Dimension (a) between pins: 329 mm
2. Connect rod (1) to work equipment lock lever

(2) and PPC lock valve (3).
a Install connecting pin (4) with the cotter
pin on the outside of the machine.
58 D85EX, PX-15E0
Measuring fan motor speed 1 6. Measure the fan motor speed when the engine
is running at high idle and low idle.
k Be sure to close the radiator mask
a Measuring instruments for fan motor speed
before starting the engine. Do not start
the engine with the radiator mask open.
R 799-205-1100 Tachometer KIT
1. Open radiator mask (1).
2. Remove fan guard (2).

parts.
3. Stick 1 sheet of reflecting tape [1] to fan (3).
4. Set probe [2] of tachometer KIT R to stand [3],

matching it to reflecting tape [1], then connect
it to multitachometer [4].
k Pay attention to the installation posi-
tion so that the probe will not interfere
with the fan.
5. Close the radiator mask, run the engine, and

set the monitor panel in the adjustment mode.
a For the operation method of the adjust-
ment mode, see “Special functions of
monitor panel (EMMS)”.
a Adjustment code:
1005 (Fan 100% speed mode)
D85EX, PX-15E0 59
Measuring fan pump circuit 5. Run the engine, and turn the monitor panel to
pressure 1 the adjustment mode.
a For the operation method of the adjust-
a Measuring instruments for fan pump circuit ment mode, see “Special functions of
pressure monitor panel (EMMS)”.
a Adjustment code:
1005 (Fan 100% speed mode)
1
790-261-1204 Digital hydraulic tester 6. Measure the oil pressure of fan circuit while the
S 2 799-401-3400 Adapter (size 05) engine is running at high idle.
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
1. Open radiator mask (1).
2. Remove fan guard (2).

parts.
3. Remove the 4th noise absorbing blade from

the right and disconnect fan motor drive circuit
hose (3).
4. Install adapter S2 and connect hose (3) again.

Install nipple S3 and connect oil pressure
gauge [1].
a Use an oil pressure gauge of 39.2 MPa
{400 kg/cm2}.
60 D85EX, PX-15E0
Bleeding air from fan pump 1

a If the fan pump was removed and installed or
its piping was disconnected and connected,
bleed air from the pump case according to the
a Before performing the following procedure,
check that the hydraulic oil is at the specified
level.
1. Remove the floor inspection cover (R.H.).
2. Loosen air bleeder (1) and leave it for 15 min-

utes.
3. After 15 minutes, run the engine at low idle.
4. When oil flows out of air bleeder (1), tighten air

bleeder (1).
D85EX, PX-15E0 61
Adjusting blade 1
a If the blade was removed and installed or dis-

assembled and assembled, adjust it according 2) Adjust the shim of lift (2). (2 pieces)
to the following procedure. Adjusted Adjusted Standard Standard thickness
point clearance clearance of shim
1. Adjusting shims for assembly
2 b Max. 1 mm 4 mm
1) Adjust the shim of center (1). (6 pieces)
Adjusted Adjusted Standard Standard thickness
point clearance clearance of shim
Refer to the
1 a 4 mm
note.
Note: Adjust the shim so that the play of

the ball in the axial direction will be
less than 1 mm and the ball can
rotate smoothly.
62 D85EX, PX-15E0
2. Adjusting blade tilting distance

1) Adjust dimension (c) of brace (3) with the
handle.
q Brace installation dimension (c):
1,287 mm
2) Measure right and left tilting distances (e1)
and (e2).
q Right tilting distance (e1):
Approx. 400 mm
q Left tilting distance (e2):
Approx. 400 mm
3) If the tilting distances are different remark-
ably, adjust installation dimension (c) of
brace (3) according to the following proce-
dure.
q (e1) > (e2): Increase installation di-
mension (c) finely.
q (e1) < (e2): Decrease installation di-
mension (c) finely.
D85EX, PX-15E0 63
Testing and adjusting operator

cab 1
Check after installing cab assembly
1. Measuring pressure in cab

q Criterion:
Measured value X 78.5 Pa {8 mmH2O}
q Engine speed: High idle
q Fan speed: 100% mode (See the User
adjustment mode of the monitor panel)
q Fan switch of air conditioner: High
q External and internal air changeover
switch of air conditioner: Fresh air position
a If the measured value is lower than the
standard value, check the seals of the 2. Check of sealing performance
holes for wiring harnesses and optional 1) Close the all openings of the cab.
parts in the cab. 2) Splash water around the hatched part of
1) A simple method of measuring the internal the cab at the rate of about 19 l/min. for
pressure is as follows. 10 minutes.
1] Prepare a transparent vinyl hose. q At this time, it is not necessary to
q Inside diameter: 6 mm, splash pressurized water.
Length: 3,000 mm 3) Splash water horizontally from a hose over
2] Secure the inside end of the hose to sealing surface (4).
the top of the back seat with a tape. 4) Check around the dashboard carefully.
3] Remove bolt (1) under the left con- a If water leaks, caulk the leaking part and
sole box. Pass the other end of the check again.
hose through the bolt hole and take it
out of inspection cover (2) on the left
side of the cab.
4] Seal the hole of bolt (1) with tape (3).

5] Fill the hose with water up to about
the half level and bend the hose in the
shape of letter U.
6] Set the water level in the vinyl hose
out of the cab to that in the cab.
7] Run the engine at high idle and mea-
sure water level difference (c). [Value
(c): Pa {mmH2O}]
a [a] side: Inside of cab
(Pressurized)
[b] side: Out of cab
(Atmospheric pressure)
64 D85EX, PX-15E0
3. Testing door lock 2] Check the relationship between the

Close the door and check the relationship door latch and striker (on both sides).
between the operator cab and door. If there is q Close door (2) and check the
any fault, repair it. engaging condition of latch (3)
1) Check of current condition and striker (4).
1] Check the installed height to damper Normal: Error of (a) must be 0.5
rubber (1). mm or less.
(Check both sides, 2 pieces on each.) a Check deviation (a) of latch center
q Stick adhesive tape [1], etc. to (y) and striker center (x) from each
the contact surface of damper other from the direction of (A).
rubber (1) and open and close
the door 2 – 3 times. Then, check
the contact surface of adhesive
tape [1] against the operator cab.
Normal:
When the door is closed, the
damper rubber comes in con-
tact lightly.
Abnormal:
When the door is closed, the
damper rubber does not come
in contact or comes in contact
so strongly that adhesive tape
is removed.
D85EX, PX-15E0 65
2) Adjusting 4. Testing open lock

1] Adjusting height of damper rubber Lock the door open and check the relationship
q Loosen the mounting bolts of between the operator cab and door. If there is
damper rubber (1). any fault, repair it.
a You can remove and install the 1) Check of current condition
s h im s wi th o ut r e m ov i ng th e 1] Check the relationship between open
mounting bolts. lock latch (3) and striker (4) from the
q Increase or decrease of shims direction of (B).
(5) under damper rubber (1) to
adjust the height of damper rub-
ber (1) properly.
a Move the door in the opening

direction to check the engage-
ment of the latch and striker.
2] Adjusting height of latch and striker 2] Check the installation height of stop-
1. Tighten the mounting bolt of per rubber.
striker (4) temporarily and close (Check both sides, 2 pieces on each.)
the door 2 – 3 times to align latch 1. Lock the door open and shake it
(3) and striker (4) with each in the forward and reverse direc-
other. tions to see if it has any play.
2. Check the engaging condition of 2. Check that the operating effort of
latch (3) and striker (4). unlock lever is not heavy.
3. Tighten the mounting bolt of 3. Check that striker (4) does not
striker (4) securely. slant from center (d) of the latch.
4. Open and close the door and 4. Check that the latch is not shifted
check that it is locked and from center (e) of the striker.
unlocked smoothly. If the door is q Normal: Error of (e) must be
not locked and unlocked less than 0.5 mm.
smoothly (if the knob is heavy),
perform the adjustment proce-
dure from the first.
a Operating effort of knob:
49 ± 19.6 N {5 ± 2 kg}
3] Apply grease (G2-LI) to latch (3).
a If latch (3) is not greased, the
knob becomes heavy. Accord-
ingly, apply grease sufficiently.
66 D85EX, PX-15E0
2) Adjusting 2. If there is any play, project

1] Adjusting latch and striker (heighten) the stopper rubber
q Loosen mounting bolt (7) of until the play is eliminated.
striker (4), adjust striker (4) a If the door is not locked eas-
upright, and tighten mounting ily or the unlock lever is
bolt (7). heavy, return (lower) the
stopper rubber in the range
that the door does not have
any play.
3. Tighten the locknut.
2] Adjusting installation height of stop-

per rubber
1. Loosen locknuts (10), (11) of the
stopper rubber upper side (8),
lower side (9).
D85EX, PX-15E0 67
SEN00630-00

© 2006 KOMATSU
All Rights Reserved
68
SEN00631-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Testing and adjusting, Part 2........................................................................................................................... 2
Special functions of monitor panel (EMMS) ......................................................................................... 2
D85EX, PX-15E0 1
Testing and adjusting, Part 2 1

Special functions of monitor panel (EMMS) 1
Display section of special functions Operation section 1 of special functions (Basic

1. Upper display section operation)
(Gear speed display section) 3. Service switch
2. Lower display section
(Multi-information section) O peration sect io n 2 o f special fun ctions
(Changeover operation)
4. Buzzer cancel switch
5. Information switch
6. Shift-up switch
7. Shift-down switch
a EMMS: Equipment Management Monitoring

System
2 D85EX, PX-15E0
Normal function and special functions of monitor panel (EMMS)

The monitor panel (EMMS) has the normal and special functions, and displays information of various types
at the gear speed display section at the center of the monitor panel and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others
are displayed according to the operation of the switches.
1. Normal function: Operator mode
With this function, an operator can view and change the items displayed normally or displayed by the
operation of the switches.
2. Special function 1: Service mode
With this function, a serviceman can display and change the displayed items by the specified switching
operation for testing, adjusting and troubleshooting.
Flow of each mode and function
D85EX, PX-15E0 3
Operation and display of operator mode information section (2). Reset after completion
(Outline) of the replacement is done in this mode.
a Gear speed display section (1) remains
a In this section, only the outline of operator the normal display.
mode is explained.
See Operation and Maintenance Manual for
details of each function and mode as well as
the operating method.
Normal display (Default)

The following information is normally displayed on
the monitor panel.
Gear speed display section (1):
q Front side: Travel direction (P, N, F, R)
q Rear side: Gear speed (1, 2, 3)
q Graphics: Engine speed
Multi-information section (2):
q Information is displayed in 2 lines of 16 charac-
ters each.
q Front side: Gear shift mode (F1-R1, F1-R2,
F2-R1, F2-R2, F2-R3) (Displayed
when preset mode is set.)
q Rear side: Service meter (Unit: 0.1h)
q Each time the information switch is set to the
right or left, the service meter and the engine
speed are displayed alternately.
a The items marked with a are displayed

but not used for this machine.
Replacement interval
2nd time
Code Display Maintenance item 1st time
and after
(Can not be
(Can be
changed)
changed)
01 ENG OIL Engine oil 500 500
02 ENG FILT Engine oil filter 500 500
FUEL
03 Fuel main filter 1000 1000
FILT
04 HYD FILT Hydraulic oil filter 250 2000
CORR
06 Corrosion resistor 1000 1000
RES
DAMP
07 Damper oil 2000 2000
OIL
08 FNL OIL Final drive oil 250 1000
10 HYD OIL Hydraulic oil 250 2000
12 HSS FILT a HSS charge filter — —
POWL
19 Power train oil 250 1000
OIL
POWL
20 Power train oil filter 250 500
1. Maintenance mode FILT
(1-OIL, FILTER MAINTENANCE MODE) 41
F.PRE-
Fuel pre-filter 500 500
In this mode, the time up to the next replace- FLT
ment of oils and filters is displayed on multi-
4 D85EX, PX-15E0
2. Pm clinic auxiliary mode (2-PM CLINIC MODE) 3. Failure code display mode
In this mode, the condition of the machine is (3-FAULT CODE DISPLAY MODE)
displayed on multi-information section (2) as In this mode, the contents of each problem in
an auxiliary function of the periodic diagnoses the machine are displayed by a 6-character
such as the Pm clinic, even if any measuring failure code on multi-information section (2).
instrument is not connected. When a user or an operator needs to be noti-
a Gear speed display section (1) remains fied of the failure code of each problem, this
the normal display. mode is applied.
a Gear speed display section (1) remains
the normal display.
No. Pm clinic auxiliary item

01 Engine speed a When a serviceman needs to check the
02 Coolant temperature failure codes for troubleshooting, “Electri-
03 Engine oil pressure cal system failure code display mode” and
“Mechanical system failure code display
05 Boost pressure
mode” is recommended to use for more
06 Boost temperature detailed information.
07 Power train oil temperature a Method of checking failure code:
08 Work equipment oil temperature Turn buzzer cancel switch (4) to the [U ]
position on the screen shown on the
09 Work equipment oil pressure
above, and all failure codes detected cur-
13 Battery voltage rently are displayed at the interval of about
2 seconds. (To finish displaying, turn the
buzzer cancel switch to the [t] position.)
D85EX, PX-15E0 5
4. Adjustment mode (4-USER ADJUST MODE) 1) Brightness of LCD

In this mode, the display condition of the moni- This mode is to adjust brightness of the
tor panel can be adjusted on multi-information backup lamp at the liquid crystal gauge
section (2). section. (See Operation and Maintenance
a Gear speed display section (1) remains Manual.)
the normal display.
2) Brightness of display
This mode is to adjust brightness of the
backup lamp at the multi-information sec-
tion. (See Operation and Maintenance
Manual.)
3) Contrast of display
This mode is to adjust contrast of the liquid
crystal at the multi-information section.
(See Operation and Maintenance Manual.)
4) Fan 100% mode

This function is to control rotation speed of
the cooling fan forcedly at approximately
100% of the maximum speed.
1] This mode is selected by operating the
information switch.
2] The mode is selected by turning the
buzzer cancel switch to the [U] position.
3] The function is effective under this con-
dition and the rotation speed of the
cooling fan is controlled to approxi-
mately 100% of the maximum speed.
a Exiting this mode disables the
function.
No. Adjustment item

01 Brightness of LCD
02 Brightness of display
03 Contrast of display
04 Fan 100% mode
05 No injection cranking mode
6 D85EX, PX-15E0
5) No injection cranking mode Action code display function

This mode is to circulate the engine oil
while applying no injection conditions to all If a trouble which is to be notified to a operator
engine cylinders before staring engine occurs during work, an action code and a phone
after an extended machine storage. number are displayed on multi-information section
1] This mode is selected by operating (2).
the information switch. a Gear speed display section (1) remains the
2] The mode is selected by turning the normal display.
buzzer cancel switch to the [U] position. a The phone number is displayed only for impor-
3] In this condition, turn the starting tant action codes. The display shown below is
switch to START position to apply no an example. (The form of the displayed phone
injection cranking. number depends on the form of the input num-
4] The mode is released by moving the ber.)
starting switch to ON position and a If an important action code is displayed, the
turning the buzzer cancel switch to caution lamp flashes and the alarm buzzer
the [t] position. sounds.
k Do not continue no injection <Reference>
cracking for more than 20 sec- An action code is displayed only when a serious
onds in order to protect the abnormality occurs.
starting motor. Even if an action code is not displayed, abnormality
k For safety, this mode cannot be
may have occurred. Therefore, if you find any inci-
operated while the engine is
dent, be sure to check for a failure code in “Electri-
running.
a Exiting from this mode disables c al sy s te m fai l ur e c od e di s pl ay m od e” an d
this function. “Mechanical system failure code display mode”.
D85EX, PX-15E0 7
Action code table

Action Remedy requested for an
Display method of trouble Examples of abnormality
code operator
• Automatic function stops or nor-
• Backup alarm does not turn on. mal function stops partially, but
E01 • Only action code is displayed. • Fan speed is kept at maximum machine can work.
level. • Contact your Komatsu distribu-
tor for repair.
• Stop engine and start it again,
• Gear is not shifted up or down.
and you can operate machine
• The action code is displayed. • Exhaust gas color is bad when
without limiting function. You
E02 • Warning lamp flashes temperature is low.
must take care, however.
• Alarm buzzer sounds. • Abnormal engine oil pressure
• Contact your Komatsu distribu-
sensor
tor for repair.
• Engine boost pressure is abnor-
mal.
• The action code is displayed. • Move machine to safe place.
• Usable gear speeds are limited.
CALL E03 • Warning lamp flashes • Contact your Komatsu distribu-
• Engine speed does not rise fully.
• Alarm buzzer sounds. tor for repair.
• Gear shift shocks become large.
• Steering performance lowers.
• The action code is displayed. • Engine cannot be controlled. • Immediately stop machine.
CALL E04 • Warning lamp flashes • Machine cannot travel. • Contact your Komatsu distribu-
• Alarm buzzer sounds. • Machine stops. tor for repair.
8 D85EX, PX-15E0
Operation and display in service mode

Gear speed
Method of changing to service mode No. Adjustment item
display section
a When using the service mode, change the
Maintenance interval change
screen by the following special operation. 5 1C
mode
Electrical system failure code
1) Special operation of switches 6 EE
display mode
Set the monitor panel in the service mode by
operating service switch (3) and buzzer cancel Mechanical system failure code
7 bE
switch (4). display mode
a Keeping the service switch in ON position, 8 Cb Adjustment mode
hold the buzzer cancel switch in the [U] 9 Ld Load saving display mode
position for more than 2.5 seconds.
10 5R Real-time monitoring mode
a If the monitor panel is set in the service
mode, [1C] is displayed on gear speed 11 dR Dual display monitoring mode
display section (1).
a Each time the monitor panel is set in the 2) Selecting and executing mode to be used
service mode, “Maintenance interval Select the mode to be used with information
change mode” is displayed first. switch (5) and execute it with buzzer cancel
switch (4).
q [>] : Next mode No.
q [<] : Previous mode No.
q [U] : Execute mode.
a For details of operation in each mode, see
the following pages.
3) Finishing mode and function

The current mode and function can be finished
by either of the following method, regardless of
the current mode and hierarchy.
1] When continuing the operation in another
mode or function or in the operator mode:
Return to the mode screen or function
screen to be used next by operating
buzzer cancel switch (4).
q [t]: Screen returns.
2] When finishing all operations:
Turn off the starting switch.
D85EX, PX-15E0 9
5. Maintenance interval change mode 2) Selecting and displaying maintenance item

(5-EXCHG. INTVAL. SET MODE) 1] Operate information switch (5) on the
In this mode, you can check and set the main- maintenance item selection screen to
tenance interval times of various filters and oils select a maintenance item.
which are the bases of the maintenance dis- q [>]: Next code
play function in the operator mode. q [<]: Previous code
2] Display the maintenance item selec-
1) Selecting and implementing a mode tion screen by operating buzzer can-
1] Select “Maintenance interval change cel switch (4).
mode” on the mode selection screen. q [U]: Execute item.
a If the mode is selected, code [1C]
is displayed on gear speed dis-
play section (1) and the title is
displayed on multi-information
section (2).
2] Display the maintenance item selec-
tion screen by operating buzzer can-
cel switch (4).
q [U]: Execute mode
3) Contents of information screen

The following items are displayed on the
information section.
1: Code
2: Maintenance item
3: Replacement interval (Set time)
a Below figure shows an example.
a If the replacement interval does not
need to be changed, finish the opera-
tion on this screen.
a If the replacement interval needs to
be changed, go to step 4).
10 D85EX, PX-15E0
4) Updating replacement interval 2] If the input time is correct, enter the

1] Change the set time by operating change of setting by operating buzzer
information switch (5), shift-up switch cancel switch (4).
(6) and shift-down switch (7). q [U]: Enter change.
q [>]: Move cursor to right. a If the change is finished normally,
q [<]: Move cursor to left. the information display screen
q [UP]: Number increases. appears after the screen shown
q [DOWN]: Number decreases. below.
a Cannot set the value beyond the
default setting time.
a If the change is not finished nor-

mally, the information display
a If you do not use the mainte- screen before the change
nance function, set all times to 0. appears after the screen shown
below. In this case, execute the
above operation again.
D85EX, PX-15E0 11
Maintenance items table

Replacement interval (H)
Code Display Maintenance item 1st time 2nd time and after
(Can not be changed) (Can be changed)
01 ENG OIL Engine oil 500 500
02 ENG FILT Engine oil filter 500 500
03 FUEL FILT Fuel filter 1000 1000
04 HYD FILT Hydraulic oil filter 250 2000
06 CORR RES Corrosion resistor 1000 1000
07 DAMP OIL Damper oil 2000 2000
08 FNL OIL Final drive oil 250 1000
10 HYD OIL Hydraulic oil 250 2000
12 HSS FILT HSS charge filter — —
19 POWL OIL Power train oil 250 1000
20 POWL FILT Power train oil filter 250 500
41 F.PRE-FLT Fuel pre-filter 500 500
a The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that
the first maintenance has been finished in the maintenance mode of the operator mode, then change
the 2nd and after interval times.
12 D85EX, PX-15E0
6. Electrical system failure code display mode 2) Display in case where no codes are
(6-ELEC. FAULT CODE MODE) recorded
In this mode, you can check the electrical sys- If the failure codes which occurred in the
tem failure codes among the information of the past, and the current active failure codes
troubles that occurred on the machine. do not exist, the below display will be
a Refer to the item of “Troubleshooting” for shown.
the failure code list.
1) Selecting and implementing a mode

1] Select “Electrical system failure code
display mode” on the mode selection
screen.
a If the mode is selected, code
[EE] is displayed on gear speed
display section (1) and the title is
section (2).
2] Display the failure code display
screen by operating buzzer cancel
switch (4).
q [U]: Execute mode 3) Display in case where 1 or more codes
are recorded
If any failure codes which happened in the
past or which are currently active exist,
the display will be as shown below.
1] : Record No. (Up to 20)
2] : Failure code
(Flash if currently active.)
3] : Number of occurrences up to now
4] : Elapsed time measured by service
meter after first occurrence
meter after last occurrence
a The below figure shows an example
of the display.
a Flashing and lighting of failure code

Flashing: Code of the failure which is
currently detected.
Lighting: Code of the failure which is
not currently detected.
D85EX, PX-15E0 13
a Conditions for detecting and keeping 7. Mechanical system failure code display mode
failure code (7-MACHINE FAULT CODE MODE)
When a failure is detected, the failure In this mode, you can check the mechanical
c ode other t han c omm unic ati on system failure codes among the information of
related or engine-related keeps flash- the troubles that occurred on the machine.
ing until the starting switch is turned a Refer to the item of “Troubleshooting” for
off. After turning the starting switch the failure code list.
OFF temporarily, if the starting switch
is turn on or the engine is started 1) Selecting and implementing a mode
again, the failure code keeps lighting 1] Select “Mechanical system failure
until the same trouble is detected. code display mode” on the mode
Communication related or engine selection screen.
related failure code is switched to the a If the mode is selected, code [bE]
lighting when the problem is solved, is displayed on gear speed dis-
even if the starting switch is not play section (1) and the title is
turned off. displayed on multi-information
section (2).
4) Operations in case that multiple codes are 2] Display the failure code display
recorded screen by operating buzzer cancel
When multiple codes are recorded, they switch (4).
can be displayed one by one by operating q [U]: Executes mode.
information switch (5).
q [>]: Go to next failure code
q [<]: Return to previous code
a The failure codes are displayed in the
order of their first occurrence times.
5) Method of deleting failure code

While displaying a failure code that is to
be deleted, operate shift up switch (6) or
shift down switch (7).
q [Up] or [Down]: Delete failure code.
a A failure code which is active cur-
rently (code is flashing) cannot be
deleted.
14 D85EX, PX-15E0
2) Display in case where no codes are 4) Operations in case that multiple codes are
recorded recorded
If the failure codes which occurred in the When multiple codes are recorded, they
past, and the current active failure codes do can be displayed one by one by operating
not exist, the below display will be shown. information switch (5).
q [>]: Go to next failure code
q [<]: Return to previous code
a All failure codes, including ones that
did not occurred in the past, are dis-
played in numerical order.
5) Method of deleting failure code

The failure codes of the mechanical sys-
tem cannot be deleted.
3) Display in case where 1 or more codes

are recorded
If any failure codes which happened in the
past or which are currently active exist,
the display will be as shown below.
1] : No.
2] : Failure code (Flash if currently active.)
3] : Number of occurrences up to now
meter after first occurrence
meter after last occurrence
a The below figure shows an example
of the display.
a Flashing and lighting of failure code

Flashing: Code of the failure which is
currently detected.
Lighting: Code of the failure which is
not currently detected.
a Conditions for detecting and keeping
failure code
A failure code of the mechanical sys-
tem is switched to the lighting when
the problem is solved, even if the
starting switch is not turned off.
D85EX, PX-15E0 15
8. Adjustment mode (8-SERVICE ADJUST MODE) 2) Selecting adjustment items

In this mode, you can adjust the control system 1] On the adjustment code input screen,
and various devices of the machine. input the 4-digit code of the item to be
adjusted by operating information
1) Selecting and implementing a mode switch (5), shift up switch (6) and shift
1] Select “Adjustment mode” on the down switch (7).
mode selection screen. q [>]: Moves cursor rightward.
a If the mode is selected, code [Cb] q [<]: Moves cursor leftward.
is displayed on gear speed dis- q [UP]: Increases number.
play section (1) and the title is q [DOWN]: Decreases number.
displayed on multi-information 2] After inputting the code, operate
section (2). buzzer cancel switch (4) to display
2] Display the adjustment code input the monitoring screen.
screen by operating buzzer cancel q [U]: Enters input mode.
switch (4).
q [U]: Executes mode.
a If an incorrect code is input, the

adjustment code input screen
appears again after showing the
below screen. In this case, execute
the above operation again.
16 D85EX, PX-15E0
3) Contents of display on adjustment screen 5) Scrolling adjustment items in order (lim-

1] : Code ited function)
2] : Adjustment item For some adjustment items once the
3] : Related information adjustment item is selected, they can be
a For the detailed information and scrolled in order by the information switch
adjustment procedure, see “Adjust- operation without inputting the codes
ment mode table and adjustment pro- again.
cedure”. q [>]: Next code
q [<]: Previous code
a This function is applied only for the
items which are distinguished by
numeric character described in the
scroll column of “Adjustment mode
table and adjustment procedure”, and
scrolled in the order of numeric char-
acter.
a Note that this operation is not
accepted while the parking brake
lever is in the released position.
a An adjustment item also can be
selected by returning to the input
screen temporarily and inputting the
4) In case of operating the machine in adjust- code for that item.
ment mode, if the parking brake lever is
set in the “free” position, gear speed dis-
play section (1) returns to the normal dis-
play and the machine can be operated
normally.
a At this time, even if the shift up or shift
down switch is pressed with the
PCCS lever in the neutral position,
the shift cannot be changed.
(The displayed number is the code of
adjustment mode selection.)
To change the shift, shift the PCCS
lever to the “forward” or “reverse”
position and press the shift up or shift
down switch while the machine is
traveling.
a To select another screen, return the
parking brake lever to the “lock” posi-
tion temporarily and perform the nec-
essary operation.
D85EX, PX-15E0 17
Adjustment mode table and adjustment procedure

Related Disassembly
No. Code Adjustment item
information and assembly
[1] 0001 INP TEL NO. Phone No. input mode Figure/Symbol
a [2] 0002 S/T S.CODE Steering and transmission controller specification set Code q
a [3] 0004 BODY TYPE Machine specification set Code q
a [4] 0005 BRAKE BASE Brake potentiometer zero point adjustment Voltage q
a [5] 0007 ENG.FULL CH Engine deceleration-cut mode Speed
Speed
[6] 0008 INJ -> 123456 Common rail reduced cylinder mode Fuel injection
rate
a [7] 0009 PITCH SENS. Pitch angle sensor initial set Voltage q
FAN 70% Adjustment
a [8] 0010 Fan 70% speed mode
MODE data
a [9] 0021 KMTRX INST KOMTRAX specification set Symbol q
FAN 100% Adjustment
a [10] 1005 Fan 100% speed mode
MODE data
[11] 1012 S/T N-SET Steering control lever neutral set Voltage
[12] 1013 S/T L-SET Steering control lever left set Voltage
[13] 1014 S/T R-SET Steering control lever right set Voltage
[14] 2222 HSS ADJUST HSS lever initial current set Current
[15] 9997 HI IDLE SET High idle limit mode Speed
[16] 9998 SFT INHIBIT Gear speed limit mode Symbol
k Check items marked with q in the Disassembly and assembly column of the above table must be
adjusted after the machine is assembled or any controller is replaced. (For the adjustment pro-
cedure, see “Adjustment after replacement of controller”)
The numbers marked with a can be displayed in order by setting the information switch in the
“>” or “<” position.
18 D85EX, PX-15E0
[1] 0001: Phone No. input mode 2) Check that the displayed specification
q This code inputs or changes a phone number code has changed from [4*4] to [444].
to be displayed simultaneously with when the a If specification code [444] is not displayed,
user code is displayed. the controller wiring harness or the con-
q The lower part displays a phone number and troller unit may be defective.
symbols. a Even if this code is turned off, the setting
q Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ? is effective.
q How to use:
1) By operating information switch (5), shift
up switch (6), and shift down switch (7),
input a phone number and symbols.
q [>]:Moves cursor rightward.
q [<]:Moves cursor leftward.
q [UP]:Advance the numeric character or
character (in the order of available charac-
ters).
q [DOWN]:Reverse the numeric character
or character. (in the order of available
characters)
2) Set buzzer cancel switch (4) in the [U]
position and check that the alarm buzzer
sounds. [3] 0004: Machine specification code setting
a 16 digits of numeric characters are pro- q This code is used to have the machine specifi-
vided. To avoid confusion, input symbols cation recognized by the controllers which
other than numeric characters at digits compose the system.
you will not use. q The machine specification code is displayed
a 0 (zero) is input at all places of the lower on the lower line.
part before shipment from our factory. (No q Adjustment method:
phone number is displayed under this con- a Since this code is reset when “Steering
dition.) and transmission controller specification
a Even if this code is turned off, the setting set” is executed, adjust it after that.
is effective. 1) Select the code of the machine specifica-
tion by setting shift up switch (6).
sounds.
k If the machine specification is different
from the setting in the controller, the
machine may move abnormally or an
error may take place. Accordingly, be
sure to match the setting to the
machine specification.
a For this machine, only 000: standard speci-
fication, is set.
a Even if this code is turned off, the setting
is effective.
[2] 0002: Steering and transmission controller
model code setting
q This code is used to initialize the specification
codes recognized by the steering and trans-
mission controller and the set values of the
memory in the controller.
q The specification code is displayed on the
lower line.
q Adjustment method:
sounds.
D85EX, PX-15E0 19
No. Specification
00 Standard specification
08 (Not used)
80 Standard cold region specification
88 (Not used)
[4] 0005: Brake pedal standard value setting

q This code is used to adjust the zero point of the
potentiometer of the brake pedal.
q The deviation from the standard is displayed
by voltage on the lower line (Display range:
–2500 to 2500 mV).
With the brake pedal released, set buzzer can- [6] 0008: Common rail reduced cylinder mode
cel switch (4) in the [U] position and check a When the engine common rail system seems
that the alarm buzzer sounds. to be defective, this code is used to stop inject-
a Even if the adjustment is carried out, the ing fuel into 1 or more cylinders (reduce the
display of the lower line does not change. number of effective cylinders) while the engine
a Even if this code is turned off, the setting is running and find out a defective cylinder
is effective. from the change of the engine speed and the
a This code is not for the adjustment of the fuel injection rate.
braking performance, etc.. a Since this function diagnoses a failure based
on the differences of the engine speed and the
fuel injection rate in the reduced cylinder mode
operation from that in the normal mode opera-
tion, use this function while the engine is run-
ning.
q Engine speed (A) and fuel injection rate (B) are
displayed on the lower line.
q How to use:
Select the cylinders to be turned off for the
reduced cylinder mode operation by operating
information switch (5) and buzzer cancel
switch (4).
Use this method to turn on the selected cylin-
ders again, too.
[5] 0007: Engine deceleration-cut mode q [>]: Moves cursor rightward.
q This code is used to stop the auto-deceleration q [<]: Moves cursor leftward.
function of the engine and check the high idle q [U]: Executes or stops reduced cylinder
speed of the engine unit. mode operation.
q The engine speed is displayed on the lower
line (Display range: 0 – 3000).
q How to use:
While this code is displayed, its function is
enabled and the auto-deceleration function is
stopped.
a If this code is turned off, its function is dis-
abled.
20 D85EX, PX-15E0
a The below figure is an example that No. 2 cyl- [7] 0009: Pitch angle sensor standard value setting
inder is turned off for reduced cylinder mode q This code is used to correct the installation
operation and turned on again (The cylinder error of the pitch angle sensor by adjusting its
No. lamp is turned OFF in the reduced cylinder zero point.
mode operation and ON in the normal mode q The deviation from the standard neutral posi-
operation). tion is displayed by voltage on the lower line
(Display range: –2500 to 2500 mV).
Stop the machine on level ground, then set
buzzer cancel switch (4) in the [U] position
and check that the alarm buzzer sounds.
a Even if the adjustment is carried out, the
display of the lower line does not change.
is effective.
[8] 0010: Fan 70% mode

q This code forcedly sets the speed of cooling
fan at approximately 70% of the maximum
speed.
q The adjustment data is displayed on the lower
a Only one or more cylinders can be turned off line.
for the reduced cylinder mode operation. q How to use:
a If this code is turned off, its function is disabled. The function is effective with this code dis-
played to control the speed of cooling fan to
approximately 70% of the maximum speed.
a If this code is turned off, its function is dis-
abled.
D85EX, PX-15E0 21
[9] 0021: KOMTRAX specification set a If this code is turned off, its function is disabled.
q This code is used to select the installation set-
ting of KOMTRAX terminal.
a Conduct this setting before the starting
operation of KOMTRAX.
q The terminal installation condition is displayed
on the lower line.
q ACTIVE: KOMTRAX is installed.
q DEACTIVE: KOMTRAX is not installed.
q Setting method:
1) By operating shift up switch (6) and shift
down switch (7), select the installation
condition of KOMTRAX terminal.
2) After correctly selecting the installation
condition of the terminal, set buzzer can-
cel switch (4) in the [U] position and
[11] 1005: Fan 100% mode
check that the alarm buzzer sounds.
q This code forcedly sets the speed of cooling fan
at approximately 100% of the maximum speed.
is effective.
Also by this code, the adjustment value for the
a If the controller is changed, be sure to
maximum speed can be set.
conduct (check) this setting, too.
q The adjustment data is displayed on the lower line.
q How to use:
a The function is effective with this code dis-
played to control the speed of cooling fan
to approximately 100% of the maximum
speed.
i) When changing the adjustment value,
operate shift up switch (6) and shift down
switch (7) to set the adjustment value for
the maximum speed.
q [UP]: Adjustment value increases.
q [DOWN]: Adjustment value decreases.
ii) For confirming the adjustment value, set
buzzer cancel switch (4) in the [U] posi-
[10] 0530: Stall speed check mode tion and check that the alarm buzzer
q This code is the function to make the cooling sounds.
fan speed maximum to check the torque con- a If this code is turned off, its function is dis-
verter stall speed. abled. However, the adjustment value
k In this machine the cooling fan speed con- once set is still effective.
trol function is installed in order to protect
the radiator when the engine is not yet
warmed up enough. However, in case that
this mode is in use, the protecting function
does not work. So use the machine after
carrying out enough warming up.
q The engine speed is displayed on the lower line.
(Display range: 0 – 3000)
q How to use
While this code is displayed, its function is
enabled and the cooling fan speed becomes
maximum.
22 D85EX, PX-15E0
[12] 1012: Swing lever neutral value setting

q This code is used to adjust the steering poten-
tiometer neutral position of the PCCS lever.
q The output signal of the steering potentiometer
is displayed by voltage on the lower line (Dis-
play range: 0 – 5000 mV).
1) Shift the PCCS lever in the steering neu-
tral position.
sounds.
a Even if this code is turned off, the setting [14] 1014: Swing lever right maximum value setting
is effective. q This code is used to adjust the rightmost steer-
a This code is not for the adjustment of the ing potentiometer position of the PCCS lever.
steering performance, etc.. q The output signal of the steering potentiometer
1) Shift the PCCS lever to the steering right
stroke end.
sounds.
is effective.
a This code is not for the adjustment of the
steering performance, etc..
[13] 1013: Swing lever left maximum value setting
q This code is used to adjust the leftmost steer-
ing potentiometer position of the PCCS lever.
q The output signal of the steering potentiometer
1) Shift the PCCS lever to the steering left
stroke end.
sounds.
is effective.
a This code is not for the adjustment of the
steering performance, etc..
D85EX, PX-15E0 23
[15] 2222: HSS initial current adjustment mode [16] 9997: High idle setting
q When the steering start feeling is different by q This code is used to limit the high idle speed.
the steering direction, this code is used to q The limited speed (0 – 400 rpm) is displayed
adjust the turning radius at the start of steering. on the lower line.
q The current to drive the HSS EPC solenoid is q Possible limit range: High idle speed to – 400 rpm
displayed on the lower line [Display range: q How to use:
–350 mV (Left end) – 0 – 350 mV (Right end)]. 1) Select a limit speed by setting information
q Adjustment method: switch (5) in the [>] position or [<] position.
1) Gradually shifting the PCCS lever to the 2) Set buzzer cancel switch (4) in the [U]
left or right, display the current to be set position and check that the alarm buzzer
and keep it. sounds.
q If the lever is shifted to the left, the current a If the high idle speed is limited, the engine
becomes negative. speed is not raised to the normal high idle
q If the lever is shifted to the right, the cur- level even if the fuel control dial is con-
rent becomes positive. trolled so.
2) Set buzzer cancel switch (4) in the [U] a Even if this code is turned off, the setting
position and check that the alarm buzzer is effective.
sounds.
a As the set current is increased in the posi-

tive or negative direction, the turning
radius at the start of steering is decreased
(the machine turns more quickly).
a The below figure is an example that the
set current for steering to the left is
reduced to increase the turning radius.
is effective.
24 D85EX, PX-15E0
[17] 9998: 3rd gear speed cut setting 9. Load saving display mode
q This code is used to restrict the shift to the 3rd (9-LOAD MEMORY DISPLAY MODE)
gear. In this mode, the load on the machine, forward
q The usable gear speeds are displayed by bits odometer, and reverse odometer can be
on the lower line (in the order of the 3rd, 2nd checked.
and 1st from the left).
q How to use: 1) Selecting and implementing a mode
Restrict or allow the use of the highest gear 1] Select “Load saving display mode” on
speed by operating information switch (5) and the mode selection screen.
buzzer cancel switch (4). a If the mode is selected, code [Ld]
q [>]: Restricts a shift to 3rd gear speed. is displayed on gear speed dis-
q [<]: Does not restrict shift to 3rd gear play section (1) and the title is
speed. displayed on multi-information
q [U]: Determine the setting. section (2).
q Display on lower line [o]: Gear speed is 2] Display the information screen by
effective. operating buzzer cancel switch (4).
q Display on lower line [ ]: Gear speed is q [U]: Execute mode
ineffective.
a If the use of a gear speed is restricted, the
transmission is not shifted to that gear
speed even if the gear shift up switch is
operated.
is effective.
2) Changing information screen

Change the information screen by operat-
ing information switch (5).
q [>]: Next screen
q [<]: Previous screen
No. Displayed information
01 1000 rpm service meter
02 Forward odometer
03 Reverse odometer
D85EX, PX-15E0 25
3) Displayed information of 1,000 rpm ser- 5) Displayed information of reverse odome-

vice meter (01) ter (03)
This code is used to display the service On this screen, the integrated reverse
meter which integrates the operation travel distance of the machine is dis-
hours only while the engine speed is played.
higher than 1,000 rpm. a The data cannot be reset.
a The data cannot be reset.
6) When operating machine in the load sav-

4) Displayed information of forward odome- ing display mode
ter (02) If the parking brake lever is set in the
On this screen, the integrated forward “free” position, gear speed display section
travel distance of the machine is dis- (1) returns to the normal display and the
played. machine can be operated normally.
a The data cannot be reset. a At this time, even if the shift up or shift
load saving display mode.)
traveling.
essary operation.
26 D85EX, PX-15E0
10. Real-time monitoring mode 2) Selecting and entering monitored items

(10-REAL TIME MONITORING MODE) 1] On the code input screen, input the 5-
In this mode, the speeds, oil pressures, tem- digits code of the item to be moni-
peratures, currents, voltages, etc. can be mon- tored by operating information switch
itored by using the signals from sensors, (5), shift up switch (6), and shift down
switches, and solenoids installed to various switch (7).
parts of the machine in real time. q [>]: Cursor moves rightward.
a This mode is used to monitor the items q [<]: Cursor moves leftward.
one by one. When monitoring two items q [UP]: Number increases.
simultaneously, use the “Dual display q [DOWN]: Number decreases.
monitoring mode”.
1) Selecting and implementing a mode

1] Select the “Real-time monitoring
mode” on the mode selection screen.
a If the mode is selected, code [5R]
section (2).
2] Display the monitoring code input
switch (4).
q [U]: Select and decide mode.
2] After inputting the code, operate
buzzer cancel switch (4) to display
the monitoring screen.
q [U]: Determine input.
a If the input code is correct, the
monitoring screen shown below
appears.
D85EX, PX-15E0 27
a If the input code is not correct, the code input

screen appears again after the screen shown
below.
5) When operating machine with monitoring

display
If the parking brake lever is set in the
3) Displayed information on monitoring “free” position, gear speed display section
screen (Below figure shows examples) (1) returns to the normal display and the
1] : Code machine can be operated normally.
2] : Monitored item a At this time, even if the shift up or shift
3] : Information down switch is pressed with the
4] : Unit (Not displayed for some items) PCCS lever in the neutral position,
a For the details, see the “Monitoring the shift cannot be changed.
mode table”. (The displayed number is the code of
monitoring mode.)
traveling.
essary operation.
4) Function of holding monitoring information

If a displayed information such as the
engine speed is not stabilized and cannot
be read easily in the monitoring mode, it
can be held and released by operating
buzzer cancel switch (4).
q [U]: Hold and release.
a While the monitored item is held, the
letter “H” is displayed at the left end of
the lower line.
28 D85EX, PX-15E0
6) Scrolling monitoring item in order (limited

function)
Once the monitoring screen is selected in
s te p 2 ) , t h e m o n i to r e d it e m c an b e
scrolled in order by operating only infor-
mation switch (5) without inputting the
code again.
q [>]: Next code
q [<]: Previous code
a This function is applied only for the
items which are distinguished by
numeric character described in the
scroll column of “Monitoring mode
table”, and scrolled in the order of
numeric character.
a Note that this operation is not
accepted while the parking brake
lever is in the “free” position.
D85EX, PX-15E0 29
Monitoring mode table

Scroll
No. Code Monitored item Unit Remarks in
order
Char-
1 00201 ENG M ID Engine controller model selection name —
acter
2 01000 ENG REV Engine speed rpm 1
3 01300 TVCSOL F/B F/B current value of pump TVC solenoid mA —
4 01301 TVCSOL OUT Output current value of pump TVC solenoid mA —
5 01603 Remote Th Second throttle opening angle % —
6 03000 FUEL DIAL Voltage of fuel control dial mV 22
7 03200 BATTERY Battery voltage mV 32
8 03201 S/T ACC ACC input voltage of ST/TM controller mV —
9 03202 S/T PWR2 Power supply voltage of ST/TM controller load mV —
10 03203 E-ECM PW Engine controller power supply voltage mV —
11 03207 S/T PWR1 Constant power supply voltage of ST/TM controller mV —
12 04104 COOLANT TP Coolant temperature °C 5
13 04105 COOLANT TP Voltage of coolant temperature sensor mV —
14 04200 FUEL SENS Voltage of fuel level sensor mV 30
15 04401 HYD.TEMP. Hydraulic oil temperature °C 6
16 08100 HSI BRAKE HSI line brake point rpm —
Char-
17 08200 TQ Sel Torque curve selection —
acter
Char-
18 08300 Droop Type Droop type selection —
acter
Char-
19 08400 Droop SW Droop switch selection —
acter
Char-
20 08500 Droop Trim Droop trim selection —
acter
21 10500 S/T 5V PW1 5V power supply voltage 1 of ST/TM controller sensor mV —
22 10505 S/T 5V PW2 5V power supply voltage 2 of ST/TM controller sensor mV —
23 10700 S/T 24V PW 24V power supply voltage of ST/TM controller sensor mV —
24 14200 FUEL TMP Fuel temperature °C —
25 14201 FUEL TMP Voltage of fuel temperature sensor mV —
26 17201 PCV TMG Valve closing timing of PCV CA —
Char-
27 17500 ENG MODE Selection of engine controller mode —
acter
28 18000 EGR IN PRS EGR valve inlet pressure kPa —
29 18001 EGR IN PRS Voltage of EGR valve inlet pressure sensor mV —
30 18100 EGR VALVE EGR valve position mm —
31 18101 EGR VALVE Voltage of EGR valve position sensor mV —
32 18200 BPS VALVE Bypass valve position mm —
33 18201 BPS VALVE Voltage of bypass valve position sensor mV —
(See detailed
34 18300 ENG IVSW 1 Idle validation switch 1 of engine controller bit —
information)
(See detailed
35 18301 ENG IVSW 2 Idle validation switch 2 of engine controller bit —
information)
30 D85EX, PX-15E0
Scroll
order
36 18500 BOOST TMP Boost temperature °C —
37 18501 BOOST TMP Voltage of boost temperature sensor mV —
38 18600 INJECT CMD Command of final injection amount mg/st —
39 18700 ENG TORQUE Engine output torque Nm —
40 18900 E-ECM TP Engine controller ECM inside temperature °C —
Char-
41 20202 S/T.PROGRM Program version of ST/TM controller —
acter
Char-
42 20216 ENG BLD Built version of engine controller —
acter
Char-
43 20217 ENG CAL Calibration data version of engine controller —
acter
44 20300 KOMTRAX KOMTRAX LED monitor LED 33
Char-
45 20400 E-ECM SN Engine controller ECM serial No. —
acter
46 30100 T/C TEMP. Torque converter oil temperature °C 7
47 31400 T/M OUT Transmission output speed rpm 2
(See detailed
48 31520 T/M-FILL Fill switch input related to transmission bit —
information)
49 31602 1st CLUTCH Command current value of 1st clutch ECMV mA —
50 31603 2nd CLUTCH Command current value of 2nd clutch ECMV mA —
51 31604 3rd CLUTCH Command current value of 3rd clutch ECMV mA —
52 31606 Rev CLUTCH Command current value of reverse clutch ECMV mA —
53 31608 Frd CLUTCH Command current value of forward clutch ECMV mA —
54 31612 1 CLUTCH F Output current (F/B) of 1st clutch ECMV mA 27
55 31613 2 CLUTCH F Output current (F/B) of 2nd clutch ECMV mA 28
56 31614 3 CLUTCH F Output current (F/B) of 3rd clutch ECMV mA 29
57 31616 R CLUTCH F Output current (F/B) of reverse clutch ECMV mA 26
58 31622 F CLUTCH F Output current (F/B) of forward clutch ECMV mA 25
59 31623 FAN PUMP.O Command current value of fan pump EPC mA —
60 31624 FAN PUMP.F Current (F/B) of fan pump EPC mA —
61 31701 DECEL Deceleration opening ratio % 8
62 31703 DECEL Potentiometer voltage of decelerator pedal mV 21
63 31706 F THROTTLE Final accelerator opening angle % 9
64 32900 BODY ANGLE Machine pitch angle ° 15
65 36001 Accel Adj Throttle correction value data % —
66 36200 PRESS CMD Command for final common rail pressure MPa —
67 36300 INJECT CMD Final fuel injection timing CA —
68 36400 RAIL PR Common rail pressure MPa 11
69 36401 RAIL PR Voltage of common rail pressure sensor mV —
70 36500 BOOST PRS Boost pressure kPa 12
71 36501 BOOST PRS Voltage of boost pressure sensor mV —
72 36700 ENG TORQUE Converted torque of engine % 13
73 37200 EG OIL PRS Engine oil pressure kPa 10
D85EX, PX-15E0 31
Scroll
order
74 37201 EG OIL PRS Voltage of engine oil pressure sensor mV —
75 37301 FUEL RATE Instantaneous fuel consumption L/h —
76 37400 AMB PRESS Atmospheric pressure kPa —
77 37401 AMB PRESS Voltage of atmospheric pressure sensor mV —
78 40001 VEHICLE SP Theoretical vehicle speed km/h 3
(See detailed
79 40905 T/M SW1 Controller switch 1 related to transmission bit —
information)
(See detailed
80 40906 T/M-SW2 Controller switch input 2 related to transmission bit —
information)
(See detailed
81 40909 T/M SOL.2 Controller on/off output 2 related to transmission bit —
information)
(See detailed
82 40910 S/T-SW1 Controller switch input 1 related to steering bit —
information)
(See detailed
information)
(See detailed
information)
(See detailed
85 40914 S/T SOL.1 Steering controller on/off output 1 bit —
information)
(See detailed
86 40915 S/T SOL.2 Steering controller on/off output 2 bit —
information)
(See detailed
87 43502 IdleCancel Cancel flag of warming up bit —
information)
88 44202 Accel Up Throttle upper limit value data % —
89 44203 Accel Low Throttle lower limit value data % —
90 50200 T/M LEVER 1 Voltage of forward-reverse lever potentiometer 1 mV 16
91 50201 T/M LEVER 2 Voltage of forward-reverse lever potentiometer 2 mV 17
92 50300 S/T LEVER 1 Voltage of steering control lever potentiometer 1 mV 18
93 50301 S/T LEVER 2 Voltage of steering control lever potentiometer 2 mV 19
94 50400 BRAKE PEDL Voltage of brake pedal potentiometer mV 20
95 50600 HSS L.H.F Output current (F/B) of left steering EPC mA 23
96 50601 HSS R.H.F Output current (F/B) of right steering EPC mA 24
97 50602 HSS L.H.O Command value of left steering EPC output current mA —
98 50603 HSS R.H.O Command value of right steering EPC output current mA —
99 50900 N-SAFTY Drive voltage of neutral safety relay mV 31
100 51000 ENG REG Command value of regulation speed rpm —
101 51100 FUEL DIAL Command speed of fuel dial rpm —
102 60000 TRACTION Theoretical traction force W 4
103 60100 BODY ANGLE Voltage of machine pitch angle sensor mV —
(See detailed
104 60400 S/T-SW6 Switch input 6 related to steering bit —
information)
105 60500 ENG.CON.PW Drive voltage of engine controller ACC cut relay mV —
106 60600 BR HOLD Battery relay drive voltage mV —
Char-
107 60700 S/T MODE Steering state variable —
acter
32 D85EX, PX-15E0
Scroll
order
Char-
108 60800 FILL MODE Variable for setting fill condition —
acter
Char-
109 60909 MOD.MODE Variable for setting modulation condition —
acter
Char-
110 70000 CHG.P.MODE Variable for setting condition of gear shift point —
acter
111 70200 T/M OUT Voltage of transmission output speed sensor mV —
112 70400 BACK ALARM Drive voltage of backup alarm relay mV —
113 70700 HYD.PUMP 1 Hydraulic oil pressure 1 MPa 14
114 70701 HYD.PUMP 1 Voltage of hydraulic oil pressure 1 sensor mV —
115 99901 TRIG T F Trigger time F msec —
116 99902 TRIG T R Trigger time R msec —
117 99903 TRIG T 1 Trigger time 1 msec —
Char-
120 99906 TM SFT Transmission shift state —
acter
121 99908 TM IN TRQ Transmission input torque Nm —
122 99913 TC IN TRQ Torque converter input torque Nm —
a The numbers in the scroll column can be displayed in the order of numeric character by operating the
information switch to the [>] or [<] position.
D85EX, PX-15E0 33
Detailed information on bit display codes 18301: Idle validation switch 2 of engine controller
Display of bit information: 1: Idle validation switch: When detecting
a The display position of the bit information in the 2: (Unused)
“Real-time monitoring mode (Display of only 1 3: (Unused)
item)” is different from that in the “Dual display 4: (Unused)
monitoring mode (Simultaneous display of 2 5: (Unused)
items)”. 6: (Unused)
a The bit information is displayed by [_] for OFF 7: (Unused)
and [o] for ON in the places from 1 to 8. 8: (Unused)
a The state of each item shown in this section is
the condition for turning on the bit.
31520: Fill switch input related to transmission

1: Forward clutch fill switch: ON
18300: Idle validation switch 1 of engine controller 2: Reverse clutch fill switch: ON
1: Idle validation switch: When detecting 3: 1st clutch fill switch: ON
2: (Unused) 4: 2nd clutch fill switch: ON
3: (Unused) 5: 3rd clutch fill switch: ON
4: (Unused) 6: (Unused)
7: (Unused)
8: (Unused)
34 D85EX, PX-15E0
40905: 40909:
Controller switch input 1 related to transmission Controller on/off output 2 related to transmission
1: Shift up switch: OFF 1: (Unused)
2: Shift up switch: ON 2: (Unused)
3: Shift down switch: OFF 3: (Unused)
4: Shift down switch: ON 4: Backup alarm relay: ON
5: (Unused) 5: Neutral safety relay: ON
40906: 40910: Controller switch input 1 related to steering

Controller switch input 2 related to transmission 1: (Unused)
1: Automatic shift down switch: ON 2: (Unused)
3. (Unused) 4: (Unused)
4: (Unused) 5: Parking brake lever switch: FREE
5: (Unused) 6: Parking brake lever switch: LOCK
8: (Unused)
D85EX, PX-15E0 35
40911: Controller switch input 2 related to steering 40914: Controller on/off output 1 related to steering
1: Buzzer cancel switch: At t 1: (Unused)
2: Buzzer cancel switch: At U 2: (Unused)
3: Information switch: At > 3: Fan reverse solenoid: ON
4: Information switch: At < 4: (Unused)
5: Service switch: ON 5: Battery relay drive: ON
40913: Controller switch input 5 related to steering 40915: Controller on/off output 2 related to steering
1: ACC signal: ON 1: (Unused)
2: (Unused) 2: Engine ACC cut relay drive: ON (*)
3: R signal: ON 3: (Unused)
5: Fan speed selecting switch: COLD position (*) 5: (Unused)
6: Fan speed selecting switch: CLN position 6: (Unused)
*: 5 is only in case that OPT is equipped. *: 2 is only in case that OPT is equipped.
36 D85EX, PX-15E0
43502: Cancel flag of warming up

1: Cancel flag of warming up: ON
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
60400: Controller switch input 6 related to steering

1: (Unused)
2: (Unused)
3: (Unused)
4: Engine ACC cut signal: ON (*)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
*: 4 is only in case that OPT is equipped.
D85EX, PX-15E0 37
11. Dual display monitoring mode 2) Selecting and entering monitored items
(11-DUAL DISPLAY MONITORING MODE) 1] On the code input screen, input the 5-
In this mode, 2 monitored items can be dis- digits codes of the items to be moni-
played simultaneously. tored by operating information switch
a Note that only codes and monitoring infor- (5), shift up switch (6), and shift down
mation are displayed in this mode since switch (7).
the available display columns are limited. q [>]: Cursor moves rightward.
(Check item names and units cannot be q [<]: Cursor moves leftward.
displayed.) q [UP]: Number increases.
q [DOWN]: Number decreases.
1) Selecting and implementing a mode 2] After inputting the code, operate
1] Select the “Dual display monitoring buzzer cancel switch (4) to display
mode” on the mode selection screen. the monitoring screen.
a If the mode is selected, code [dR] q [U]: Determine input.
section (2).
2] Display the monitoring code input
switch (4).
q [U]: Execute mode
a If the input codes are correct, the

monitoring screen shown below
appears.
38 D85EX, PX-15E0
a If the input codes are not correct, the code a To select another screen, return the
input screen appears again after the screen parking brake lever to the “lock” posi-
shown below. tion temporarily and perform the nec-
essary operation.
3) Displayed information on monitoring

screen (Below figure shows examples)
1: Code 1
2: Information 1
3: Code 2
4: Information 2
a For the details, see the “Monitoring
mode table”.
4) In case of operating the machine in moni-

toring mode, if the parking brake lever is
set in the “free” position, gear speed dis-
play section (1) returns to the normal dis-
play and the machine can be operated
normally.
a At this time, even if the shift up or shift
monitoring mode.)
traveling.
D85EX, PX-15E0 39
SEN00631-00

© 2006 KOMATSU
All Rights Reserved
40
SEN00632-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Testing and adjusting, Part3............................................................................................................................ 2
Handling of voltage circuit of engine controller .................................................................................... 2
Adjustment method when controller has been replaced ...................................................................... 2
Preparation work for troubleshooting for electrical system .................................................................. 4
Inspection procedure of diode.............................................................................................................. 7
Pm Clinic service.................................................................................................................................. 8
How to start operation of KOMTRAX terminal ................................................................................... 18
Lamp display of KOMTRAX terminal ................................................................................................. 21
D85EX, PX-15E0 1
Testing and adjusting, Part3 1

Handling of voltage circuit of Adjustment method when
engine controller 1 controller has been replaced 1
1. When disconnecting or connecting a connec- a After the machine is assembled or steering
tor, be sure to turn off the starting switch. and transmission controller is replaced, adjust
a Before connecting the harness connector, the system according to the following proce-
be sure to completely remove sand, dust, dure.
water, etc., from inside of controller side k If the system is not adjusted, the machine
connector. may not operate normally and may move
suddenly. Accordingly, be sure to adjust it.
2. Do not start the engine with T-adapter inserted a Precautions for replacing a controller:
in or connected to a connector for trouble- If a controller is replaced, the memory of the oil
shooting. and filter maintenance mode is reset. Accord-
a You may turn the starting switch to the ingly, take a record of the next replacement
OFF or ON position but must not turn it to periods of the oils and filters.
the START position. a Precautions for replacing a controller:
When replacing a controller, stop the machine
in a safe place and turn the starting switch OFF.
1. Controller initial setting

After replacing controller, turn the switch ON
temporarily (ACC position) and after approx.
10 seconds, turn the switch OFF.
q After turning the switch OFF, the controller
is initialized. Therefore leave it for approx.
1 minute after turning the switch OFF
even if the battery relay shuts down.
2. Setting system in service mode

After step 1, turn the starting switch ON again
and set the monitor panel in the “Adjustment
mode” of the service mode.
3. Adjusting steering and transmission con-

troller
Select steering and transmission controller
specification set (0002) and adjust the steering
and transmission controller.
2 D85EX, PX-15E0
4. Turning power on again 8. Adjusting KOMTRAX specification

Turn starting switch OFF once and leave it for Select KOMTRAX specification settings (0021)
approx. 1 minute after the battery relay shuts and adjust the KOMTRAX specification.
down. Turn ON again and set the monitor
panel in the “Adjustment mode” of the service
mode again.
5. Adjusting machine specification

Select Machine specification set (0004) and
adjust the machine specification.
9. Turning power on again

Turn the starting switch OFF and after leaving
it for 1 minute, turn it ON again.
10. Checking failure codes

1) Set the monitor panel in the “Electrical
system failure code display mode” of the
6. Adjusting brake potentiometer service mode.
Select brake potentiometer initial set (0005) 2) Check if any active failure codes exist. If
and adjust the brake potentiometer. not, delete all the failure codes recorded.
a If any active failure codes exist, elimi-
nate the cause of the incident by trou-
bleshooting, then carry out steps 9
and 10 again.
a Precautions after replacing controller:
If any controller is replaced, the ser-
vice meter in the oil and filter mainte-
nance mode is reset to 0.
As a result, the replacement period
displayed on the monitor panel may
be different from the actual operating
hours. To solve this problem, deter-
mine the first replacement periods of
the oils and filters after the replace-
7. Adjusting pitch angle sensor ment of the controller according to the
Select the initial setting (0009) of the pitch replacement periods recorded before
angle sensor and adjust the pitch angle sen- the replacement of the controller.
sor.
D85EX, PX-15E0 3
Preparation work for troubleshooting 2. Steering and transmission controller

for electrical system 1 1) Remove left console box inspection cover
(1).
a When carrying out troubleshooting for an elec-
trical circuit related to the monitor panel,
engine controller, steering and transmission
controller, or KOMTRAX communication
mod em, ex pos e the rel ated c onnec tor s
1. Monitor panel
1) Remove cover (1) above the dashboard.
2) Insert or connect T-adapters in or to con-

nectors PTC1, PTC2 and PTC3 of steer-
ing and transmission controller (2).
a If the connectors cannot be discon-
nected and connected easily, remove
the controller from the floor frame.
a Since the connectors are secured
with screws, loosen those screws
before disconnecting.
2) Insert or connect T-adapters in or to con- a When connecting the connectors
nectors S03 and S04 on the back side of again, tighten their screws with the
monitor panel (2). specified torque.
3 Screw: 2.8 Nm {0.29 kgm}
4 D85EX, PX-15E0
3. Engine controller
1) Open the left upper side cover (1) of
engine and remove under side cover (2).
k In order to prevent malfunction

and mistaken system error warn-
ing, be sure to completely remove
2) Remove engine controller covers (3) and foreign object (b) such as sand,
(4). dust, water, etc., from inside of
controller side connector (a) with
air blow etc., before connecting to
harness connector.
3) Insert or connect T-adapters in or to con-

ne c t or s E G C1 , E G C2 a nd E G C 3 o f
engine controller (5).
a Since the connectors (EGC1 and
EGC2) are secured with screws,
loosen those screws before discon-
necting.
a When connecting the connectors
again, tighten their screws with the
specified torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
D85EX, PX-15E0 5
4. KOMTRAX controller
1) KOMTRAX controller is installed inside the
box under the operator seat.
2) Insert or connect T-adapters in or to
KOM1 connector of KOMTRAX controller
(1).
a Since the connectors are secured
with screws, loosen those screws
before disconnecting.
a When connecting the connectors
again, tighten their screws with the
specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
a Cable (2) is for communication
antenna.
a Cable (3) is for GPS communication
antenna.
6 D85EX, PX-15E0
Inspection procedure of diode 1 2. When using analog tester

1) Switch to resistance range.
a The direction of continuity of diode is marked 2) Check the deflection of needle while con-
on the surface of the diode. necting as follows.
i) Set red (+) test lead to diode anode
(P) side and black (–) test lead to
cathode (N) side.
ii) Set red (+) test lead to diode cathode
(N) side and black (–) test lead to
anode (P) side.
3) Based on the deflection of needle, judge
the quality of diode.
q Needle does not deflect with connec-
tion i) but deflects with connection ii):
Normal. (However deflection range
(resistance value) varies depending
on the type of tester and measuring
range.)
1. When using digital tester
q Needle deflects with both connection
1) Switch to diode range and check dis-
i) and ii): Defective (internal short cir-
played value.
cuit)
a Voltage of internal battery is dis-
q Needle does not deflect with either
played by normal tester.
connection i) or ii): Defective (internal
2) Set red (+) test lead to diode anode (P)
disconnection)
side and black (–) test lead to cathode (N)
side. Check displayed value.
3) Judge quality of diode from displayed
value.
q Displayed value does not change:
No continuity (defect)
q Displayed value changes:
Continue (normal) (note)
Note: In the case of silicon diode, the
value between 460 – 600 mV is dis-
played.
q Displayed value becomes 0 or near 0 :
Short-circuiting of diode internal part
(defect)
D85EX, PX-15E0 7
Pm Clinic service 1
Model Serial No. Service meter
T D85EX-15E0
h
T D85PX-15E0
User name Date of clinic Serviceman

/ /
Specifications
Blade Attachment Shoe width
T Semi U blade (EX) T Multi-shank ripper T 560 mm (EX) %
T U blade (EX) T Counterweight ( kg) T 610 mm (EX) %
T Straight tilt blade (EX, PX) T T 660 mm (EX) %
T T T 910 mm (PX) %
Operating conditions
Quarry, mine Construction Type of soil (specific gravity) Type of work
T Construction, civil engineer-
T Coal T Rock T Dozing
ing
T Gold T Roads T Gravel T Side cutting
T Limestone T Tunnels T Sand T Ripping
T T T Clay T Travel
Existence of abnormalities
Oil, coolant level check
T Engine coolant level When necessary
T Engine oil level T Power train T Damper case
T Hydraulic oil level T Final drive T( )
Ambient temperature Height above sea level

Max.
°C
Min.
Operator's opinion
Visual check results
Failure code history

[ ] h [ ] h
Content: Content:
[ ] h [ ] h
Content: Content:
a Engine coolant temperature: Max. range a Power train oil temperature: Max. range
8 D85EX, PX-15E0
Pm-clinic measuring points (1/2)
Reference pages for measurement procedure designated

*1. Engine speed: Testing and adjusting, Part 1; pages 5 – 7
*2. Blow-by pressure: Testing and adjusting, Part 1; page 17
*3. Engine oil pressure: Testing and adjusting, Part 1; page 18
*4. Boost pressure: Testing and adjusting, Part 1; pages 8 – 9
*5. Exhaust temperature: Testing and adjusting, Part 1; pages 10 – 11
D85EX, PX-15E0 9
Pm-clinic measuring points (2/2)
10 D85EX, PX-15E0
Reference pages for measurement procedure designated

*6. Torque converter related : Testing and adjusting, Part 1; page 32, 33
*7. Transmission related : Testing and adjusting, Part 1; pages 33 – 36
*8. Steering brake related : Testing and adjusting, Part 1; page 36
*9. Work equipment and HSS related : Testing and adjusting, Part 1; page 47 – 50
D85EX, PX-15E0 11
T D85EX-15E0 #
Pm clinic check sheet Serial number
T D85PX-15E0 #
Work order Date Service meter Serviceman

/ / h
Standard value Service limit Measurement

Check item Measurement conditions Unit Pass Fail
for new machine value results
Low idle 750 – 800 750 – 800
Deceleration pedal
Full throttle 1,000 – 1,050 1,000 – 1,050
depressed
Engine speed rpm
Full throttle 2,050 – 2,150 2,050 – 2,150
Torque converter stall 1,710 – 1,810 1,710 – 1,810
Torque converter stall + Work equipment relief 1,660 – 1,760 1,660 – 1,760
kPa Max. 0.98 Max. 1.96
Blow-by pressure Torque converter stall
{mmAq} {Max. 100} {Max. 200}
Engine
Engine at low idle SAE0W30EOS Min. 0.05 0.03

Oil temperature: Min 80°C SAE5W40EOS {Min. 0.5} {0.3}
Engine oil pres- MPa
SAE10W30DH
sure Engine at full throttle {kg/cm2} 0.29 – 0.69 0.18
SAE15W40DH
Oil temperature: Min 80°C SAE30DH {3.0 – 7.0} {1.8}
kPa Min. 93 73
Boost pressure Torque converter stall
{mmHg} {Min. 700} {550}
Exhaust tempera-
Torque converter stall °C Max. 650 700
ture

0.1 – 0.5 0.1 – 0.5
Inlet oil pressure
{1 – 5} {1 – 5}
Torque converter
Engine at low idle

Outlet oil pres- 0.1 – 0.31 0.1 – 0.31
sure Transmission: Neutral {1 – 3} {1 – 3}
MPa
Oil temperature: 70 –
{kg/cm2} Max. 1.02 Max. 1.02
Inlet oil pressure 90°C
{Max. 10} {Max. 10}
Engine at full throttle
Outlet oil pres- 0.61 – 0.81 0.61 – 0.81
sure {6 – 8} {6 – 8}

2.82 – 3.02 Min. 2.65
Engine at low idle
Main relief {28.8 – 30.8} {Min. 24}
pressure 3.24 – 3.53 Min. 3.04
{33.0 – 36.0} {Min. 31.0}
Transmission: Neutral
– –
Lubricating oil Engine at low idle
– –
pressure
(Reference) 0.1 – 0.25 0.1 – 0.25
Transmission
{1.0 – 2.5} {1.0 – 2.5}

MPa 2.16 – 2.45 Min. 1.96
F clutch pressure Transmission: F Engine at low idle
{kg/cm2} {22.0 – 25.0} {Min. 20}
2.75 – 3.02 Min. 2.55
R clutch pressure Transmission: R Engine at low idle
{28.0 – 30.8} {Min. 26.0}
1st clutch pres- 2.35 – 2.65 Min. 2.16
Transmission: F1 Engine at low idle
sure {24.0 – 27.0} {Min. 22.0}
2nd clutch pres- 2.55 – 2.84 Min. 2.35
sure {26.0 – 29.0} {Min. 24.0}
3rd clutch pres- 2.75 – 3.02 Min. 2.55
sure {28.0 – 30.8} {Min. 26.0}
• Fan 100% speed mode Min.
750 – 850 400
• Engine at low idle speed
Cooling fan
Fan speed rpm

• Fan 100% speed mode Max.
1,600 – 1,700 1,550
• Engine at high idle speed
Fan pump • Fan 100% speed mode MPa 14.7 – 17.6 14.7 – 17.6
pressure • Engine at high idle {kg/cm2} {150 – 180} {150 – 180}
12 D85EX, PX-15E0
T D85EX-15E0 #
Pm clinic check sheet Serial number
T D85PX-15E0 #

/ / h
Standard
Measurement Service limit Measurement
Check item Unit value for new Pass Fail
conditions value results
machine
2.75 – 2.94 Min. 2.26
Engine at low idle
Transmission: Neu- MPa {28.0 – 30.0} {Min. 23.0}
Brake pressure
Steering tral Engine at full {kg/cm2} 2.75 – 2.94 Min. 2.45
brake throttle {28.0 – 30.0} {Min. 25.0}
Brake perfor-
Engine at full throttle, forward 2nd, brake applied Machine must not move
mance
38.2 – 41.7 38.2 – 41.7
Travel lever right full
HSS HSS main relief Engine at full MPa {390 – 425} {390 – 425}
pressure pressure throttle {kg/cm2} 38.2 – 41.7 38.2 – 41.7
Travel lever left full
{390 – 425} {390 – 425}
Standard
Service limit Measurement
Check item Measurement conditions Unit value for new Pass Fail
value results
machine
Ripper lift 20.4 – 22.8 20.4 – 22.8
relief (EX) {208 – 232} {208 – 232}
Engine at low idle
Blade tilt 20.4 – 22.8 20.4 – 22.8
HSS and relief {208 – 232} {208 – 232}
work equipment
Hydraulic pump Ripper lift MPa 21.3 – 23.7 21.3 – 23.7
system relief (EX) {kg/cm2} {218 – 242} {218 – 242}
Blade tilt Engine at full 21.3 – 23.7 21.3 – 23.7
relief throttle {218 – 242} {218 – 242}
PPC valve Blade tilt 3.82 – 4.12 3.82 – 4.12
output pressure relief {39.0 – 42.0} {39.0 – 42.0}
Standard
machine
Engine at low idle 8 – 15 Max. 20
Blade RAISE Engine at full EX: 2.5 – 4.5 Max. 5.5
throttle PX: 2.2 – 4.2 Max. 5.2
Work Engine at low idle 3–5 Max. 7
equip-
Single tilt (left o right) Engine at full Second
ment 1.7 – 2.7 Max. 3.5
speed throttle
Engine at low idle 7 – 10 Max. 13
Ripper RAISE (EX) Engine at full
2.0 – 3.0 Max. 4.0
throttle
Standard
machine
Hydraulic oil temperature °C — —
Hydraulic
Blade lift cylinder Engine stopped mm/15 Max. 200 Max. 300
drift
Ripper lift cylinder (EX) min. Max. 80 Max. 160
Standard
machine
There must be no excessive
Visual inspection of final drive drain plug Engine stopped —
metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date Service meter Repair record Date Service meter Repair record
D85EX, PX-15E0 13
Pm clinic
Serial number T D85EX-15E0 #
Undercarriage check sheet
/ / h
q Measure the bushing temperature immediately after operations

Left side of machine
Right side of machine
a Measurement results
Pass Fail
Left side of
machine
Right side of
machine
q Opening of track link
Left A: Clearance between Right A: Clearance between

track links track links
Pin No. 1.4 Pin No. 1.4
14 D85EX, PX-15E0
Pm clinic
Serial number T D85EX-15E0 #
Undercarriage check sheet
/ / h
q Measure the bushing temperature immediately after operations

Left side of machine
Right side of machine
a Measurement results
Pass Fail
Left side of
machine
Right side of
machine
q Opening of track link
Left A: Clearance between Right A: Clearance between

track links track links
Pin No. 1.4 Pin No. 1.4
D85EX, PX-15E0 15
Undercarriage troubleshooting report (Normal) (Program form NO.: SELA195001)
16 D85EX, PX-15E0
Undercarriage troubleshooting report (Impact) (Program form NO.: SELA195001)
D85EX, PX-15E0 17
How to start operation of

KOMTRAX terminal 1
In the case where the KOMTRAX terminal has
already been installed at the plant before shipment:
a Implement the following procedure in the case
where the KOMTRAX terminal has already
been installed at the plant before shipment (as
standard equipment).
1. Notification of model, model number and

serial number
Notify the model, model number and serial
number of the machine to the KOMTRAX oper-
ations administrator. 6) Connect KACC connector (2). Keep that
condition for 5 seconds.
2. Registration of machine q Check that display (b) on the monitor
The KOMTRAX operations administrator regis- panel or KOMTRAX terminal shows
ters the machine using a KOMTRAX client per- the mark “–”.
sonal computer. 7) Disconnect test connector (1) and keep
a Refer to “Manual for KOMTRAX opera- that condition for 5 seconds.
tions administrator” for the procedure. 8) Reconnect test connector (1) and keep
a Now the terminal is ready for use. that condition for 5 seconds. [Dot (a)
blinks on and off]
In the case where the KOMTRAX terminal is ret- q Blinking of dot (a): When the terminal
detects insert
rofitted on the machine after the shipment:
or removal of the connector, dot (a)
a Implement the following procedure in the case blinks on and off.
where the KOMTRAX terminal is retrofitted
after shipment of the machine (retrofitted a Complete procedure 6) – 8) within 60
machine) seconds.
1. Sign-up test on the machine side Monitor panel

1) Move the machine to a place with good
visibility of upper direction.
2) Switch the monitor panel display to “Adjust
mode”, enter “Setting KOMTRAX specifica-
tion”, and enable the KOMTRAX function.
q Adjust code: 0021
q Specification: ACTIVE
3) Switch the monitor panel display to “Moni-
toring mode” and enter “KOMTRAX LED
display”.
q Monitoring code: 20300
method.
4) Disconnect KACC connector (2), and
move on to the next step after confirming
that more than 5 seconds have passed
since the disconnection.
5) Check visually that test connector (1) is
connected.
q Test connector (1):
T1F (female) and T1M (male)
18 D85EX, PX-15E0
KOMTRAX terminal a If [B: GPS position data detection

trouble] is indicated, check if there is
any abnormality on the GPS antenna
or cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [C: Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [D: GPS position data detection
trouble and reception trouble] is indi-
cated, check if there is any abnormal-
9) Check that the display (b) on the monitor ity on the GPS antenna/cable or
panel or KOMTRAX terminal is displayed communication antenna/cable. If
normally. there is any abnormality, repair it and
a The normal display shows start from procedure 1) again.
“d“ o “0“ o “–” repeatedly for 30 sec- a If [E: Network trouble] is indicated,
onds on the monitor panel after 8) is check the display of [LED-C4] refer-
finished. ring to “Lamp display of KOMTRAX
a Move on to the next step if you can terminal”. If the CAN is not recog-
check that the display is [normal]. nized, check the CAN harness of the
a If the display is [abnormal], start from KOMTRAX terminal, and then if there
procedure 1) again. is any abnormality, repair it and start
from procedure 1) again.
10) Turn the starting switch to the START

position, keep it more than 5 seconds, and
check that the engine does not start up.
a If the engine starts up or the starting
switch is turned off, start from proce-
dure 1) again.
11) Turn the starting switch to the START
position again, and check that the engine
starts up.
12) Check that the display (b) on the monitor
panel or KOMTRAX terminal is displayed
normally.
a Move on to the next step if you can
check that the display is [A: normal].
(It takes from 90 seconds to 15 min-
utes before the display turns normal.)
D85EX, PX-15E0 19
13) Disconnect KACC connector (2). 2. Application for the start of use
14) Check that the display (b) on the monitor a Application for the start of use should be
panel or KOMTRAX terminal is displayed made only after the sign-up test is fin-
normally in 5 seconds. ished.
a If you can check that the display is 1) Notify to the KOMTRAX operations
[normal], that is the end of sign-up administrator the following information
test. concerning the machine whose sign-up
a If the display shows [abnormal], test on the machine side is completed.
r ep eat fr om p ro ce dur e 1) a gai n (1) Information on the machine whose
because the sign-up test has not sign-up test on the machine side is
been completed successfully. completed (model, model number
and serial number)
(2) Part number and serial number of the
KOMTRAX terminal
(3) Reading of the service meter when
the KOMTRAX terminal is installed
(0.1 h unit)
15) Turn the buzzer cancel switch to the right

and finish the “KOMTRAX LED display”
mode.
16) Connect KACC connector (2).
17) Turn the starting switch OFF.
2) The KOMTRAX operations administrator

registers the machine using a KOMTRAX
client personal computer.
a Refer to “Manual for KOMTRAX oper-
ations administrator” for the proce-
dure.
a Now the terminal is ready for use.
20 D85EX, PX-15E0
Lamp display of KOMTRAX terminal 1
CPU LED 7-segment and dot for CPU

1. LED-C1 (R signal and ACC signal status) 7. 7-segment (number of mails not yet sent)
2. LED-C2 (Engine control signal status) 8. Dot (GPS positioning status)
3. LED-C3 (S-NET and C signal status)
4. LED-C4 (CAN status)
5. LED-C5 (downloading and writing status)
6. LED-C6 (downloading and writing status)
D85EX, PX-15E0 21
In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Application for the start of use and sign-up test on the machine side should be completed in advance in order
to use KOMTRAX system.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

1. Meaning of CPU LED displays
a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
No. LED Name, Function Display (*1) Contents of display
ON Starting switch ACC signal: ON, alternator R signal: ON
Starting switch ACC signal Fast blinking Starting switch ACC signal: OFF, alternator R signal: ON
1 LED-C1 status and alternator R signal
status Slow blinking Starting switch ACC signal: ON, alternator R signal: OFF
OFF Starting switch ACC signal: OFF, alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 Engine control signal status
OFF Engine control signal: OFF
ON S-NET: connected, starting switch C signal: OFF
S-NET connection status and Fast blinking Starting switch C signal: ON
3 LED-C3
starting switch C signal status Slow blinking (Not used)
OFF S-NET: unconnected, starting switch C signal: OFF
ON CAN: active (fuel sensor: no communication)
Fast blinking CAN: active (fuel sensor: in communication)
4 LED-C4 CAN connection status
Slow blinking CAN: inactive (fuel sensor: in communication)
OFF CAN: inactive (fuel sensor: no communication)
Either one is Downloading and writing status (special function for sys-
5 LED-C5
Downloading and writing sta- ON tem administrator)
tus Both are
6 LED-C6 Normal operation mode
OFF
*1 Type and time of blinking

Fast blinking: blinking on an approximately 1 second cycle
Slow blinking: blinking on an approximately 4 seconds cycle
a The LED displays can be checked in “monitoring mode” of the monitor panel.
22 D85EX, PX-15E0
2. Contents of 7-segment and dot displays for CPU

a LED displays should be checked with the starting switch ON.
No. Display section Name, Function Display (*2) Contents of display
The numbers are numbers of mails not yet sent (If there is
0–9
more than 9 mails, 9 is displayed)
Number of mails not ON
Lighting ON indicates satellite acquisition is in process.
7 7-segment yet sent and satellite
acquisition condition 0–9 The numbers are numbers of mails not yet sent (If there is
Fast blink- more than 9 mails, 9 is displayed)
ing Fast blinking indicates satellite is not being acquired.
GPS positioning has been completed. (Position has been rec-
ON
GPS positioning sta- ognized *3)
8 Dot
tus GPS positioning has not been completed. (Position has not
OFF
been recognized *3)
*2: Type and time of blinking

Fast blinking: blinking on an approximately 0.5 second cycle
Slow blinking: blinking on an approximately 2.0 seconds cycle
*3: Remarks on GPS positioning status
It may take more than 1 minute from turning on the starting switch to the completion of positioning
even in an outdoor place where radio wave can reach.
Positioning is impossible in areas with extremely weak radio waves or areas beyond the reach of
radio waves.
a The LED displays can be checked in “monitoring mode” of the monitor panel.
D85EX, PX-15E0 23
SEN00632-00

© 2006 KOMATSU
All Rights Reserved
24
SEN00633-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
40 Troubleshooting 1
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting........................................................................................... 2
How to proceed troubleshooting .......................................................................................................... 3
Checks before troubleshooting ............................................................................................................ 4
Classification and procedures of troubleshooting ................................................................................ 5
How to distinguish wire code................................................................................................................ 8
Wiring table for connector pin numbers ..............................................................................................11
T-adapter box and T-adapter table ..................................................................................................... 34
D85EX, PX-15E0 1
SEN00633-00 40 Troubleshooting
General information on troubleshooting 1

Points to remember when troubleshooting 1
k Stop the machine on a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled in confusion immediately after any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Check for any sign of abnormality on the machine.
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reproduce the symptom of failure for troubleshooting, do not carry
out any investigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of fail-
ure, then use the troubleshooting table or flowchart (matrix) to find out the failure part exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause of
the failure is repaired. To prevent this, always investigate why the cause of the failure occurred.
Then, remove the root cause.
2 D85EX, PX-15E0
How to proceed troubleshooting 1
D85EX, PX-15E0 3
Checks before troubleshooting 1

Check item Judgement value Action
1. Check fuel level and type. — Add fuel
2. Check for impurities in fuel. — Clean and drain
Lubricating oil, coolant
3. Check hydraulic oil level. Between H and L Add oil

4. Check oil level in damper case. — Add oil
5. Check power train oil level. Between H and L Add oil
6. Check engine oil level (engine oil pan level). Between H and L Add oil
7. Check coolant level (sub-tank level). Between H and L Add coolant
8. Check dust indicator for clogging. No red color Clean or replace
9. Check brake pedal travel — Adjust
Hydraulic and
1. Check for abnormal noise and smell. — Repair

mechanical
equipment
2. Check for oil leakage. — Repair
3. Carry out air bleeding. — Bleed air

1. Check for looseness and corrosion of battery cable terminals — Retighten or replace
2. Check for looseness and corrosion of alternator harness termi-
— Retighten or replace
nals.
3. Check for looseness and corrosion of starting motor harness ter-
— Retighten or replace
minals
4. Check battery voltage (engine stopped) 20 – 30 V Charge or replace
Electrical equipment
5. Check battery electrolyte level Between H and L Add or replace

6. Check for discoloration, burnout of wiring, and peeling of harness
— Repair or replace
coating.
7. Check for missing wiring clamps and a slack of wire. — Repair
8. Check for water leaking on wiring (pay particularly careful atten-
— Dry
tion to water leaking on connectors or terminals)
9. Check for blown or corroded fuse — Replace
After running for
10. Check alternator voltage (engine running at half speed or
several minutes: Replace
above)
27.5 – 29.5 V
11. Check operating sound of battery relay (when turning the start-
— Replace
ing switch ON or OFF)
4 D85EX, PX-15E0
Classification and procedures of troubleshooting 1

Classification of troubleshooting
Mode Content
Code display Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Troubleshooting procedures
When any symptom supposed to be a failure appeared on the machine, select a troubleshooting No. accord-
ing to the procedures below and proceed to the text of the relevant troubleshooting:
1. Troubleshooting procedures when any action code is displayed on the monitor panel:
When an action code is displayed on the monitor panel, display a failure code in the failure code display
mode (electrical system, mechanical system) on the monitor display (EMMS).
Carry out the troubleshooting of the relevant [failure code] in accordance with the displayed failure
code.
a Since a failure code flashes when a failure is detected, the failure has not always been corrected
even if it lights when the starting switch is set to ON. (For some codes, failures can be detected by
only turning the starting switch ON.)
a When a failure code has been recorded, be sure to perform the duplication operation corresponding
to the failure code and confirm if the failure has still remained or has been already corrected. (For
the duplication method, refer to the troubleshooting relevant to the failure code.)
2. Troubleshooting procedures when a failure code has been recorded:

When no action code is displayed on the monitor panel, confirm a failure code in the failure code display
mode (electrical system, mechanical system) on the monitor display (EMMS).
When a failure code has been recorded, carry out the troubleshooting of the relevant [failure code] in
accordance with the displayed failure code.
a Since a failure code flashes when a failure is detected, the failure has not always been corrected
even if it lights when the starting switch is set to ON. (For some codes, failures can be detected by
only turning the starting switch ON.)
a When a failure code has been recorded, be sure to perform the duplication operation corresponding
to the failure code and confirm if the failure has still remained or has been already corrected. (For
the duplication method, refer to the troubleshooting relevant to the failure code.)
3. Troubleshooting procedures when no action code is displayed and a failure code has not been
recorded:
When a failure code has not been recorded in the monitor panel (EMMS), a failure that the machine
cannot diagnose by itself is supposed to have occurred in the electrical system or the hydraulic and
mechanical system.
In this case, check again a symptom supposed to be a failure and select the relevant symptom out of
the table of “Symptom supposed to be failure and troubleshooting No.” Then, carry out the trouble-
shooting in the [E-Mode], [H-Mode] or [S-Mode] related to the symptom.
D85EX, PX-15E0 5
Symptom supposed to be failure and troubleshooting No.

Troubleshooting
No. Symptom that can be suspected to be a failure
Code display E-mode H-mode S-mode
Symptom related to action code and failure code
Check failure
1 Display action code on monitor panel.
code.
2 Display failure code in failure code display mode. q
Engine system
3 Engine is hard to start. (Engine starting always takes time.) S-1
4 Engine does not crank. E-1 S-2a)
5 Engine cranks but no exhaust smoke comes out. S-2b)
Engine does not start.
Exhaust smoke comes out but engine does not
6 S-2c)
start.
7 Engine does not pick-up smoothly. (Poor follow-up performance) S-3
8 Engine stops during operation. S-4
9 Engine does not rotate smoothly (hunting). S-5
10 Engine lacks in output or power. S-6
11 Exhaust gas color is black (incomplete combustion). S-7
12 Oil consumption is excessive or exhaust gas color is blue. S-8
13 Oil gets contaminated prematurely. S-9
14 Fuel consumption is excessive. S-10
15 Oil is in coolant, coolant spurts back or coolant level goes down. S-11
16 Engine oil pressure drops. S-12
17 Oil level rises (water or fuel mixes). S-13
18 Coolant temperature rises too high. (overheat) S-14
19 Abnormal noise comes out. S-15
20 Vibration is excessive. S-16
21 Preheater does not operate. E-2
Power train related
22 There is no travel power. (no drawbar pull) H-1 S-6
23 Machine does not travel (at 2nd or 3rd speed) H-2
24 Machine does not start at any gear speed. H-3
25 Machine travels only in one direction, forward or reverse. H-4
26 Time lag is excessive at shifting gear speed or shifting forward-reverse. H-5
27 Machine cannot be steered. (Machine does not turn leftward or rightward.) H-6
28 Steering speed or power is insufficient. H-7
29 Brake does not work. H-8
30 Power train oil overheats. H-9
31 Abnormal noise comes out around HSS and hydraulic pump or HSS motor. H-10
Work equipment-related
32 Speed of all work equipments is slow. H-11
33 All work equipments do not move. H-12
34 Blade lift moves slowly or lacks power. H-13
35 Blade tilt moves slowly or lacks power. H-14
36 Ripper lift moves slowly or lacks power. H-15
37 Hydraulic drift of blade lift is excessive. H-16
38 Hydraulic drift of blade tilt is excessive. H-17
39 Hydraulic drift of ripper lift is excessive. H-18
6 D85EX, PX-15E0
Troubleshooting
No. Symptom that can be suspected to be a failure
Code display E-mode H-mode S-mode
Monitor panel related (operator mode: normal screen)
40 Monitor panel does not light up at all when starting switch is turned ON. E-3
When starting switch is turned ON, monitor panel completely remains lighted and
41 E-4
does not go out.
42 When starting switch is turned ON, radiator coolant level caution lamp flashes. E-5
43 While engine is running, battery charge level caution lamp flashes. E-6
44 While engine is running, emergency warning item lamp flashes. E-7
45 While preheater is operating, preheating pilot lamp does not light up. E-8
46 Coolant temperature gauge does not indicate properly. E-9
47 Power train oil temperature gauge does not indicate properly. E-10
48 Hydraulic oil temperature gauge does not indicate properly. E-11
49 Fuel gauge does not indicate properly. E-12
50 Gear speed and engine speed are not indicated properly. E-13
51 Preset mode and service meter do not indicate properly. E-14
52 Warning lamp does not flash or does not go out. E-15
53 Alarm buzzer does not sound or does not stop. E-16
54 Auto shift down does not operate or does not release. E-17
55 Buzzer cancel switch does not work. E-18
56 Information switch does not work. E-19
57 Manual mode does not operate or does not release. E-20
Monitor panel related (service mode: special function screen)
Monitor panel cannot be set in service mode or cannot be set out of service
58 E-21
mode.
Other items
59 Backup alarm does not sound. E-22
60 Headlamp or rear lamp does not come on. E-23
61 Horn does not sound or does not stop. E-24
62 Windshield wiper is defective. E-25
63 Washer does not spray water. E-26
64 Air conditioner does not operate. E-27
65 KOMTRAX system does not operate properly. E-28
D85EX, PX-15E0 7
How to distinguish wire code 1

In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electrical circuit diagram.
Indicates heat resistant low voltage wire for automobile application and nomi-
Example: AEX 0.85 L --- nal No. of 0.85 with blue color.
Indicates color of wire by color code.

Color code is referred to table 3.
Indicates diameter of wire by nominal No.

Diameter (nominal No.) is referred to table 2.
Indicates type of wire by code.

Type, code, and material of wire is referred to table 1.
(As for AV and AVS, they are not indicated,
as they are used differently by size (nominal No.)).
1. Type, symbol, and material

AV is different from AVS only in terms of thickness and outer diameter of cover. And AEX is similar to AV
in terms of thickness and outer diameter of coating, but different from AV and AVS in coating material.
(Table 1)
Tempera-
ture range Reference
Type Symbol Material
(°C) for Applied sample
application
Annealed copper wire for
Low voltage wire Conductor
electricity For ordinary wiring
for automobile AV
Plasticized type polyvinyl (nominal No. is more than 5.)
application Insulator
chloride
–30 – +60
Thin-covered Annealed copper wire for
Conductor
low voltage wire electricity For ordinary wiring
AVS
for automobile Plasticized type polyvinyl (nominal No. is less than 3.)
application Insulator
chloride
Heat resistant Annealed copper wire for
Conductor For ordinary wiring of extremely
low voltage wire electricity
AEX –50 – +110 cold region specification, wiring in
for automobile Heat resistant crosslinked
Insulator high ambient temperature
application polyethylene
8 D85EX, PX-15E0
2. Size
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
wires and
20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
diameter of
Con- element wire
ductor Section area
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approxi-
1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
mately)
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 —
Coating D
AV Standard — — — — — — — 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 — 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
wires and
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
diameter of
Con- element wire
ductor Section area
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approxi-
3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
mately)
AVS Standard — — — — — — — — —
Coating D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes “flexible”.
D85EX, PX-15E0 9
3. Color codes table

(Table 3)
Color code Wire color Color code Wire color
B Black LgY Light green & Yellow
Br Brown LR Blue &Red
BrB Brown & Black LW Blue & White
BrR Brown & Red LY Blue & Yellow
BrW Brown & White O Orange
BrY Brown & Yellow P Pink
Ch Charcoal R Red
Dg Dark green RB Red & Black
G Green RG Red & Green
GB Green & Black RL Red & Blue
GL Green & Blue RW Red & White
Gr Gray RY Red & Yellow
GR Green & Red Sb Sky Blue
GW Green & White W White
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
LgW Light green & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the
second color is the color of the marking. Color code “W” is not used. “W” is used for marking.
Example: “GW” means that the background is Green and marking is White.
10 D85EX, PX-15E0
Wiring table for connector pin numbers 1

a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
D85EX, PX-15E0 11
12 D85EX, PX-15E0
D85EX, PX-15E0 13
14 D85EX, PX-15E0
D85EX, PX-15E0 15
16 D85EX, PX-15E0
D85EX, PX-15E0 17
18 D85EX, PX-15E0
D85EX, PX-15E0 19
20 D85EX, PX-15E0
D85EX, PX-15E0 21
22 D85EX, PX-15E0
D85EX, PX-15E0 23
24 D85EX, PX-15E0
D85EX, PX-15E0 25
26 D85EX, PX-15E0
D85EX, PX-15E0 27
28 D85EX, PX-15E0
D85EX, PX-15E0 29
30 D85EX, PX-15E0
D85EX, PX-15E0 31
32 D85EX, PX-15E0
D85EX, PX-15E0 33
T-adapter box and T-adapter table 1

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of T-Branch.
T-adapter kit
Identification
No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
out of kit
code
Part No. Part name
799-601-2600 T-adapter box (for ECONO) 21 q q q q q q

799-601-3100 T-adapter box (for MS) 37 q
799-601-3200 T-adapter box (for MS) 37 q
799-601-3300 T-adapter box (for ECONO) 24 q
799-601-3360 • Plate for MS (24 pins) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q q
MIC-
799-601-2720 Adapter for MIC 13 q q q q
13P
MIC-
799-601-2730 Adapter for MIC 17 q q q q q q q
17P
MIC-
799-601-2740 Adapter for MIC 21 q q q q q q q
21P
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
ECONO
799-601-2750 Adapter for ECONO 2 q q
2P
ECONO
3P
ECONO
4P
ECONO
8P
ECONO
12P
799-601-2810 Adapter for DLI 8 DLI-8P q q
Extension cable ECONO
799-601-2840 12 q q q
(ECONO type) 12P
799-601-2850 Case q
799-601-4210 Adapter for DRC 50 DRC50 q
799-601-7010 Adapter for X (T adapter) 1 q q
34 D85EX, PX-15E0
T-adapter kit
Identification
No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
out of kit
code
Part No. Part name
799-601-7020 Adapter for X 2 X2P q q q q

799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (white) 10 S10P q q q q
799-601-7160 Adapter for S (blue) 12 S12P q q q
799-601-7170 Adapter for S (blue) 16 S16P q q q q
799-601-7330 Adapter for S (white) 16 S16PW q
799-601-7350 Adapter for S (white) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short socket adapter for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q
799-601-9060 Adapter for DT (gray) 8 DT8GR q q
799-601-9070 Adapter for DT (black) 8 DT8B q q
799-601-9080 Adapter for DT (green) 8 DT8G q q
799-601-9090 Adapter for DT (brown) 8 DT8BR q q
D85EX, PX-15E0 35
T-adapter kit
Identification
No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
out of kit
code
Part No. Part name
DT12G
799-601-9110 Adapter for DT (gray) 12 q q
R
799-601-9120 Adapter for DT (black) 12 DT12B q q
799-601-9130 Adapter for DT (green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24 pins) q q q
T-adapter box
799-601-9320 12 q q q
(for DT and HD)
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410 Adapter for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q
799-601-9430 2 P q
799-601-9440 Adapter for engine (CRI-T2) 3 1,2,3 q
795-799-5520 Adapter for engine (HPI-T2) 2 S q
Adapter for engine (HPI-T2)
795-799-5530 2 C q
Adapter for engine (HPI-T2)
795-799-5540 2 A q
795-799-5460 Cable for engine (HPI-T2) 3 q
799-601-4160 Adapter for engine (CRI-T3) 2 OIL q
799-601-4130 Adapter for engine (CRI-T3) 3 FCIN q
799-601-4140 Adapter for engine (CRI-T3) 3 FCIG q
799-601-4150 Adapter for engine (CRI-T3) 3 FCIB q
799-601-4180 Adapter for engine (CRI-T3) 3 FCIP3 q
799-601-4230 Adapter for engine (CRI-T3) 4 1,2,3,4 q
36 D85EX, PX-15E0
T-adapter kit
Identification
No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
out of kit
code
Part No. Part name
799-601-4260 Adapter for controller (ENG) 4 DTP4 q

799-601-4210 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4280 Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9370 Adapter for controller (HST) 26 HST26A q
D85EX, PX-15E0 37
SEN00633-00

© 2006 KOMATSU
All Rights Reserved
38
SEN00634-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
Troubleshooting by failure code
(Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 1 .............................................................................. 3
Failure code table................................................................................................................................. 3
Before troubleshooting by failure codes............................................................................................. 10
Contents of troubleshooting table....................................................................................................... 12
Failure code [1500L0] Transmission clutch: Dual engagement ......................................................... 14
Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF.................. 16
Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON ................. 18
Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF ................. 20
Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON ................. 22
Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF .......................... 24
Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON ......................... 26
Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF ......................... 28
Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON ........................ 30
Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF ......................... 32
D85EX, PX-15E0 1
Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON......................... 34
Failure code [AA10NX] Air cleaner: Clogged ..................................................................................... 36
Failure code [AB00MA] Abnormal battery charge: Malfunction.......................................................... 38
Failure code [B@BAZG] Engine oil: Oil pressure too low .................................................................. 38
Failure code [B@BCNS] Radiator coolant: Overheat......................................................................... 39
Failure code [B@BCZK] Radiator coolant: Level too low................................................................... 39
Failure code [B@CENS] Power train oil: Overheat ............................................................................ 40
Failure code [B@HANS] Hydraulic oil: Overheat ............................................................................... 40
Failure code [CA111] Engine controller: Abnormality in controller...................................................... 41
Abnormal speed sensor signal.................................................................................................... 42
Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected ............ 44
Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected ............... 46
Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected........... 48
Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected ............. 50
Failure code [CA135] Oil pressure sensor too high: Excessively high voltage detected.................... 52
Failure code [CA141] Oil pressure sensor too low: Excessively low voltage detected ...................... 54
Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected ...... 56
Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected ......... 58
Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected....... 60
Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected.......... 62
Failure code [CA187] Sensor power source 2 too low: Low voltage detected ................................... 64
Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected .... 66
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected ....... 68
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected.............. 70
Failure code [CA234] Engine over speed: Excessively high speed ................................................... 72
Excessively low voltage detected................................................................................................ 74
Failure code [CA263] Fuel temperature sensor too high: Excessively high voltage detected............ 76
Failure code [CA265] Fuel temperature sensor too low: Excessively low voltage detected .............. 78
Failure code [CA271] PCV1 short circuit: Short circuit....................................................................... 79
Failure code [CA272] PCV1 disconnection: Disconnection................................................................ 80
Failure code [CA273] PCV2 short circuit: Short circuit....................................................................... 81
Failure code [CA274] PCV2 disconnection: Disconnection................................................................ 82
2 D85EX, PX-15E0
Troubleshooting by failure code (Display of code), Part 1 1

Failure code table 1
Action Failure Alarm Con- History

Failed section Symptom of failure
code code buzzer troller classification
Electrical
CALL E03 1500L0 Transmission clutch Dual engagement q S/T
system
Fill signal is ON when Electrical
CALL E03 15SAL1 Forward clutch q S/T
command current is OFF. system
Fill signal is OFF when Electrical
CALL E03 15SALH Forward clutch q S/T
command current is ON. system
CALL E03 15SBL1 Reverse clutch q S/T
CALL E03 15SBLH Reverse clutch q S/T
CALL E03 15SEL1 1st clutch q S/T
CALL E03 15SELH 1st clutch q S/T
CALL E03 15SFL1 2nd clutch q S/T
CALL E03 15SFLH 2nd clutch q S/T
CALL E03 15SGL1 3rd clutch q S/T
CALL E03 15SGLH 3rd clutch q S/T
Mechanical
— AA10NX Air cleaner Clogging MON
system
Mechanical
— AB00MA Alternator Malfunction S/T
system
Mechanical
— B@BAZG Engine oil Oil pressure too low q ENG
system
Mechanical
— B@BCNS Radiator coolant Overheat q ENG
system
Mechanical
— B@BCZK Radiator coolant level Level too low S/T
system
Mechanical
— B@CENS Power train oil Overheat q S/T
system
Mechanical
— B@HANS Hydraulic oil Overheat q S/T
system
Electrical
CALL E04 CA111 Engine controller Abnormality in controller q ENG
system
Abnormal engine NE, Bkup Electrical
CALL E04 CA115 Abnormal speed sensor signal q ENG
speed sensor system
Charge pressure sensor too Excessively high voltage Electrical
CALL E03 CA122 q ENG
high detected system
Excessively low voltage Electrical
CALL E03 CA123 Charge pressure sensor too low q ENG
detected system
Decelerator pedal sensor too Excessively high voltage Electrical
D85EX, PX-15E0 3

Decelerator pedal sensor too Excessively low voltage Electrical
low detected system
Excessively high voltage Electrical
E02 CA135 Oil pressure sensor too high q ENG
detected system
E02 CA141 Oil pressure sensor too low q ENG
detected system
Coolant temperature sensor too Excessively high voltage Electrical
E01 CA144 ENG
Coolant temperature sensor too Excessively low voltage Electrical
E01 CA145 ENG
low detected system
Charge temperature sensor too Excessively high voltage Electrical
E01 CA153 ENG
Charge temperature sensor too Excessively low voltage Electrical
E01 CA154 ENG
low detected system
CALL E03 CA187 Sensor power source 2 too low q ENG
detected system
Atmospheric pressure sensor Excessively high voltage Electrical
E01 CA221 ENG
too high detected system
Atmospheric pressure sensor Excessively low voltage Electrical
E01 CA222 ENG
too low detected system
CALL E03 CA227 Sensor power source 2 too high q ENG
detected system
Mechanical
— CA234 Engine overspeed Excessively high speed q ENG
system
Abnormal power source for Ne Excessively low voltage Electrical
speed sensor detected system
Fuel temperature sensor too Excessively high voltage Electrical
E01 CA263 ENG
Fuel temperature sensor too Excessively low voltage Electrical
E01 CA265 ENG
low detected system
Electrical
CALL E03 CA271 PCV1 short circuit Short circuit q ENG
system
Electrical
CALL E03 CA272 PCV1 disconnection Disconnection q ENG
system
Electrical
CALL E03 CA273 PCV2 short circuit Short circuit q ENG
system
Electrical
CALL E03 CA274 PCV2 disconnection Disconnection q ENG
system
Disconnection and short circuit Electrical
CALL E03 CA322 Disconnection and short circuit q ENG
in injector #1 system
4 D85EX, PX-15E0

Abnormal engine controller data Electrical
CALL E04 CA342 Abnormal consistency q ENG
consistency system
Electrical
CALL E03 CA351 Abnormal injector drive circuit Abnormal circuit q ENG
system
Sensor power source (1) too Excessively low voltage Electrical
low detected system
Sensor power source (1) too Excessively high voltage Electrical
CALL E04 CA441 Power source voltage too low q ENG
detected system
CALL E04 CA442 Power source voltage too high q ENG
detected system
Common rail pressure too high Excessively high pressure Electrical
(2) detected system
Common rail pressure sensor Excessively high voltage Electrical
too high detected system
Common rail pressure sensor Excessively low voltage Electrical
too low detected system
Common rail pressure too high Excessively high pressure Electrical
(1) detected system
In-range error in common rail Electrical
CALL E03 CA554 In-range error detected q ENG
pressure sensor system
Loss of pressure feed from Electrical
E02 CA559 Loss of pressure feed detected q ENG
supply pump (1) system
Abnormal engine NE speed Electrical
CALL E03 CA689 Abnormal signal q ENG
sensor system
Abnormal engine Bkup speed Electrical
CALL E03 CA731 Abnormal phase q ENG
sensor phase system
Loss of all data of engine Electrical
CALL E04 CA757 Loss of all data q ENG
controller system
Abnormal engine Bkup speed Electrical
CALL E03 CA778 Abnormal Bkup signal q ENG
sensor system
Electrical
E02 CA1228 Abnormal EGR valve servo (1) EGR cannot be controlled. q ENG
system
Electrical
CALL E03 CA1625 Abnormal EGR valve servo (2) EGR cannot be controlled. q ENG
system
Electrical
CALL E03 CA1633 Abnormal KOMNET Abnormal communication q ENG
system
Decelerator sensor power Excessively high voltage Electrical
source too high detected system
Decelerator sensor power Excessively low voltage Electrical
source too low detected system
Loss of pressure feed from Electrical
CALL E03 CA2249 Loss of pressure feed detected q ENG
supply pump (2) system
CALL E03 CA2271 EGR valve lift sensor too high q ENG
detected system
CALL E03 CA2272 EGR valve lift sensor too low q ENG
detected system
Short circuit in EGR valve Electrical
CALL E03 CA2351 Short circuit q ENG
solenoid drive system
D85EX, PX-15E0 5

Disconnection in EGR valve Electrical
CALL E03 CA2352 Disconnection q ENG
solenoid drive system
Disconnection in intake air Electrical
E01 CA2555 Disconnection ENG
heater relay system
Short circuit in intake air heater Electrical
E01 CA2556 Short circuit ENG
relay system
Electrical
— D110KA Battery relay Disconnection S/T
system
Electrical
— D110KB Battery relay Short circuit S/T
system
Electrical
E02 D130KA Neutral safety relay Disconnection q S/T
system
Electrical
E02 D130KB Neutral safety relay Short circuit q S/T
system
Electrical
E01 D161KA Backup alarm relay Disconnection S/T
system
Electrical
E01 D161KB Backup alarm relay Short circuit S/T
system
Engine controller ACC signal Electrical
— D190KA Disconnection S/T
cut relay system
Engine controller ACC signal Electrical
— D190KB Short circuit S/T
cut relay system
KOMTRAX controller CAN Electrical
— D811KR Defective communication S/T
communication system
Monitor panel CAN Electrical
CALL E03 DAFRKR Defective communication q MON
DAQ0KT Steering and transmission Abnormal controller memory Electrical
E01 S/T
(DB30KT) controller information system
DAQ1KK Main power source of steering Power supply voltage drop and Electrical
CALL E04 q S/T
(DB31KK) and transmission controller input system
DAQ2KK Steering and transmission Power supply voltage drop and Electrical
CALL E04 q S/T
(DB32KK) controller load power source input system
5V power source of steering
DAQ5KK Power supply voltage drop and Electrical
CALL E03 and transmission controller q S/T
(DB35KK) input system
sensor (1)
sensor
E01 and transmission controller S/T
sensor (2)
DAQ9KQ Steering and transmission Inconsistent model selection Electrical
CALL E04 q S/T
(DB39KQ) controller model selection signal system
DAQRKR Steering and transmission Electrical
CALL E03 Defective communication q S/T
(DB3RKR) controller CAN communication system
Defective communication
Engine controller CAN Electrical
CALL E03 DB2RKR (Abnormality in target q ENG
component system)
DB30KT Steering and transmission Abnormal controller memory Electrical
E01 S/T
(DAQ0KT) controller information system
DB31KK Main power source of steering Power supply voltage drop and Electrical
CALL E04 q S/T
(DAQ1KK) and transmission controller input system
6 D85EX, PX-15E0

DB32KK Steering and transmission Power supply voltage drop and Electrical
CALL E04 q S/T
(DAQ2KK) controller load power source input system
DB35KK Power supply voltage drop and Electrical
(DAQ5KK) input system
sensor (1)
sensor
E01 and transmission controller S/T
sensor (2)
DB39KQ Steering and transmission Inconsistent model selection Electrical
CALL E04 q S/T
(DAQ9KQ) controller model selection signal system
DB3RKR Steering and transmission Electrical
CALL E03 Defective communication q S/T
(DAQRKR) controller CAN communication system
Electrical
E02 DD12KA Shift up switch Disconnection q S/T
system
Electrical
E02 DD12KB Shift up switch Short circuit q S/T
system
Electrical
E02 DD13KA Shift down switch Disconnection q S/T
system
Electrical
E02 DD13KB Shift down switch Short circuit q S/T
system
DD14KA Electrical
CALL E03 Parking lock switch Disconnection q S/T
(DDQ2KA) system
DD14KB Electrical
CALL E03 Parking lock switch Short circuit q S/T
(DDQ2KB) system
DDQ2KA Electrical
CALL E03 Parking lock switch Disconnection q S/T
(DD14KA) system
DDQ2KB Electrical
CALL E03 Parking lock switch Short circuit q S/T
(DD14KB) system
Hydraulic oil temperature Electrical
— DGS1KX Input signal out of range S/T
sensor system
Power train oil temperature Electrical
E01 DGT1KA Abnormal input signal S/T
sensor system
Power train oil temperature Electrical
E01 DGT1KX Input signal out of range S/T
sensor system
HSS and work equipment pump Electrical
— DH22KA Disconnection S/T
oil pressure sensor system
HSS and work equipment pump Electrical
— DH22KB Short circuit S/T
oil pressure sensor system
Electrical
CALL E03 DK10KA Fuel control dial Disconnection q S/T
system
Electrical
CALL E03 DK10KB Fuel control dial Short circuit q S/T
system
Electrical
CALL E03 DK30KA Steering potentiometer (1) Disconnection q S/T
system
Electrical
CALL E03 DK30KB Steering potentiometer (1) Short circuit q S/T
system
Electrical
CALL E04 DK30KX Steering potentiometer Input signal out of range q S/T
system
D85EX, PX-15E0 7

Electrical
CALL E04 DK30KZ Steering potentiometer Disconnection or Short circuit q S/T
system
Electrical
CALL E03 DK30L8 Steering potentiometer Inconsistent analog signals q S/T
system
Electrical
CALL E03 DK31KA Steering potentiometer (2) Disconnection q S/T
system
Electrical
CALL E03 DK31KB Steering potentiometer (2) Short circuit q S/T
system
Electrical
E01 DK40KA Brake potentiometer Disconnection S/T
system
Electrical
E01 DK40KB Brake potentiometer Short circuit S/T
system
Electrical
CALL E04 DK55KX Forward-reverse potentiometer Input signal out of range q S/T
system
Electrical
CALL E04 DK55KZ Forward-reverse potentiometer Disconnection or short circuit q S/T
system
Electrical
CALL E03 DK55L8 Forward-reverse potentiometer Inconsistent analog signals q S/T
system
Forward-reverse potentiometer Electrical
CALL E03 DK56KA Disconnection q S/T
(1) system
CALL E03 DK56KB Short circuit q S/T
(1) system
CALL E03 DK57KA Disconnection q S/T
(2) system
CALL E03 DK57KB Short circuit q S/T
(2) system
DKH1KA Electrical
CALL E03 Pitch angle sensor Short circuit q S/T
(DKH1KX) system
DKH1KB Electrical
CALL E03 Pitch angle sensor Disconnection q S/T
(DKH1KX) system
DKH1KX
Electrical
CALL E03 (DKH1KA) Pitch angle sensor Input signal out of range q S/T
system
(DKH1KB)
Transmission output speed Electrical
E01 DLT3KA Disconnection S/T
sensor system
Transmission output speed Electrical
E01 DLT3KB Short circuit S/T
sensor system
Electrical
E02 DV00KB Alarm buzzer Short circuit MON
system
Electrical
E01 DW7BKA Fan reverse solenoid Disconnection S/T
system
Electrical
E01 DW7BKB Fan reverse solenoid Short circuit S/T
system
Electrical
E02 DW7BKY Fan reverse solenoid Hot short q S/T
system
Electrical
CALL E03 DWN1KA HSS EPC solenoid right Disconnection q S/T
system
Electrical
CALL E03 DWN1KB HSS EPC solenoid right Short circuit q S/T
system
Electrical
CALL E04 DWN1KY HSS EPC solenoid right Hot short q S/T
system
8 D85EX, PX-15E0

Electrical
CALL E03 DWN2KA HSS EPC solenoid left Disconnection q S/T
system
Electrical
CALL E03 DWN2KB HSS EPC solenoid left Short circuit q S/T
system
Electrical
CALL E04 DWN2KY HSS EPC solenoid left Hot short q S/T
system
Electrical
E01 DWN5KA Fan pump TVC solenoid Disconnection S/T
system
Electrical
E01 DWN5KB Fan pump TVC solenoid Short circuit S/T
system
Electrical
E02 DWN5KY Fan pump TVC solenoid Hot short q S/T
system
Electrical
E01 DXA0KA HSS pump TVC solenoid Disconnection S/T
system
Electrical
E01 DXA0KB HSS pump TVC solenoid Short circuit S/T
system
Electrical
E01 DXA0KY HSS pump TVC solenoid Hot short S/T
system
Electrical
CALL E03 DXH4KA 1st clutch ECM solenoid Disconnection q S/T
system
Electrical
CALL E03 DXH4KB 1st clutch ECM solenoid Short circuit q S/T
system
Electrical
CALL E03 DXH4KY 1st clutch ECM solenoid Hot short q S/T
system
Electrical
CALL E03 DXH5KA 2nd clutch ECM solenoid Disconnection q S/T
system
Electrical
CALL E03 DXH5KB 2nd clutch ECM solenoid Short circuit q S/T
system
Electrical
CALL E03 DXH5KY 2nd clutch ECM solenoid Hot short q S/T
system
Electrical
CALL E03 DXH6KA 3rd clutch ECM solenoid Disconnection q S/T
system
Electrical
CALL E03 DXH6KB 3rd clutch ECM solenoid Short circuit q S/T
system
Electrical
CALL E03 DXH6KY 3rd clutch ECM solenoid Hot short q S/T
system
Electrical
CALL E03 DXH7KA Reverse clutch ECM solenoid Disconnection q S/T
system
Electrical
CALL E03 DXH7KB Reverse clutch ECM solenoid Short circuit q S/T
system
Electrical
CALL E03 DXH7KY Reverse clutch ECM solenoid Hot short q S/T
system
Electrical
CALL E03 DXH8KA Forward clutch ECM solenoid Disconnection q S/T
system
Electrical
CALL E03 DXH8KB Forward clutch ECM solenoid Short circuit q S/T
system
Electrical
CALL E03 DXH8KY Forward clutch ECM solenoid Hot short q S/T
system
D85EX, PX-15E0 9
Before troubleshooting by failure codes 1

Wiring table for fuse box and circuit breaker
a This wiring table shows apparatuses to which electric power is supplied through the fuse box and circuit
breaker. (A switching power source supplies power with the starting switch ON. Constant power source
supplies power with starting switch either ON or OFF.)
a When carrying out troubleshooting related to the electrical systems, firstly check the fuse or circuit
breaker to see whether the power is supplied normally or not.
Fuse box A [FS1]
Fuse Electric supply Fuse

Destinations of electric power distribution
No. source capacity (A)
1 30 Standby electric power supply
2 Switched electric 20 Horn, Electrical intake air heater, Air suspension seat
3 power supply 20 Head lamp
4 20 Rear lamp
Constant power Transmission steering controller, Monitor panel,
5 20
source KOMTRAX
Fuse box B [FS2]

Constant power
1 20 Starting switch (B) (with 20 A circuit breaker in the subsequent circuit)
source
2 30 Steering and transmission controller (main electric power supply)
3 Switched electric 30 Backup alarm
4 power supply 30 Air conditioner (with 20 A circuit breaker in the subsequent circuit)
5 5 Starting switch (ACC), Engine controller
Cab fuse box C

1 10 Accessory electric power supply (12 V electric power supply)
2 20 Radio, Room lamp, Cigarette lighter, Additional light
3 Switched electric 20 Glass with heating wire
4 power supply 10 Rear wiper
5 10 Front wiper
6 10 Left and right door wipers
10 D85EX, PX-15E0
Fuse installation position and No.
Circuit breaker
No. Connector No. Capacity (A) Circuit Remarks
1 CB105 105 Main power source Installed in the
2 CB30H 30 Engine controller constant power source battery box
located at the left
3 CB105 105 Main power source for electrical intake air heater side of the opera-
4 CB30 30 Constant power source tor cab
5 CB1 20 Starting switch Installed in the
dash board air
6 CB2 20 Air conditioner conditioner filter
a Recovery operation of circuit breaker

Turn the starting switch OFF and push in reset button (7) which is pushed out. If the button returns
immediately after it is pushed in, carry out the troubleshooting and repair the defective part.
D85EX, PX-15E0 11
Contents of troubleshooting table 1

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code

Failure
Display of Trouble that appears in the machine
Display of panel symptom
panel
Failure content State where the monitor panel or controller detects the trouble
Controller's Action to be taken to protect the system and equipment when the monitor panel or controller
action detects a trouble
Symptoms that
Problem that appears as an abnormality in the main unit by the action taken by the monitor
appears
panel or controller (above)
on machine
General
Information related to troubles occurred or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state required to judge the
assumed cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Causes by which a trouble A harness of an independent circuit abnormally comes into
and standard is assumed to be defected contact with one of another circuit.
value in normal (The order number indi-
state cates a serial number, not <Notes on troubleshooting>
a priority sequence.) (1) Method of indicating connector numbers and handling of T-
adapter
For troubleshooting, insert or connect T-adapter shown
3 below unless especially specified.
• When “male” or “female” is not indicated for a connector
number, disconnect the connector, and insert the T-
adapters in both the male and female.
• When “male” or “female” is indicated for a connector
number, disconnect connector, and insert the T-adapter
in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated in
the front.
• Connect the minus (–) lead to a pin or harness indicated
in the rear.
12 D85EX, PX-15E0
Related circuit diagram
This is the excerpted circuit diagram related to troubleshooting.

• Connector No.: Indicates (model – number of pins) (color)
• Arrow (io): Indicates the approximate mounting place on machine
D85EX, PX-15E0 13
Failure code [1500L0] Transmission clutch: Dual engagement 1
Action code Failure code Symptom Transmission clutch: Dual engagement

CALL E03 1500LO of failure (Steering and transmission controller system)
• Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Gear speed is limited.)
(1) Either [DXH4KA] or [DXH4KB] and either [DXH5KA] or [DXH5KB]
• Of the failure codes related to the transmission clutch, the following codes were displayed at the
same time. (Machine can not travel.)
(2) Either [DXH8KA] or [DXH8KB] and either [DXH7KA] or [DXH7KB]
Failure content (3) Either of [DXH6KA] or [DXH6KB] and (1) above
(4) [15SALH] and [15SBLH]
(5) Either [15SAL1] or [DXH8KY] and either [15SBL1] or [DXH7KY]
(6) [15SELH], [15SFLH], and [15SGLH]
(7) Either [15SEL1] or [DXH4KY] and either [15SFL1] or [DXH5KY]
(8) Either [15SEL1] or [DXH4KY] and either [15SGL1] or [DXH6KY]
(9) Either [15SFL1] or [DXH5KY] and either [15SGL1] or [DXH6KY]
Controller's • Flashes warning lamp and turns on alarm buzzer.
action • Limits operation of engine and transmission.
Symptoms that • Once machine is stopped, engine speed is limited to medium (half).
appear on • Once machine is stopped, traveling is limited to specific gear speeds.
machine • Machine cannot travel.
General
• Duplication of failure code: Engine start + travel
information
Causes Standard values when normal and remarks for troubleshooting

Possible Confirm the failure codes displayed at the same time, then carry out troubleshooting for the codes.
causes and the [15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
standard values [15SGLH]
when normal [DXH4KA], [DXH4KB], [DXH4KY], [DXH5KA, [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB],
[DXH6KY], [DXH7KA, [DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]
14 D85EX, PX-15E0
Failure code [15SAL1] Forward clutch: Fill signal is ON when command

current is OFF 1
Action code Failure code Symptom Forward clutch: Fill signal is ON when command current is OFF
CALL E03 15SAL1 of failure (Steering and transmission controller system)
• The fill switch signal does not become off when the output of the transmission forward clutch sole-
Failure content
noid circuit has stopped.
• Flashes warning lamp and turns on alarm buzzer.
Controller's
• Even if operating the gear to the reverse, the gear is shifted to N (neutral).
action
• Limits operation of engine and transmission.
Symptoms that
• Once machine is stopped, engine speed is limited to medium (half).
appear on
• Once machine is stopped, travel is limited to F1.
machine
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
General
(Code 31520: Transmission fill switch input state)
information
• Duplication of failure code: Engine start + travel neutral

a Prepare with starting switch OFF and start the engine to diag-
nose.
Defective forward clutch
1 fill switch FFT (male) PCCS lever Resistance
(internal short circuit) Between (1) and N Min. 1 Mz
ground F (Forward) Max. 1 z
a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Possible Defective harness grounding
2
causes and the (contact with ground circuit) Between ground and wiring harness Resis-
standard values between PTC2 (female) (35) – FFT (female) Min. 1 Mz
tance
when normal (1)
nose.
Defective steering and PTC2 PCCS lever Voltage
3
transmission controller
Between (35) and N 5 – 11 V
ground F (Forward) Max. 1 V
When no fault is detected in the electrical system, the hydraulic
Defective hydraulic pressure
4 pressure system can be suspected to be abnormal. Carry out the
system
related troubleshooting (H mode).
16 D85EX, PX-15E0
Circuit diagram related to transmission forward clutch ECMV
D85EX, PX-15E0 17
Failure code [15SALH] Forward clutch: Fill signal is OFF when

command current is ON 1
Action code Failure code Symptom Forward clutch: Fill signal is OFF when command current is ON
CALL E03 15SALH of failure (Steering and transmission controller system)
• The fill switch signal does not become ON when the output of the transmission forward clutch sole-
Failure content
noid circuit is ON.
Controller's
• Even if operating the gear to the forward, the gear is shifted to N (neutral).
action
Symptoms that
appear on
• Once machine is stopped, travel is limited to R1.
machine
• The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
General
information
• Duplication of failure code: Engine start + Forward travel

nose.
1 fill switch FFT (male) PCCS lever Resistance
ground F (Forward) Max. 1 z
Disconnection in wiring a Prepare with starting switch OFF and diagnose with starting
Possible harness (Disconnection in switch still OFF.
2
causes and the wiring or defective contact of Wiring harness between PTC2 (female) (35) Resis-
standard values connectors) Max. 1 z
– FFT (female) (1) tance
when normal
nose.
3
ground F (Forward) Max. 1 V
system
18 D85EX, PX-15E0
D85EX, PX-15E0 19
Failure code [15SBL1] Reverse clutch: Fill signal is ON when command

current is OFF 1
Action code Failure code Symptom Reverse clutch: Fill signal is ON when command current is OFF
CALL E03 15SBL1 of failure (Steering and transmission controller system)
• The fill switch signal does not become off when the output of the transmission reverse clutch sole-
Failure content
noid circuit has stopped.
Controller's
• Even if operating the gear to the forward, the gear is shifted to N (neutral).
action
Symptoms that
appear on
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
General
information
• Duplication of failure code: Engine start + travel neutral

nose.
Defective reverse clutch
1 fill switch FRT (male) PCCS lever Resistance
ground R (Reverse) Max. 1 z
switch still OFF.
2
standard values between PTC2 (female) (25) – FRT (female) Min. 1 Mz
tance
when normal (1)
nose.
3
ground R (Reverse) Max. 1 V
system
20 D85EX, PX-15E0
Circuit diagram related to transmission reverse clutch ECMV
D85EX, PX-15E0 21
Failure code [15SBLH] Reverse clutch: Fill signal is OFF when

command current is ON 1
Action code Failure code Symptom Reverse clutch: Fill signal is OFF when command current is ON
CALL E03 15SBLH of failure (Steering and transmission controller system)
• The fill switch signal does not become ON when the output of the transmission reverse clutch sole-
Failure content
noid circuit is ON.
Controller's
• Even if operating the gear to the reverse, the gear is shifted to N (neutral).
action
Symptoms that
appear on
machine
• The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
General
information
• Duplication of failure code: Engine start + reverse travel

nose.
1 fill switch FRT (male) PCCS lever Resistance
ground R (Reverse) Max. 1 z
Possible harness switch still OFF.
2
causes and the (disconnection or defective Wiring harness between PTC2 (female) (25) Resis-
standard values contact of connectors) Max. 1 z
– FRT (female) (1) tance
when normal
nose.
3
ground R (Reverse) Max. 1 V
system
22 D85EX, PX-15E0
D85EX, PX-15E0 23
Failure code [15SEL1] 1st clutch: Fill signal is ON when command

current is OFF 1
Action code Failure code Symptom 1st clutch: Fill signal is ON when command current is OFF
CALL E03 15SEL1 of failure (Steering and transmission controller system)
• The fill switch signal does not become OFF when the output of the transmission 1st clutch solenoid
Failure content
circuit has stopped.
Symptoms that
appear on
• Once machine is stopped, travel is limited to F1 and R1.
machine
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
General
information
• Duplication of failure code: Engine start + F1 or R1 o travel neutral

nose.
Defective 1st clutch
1 fill switch F1T (male) PCCS lever Resistance
(internal short circuit) Between (1) and Other than F1 and R1 Min. 1 Mz
ground F1 and R1 Max. 1 z
switch still OFF.
2
standard values between PTC3 (female) (19) – F1T (female) Min. 1 Mz
tance
when normal (1)
nose.
3
Between (19) and Other than F1 and R1 5 – 11 V
ground F1 and R1 Max. 1 V
system
24 D85EX, PX-15E0
Circuit diagram related to transmission 1st clutch ECMV
D85EX, PX-15E0 25
Failure code [15SELH] 1st clutch: Fill signal is OFF when command
current is ON 1
Action code Failure code Symptom 1st clutch: Fill signal is OFF when command current is ON
CALL E03 15SELH of failure (Steering and transmission controller system)
• The fill switch signal does not become ON when the output of the transmission 1st clutch solenoid
Failure content
circuit is ON.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
General
information
• Duplication of failure code: Engine start + F1 or R1 travel

nose.
Defective 1st clutch
2
– F1T (female) (1) tance
when normal
nose.
3
system
26 D85EX, PX-15E0
D85EX, PX-15E0 27
Failure code [15SFL1] 2nd clutch: Fill signal is ON when command

current is OFF 1
Action code Failure code Symptom 2nd clutch: Fill signal is ON when command current is OFF
CALL E03 15SFL1 of failure (Steering and transmission controller system)
• The fill switch signal does not become off when the output of the transmission 2nd clutch solenoid
Failure content
circuit has stopped.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
General
information

nose.
Defective 2nd clutch
switch still OFF.
2
tance
when normal (1)
nose.
3
system
28 D85EX, PX-15E0
Circuit diagram related to transmission 2nd clutch ECMV
D85EX, PX-15E0 29
Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command
current is ON 1
Action code Failure code Symptom 2nd clutch: Fill signal is OFF when command current is ON
CALL E03 15SFLH of failure (Steering and transmission controller system)
• The fill switch signal does not become ON when the output of the transmission 2nd clutch solenoid
Failure content
circuit is ON.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
General
information

nose.
Defective 2nd clutch
2
when normal
nose.
3
system
30 D85EX, PX-15E0
D85EX, PX-15E0 31
Failure code [15SGL1] 3rd clutch: Fill signal is ON when command

current is OFF 1
Action code Failure code Symptom 3rd clutch: Fill signal is ON when command current is OFF
CALL E03 15SGL1 of failure (Steering and transmission controller system)
• The fill switch signal does not become off when the output of the transmission 3rd clutch solenoid cir-
Failure content
cuit has stopped.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
General
information

nose.
Defective 3rd clutch
switch still OFF.
2
tance
when normal (1)
nose.
3
system
32 D85EX, PX-15E0
Circuit diagram related to transmission 3rd clutch ECMV
D85EX, PX-15E0 33
Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command
current is ON 1
Action code Failure code Symptom 3rd clutch: Fill signal is OFF when command current is ON
CALL E03 15SGLH of failure (Steering and transmission controller system)
• The fill switch signal does not become ON when the output of the transmission 3rd clutch solenoid
Failure content
circuit is ON.
Symptoms that
appear on
machine
• The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
General
information

nose.
Defective 3rd clutch
2
when normal
nose.
3
system
34 D85EX, PX-15E0
D85EX, PX-15E0 35
Failure code [AA10NX] Air cleaner: Clogged 1
Action code Failure code Symptom Air cleaner: Clogged

— AA10NX of failure (Mechanical system)
Failure content • The air cleaner clogging state is detected during the engine running.
action • Flashes caution lamp.
Symptoms that
• If the machine is operated in such a condition, the engine output may decrease or the engine may be
appear on
damaged.
machine
General • The air cleaner clogging caution symbol on the monitor panel flashes and this failure code is
information recorded.

Clogged air cleaner
1 a Check the air cleaner, then clean and change if it is clogged.
(When system is normal)
nose.
Defective air cleaner
2 clogging switch (Internal AF2 (male) Air cleaner Resistance
disconnection) When normal Max. 1 z
Between (1) – (2)
When clogged Min. 1 Mz
Possible
causes and the
Disconnection in wiring switch still OFF.
standard values
when normal harness Wiring harness between S03 (female) (13) – Resis-
3 Max. 1 z
(disconnection or defective AF2 (female) (1) tance
contact of connectors) Wiring harness between AF2 (female) (2) Resis-
Max. 1 z
and ground tance
nose.
4 Defective monitor panel S03 Air cleaner Voltage
Between (13) and When normal Max. 1V
ground When clogged Min. 7 V
36 D85EX, PX-15E0
Circuit diagram related to clogged air cleaner
D85EX, PX-15E0 37
Failure code [AB00MA] Abnormal battery charge: Malfunction 1
Action code Failure code Symptom Abnormal battery charge: Malfunction

— AB00MA of failure (Mechanical system)
Failure content • The voltage of charge level circuit decreased during the engine running.
Controller's
• Flashes warning lamp.
action
Symptoms that
appear on • If the machine is operated in such a condition, battery may be discharged.
machine
General • The charge level caution symbol on the monitor panel flashes and this failure code is recorded.
information • Duplication of failure code: Start engine + fuel dial full

It can be suspected that the problem causing the detection of defec-
Possible Defective battery charge
1 tive battery charge is currently occurring or occurred in the past.
causes and the (When system is normal)
Investigate the cause and damage condition, and correct it.
standard values
when normal Carry out troubleshooting of charge level caution lamp system in
Defective charge level
2 accordance with‚ “While engine is running, battery charge level cau-
caution lamp circuit
tion lamp flashes” in E mode.
Failure code [B@BAZG] Engine oil: Oil pressure too low 1
Action code Failure code Symptom Engine oil: Oil pressure too low
— B@BAZG of failure (Mechanical system)
Failure content • The engine oil pressure abnormality takes place during the engine running.
Controller's • Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel)
action • Limits operation of engine.
Symptoms that • If the machine is operated in such a condition, the engine output may decrease and the engine may
appear on be damaged.
machine • After warning, engine speed is limited to medium (half).
• The engine oil pressure caution symbol on the monitor panel flashes and this failure code is
General
recorded.
information
• Duplication of failure code: Start the engine.

It can be suspected that the problem causing the detection of
Reduction of engine oil
Possible engine oil pressure reduction is currently occurring or occurred in
1 pressure
causes and the the past. Investigate the cause and damage condition, and correct
standard values it.
when normal Carry out troubleshooting of engine oil pressure caution lamp sys-
Defective engine oil pressure
2 tem in accordance with‚ “While engine is running, emergency warn-
caution lamp circuit
ing item flashes” in E mode.
38 D85EX, PX-15E0
Failure code [B@BCNS] Radiator coolant: Overheat 1
Action code Failure code Symptom Radiator coolant: Overheat

— B@BCNS of failure (Mechanical system)
Failure content • The radiator coolant becomes overheated during the engine running.
Controller's • Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel)
action • Limits operation of engine.
Symptoms that
• If the machine is operated in such a condition, engine may be damaged.
appear on
• After warning, engine output is limited to half of rated horsepower.
machine
• The engine coolant temperature caution symbol on the monitor panel flashes and this failure code is
General
recorded.
information

It can be suspected that the problem causing a detection of coolant
Possible Coolant overheats
1 overheat is currently occurring or occurred in the past. Investigate
the cause and damage condition, and correct it.
standard values
when normal Defective engine coolant Carry out troubleshooting of coolant temperature caution lamp cir-
2 temperature caution lamp cuit in accordance with “While engine is running, emergency warn-
circuit ing item flashes” in E mode.
Failure code [B@BCZK] Radiator coolant: Level too low 1
Action code Failure code Symptom Radiator coolant: Level too low
— B@BCZK of failure (Mechanical system)
Failure content • Radiator coolant level decreases when starting switch is turned ON.
Controller's
action
Symptoms that
appear on • If the machine is operated in such a condition, engine may be damaged.
machine
• The radiator coolant level caution symbol on the monitor panel flashes and this failure code is
General
recorded.
information
• Duplication of failure code: turn ON the starting switch.

Possible Radiator coolant level is too It can be suspected that the problem causing the detection of radia-
causes and the 1 low. tor coolant level too low is currently occurring or occurred in the
standard values (When system is normal) past. Investigate the cause and damage condition, and correct it.
when normal Defective radiator coolant Carry out troubleshooting in accordance with “When starting switch
2
level caution lamp circuit is turned ON, radiator coolant level caution flashes” in E mode.
D85EX, PX-15E0 39
Failure code [B@CENS] Power train oil: Overheat 1
Action code Failure code Symptom Power train oil: Overheat

— B@CENS of failure (Mechanical system)
Failure content • The power train oil becomes overheated during the engine running.
Controller's
• Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel)
action
Symptoms that
appear on • If the machine is operated in such a condition, power train may be damaged.
machine
• The power train oil temperature caution symbol on the monitor panel flashes and this failure code is
General
recorded.
information

Power train oil temperature It can be suspected that the problem causing a detection of power
Possible
1 overheat train oil overheat is currently occurring or occurred in the past.
causes and the
(When system is normal) Investigate the cause and damage condition, and correct it.
standard values
when normal Defective caution lamp Carry out troubleshooting of power train oil temperature caution
2 circuit for power train oil lamp system in accordance with‚ “While engine is running, emer-
overheat gency warning item flashes” in E mode.
Failure code [B@HANS] Hydraulic oil: Overheat 1
Action code Failure code Symptom Hydraulic oil: Overheat

— B@HANS of failure (Mechanical system)
Failure content • The hydraulic oil temperature becomes overheated during the engine running.
Controller's
• Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel)
action
Symptoms that
• If the machine is operated in such a condition, the devices for hydraulic circuit of the work equipment
appear on
may be damaged.
machine
• The hydraulic oil temperature caution symbol on the monitor panel flashes and this failure code is
General
recorded.
information

It can be suspected that the problem causing a detection of
Possible Hydraulic oil overheat
1 hydraulic oil overheat is currently occurring or occurred in the past.
Investigate the cause and damage condition, and correct it.
standard values
when normal Carry out troubleshooting of hydraulic oil temperature caution lamp
Defective hydraulic oil tem-
2 circuit in accordance with “While engine is running, emergency
perature caution lamp circuit
warning item flashes” in E mode.
40 D85EX, PX-15E0
Failure code [CA111] Engine controller: Abnormality in controller 1
Action code Failure code Symptom Engine controller: Abnormality in controller

CALL E04 CA111 of failure (Engine controller system)
Failure content • Abnormality has occurred in engine controller.
Controller's
action
Symptoms that
• Though the engine can operate normally, it may stall during the operation and may not start when the
appear on
engine is stopped.
machine
General
information

Since the breaker can be suspected to be defective, inspect the
breaker.
1 Defective breaker
(When the breaker is cut off, it is highly possible that a defective har-
ness grounding has occurred in the circuit.)
harness Wiring harness between EGC3 (female) (3), Resis-
2 Max. 1 z
Possible (disconnection or defective (4) – battery (+) tance
causes and the contact of connectors) Wiring harness between EGC3 (female) (1), Resis-
standard values Max. 1 z
(2) and ground tance
when normal
Defective harness grounding switch still OFF.
3
(contact with ground circuit) Between ground and wiring harness Resis-
Min. 1 Mz
between EGC3 (female) (3), (4) – battery (+) tance
switch ON.
4 Defective engine controller
EGC3 Voltage
Between (3), (4) – (1), (2) 20 – 30 V
Circuit diagram related to controller power source
D85EX, PX-15E0 41

Abnormal speed sensor signal 1
Action code Failure code Symptom of Abnormal engine Ne and Bkup speed sensors: Abnormal speed
CALL E04 CA115 failure sensor signal (Engine controller system)
• Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor cir-
Failure content
cuit.
Controller's
action
Symptoms that
• Engine does not start (during engine stop).
appear on
• Engine stops (during engine running).
machine
General
information

Defective Ne speed sensor
1 Carry out troubleshooting of [CA689].
circuit
Defective Bkup speed sensor
2 Carry out troubleshooting of [CA778].
circuit
Since a mounting section of Ne speed sensor can be suspected to
Defective Ne speed sensor
Possible 3 be defective, directly check the mounting section. (Defective
mounting section
causes and the installation of sensor itself, internal defect of flywheel, etc.)
standard values Since a mounting section of Bkup speed sensor can be suspected
when normal Bkup speed sensor mounting
4 to be defective, directly check the mounting section. (Defective
section
installation of sensor itself, internal defect of supply pump, etc.)
Defective connection of sensor The defective (wrong) connections of Ne speed sensor and Bkup
5
(wrong connection) speed sensor can be suspected. Directly check them.
Engine controller can be suspected to be defective if no problem
6 Defective engine controller is found in causes 1 – 5 (since this is an internal defect, it cannot
be diagnosed).
42 D85EX, PX-15E0
Failure code [CA122] Charge pressure sensor too high: Excessively

high voltage detected 1
Action code Failure code Symptom Charge pressure sensor too high: Excessively high voltage detected
Failure content • Excessively high voltage is detected at circuit of charge pressure (boost pressure) sensor.
Controller's • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
action • Flashes warning lamp and turns on alarm buzzer.
Symptoms that
appear on • Acceleration performance of engine deteriorates.
machine
• The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
General
function. (Code: 36501 Boost pressure sensor voltage)
information

Defective sensor power If failure code [CA227] is displayed at the same time, carry out trou-
1
source circuit bleshooting for it first.
a Prepare with starting switch OFF, and diagnose with starting
switch ON or with engine started.
PIM Voltage
Defective charge pressure
2 (boost pressure) Between (1) – (3) Power source 4.75 – 5.25 V
sensor (internal defect) Since the sensor voltage is measured with the harness being con-
nected, if the voltage is abnormal, first check the harness and the
controller to make it sure if there is no other cause of the trouble,
and then judge the sensor voltage.
switch still OFF.
Disconnection in wiring Wiring harness between EGC1 (female) (37) Resis-
Max. 1 z
harness – PIM (female) (1) tance
3
(disconnection or defective Wiring harness between EGC1 (female) (44) Resis-
contact of connectors) Max. 1 z
– PIM (female) (2) tance
Possible Wiring harness between EGC1 (female) (47) Resis-
causes and the Max. 1 z
– PIM (female) (3) tance
standard values
when normal
switch still OFF.
Between ground and wiring harness between Resis-
Min. 1 Mz
Defective harness grounding EGC1 (female) (37) – PIM (female) (1) tance
4
(contact with ground circuit) Between ground and wiring harness between Resis-
Min. 1 Mz
EGC1 (female) (44) – PIM (female) (2) tance
Min. 1 Mz
EGC1 (female) (47) – PIM (female) (3) tance
switch still OFF.
Between wiring harness from EGC1 (female)
Resis-
(37) to PIM (female) (1) and wiring harness Min. 1 Mz
tance
from ENG (female) (44) to PIM (female) (2)
Harness short
5 Between wiring harness from EGC1 (female)
(Harness internal short) Resis-
tance
Resis-
tance
44 D85EX, PX-15E0

Possible a Prepare with starting switch OFF, and diagnose with starting
causes and the switch ON or with engine started.
standard values 6 Defective engine controller
when normal EGC1 Voltage
Between (37) – (47) Power source 4.75 – 5.25 V
Circuit diagram related to charge pressure sensor
D85EX, PX-15E0 45
Failure code [CA123] Charge pressure sensor too low: Excessively low
voltage detected 1
Action code Failure code Symptom Charge pressure sensor too low: Excessively low voltage detected
Failure content • Excessively low voltage is detected at circuit of charge pressure (boost pressure) sensor.
Controller's • Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
Symptoms that
appear on • Acceleration performance of engine deteriorates.
machine
• The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
General
function. (Code: 36501 Boost pressure sensor voltage)
information
Possible Causes Standard values when normal and remarks for troubleshooting
causes and the
standard values Defective sensor power If failure code [CA187] is displayed at the same time, carry out trou-
1
when normal source circuit bleshooting for it first.
46 D85EX, PX-15E0
Failure code [CA131] Decelerator pedal sensor too high: Excessively

Action code Failure code Symptom Decelerator pedal sensor too high: Excessively high voltage
CALL E03 CA131 of failure detected (Engine controller system)
Failure content • Excessively high voltage is detected at signal circuit of decelerator pedal.
• Operates with the fixed value that is same as the value just before the abnormality is detected, if
abnormality occurs with the starting switch in the ON position.
Controller's
• If the starting switch is turned to the ON position in as-is abnormal condition, the controller operates
action
with 100% value.
Symptoms that
appear on • Engine speed cannot be controlled by decelerator pedal.
machine
• The signal voltage of decelerator pedal can be checked in monitoring mode.
General
(Code: 31703 Decelerator voltage)
information

Defective throttle sensor If failure code [CA2185] is displayed at the same time, carry out
1
power supply circuit troubleshooting for it first.
switch ON.
DCL Voltage
2 Defective decelerator pedal Between (A) – (C) Power source 4.75 – 5.25 V
Since voltage is measured with the harness connected, additionally
diagnose the harness and the controller if the voltage is abnormal,
and then make judgment after it is determined that there is no other
cause of the abnormality.
Hot short of harness switch ON.
3 (a contact with 5V circuit or Between ground and wiring harness
Possible 24V circuit) between EGC2 (female) (9) – DCL (female) Voltage Max. 1V
causes and the (B)
standard values
when normal
switch still OFF.
Harness short
(9) to DCL (female) (B) and wiring harness Min. 1 Mz
tance
from EGC2 (female) (22) to DCL (female) (A)
Since the connections among decelerator pedal – body harness –
engine controller are suspected to be defective, Check the connec-
tions directly.
Defective wiring harness
5 • Connector is loose, lock is broken, seal is broken
connector
• Pin is corroded, bent, broken, pushed in, expanded.
• Moisture in connector, entry of dirt or sand, etc., and insufficient
insulation
switch ON.
EGC2 Voltage
48 D85EX, PX-15E0
Circuit diagram related to decelerator pedal
D85EX, PX-15E0 49
Failure code [CA132] Decelerator pedal sensor too low: Excessively low
voltage detected 1
Action code Failure code Symptom Decelerator pedal sensor too low: excessively low voltage detected
Failure content • Excessively low voltage is detected at signal circuit of decelerator pedal.
Controller's
action
with 100% value.
Symptoms that
machine
• The signal voltage of decelerator pedal can be checked in monitoring mode.
General
(Code: 31703 Decelerator voltage)
information

Defective throttle sensor If failure code [CA2186] is displayed at the same time, carry out
1
power supply circuit troubleshooting for it first.
switch ON.
DCL Voltage
2 Defective decelerator pedal Between (A) – (C) Power source 4.75 – 5.25 V
Since voltage is measured with the harness connected, additionally
diagnose the harness and the controller if the voltage is abnormal,
and then make judgment after it is determined that there is no other
cause of the abnormality.
switch still OFF.
Defective harness grounding
3
Possible between EGC2 (female) (9) – DCL (female) Min. 1 Mz
causes and the tance
(B)
standard values
when normal
switch still OFF.
Harness short
tance
from EGC2 (female) (23) to DCL (female) (C)
tions directly.
connector
insulation
switch ON.
EGC2 Voltage
50 D85EX, PX-15E0
D85EX, PX-15E0 51
Failure code [CA135] Oil pressure sensor too high: Excessively high
voltage detected 1
Action code Failure code Symptom Oil pressure sensor too high: Excessively high voltage detected
E02 CA135 of failure (Engine controller system)
Failure content • Excessively high voltage is detected at oil pressure sensor circuit.
Controller's • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Symptoms that
appear on
machine
• The signal voltage of engine oil pressure sensor can be checked in monitoring function.
General
(Code: 37201 Engine oil pressure sensor voltage)
information

Defective sensor power If failure code [CA187] or [CA227] is displayed at the same time,
1
source circuit carry out troubleshooting for it first.
POIL Voltage
Defective oil pressure sensor Between (1) – (2) Power source 4.75 – 5.25 V
2
(internal defect)
Since the sensor voltage is measured with the harness being con-
switch still OFF.
Max. 1 z
harness – POIL (female) (1) tance
3
– POIL (female) (2) tance
– POIL (female) (3) tance
standard values
when normal
switch still OFF.
Min. 1 Mz
Defective harness grounding EGC1 (female) (37) – POIL (female) (1) tance
4
Min. 1 Mz
EGC1 (female) (47) – POIL (female) (2) tance
Min. 1 Mz
EGC1 (female) (13) – POIL (female) (3) tance
switch still OFF.
Resis-
(37) to POIL (female) (1) and wiring harness Min. 1 Mz
tance
from EGC1 (female) (47) to POIL (female) (2)
Harness short
tance
Resis-
tance
52 D85EX, PX-15E0

Circuit diagram related to oil pressure sensor
D85EX, PX-15E0 53
Failure code [CA141] Oil pressure sensor too low: Excessively low
voltage detected 1
Action code Failure code Symptom Oil pressure sensor too low: Excessively low voltage detected
Failure content • Excessively low voltage is detected at oil pressure sensor circuit.
Controller's • Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Symptoms that
appear on
machine
• The signal voltage of engine oil pressure sensor can be checked in monitoring function.
General
(Code: 37201 Engine oil pressure sensor voltage)
information
causes and the
standard values Defective sensor power If failure code [CA187] is displayed at the same time, carry out trou-
1
when normal source circuit bleshooting for it first.
54 D85EX, PX-15E0
Failure code [CA144] Coolant temperature sensor too high: Excessively

Action code Failure code Symptom Coolant temperature sensor too high: Excessively high voltage
E01 CA144 of failure detected (Engine controller system)
Failure content • Excessively high voltage is detected at signal circuit of coolant temperature sensor.
Controller's • Operates with a fixed coolant temperature (90°C).
Symptoms that
appear on • Exhaust gas color becomes white.
machine
• The signal voltage of coolant temperature sensor can be checked in monitoring function.
General
(Code: 04105 Coolant temperature sensor voltage)
information

Defective coolant switch still OFF.
1
temperature sensor TWTR (male) Resistance
Between (A) – (B) 0.18 – 160 kz
harness Wiring harness between EGC1 (female) (15) Resis-
2 Max. 1 z
(disconnection or defective – TWTR (female) (A) tance
contact of connectors) Wiring harness among EGC1 (female) (38) – Resis-
Max. 1 z
JM03 – TWTR (female) (B) tance
switch still OFF.
Possible Harness short
3 Between EGC1 (female) (15) – all pins of
causes and the (Harness internal short) Resis-
EGC1 (female) (with all connectors in the Min. 1 Mz
standard values tance
harness disconnected)
when normal
Since the connections among coolant temperature sensor – engine
harness – engine controller are suspected to be defective, check for
a defective connection.
connector
insulation
Defect in other locations than switch still OFF.
5
engine controller EGC1 (female) Resistance
Between (15) – (38) 0.18 – 160 kz
Engine controller is possibly defective if no problem is found in
6 Defective engine controller causes 1 – 5.
(Since this is an internal defect, it cannot be diagnosed.)
56 D85EX, PX-15E0
Circuit diagram related to coolant temperature sensor
D85EX, PX-15E0 57
Failure code [CA145] Coolant temperature sensor too low: Excessively

low voltage detected 1
Action code Failure code Symptom Coolant temperature sensor too low: Excessively low voltage
Failure content • Excessively low voltage is detected at signal circuit of coolant temperature sensor.
Controller's • Operates with a fixed coolant temperature (90°C).
Symptoms that
machine
General • The signal voltage of coolant temperature sensor can be checked in monitoring function.
information (Code: 04105 Coolant temperature sensor voltage)

switch still OFF.
Defective coolant TWTR (male) Resistance
1
temperature sensor
Between (A) – (B) 0.18 – 160 kz
Between (A) and ground Min. 1 Mz
2
Min. 1 Mz
EGC1 (female) (15) – TWTR (female) (A) tance
switch still OFF.
Harness short
Possible (Harness internal short) Resis-
causes and the tance
standard values
when normal Since the connections among coolant temperature sensor – engine
harness – engine controller are suspected to be defective, check for
a defective connection.
connector
insulation
switch still OFF.
Defect in other locations than EGC1 (female) Resistance
5
engine controller
Between (15) – (38) 0.18 – 160 kz
Between (15) and ground Min. 1 Mz
58 D85EX, PX-15E0
Circuit diagram related to coolant temperature sensor
D85EX, PX-15E0 59
Failure code [CA153] Charge temperature sensor too high: Excessively

Action code Failure code Symptom Charge temperature sensor too high: Excessively high voltage
E01 CA153 of failure detected. (Engine controller system)
• Excessively high voltage is detected at signal circuit of charge temperature (boost temperature)
Failure content
sensor.
Controller's
• Operates with a fixed charge temperature (boost temperature) (70°C).
action
Symptoms that
machine
• The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
General
monitoring function. (Code: 18501 Boost temperature sensor voltage)
information
Defective charge a Prepare with starting switch OFF and diagnose with starting
temperature switch still OFF.
1
(boost temperature) sensor TIM (male) Resistance
(internal defect) Between (A) – (B) 0.18 – 160 kz
2 Max. 1 z
(disconnection or defective – TIM (female) (A) tance
contact of connectors) Wiring harness between EGC1 (female) (47) Resis-
Max. 1 z
– JM02 – TIM (female) (B) tance
switch still OFF.
Possible Harness short
causes and the (Harness internal short) Resis-
when normal
Since the connections among charge temperature (boost tempera-
ture) sensor – engine harness – engine controller are suspected to
be defective, check for a defective connection.
connector
insulation
Defect in other locations than switch still OFF.
5
engine controller EGC1 (female) Resistance
Between (23) – (47) 0.18 – 160 kz
60 D85EX, PX-15E0
Circuit diagram related to charge temperature sensor
D85EX, PX-15E0 61
Failure code [CA154] Charge temperature sensor too low: Excessively

low voltage detected 1
Action code Failure code Symptom Charge temperature sensor too low: Excessively low voltage
• Excessively low voltage is detected at signal circuit of charge temperature (boost temperature)
Failure content
sensor.
Controller's
• Operates with a fixed charge temperature (boost temperature) (70°C).
action
Symptoms that
machine
• The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
General
monitoring function. (Code: 18501 Boost temperature sensor voltage)
information

Defective charge switch still OFF.
temperature TIM (male) Resistance
1
(boost temperature) sensor
(internal defect) Between (A) – (B) 0.18 – 160 kz
Between (A) and ground Min. 1 Mz
switch still OFF.
2
between EGC1 (female) (23) – TIM (female) Min. 1 Mz
tance
(A)
switch still OFF.
Harness short
Possible 3 Between EGC1 (female) (23) – all pins of
causes and the EGC1 (female) (with all connectors in the Min. 1 Mz
tance
standard values harness disconnected)
when normal Since the connections among charge temperature (boost tempera-
ture) sensor – engine harness – engine controller are suspected to
be defective, check for a defective connection.
connector
insulation
switch still OFF.
Defect in other locations than EGC1 (female) Resistance
5
engine controller
Between (23) – (47) 0.18 – 160 kz
62 D85EX, PX-15E0
Circuit diagram related to charge temperature sensor
D85EX, PX-15E0 63
Failure code [CA187] Sensor power source 2 too low: Low voltage
detected 1
Action code Failure code Symptom Sensor power source 2 too low: Excessively low voltage detected
Failure content • Excessively low voltage has been detected in sensor power source 2 (5V) circuit.
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
• Operates oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm2})
• Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2})
Controller's • Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}).
action • Operates with EGR inlet pressure sensor value defaulted to (102 kPa {1.0 kg/cm2}) and runs by limit-
ing output.
• Restricts the EGR valve lift sensor output and closes EGR valve.
Symptoms that
appear on • Output decreases.
machine
General
information
causes and the
standard values Carry out troubleshooting of failure code [CA227].
when normal
64 D85EX, PX-15E0
Failure code [CA221] Atmospheric pressure sensor too high:

Excessively high voltage detected 1
Action code Failure code Symptom Atmospheric pressure sensor too high: Excessively high voltage
Failure content • Excessively high voltage is detected at signal circuit of atmospheric pressure sensor.
Controller's • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Symptoms that
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
General
(Code: 37401 Atmospheric pressure sensor voltage)
information

Defective sensor power If failure code [CA187] or [CA227] is displayed at the same time,
1
source circuit carry out troubleshooting for it first.
switch ON.
PAMB Voltage
Defective atmospheric
2 pressure sensor Between (1) – (3) Power source 4.75 – 5.25 V
(internal defect) Since the sensor voltage is measured with the harness being con-
switch still OFF.
Max. 1 z
harness – PAMB (female) (1) tance
3
– PAMB (female) (2) tance
– PAMB (female) (3) tance
standard values
when normal
switch still OFF.
Min. 1 Mz
Defective harness grounding EGC1 (female) (37) – PAMB (female) (1) tance
4
Min. 1 Mz
EGC1 (female) (3) – PAMB (female) (2) tance
Min. 1 Mz
EGC1 (female) (38) – PAMB (female) (3) tance
switch still OFF.
Resis-
(37) to PAMB (female) (1) and wiring harness Min. 1 Mz
tance
from EGC1 (female) (3) to PAMB (female) (2)
Harness short
tance
Resis-
tance
66 D85EX, PX-15E0

Between (37) – (38) 4.75 – 5.25 V
Circuit diagram related to atmospheric pressure sensor
D85EX, PX-15E0 67
Failure code [CA222] Atmospheric pressure sensor too low:

Excessively low voltage detected 1
Action code Failure code Symptom Atmospheric pressure sensor too low: Excessively low voltage
Failure content • Excessively low voltage is detected at signal circuit of atmospheric pressure sensor.
Controller's • Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Symptoms that
machine
• The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
General
(Code: 37401 Atmospheric pressure sensor voltage)
information
causes and the
when normal
68 D85EX, PX-15E0
Failure code [CA227] Sensor power source 2 too high: Excessively high
voltage detected 1
Action code Failure code Symptom Sensor power source 2 too high: Excessively high voltage detected
Failure content • Excessively high voltage has occurred in sensor power source 2 (5V) circuit.
• Operates using Ne speed sensor signal instead of Bkup speed sensor signal.
• Operate oil pressure sensor with oil pressure at default value (250 kPa {2.5 kg/cm2})
• Operates with atmospheric pressure sensor value defaulted to (52.44 kPa {0.5 kg/cm2})
Controller's • Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}).
action • Operates with EGR inlet pressure sensor value defaulted to (102 kPa {1.0 kg/cm2}) and runs by
limiting output.
• Restricts the EGR valve lift sensor output and closes EGR valve.
Symptoms that
machine
General
information

Check the codes that are displayed at the same time. If any other
1 Defective related circuits
codes are displayed, carry out troubleshooting for those codes.
switch ON.
Bkup speed sensor G connector
Disconnect the Oil pressure sensor POIL connector

Defective sensor devices on the right Atmospheric
2 PAMB connector
(internal defect) one at a time. pressure sensor
If the code disap- Charge pressure
pears, that device is PIM connector
sensor
internally defective.
EGR valve
SEGR connector
lift sensor
Possible Disconnection in wiring switch still OFF.
causes and the harness Wiring harness between EGC1 (female) (37) Resis-
3 Max. 1 z
standard values (disconnection or defective – each sensor (female) tance
when normal contact of connectors) Wiring harness between EGC1 (female) (47) Resis-
Max. 1 z
– each sensor (female) tance
switch still OFF.
Between ground and wiring harness
Resis-
Defective harness grounding between EGC1 (female) (37) – each sensor Min. 1 Mz
4 tance
(contact with ground circuit) (female)
Resis-
between EGC1 (female) (47) – each sensor Min. 1 Mz
tance
(female)
switch still OFF.
Harness short Between wiring harness from EGC1 (female)
5
(Harness internal short) (37) to each sensor (female) and wiring har- Resis-
Min. 1 Mz
ness from EGC1 (female) (47) to each sen- tance
sor (female)
70 D85EX, PX-15E0

Possible a Prepare with starting switch OFF and diagnose with starting
causes and the switch ON.
Between (37) – (47) 4.75 – 5.25 V
Circuit diagram related to sensor power source 2 (5V)
D85EX, PX-15E0 71
Failure code [CA234] Engine over speed: Excessively high speed 1
Action code Failure code Symptom Engine over speed: Excessively high speed
— CA234 of failure (Engine controller system)
• The engine speed exceeds upper control limit speed.
Failure content
Controller's
• Stops operation of injector until the engine speed drops to the normal speed.
action
Symptoms that
appear on • Engine speed fluctuates.
machine
• The engine speed can be checked in monitoring function.
General
(Code: 01000 Engine speed)
information
• Duplication of failure code: Start engine and operate at high idle.

Possible codes are displayed, carry out troubleshooting for those codes.
causes and the The improper usage of equipped machine can be suspected.
standard values 2 Improper usage
Instruct the proper usage.
when normal
Engine controller can be suspected to be defective if no problem is
3 Defective engine controller found in causes 1 – 2 (since this is an internal defect, it cannot be
diagnosed).
72 D85EX, PX-15E0

Action code Failure code Symptom Abnormal power source for Ne speed sensor: Excessively low volt-
CALL E03 CA238 of failure age detected (Engine controller system)
Failure content • Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controller's • Controls using Bkup speed sensor signal.
Symptoms that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information

switch still OFF.
Defective Ne speed sensor Disconnect a device

1 shown on the right.
(internal defect)
If the failure code dis- Ne speed sensor NE connector
appears, that device
is internally defective.
2 Max. 1 z
(disconnection or defective – NE (female) (1) tance
Max. 1 z
Possible – NE (female) (2) tance
causes and the a Prepare with starting switch OFF and diagnose with starting
standard values switch still OFF.
when normal
Defective harness grounding Between ground and wiring harness between Resis-
3 Min. 1 Mz
(contact with ground circuit) EGC1 (female) (16) – NE (female) (1) tance
Min. 1 Mz
EGC1 (female) (48) – NE (female) (2) tance
switch still OFF.
Harness short
(16) to NE (female) (1) and wiring harness Min. 1 Mz
tance
from EGC1 (female) (48) to NE (female) (2)
switch ON.
EGC1 Voltage
Between (16) – (48) 4.75 – 5.25 V
74 D85EX, PX-15E0
Circuit diagram related to Ne speed sensor power source
D85EX, PX-15E0 75
Failure code [CA263] Fuel temperature sensor too high: Excessively

Action code Failure code Symptom Fuel temperature sensor too high: Excessively high voltage
Failure content • Excessively high voltage is detected at fuel temperature sensor circuit.
Controller's
• Operates with a fixed fuel temperature (90°C).
action
Symptoms that
appear on
machine
General • The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
information (Code: 14201 Engine fuel temperature sensor voltage)

Defective fuel temperature switch still OFF.
1
sensor (internal defect) TFUEL (male) Fuel temperature Resistance
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Possible 2 Max. 1 z
(disconnection or defective – TFUEL (female) (A) tance
causes and the contact of connectors)
standard values Wiring harness between EGC1 (female) (47) Resis-
Max. 1 z
when normal – TFUEL (female) (B) tance
switch still OFF.
3 Min. 1 Mz
(contact with ground circuit) EGC1 (female) (30) – TFUEL (female) (A) tance
switch still OFF.
EGC1 (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100°C 0.6 – 20 kz
76 D85EX, PX-15E0
Circuit diagram related to fuel temperature sensor
D85EX, PX-15E0 77
Failure code [CA265] Fuel temperature sensor too low: Excessively low
voltage detected 1
Action code Failure code Symptom Fuel temperature sensor too low: Excessively low voltage detected
Failure content • Excessively low voltage is detected at fuel temperature sensor circuit.
Controller's
• Operates with a fixed fuel temperature (90°C).
action
Symptoms that
appear on
machine
General • The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
information (Code: 14201 Engine fuel temperature sensor voltage)
causes and the
when normal
78 D85EX, PX-15E0
Failure code [CA271] PCV1 short circuit: Short circuit 1
Action code Failure code Symptom PCV1 short circuit: Short circuit
Failure content • Short circuit has occurred in supply pump PCV1 circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
Defective supply pump PCV1 (male) Resistance
1
PCV1 (internal short circuit)
Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) and ground Min. 1 Mz
switch still OFF.
2 Min. 1 Mz
(contact with ground circuit) EGC1 (female) (4) – PCV1 (female) (1) tance
Possible
causes and the Min. 1 Mz
EGC1 (female) (5) – PCV1 (female) (2) tance
standard values
when normal a Prepare with starting switch OFF and diagnose with starting
switch ON.
Hot short of wiring harness Between ground and wiring harness between
3 Voltage Max. 1V
(contact with 24 V circuit) EGC1 (female) (4) – PCV1 (female) (1)
Between ground and wiring harness between
Voltage Max. 1V
EGC1 (female) (5) – PCV1 (female) (2)
switch still OFF.
4 Defective engine controller EGC1 (female) Resistance
Between (4) – (5) 2.3 – 5.3 z
Circuit diagram related to supply pump PCV1
D85EX, PX-15E0 79
Failure code [CA272] PCV1 disconnection: Disconnection 1
Action code Failure code Symptom PCV1 disconnection: Disconnection

Failure content • Disconnection has occurred in supply pump PCV1 circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
Defective supply pump
1 PCV1 (internal disconnec- PCV1 (male) Resistance
tion) Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
(disconnection or defective – PCV1 (female) (1) tance
Possible contact of connectors) Wiring harness between EGC1 (female) (5) Resis-
– PCV1 (female) (2) tance
standard values
switch still OFF.
3 Min. 1 Mz
Min. 1 Mz
EGC1 (female) (5) – PCV1 (female) (2) tance
switch still OFF.
Between (4) – (5) 2.3 – 5.3 z
80 D85EX, PX-15E0
Failure code [CA273] PCV2 short circuit: Short circuit 1
Action code Failure code Symptom PCV2 short circuit: Short circuit
Failure content • Short circuit has occurred in supply pump PCV2 circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
Defective supply pump PCV2 (male) Resistance
1
PCV2 (internal short circuit)
Between (1) – (2) 2.3 – 5.3 z
switch still OFF.
2 Min. 1 Mz
Possible
Wiring harness between EGC1 (female) (10) Resis-
– PCV2 (female) (2) tance
standard values
switch ON.
Hot short of wiring harness Between ground and wiring harness between
3 Voltage Max. 1V
(contact with 24 V circuit) EGC1 (female) (9) – PCV2 (female) (1)
Voltage Max. 1V
EGC1 (female) (10) – PCV2 (female) (2)
switch still OFF.
Between (9) – (10) 2.3 – 5.3 z
D85EX, PX-15E0 81
Failure code [CA274] PCV2 disconnection: Disconnection 1
Action code Failure code Symptom PCV2 disconnection: Disconnection

Failure content • Disconnection has occurred in supply pump PCV2 circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

Defective supply pump switch still OFF.
1 PCV2
PCV2 (male) Resistance
(internal disconnection)
Between (1) – (2) 2.3 – 5.3 z
2 Max. 1 z
(disconnection or defective – PCV2 (female) (1) tance
Possible Max. 1 z
causes and the – PCV2 (female) (2) tance
standard values a Prepare with starting switch OFF and diagnose with starting
when normal switch still OFF.
Defective harness grounding Between ground and wiring harness between Resis- Min.
3
(contact with ground circuit) EGC1 (female) (9) – PCV2 (female) (1) tance 1 Mz
Between ground and wiring harness between Resis- Min.
EGC1 (female) (10) – PCV2 (female) (2) tance 1 Mz
switch still OFF.
Between (9) – (10) 2.3 – 5.3 z
82 D85EX, PX-15E0
SEN00634-00

© 2006 KOMATSU
All Rights Reserved
84
SEN00635-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
Disconnection, short circuit ........................................................................................................... 3
Failure code [CA342] Engine controller data matching error: Matching error ...................................... 9
D85EX, PX-15E0 1
Failure code [CA351] Abnormal injector drive circuit: Abnormal circuit.............................................. 10

Failure code [CA352] Sensor power source (1) too low: Excessively low voltage detected .............. 12
Failure code [CA386] Sensor power source (1) too high: Excessively high voltage detected ........... 14
Failure code [CA441] Power source voltage too low: Excessively low voltage detected ................... 16
Failure code [CA442] Power source voltage too high: Excessively high voltage detected ................ 16
Failure code [CA449] Common rail pressure too high (2):
Excessively high pressure trouble occurred................................................................................ 17
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected.... 18
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected ...... 20
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected........ 20
Failure code [CA554] In-range error in common rail pressure sensor: In-range error ....................... 21
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected 22
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal ..................................... 26
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase....................... 28
Failure code [CA757] Loss of all engine controller data: Loss of all data........................................... 29
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal......................... 30
Failure code [CA1228] Abnormal EGR valve servo (1): EGR out of control ...................................... 32
Failure code [CA1625] Abnormal EGR valve servo (2): EGR out of control ...................................... 33
Failure code [CA1633] Abnormal KOMNET: Abnormal communication............................................. 34
Excessively high voltage detected .............................................................................................. 36
Excessively low voltage detected................................................................................................ 37
Loss of pressure feed detected................................................................................................... 38
Failure code [CA2271] EGR valve lift sensor too high: Excessively high voltage detected ............... 40
Failure code [CA2272] EGR valve lift sensor too low: Excessively low voltage detected .................. 42
Failure code [CA2351] EGR valve solenoid drive short circuit: Short circuit...................................... 44
Failure code [CA2352] EGR valve solenoid drive disconnection: Disconnection............................... 46
Failure code [CA2555] Intake air heater relay disconnection: Disconnection .................................... 47
Failure code [CA2556] Intake air heater relay short circuit: Short circuit ........................................... 48
2 D85EX, PX-15E0

Disconnection, short circuit 1
Action code Failure code Symptom Injector No. 1 system disconnection or short circuit: Disconnection,
CALL E03 CA322 of failure short circuit (Engine controller system)
Failure content • A disconnection or short circuit has occurred in injector No. 1 circuit.
Controller's
action
Symptoms that
• Output decreases.
appear on
• Speed is not stable.
machine
General
information

switch still OFF.
Defective injector No. 1 CN1 (male) Resistance
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
(disconnection or defective – CN1 (female) (1) tance
– CN1 (female) (2) tance
standard values
switch still OFF.
3 Min. 1 Mz
(contact with ground circuit) EGC1 (female) (45) – CN1 (female) (1) tance
Min. 1 Mz
EGC1 (female) (53) – CN1 (female) (2) tance
switch still OFF.
Between (45) – (53) 0.4 – 1.1 z
Circuit diagram related to injector No. 1
D85EX, PX-15E0 3
Failure code [CA323] Injector No. 5 system disconnection or short

circuit: Disconnection, short circuit 1
Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
standard values
switch still OFF.
3 Min. 1 Mz
Min. 1 Mz
switch still OFF.
Between (46) – (60) 0.4 – 1.1 z
4 D85EX, PX-15E0

Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
standard values
switch still OFF.
3 Min. 1 Mz
Min. 1 Mz
switch still OFF.
Between (55) – (52) 0.4 – 1.1 z
D85EX, PX-15E0 5

Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
standard values
switch still OFF.
3 Min. 1 Mz
Min. 1 Mz
switch still OFF.
Between (57) – (59) 0.4 – 1.1 z
6 D85EX, PX-15E0

Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
standard values
switch still OFF.
3 Min. 1 Mz
Min. 1 Mz
switch still OFF.
Between (54) – (51) 0.4 – 1.1 z
D85EX, PX-15E0 7

Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1
(internal defect)
Between (1) – (2) 0.4 – 1.1 z
2 Max. 1 z
standard values
switch still OFF.
3 Min. 1 Mz
Min. 1 Mz
switch still OFF.
Between (56) – (58) 0.4 – 1.1 z
8 D85EX, PX-15E0
Failure code [CA342] Engine controller data matching error: Matching

error 1
Action code Failure code Symptom Engine controller data matching error: Matching error
Failure content • Data matching error has occurred in engine controller.
Controller's
action
Symptoms that
appear on
engine is stopped.
machine
General
information
causes and the
standard values Carry out troubleshooting of [CA111].
when normal
D85EX, PX-15E0 9
Failure code [CA351] Abnormal injector drive circuit: Abnormal circuit 1
Action code Failure code Symptom Abnormal injector drive circuit: Abnormal circuit
Failure content • Abnormality has occurred in injector drive circuit.
Controller's • Operates with limited output. (Limits common rail pressure.)
Symptoms that
machine
General
information

Check the failure codes (codes for injector system trouble) that are
1 Defective related circuits displayed at the same time. If any other codes are displayed, carry
out troubleshooting for those codes.
Since a fuse or breaker of equipped machine side can be suspected
to be defective, directly check them.
2 Defective breaker
(If fuse is blown, or breaker is shut off, it is highly possible that a
defective grounding, etc. has occurred in the circuit.)
Possible
causes and the harness Wiring harness between EGC3 (female) (3), Resis-
3 Max. 1 z
standard values (disconnection or defective (4) – battery (+) tance
when normal contact of connectors) Wiring harness between EGC3 (female) (1), Resis-
Max. 1 z
(2) and ground tance
4
Min. 1 Mz
between EGC3 (female) (3), (4) – battery (+) tance
switch ON.
EGC3 Voltage
Between (3), (4) – (1), (2) 20 – 30V
10 D85EX, PX-15E0
Circuit diagram related to controller power source
D85EX, PX-15E0 11
Failure code [CA352] Sensor power source (1) too low: Excessively low
voltage detected 1
Action code Failure code Symptom Sensor power source (1) too low: Excessively low voltage detected
Failure content • Excessively low voltage has been detected in sensor power source 1 (5V) circuit.
Controller's • Common rail pressure sensor functions with limited output. (Limits common rail pressure.)
Symptoms that
machine
General
information
causes and the
when normal
12 D85EX, PX-15E0
Failure code [CA386] Sensor power source (1) too high: Excessively
Action code Failure code Symptom Sensor power source (1) too high: Excessively high voltage
Failure content • Excessively high voltage has been detected in the sensor power source 1 (5V) circuit.
Controller's • Common rail pressure sensor functions with limited output. (Limits common rail pressure.)
Symptoms that
machine
General
information

switch ON.
Defective sensor Disconnect a device

2 shown on the right.
(internal defect) Common rail
If the failure code dis- PFUEL connector
pressure sensor
appears, that device
is internally defective.
3 Max. 1 z
(disconnection or defective – PFUEL (female) (1) tance
Possible Max. 1 z
causes and the – PFUEL (female) (3) tance
4 Min. 1 Mz
(contact with ground circuit) EGC1 (female) (33) – PFUEL (female) (1) tance
Min. 1 Mz
EGC1 (female) (47) – PFUEL (female) (3) tance
switch still OFF.
5
(Harness internal short) (33) to PFUEL (female) (1) and wiring har- Resis-
Min. 1 Mz
ness from EGC1 (female) (47) to PFUEL tance
(female) (3)
switch ON.
EGC1 Voltage
Between (33) – (47) 4.75 – 5.25 V
14 D85EX, PX-15E0
Circuit diagram related to sensor power source 1 (5V)
D85EX, PX-15E0 15
Failure code [CA441] Power source voltage too low: Excessively low
voltage detected 1
Action code Failure code Symptom Power source voltage low trouble: Excessively low voltage detected
Failure content • Excessively low voltage has occurred in the power source voltage circuit.
Controller's
action
Symptoms that
appear on
engine is stopped.
machine
General
information
causes and the
when normal
Failure code [CA442] Power source voltage too high: Excessively high
voltage detected 1
Action code Failure code Symptom Power source voltage too high: Excessively high voltage detected
Failure content • Excessively high voltage has occurred in the power source voltage circuit.
Controller's
action
Symptoms that
appear on
engine is stopped.
machine
General
information
causes and the
when normal
16 D85EX, PX-15E0
Failure code [CA449] Common rail pressure too high (2): Excessively
high pressure trouble occurred 1
Action code Failure code Symptom Common rail pressure high trouble (2): Excessively high pressure
CALL E03 CA449 of failure trouble occurred (Engine controller system)
Failure content • Excessively high pressure (level 2) has been detected with common rail pressure sensor circuit.
Symptoms that
machine
General
information
causes and the
when normal
D85EX, PX-15E0 17
Failure code [CA451] Common rail pressure sensor too high:

Action code Failure code Symptom Common rail pressure sensor too high: Excessively high voltage
Failure content • Excessively high voltage has occurred in the common rail pressure sensor circuit.
Controller's • Operates with limited output.(Limits common rail pressure.)
Symptoms that
machine
General • The signal voltage of the common rail pressure sensor can be checked with the monitoring function.
information (Code: 36401 Common rail pressure sensor voltage)

Defective sensor power If failure code [CA352] or [CA386] is displayed, carry out trouble-
1
source circuit shooting for it first.
PFUEL Voltage
Defective common rail Between (1) – (3) Power source 4.75 – 5.25 V
2 pressure sensor Between (2) – (3) Signal 0.25 – 4.6 V
(internal defect)
Since the sensor voltage is measured with the harness being con-
causes and the switch still OFF.
standard values Wiring harness between EGC1 (female) (33) Resis-
Disconnection in wiring Max. 1 z
when normal – PFUEL (female) (1) tance
harness
3
– PFUEL (female) (2) tance
Max. 1 z
– PFUEL (female) (3) tance
switch still OFF.
Min. 1 Mz
Defective harness grounding EGC1 (female) (33) – PFUEL (female) (1) tance
4
Min. 1 Mz
Min. 1 Mz
18 D85EX, PX-15E0

switch still OFF.
(33) to PFUEL (female) (1) and wiring har- Resis-
Min. 1 Mz
(female) (2)
5
(Harness internal short) (33) to PFUEL (female) (1) and wiring har- Resis-
Possible Min. 1 Mz
causes and the ness from EGC1 (female) (47) to PFUEL tance
standard values (female) (3)
when normal Between wiring harness from EGC1 (female)
(25) to PFUEL (female) (2) and wiring har- Resis-
Min. 1 Mz
(female) (3)
6 Defective engine controller EGC1 Voltage
Between (33) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
Circuit diagram related to common rail pressure sensor
D85EX, PX-15E0 19
Failure code [CA452] Common rail pressure sensor too low:

Action code Failure code Symptom Common rail pressure sensor too low: Excessively low voltage
Failure content • Excessively low voltage has occurred in the common rail pressure sensor circuit.
Symptoms that
machine
General • The signal voltage of the common rail pressure sensor can be checked with the monitoring function.
information (Code: 36401 Common rail pressure sensor voltage)
causes and the
when normal
Failure code [CA553] Common rail pressure too high (1): Excessively
high pressure detected 1
Action code Failure code Symptom Common rail pressure high trouble (1): high pressure trouble
E02 CA553 of failure occurred (Engine controller system)
Failure content • Excessively high pressure (level 1) has been detected in the common rail pressure sensor circuit.
Controller's
action
Symptoms that
machine
General • Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)

Since the use of improper fuel can be suspected, check the fuel.
2 Improper fuel has been used.
(Viscosity is too high)
Since an electrical defect of common rail pressure sensor is sus-
Defective electrical system of
Possible 3 pected, carry out troubleshooting for the following code.
common rail pressure sensor
causes and the [CA451]
standard values Defective mechanical system
when normal Since a mechanical defect of common rail pressure sensor is sus-
4 of common rail pressure
pected, directly check the sensor.
sensor
Since a damage of spring, wear of seat or sticking of ball is sus-
5 Defective overflow valve
pected, directly check them.
6 Clogged overflow piping Since an overflow piping is suspected to be clogged, directly check it.
Since a mechanical defect of pressure limiter is suspected, directly
7 Defective pressure limiter
check the limiter.
20 D85EX, PX-15E0
Failure code [CA554] In-range error in common rail pressure sensor:

In-range error 1
Action code Failure code Symptom In-range error in common rail pressure sensor: In-range error
CALL E03 CA554 of failure occurred (Engine controller system)
Failure content • In-range error has occurred in common rail pressure sensor circuit.
Controller's • Operates with limited output.(Limits common rail pressure.)
Symptoms that
machine
General
information
causes and the
when normal
D85EX, PX-15E0 21
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss
of pressure feed detected 1
Action code Failure code Symptom Loss of pressure feed from supply pump (1): Loss of pressure feed
Failure content • Loss of pressure feed (level 1) from supply pump has occurred.
Controller's
• Limits common rail pressure.
action
Symptoms that
appear on
machine
General
information

2 Improper fuel has been used. Since the use of improper fuel is suspected, directly check the fuel.
a See “Note 1” for the contents of diagnosis. See Testing and
adjusting “Testing fuel pressure” for the pressure inspection of the
fuel low pressure circuit.
Defective low pressure
3 Pressure in fuel low pressure
circuit device
circuit Min. 0.15 MPa
(At high idle or under the load {Min. 1.5 kg/cm2}
equivalent to rating (stalling))
4 Clogged filter or strainer a See “Note 2” for the contents of diagnosis.
Since an electrical defect of supply pump PCV is suspected, carry
Defective electrical system of
5 out troubleshooting for the following codes.
supply pump PCV
[CA271], [CA272], [CA273], and [CA274]
Defective common rail Since a defect of common rail pressure sensor is suspected, check
Possible 6
pressure sensor for a damage in harnesses.
causes and the
standard values a As for testing an amount of pressure limiter leak, see testing and
when normal adjusting “Testing fuel return and leak amount”.
7 Defective pressure limiter Max. 10 cc/min.
Pressure limiter leak amount [Equivalent to rated operation
(stalling)]
a As for the test relating to return (spill) limit amount of injector, see
Testing and adjusting “Testing fuel return and leak amount”.
Speed under the conditions
which are equivalent to rated Injector return (spill) limit amount
operation (stalling)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Supply pump can be suspected to be defective if no problem is
9 Defective supply pump
found in causes 1 – 8.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed”.
22 D85EX, PX-15E0
Note 1: When low-pressure circuit is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
D85EX, PX-15E0 23
Check sheet for no-pressure feed
Model Operation No.

Model and serial No. # Date inspected / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual inspections Pass Fail

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation) Pass Fail
3 Checking failure codes / / / /
Checking monitoring information
Standard value
Code Display item Condition for inspection Unit Measured value Pass Fail
(reference value)
Low idle rpm 750(+50/0)
*1 Engine speed High idle rpm 2,100 ± 50
Equivalent to rating rpm 1,900
Low idle % 0
*2 Throttle speed
High idle % 100
Command for fuel injec-
*3 Equivalent to rating mm3 — — —
tion rate
Command for common
*4 Equivalent to rating MPa
4 rail pressure
Fuel pressure in
*5 Equivalent to rating MPa
common rail
Low idle CA — — —
Command for
*6 High idle CA — — —
fuel injection timing
Equivalent to rating CA — — —
*7 Boost pressure Equivalent to rating kPa — — —
Coolant temperature
*8 Low idle °C — — —
(high temperature)
Coolant temperature
*9 Low idle °C — — —
(low temperature)
*10 Fuel temperature Low idle °C — — —
Checking reduced cylinder mode operation (engine speed)
Func- Standard value
Cut-out cylinder Condition for inspection Unit Measured value Pass Fail
tion (reference value)
Cylinder No. 1 Low idle rpm — — —
5 Cylinder No. 2 Low idle rpm — — —

*11
Standard value
C. Inspection of pressure in fuel circuit Condition for inspection Unit Measured value Pass Fail
(reference value)
Pressure in fuel low pressure cir- At high idle or under the load equiva- MPa Min. 0.15
6
cuit lent to rating (stalling) {kg/cm2} {Min. 1.5}
24 D85EX, PX-15E0
D. Inspection of strainer and filter Pass Fail

7 Visual inspection of strainer
8 Visual inspection of gauze filter
9 Visual inspection of fuel filter
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return Standard value

Condition for inspection Unit Measured value Pass Fail
amount (reference value)
Pressure limiter Under the load equivalent to rating
11 cc/min Max 10
leak amount (stalling)
Equivalent to rating: 1,600 rpm cc/min 960
Equivalent to rating: 1,700 rpm cc/min 1,020 Rotation speed:
12 Injector return amount Equivalent to rating: 1,800 rpm cc/min 1,080
Equivalent to rating: 1,900 rpm cc/min 1,140 Return amount:
Equivalent to rating: 2,000 rpm cc/min 1,200
Inspection items *1 – *10 of B-4:

When inspecting with the monitoring function, see “Monitoring code table”.
Inspection items *11 of B-5:
When inspecting with the monitoring function, see “Adjustment mode table”.
Equivalent to rating: 1) Engine at full throttle, 2) Relieve pressure in each work equipment cylinder
D85EX, PX-15E0 25
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal

signal 1
Action code Failure code Symptom Abnormal engine Ne speed sensor: Abnormal signal
Failure content • Abnormal signal of the engine Ne speed sensor has been detected.
Controller's • Operates using Bkup speed sensor signal.
Symptoms that
• Engine stops during operation (when Bkup speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Bkup speed sensor is defective at the same time).
machine
General
information

Defective sensor power If failure code [CA238] is displayed at the same time, carry out trou-
1
source circuit bleshooting for it first.
switch still OFF.
Max. 1 z
harness – NE (female) (1) tance
2
– NE (female) (2) tance
Max. 1 z
– NE (female) (3) tance
switch still OFF.
Min. 1 Mz
Defective harness grounding EGC1 (female) (16) – NE (female) (1) tance
3
Min. 1 Mz
EGC1 (female) (48) – NE (female) (2) tance
Possible causes Between ground and wiring harness between Resis-
Min. 1 Mz
and the EGC1 (female) (27) – NE (female) (3) tance
Resis-
tance
Harness short
tance
Resis-
tance
Defective mounting of sensor Since defective mounting of Ne speed sensor (improper gap) or
5 or defective parts for speed defective parts for speed detection (flywheel) can be suspected,
detection directly check it.
Engine Ne speed sensor can be suspected to be defective if no
Defective engine Ne speed
6 problem is found in causes 1 – 5 (since this is an internal defect, it
sensor
cannot be diagnosed).
diagnosed).
26 D85EX, PX-15E0
Circuit diagram related to engine Ne speed sensor
D85EX, PX-15E0 27
Failure code [CA731] Abnormal engine Bkup speed sensor phase:

Abnormal phase 1
Action code Failure code Symptom Abnormal engine Bkup speed sensor phase: Abnormal phase
Failure content • Abnormal phase has been detected in the engine Bkup sensor circuit.
Controller's • Operates using engine Ne speed sensor signal.
Symptoms that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
General
information

Since a defect of engine Ne speed sensor can be suspected, carry
Possible Defective engine Ne speed
1 out troubleshooting for the following code.
causes and the sensor circuit
[CA689]
standard values
when normal Since a defect of engine Bkup speed sensor can be suspected,
Defective engine Bkup
2 carry out troubleshooting for the following code.
speed sensor system
[CA778]
28 D85EX, PX-15E0
Failure code [CA757] Loss of all engine controller data: Loss of all data1
Action code Failure code Symptom Loss of all engine controller data: Loss of all data
Failure content • Loss of all data in engine controller has been detected.
Controller's
action
Symptoms that
appear on
engine is stopped.
machine
General
information
causes and the
when normal
D85EX, PX-15E0 29
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal

Bkup signal 1
Action code Failure code Symptom Abnormal engine Bkup speed sensor: Abnormal Bkup signal
Failure content • Abnormal engine Bkup speed sensor signal has been detected.
Controller's • Operates using Ne speed sensor signal.
Symptoms that
• Engine stops during operation (when Ne speed sensor is defective at the same time).
appear on
• Engine cannot be started while stopping (when Ne speed sensor is defective at the same time).
machine
General
information

1
switch still OFF.
Max. 1 z
harness – G (female) (1) tance
2
– G (female) (2) tance
Max. 1 z
– G (female) (3) tance
switch still OFF.
Min. 1 Mz
Defective harness grounding EGC1 (female) (37) – G (female) (1) tance
3
Min. 1 Mz
EGC1 (female) (47) – G (female) (2) tance
Possible Between ground and wiring harness between Resis-
Min. 1 Mz
causes and the EGC1 (female) (26) – G (female) (3) tance
Resis-
(37) to G (female) (1) and wiring harness Min. 1 Mz
tance
from EGC1 (female) (47) to G (female) (2)
Harness short
tance
Resis-
tance
Defective mounting of sensor Since defective mounting of Bkup speed sensor (improper gap) or
5 or defective parts for speed defective parts for speed detection (in supply pump) can be sus-
detection pected, directly check it.
Engine Bkup speed sensor can be suspected to be defective if no
Defective engine Bkup
6 problem is found in causes 1 – 5 (since this is an internal defect, it
speed sensor
cannot be diagnosed).
diagnosed).
30 D85EX, PX-15E0
Circuit diagram related to engine Bkup speed sensor
D85EX, PX-15E0 31
Failure code [CA1228] Abnormal EGR valve servo (1): EGR out of
control 1
Action code Failure code Symptom Abnormal EGR valve servo (1): EGR out of control
Failure content • An abnormality has occurred in EGR valve servo (level 1).
Controller's • Executes open loop control.
Symptoms that
appear on
machine
General
information

Check the failure codes that are displayed at the same time.
1 Defective related circuits If any other codes are displayed, carry out troubleshooting for those
codes.
a See Testing and adjusting “Testing oil pressure” for engine oil
pressure inspection.
Engine Engine oil pressure
Defective engine hydraulic
2 Low idle 0.03 MPa {0.3 kg/cm2}
system (main circuit)
High idle 0.18 MPa {1.8 kg/cm2}
Possible If engine oil pressure is out of range, carry out troubleshooting for
causes and the mechanical system (S-12 Oil pressure drops).
standard values
when normal Defective oil pump for EGR Since the oil pump relief valve for the EGR valve circuit can be sus-
3
valve pected to be defective, directly check it.
Defective hydraulic feed Since the hydraulic feed piping for the EGR valve circuit can be sus-
4
piping for EGR valve pected to be defective, directly check it.
Defective hydraulic return Since the hydraulic return piping for the EGR valve circuit can be
5
piping for EGR valve suspected to be defective, directly check it.
Since a mechanical defect of EGR valve can be suspected, directly
6 Defective EGR valve
check it.
diagnosed).
32 D85EX, PX-15E0
Failure code [CA1625] Abnormal EGR valve servo (2): EGR out of
control 1
Action code Failure code Symptom Abnormal EGR valve servo (2): EGR out of control
Failure content • An abnormality has occurred in EGR valve servo (level 2).
• Operates by limiting output.
Controller's
• Closes the EGR valve.
action
Symptoms that
machine
General
information
causes and the
when normal
D85EX, PX-15E0 33
Failure code [CA1633] Abnormal KOMNET: Abnormal communication 1
Action code Failure code Symptom Abnormal KOMNET: Abnormal communication

• Engine controller detected an abnormal communication in the KOMNET communication circuit
Failure content
between steering and transmission controller and monitor panel.
• Operate in a default mode.
Controller's
• When the cause of the failure has been eliminated, it returns to normal.
action
Symptoms that • Machine may not operate normally because the information which are exchanged through KOMNET
appear on communication are not transmitted properly.
machine (A symptom of failure depends on the location where it occurs.)
General
information

switch still OFF.
Wiring harness between S04 (female) (1) (2)
– EGC2 (female) (46), S04 (female) (1) (2) –
Resis-
Disconnection in wiring PTC2 (female) (32), S04 (female) (1) (2) – Max. 1 z
tance
harness CA2 (female) (A) and S04 (female) (1) (2) –
1
(disconnection or defective CA1 (female) (A)
contact of connectors) Wiring harness between S04 (female) (3) (4)
– EGC2 (female) (47), S04 (female) (3) (4) –
Resis-
PTC2 (female) (22), S04 (female) (3) (4) – Max. 1 z
tance
CA2 (female) (B) and S04 (female) (3) (4) –
CA1 (female) (B)
switch still OFF.
Between ground and wiring harnesses
between S04 (female) (1) (2) – EGC2
Possible (female) (46), S04 (female) (1) (2) – PTC2
causes and the Resis-
(female) (32), S04 (female) (1) (2) – CA2 Min. 1 Mz
(female) (A), S04 (female) (1) (2) – CA1
when normal Defective harness grounding (female) (A) and S04 (female) (1) (2) – SRV
2
(contact with ground circuit) (male) (3)
(female) (47), S04 (female) (3) (4) – PTC2
Resis-
(female) (22), S04 (female) (3) (4) – CA2 Min. 1 Mz
tance
(female) (B), S04 (female) (3) (4) – CA1
(female) (B) and S04 (female) (3) (4) – SRV
(male) (10)
switch ON.
Hot short of wiring harness between S04 (female) (1) (2) – EGC2
3 (female) (46), S04 (female) (1) (2) – PTC2
(contact with 24 V circuit) Max.
(female) (32), S04 (female) (1) (2) – CA2 Voltage
5.5 V
(female) (A), S04 (female) (1) (2) – CA1
(female) (A) and S04 (female) (1) (2) – SRV
(male) (3)
34 D85EX, PX-15E0

(female) (47), S04 (female) (3) (4) – PTC2
Hot short of wiring harness Max.
3 (female) (22), S04 (female) (3) (4) – CA2 Voltage
(contact with 24 V circuit) 5.5 V
Possible (female) (B) and S04 (female) (3) (4) – SRV
causes and the (male) (10)
when normal Defective CAN terminal
resistance switch still OFF.
4
(internal short circuit and dis- CA1 (male) and CA2 (male) Resistance
connection) Between (A) – (B) 120 ± 12 z
5 Defective engine controller found in causes 1 – 4. (Since this is an internal defect, it cannot be
diagnosed.)
Circuit diagram related to CAN communication
D85EX, PX-15E0 35
Action code Failure code Decelerator pedal sensor power source too high: Excessively high
Symptom
voltage detected
CALL E03 CA2185 of failure
(Engine controller system)
• Excessively high voltage (Min. 5.25 V) is detected in the decelerator pedal sensor power source cir-
Failure content
cuit.
Controller's
action
with 100% value.
Symptoms that
machine
General
information

switch still OFF.
Between EGC2 (female) (22) – all pins of Resis-
Harness short Min. 1 Mz
1 EGC2 (female) (with DCL disconnected) tance
(Harness internal short)
Resis-
Possible tance
from EGC2 (female) (22) to DCL (female) (A)
causes and the
standard values
when normal
tions directly.
connector
insulation
diagnosed.)
36 D85EX, PX-15E0
Action code Failure code Decelerator pedal sensor power source too low: Excessively low
Symptom
voltage detected
Failure content • Excessively low voltage is detected in the decelerator pedal sensor (5V) power source circuit.
Controller's
action
with 100% value.
Symptoms that
machine
General
information

1
Min. 1 Mz
EGC2 (female) (22) – DCL (female) (A) tance
Harness short switch still OFF.
2
Possible (Harness internal short) Between EGC2 (female) (9) – all pins of Resis-
Min. 1 Mz
causes and the CE02 (female) (with DCL also disconnected) tance
standard values Since the connections among decelerator pedal – body harness –
when normal engine controller are suspected to be defective, Check the connec-
tions directly.
connector
insulation
diagnosed.)
D85EX, PX-15E0 37
Loss of pressure feed detected 1
Action code Failure code Loss of pressure feed from supply pump (2): Loss of pressure feed
Symptom
detected
Failure content • Loss of pressure feed (2) occurred in the common rail circuit.
Controller's • Operates with limited output.
Symptoms that • Engine is hard to start.
appear on • Exhaust gas color becomes black.
machine • Output decreases.
General • Common rail pressure can be checked with the monitoring function.
information (Code: 36400 Common rail pressure)
causes and the
standard values 1 Carry out troubleshooting of [CA559].
when normal
38 D85EX, PX-15E0
Failure code [CA2271] EGR valve lift sensor too high: Excessively high
voltage detected 1
Action code Failure code Symptom EGR valve lift sensor too high: Excessively high voltage detected
Failure content • Excessively high voltage has occurred in the EGR valve lift sensor circuit.
Controller's
action
Symptoms that
machine
General
information

1
SEGR Voltage
Defective EGR valve lift sen-
2 sor Between (1) – (2) Power source 4.75 – 5.25 V
(internal defect) Since the sensor voltage is measured with the harness being con-
Possible switch still OFF.
causes and the
standard values Disconnection in wiring Wiring harness between EGC1 (female) (37) Resis-
Max. 1 z
when normal harness – SEGR (female) (1) tance
3
– SEGR (female) (2) tance
Max. 1 z
– SEGR (female) (3) (4) tance
switch still OFF.
Min. 1 Mz
Defective harness grounding EGC1 (female) (37) – SEGR (female) (1) tance
4
Min. 1 Mz
EGC1 (female) (47) – SEGR (female) (2) tance
Min. 1 Mz
EGC1 (female) (19) – SEGR (female) (3) (4) tance
40 D85EX, PX-15E0

switch still OFF.
(37) to SEGR (female) (1) and wiring har- Resis-
Min. 1 Mz
ness from EGC1 (female) (47) to SEGR tance
(female) (2)
Possible 5
(Harness internal short) (37) to SEGR (female) (1) and wiring har- Resis-
standard values (female) (3) (4)
when normal
(47) to SEGR (female) (2) and wiring har- Resis-
Min. 1 Mz
(female) (3) (4)
EGC1 Voltage
Between (37) – (47) 4.75 – 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
D85EX, PX-15E0 41
Failure code [CA2272] EGR valve lift sensor too low: Excessively low
voltage detected 1
Action code Failure code Symptom EGR valve lift sensor too low: Excessively low voltage detected
Failure content • Excessively low voltage has occurred in the EGR valve lift sensor circuit.
Controller's
action
Symptoms that
machine
General
information
causes and the
when normal
42 D85EX, PX-15E0
Failure code [CA2351] EGR valve solenoid drive short circuit: Short
circuit 1
Action code Failure code Symptom EGR valve solenoid drive short circuit: Short circuit
Failure content • Short circuit has occurred in the drive circuit of EGR valve solenoid.
Controller's
action
Symptoms that
machine
General
information

Defective EGR valve sole- switch still OFF.
1 noid
EGR (male) Resistance
(internal defect)
Between (1) – (2) 10 – 21 z
2 Max. 1 z
(disconnection or defective – EGR (female) (1) tance
Max. 1 z
– EGR (female) (2) tance
causes and the
standard values Defective harness grounding Between ground and wiring harness EGC1 Resis-
3 Min. 1 Mz
when normal (contact with ground circuit) (female) (22) – EGR (female) (1) tance
Between ground and wiring harness EGC1 Resis-
Min. 1 Mz
(female) (11) – EGR (female) (2) tance
switch ON.
Hot short of wiring harness Between ground and wiring harness EGC1
4 Voltage Max. 1V
(a contact with 24V circuit) (female) (22) – EGR (female) (1)
Between ground and wiring harness EGC1
Voltage Max. 1V
(female) (11) – EGR (female) (2)
switch still OFF.
EGC1 (female) Resistance
Between (22) – (11) 10 – 21 z
44 D85EX, PX-15E0
Circuit diagram related to EGR valve solenoid & lift sensor
D85EX, PX-15E0 45
Failure code [CA2352] EGR valve solenoid drive disconnection:

Disconnection 1
Action code Failure code Symptom EGR valve solenoid drive disconnection: Disconnection
Failure content • Disconnection has occurred in the drive circuit of EGR valve solenoid.
Controller's
action
Symptoms that
machine
General
information
causes and the
when normal
46 D85EX, PX-15E0
Failure code [CA2555] Intake air heater relay disconnection:

Disconnection 1
Action code Failure code Symptom Intake air heater relay disconnection: Disconnection
Failure content • Disconnection has occurred in intake air heater relay circuit.
Controller's
• Takes no particular action.
action
Symptoms that
appear on • Startability of engine deteriorates in low temperature.
machine
General
information
causes and the
when normal
D85EX, PX-15E0 47
Failure code [CA2556] Intake air heater relay short circuit: Short circuit1
Action code Failure code Symptom Intake air heater relay short circuit: Short circuit
Failure content • Short circuit has occurred in intake air heater relay circuit.
Controller's
• Takes no particular action.
action
Symptoms that
appear on • Startability of engine deteriorates in low temperature.
machine
General
information

Defective intake air heater switch still OFF.
1 relay
RHR (male) Resistance
(internal defect)
Between (1) – (2) 200 – 400 z
2 Max. 1 z
Possible (disconnection or defective – RHR (female) (1) tance
causes and the contact of connectors) Wiring harness between RHR (female) (2) Resis-
Max. 1 z
standard values and ground tance
3
(contact with ground circuit) Between ground and wiring harness EGC2 Resis-
Min. 1 Mz
(female) (40) – RHR (female) (1) tance
switch ON.
4 Defective engine controller EGC2 Heater relay Voltage
Between (40) and At working condition 20 – 30V
ground At stopping condition Max. 1V
48 D85EX, PX-15E0
Circuit diagram related to intake air heater relay
D85EX, PX-15E0 49
SEN00635-00

© 2006 KOMATSU
All Rights Reserved
50
SEN00636-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
Failure code [D110KA] Battery relay: Disconnection ........................................................................... 4
Failure code [D110KB] Battery relay: Short circuit ............................................................................... 6
Failure code [D130KA] Neutral safety relay: Disconnection ................................................................ 8
Failure code [D130KB] Neutral safety relay: Short circuit .................................................................. 10
Failure code [D161KA] Back-up alarm relay: Disconnection ............................................................. 12
Failure code [D161KB] Back-up alarm relay: Short circuit ................................................................. 14
Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection............................ 16
Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit ............................... 18
Failure code [D811KR] KOMTRAX controller CAN communication: Defective communication......... 20
Failure code [DAFRKR] Monitor panel CAN communication: Defective communication ................... 24
Failure codes [DAQ0KT] and [DB30KT] Steering and transmission controller:
Abnormal controller memory information .................................................................................... 27
D85EX, PX-15E0 1
Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller:
Power source voltage drop and input.......................................................................................... 28
Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller:
5 V power source (1): Power source voltage drop and input ...................................................... 32
Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor
24 V power source: Power source voltage drop and input.......................................................... 34
Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection:
Inconsistency in model select signal ........................................................................................... 38
Failure codes [DAQRKR] and [DB3RKR] Steering and transmission controller
CAN communication: Defective communication ......................................................................... 40
Failure code [DB2RKR] Engine controller CAN communication: Defective communication .............. 44
Abnormal controller memory information .................................................................................... 47
Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission controller:
Failure code [DB32KK] [DAQ2KK] Load power source of steering and
transmission controller: Power source voltage drop and input.................................................... 47
Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor
24 V power source: Power source voltage drop and input.......................................................... 47
Failure codes [DB39KQ] and [DAQ9KQ] Steering and transmission controller model selection:
Inconsistent model selection signal............................................................................................. 47
Failure codes [DB3RKR] and [DAQRKR] Steering and transmission controller
CAN communication: Defective communication ......................................................................... 47
Failure code [DD12KA] Shift up switch: Disconnection...................................................................... 48
Failure code [DD12KB] Shift up switch: Short circuit ......................................................................... 50
Failure code [DD13KA] Shift down switch: Disconnection ................................................................. 52
Failure code [DD13KB] Shift down switch: Short circuit..................................................................... 54
Failure codes [DD14KA] and [DDQ2KA] Parking lock switch: Disconnection.................................... 56
Failure codes [DD14KB] and [DDQ2KB] Parking lock switch: Short circuit ....................................... 58
Failure codes [DDQ2KA] and [DD14KA] Parking lock switch: Disconnection.................................... 60
Failure codes [DDQ2KB] and [DD14KB] Parking lock switch: Short circuit ....................................... 60
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range ......... 62
Failure code [DGT1KA] Power train oil temperature sensor: Disconnection ...................................... 64
Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range ...... 66
Failure code [DH22KA] HSS and work equipment pump oil pressure sensor: Disconnection........... 68
Failure code [DH22KB] HSS and work equipment pump oil pressure sensor: Short circuit .............. 70
Failure code [DK10KA] Fuel dial: Disconnection................................................................................ 72
Failure code [DK10KB] Fuel dial: Short circuit ................................................................................... 74
Failure code [DK30KA] Steering potentiometer (1): Disconnection.................................................... 76
Failure code [DK30KB] Steering potentiometer (1): Short circuit ....................................................... 78
Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range ......................... 80
Failure code [DK30KZ] Steering potentiometer: Disconnection or short circuit (Double failure) ........ 80
Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal ....................................... 81
Failure code [DK31KA] Steering potentiometer (2): Disconnection.................................................... 82
Failure code [DK31KB] Steering potentiometer (2): Short circuit ....................................................... 84
Failure code [DK40KA] Brake potentiometer: Disconnection............................................................. 86
Failure code [DK40KB] Brake potentiometer: Short circuit ................................................................ 87
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range ............ 88
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or
short circuit (Double failure) ........................................................................................................ 88
2 D85EX, PX-15E0
Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal.......................... 89

Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection ...................................... 90
Failure code [DK56KB] Forward-reverse potentiometer (1): Short circuit.......................................... 92
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection ...................................... 94
Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit.......................................... 96
D85EX, PX-15E0 3

Failure code [D110KA] Battery relay: Disconnection 1
Action code Failure code Symptom Battery relay: Disconnection

— D110KA of failure (Steering and transmission controller system)
Failure content • Current does not flow during output to battery relay circuit.
Controller's
• Stops output to battery relay circuit.
action
Symptoms that
appear on • Problem may occur in data writing to ROM (non volatile memory) of each controller.
machine
• Output state (voltage) to battery relay can be checked in monitoring mode.
General
(Code 60600: Battery relay drive voltage)
information

switch still OFF.
Defective battery relay
1 Battery relay Continuity
Between SW terminal and
Continue
ground BRE terminal
Possible harness Wiring harnesses between PTC3 (female) Resis-
causes and the 2 Max. 1 z
(disconnection or defective (4) – battery relay SW terminal tance
standard values contact of connectors) Wiring harnesses between ground BRE ter- Resis-
when normal Max. 1 z
minal and ground tance
switch ON.
Hot short of wiring harness Between ground and wiring harnesses
3
(contact with 24 V circuit) between PTC3 (female) (4) – battery relay
Voltage Max. 1V
SW terminal and DS1 (female) (8) – RSD
(female) (1)
Defective steering and
4 Since this is an internal defect, it cannot be diagnosed.
4 D85EX, PX-15E0
Circuit diagram related to battery relay
D85EX, PX-15E0 5
Failure code [D110KB] Battery relay: Short circuit 1
Action code Failure code Symptom Battery relay: Short circuit

— D110KB of failure (Steering and transmission controller system)
Failure content • Abnormal current flowed during the output to battery relay circuit.
Controller's
• Stop output to battery relay circuit.
action
Symptoms that
appear on • Problem may occur in data writing to ROM (non volatile memory) of each controller.
machine
• Output state (voltage) to battery relay can be checked in monitoring mode.
General
(Code 60600: Battery relay drive voltage)
information
• Duplication of failure code: turn starting switch from ON o OFF.

switch still OFF.
Battery relay Continuity
1 Between SW terminal and BRE
(internal disconnection) Continue
terminal
Between SW terminal and
Min. 1 Mz
Possible ground
Disconnection in wiring
when normal
harness Between ground and wiring harnesses
2
(disconnection or defective between PTC3 (female) (4) – battery relay Resis-
contact of connectors) Min. 1 Mz
SW terminal and DS1 (female) (8) – RSD tance
(female) (1)
Defective diode
3 See “Inspection procedure of diode” (Testing and adjusting).
(Internal short circuit)
6 D85EX, PX-15E0
Circuit diagram related to battery relay
D85EX, PX-15E0 7
Failure code [D130KA] Neutral safety relay: Disconnection 1
Action code Failure code Symptom Neutral safety relay: Disconnection

E02 D130KA of failure (Steering and transmission controller system)
Failure content • The voltage of the neutral safety relay circuit is inconsistent with the output state of the controller.
Controller's • Flashes warning lamp and turns on alarm buzzer
action • Stop ground output to neutral safety relay circuit.
Symptoms that
appear on • Engine can not be started, or engine can be started regardless of position of parking brake lever.
machine
• Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
General
• Duplication of failure code: Turn starting switch ON + operate parking brake lever (to free or lock position)
information
a This failure code identifies a detected abnormality in primary side (coil side) of neutral safety relay,
but an abnormality in secondary side (contact side) can not be detected.

Defective neutral safety relay switch still OFF.
1
(internal disconnection) NSF (male) Resistance
Between (1) – (2) 200 – 400 z
harness Wiring harness between PTC2 (female) (8) – Resis-
2 Max. 1 z
(disconnection or defective NSF (female) (2) tance
contact of connectors) Wiring harness between NSF (female) (1) – Resis-
Max. 1 z
Possible starting switch ACC (270) tance
standard values Defective harness grounding switch still OFF.
when normal 3
Min. 1 Mz
PTC2 (female) (8) – NSF (female) (2) tance
Hot short of wiring harness switch ON, parking brake lever lock position.
4
(contact with 24 V circuit) Between ground and wiring harness between
Voltage Max. 1V
PCT2 (female) (8) – NSF (female) (2)
switch ON.
Defective steering and PTC2 Parking lever Voltage
5
Between (8) and Free position 20 – 30 V
ground Lock position Max. 1V
8 D85EX, PX-15E0
Circuit diagram related to neutral safety relay
D85EX, PX-15E0 9
Failure code [D130KB] Neutral safety relay: Short circuit 1
Action code Failure code Symptom Neutral safety relay: Short circuit
E02 D130KB of failure (Steering and transmission controller system)
Failure content • Abnormal current flowed when neutral safety relay circuit is output.
action • Stops ground output to neutral safety relay circuit.
Symptoms that
appear on • Engine does not start.
machine
• Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
General
• Duplication of failure code: Turn starting switch ON + operate parking brake lever (to lock position)
information
a This failure code identifies a detected abnormality in primary side (coil side) of neutral safety relay,

Defective neutral safety relay switch still OFF.
1
(internal disconnection) NSF (male) Resistance
Between (1) – (2) 200 – 400 z
causes and the Defective harness grounding switch still OFF.
2
standard values (contact with ground circuit) Between ground and wiring harness between Resis-
when normal Min. 1 Mz
PTC2 (female) (8) – NSF (female) (2) tance
switch ON.
Defective steering and PTC2 Parking lever Voltage
3
Between (8) and Free position 20 – 30 V
ground Lock position Max. 1V
10 D85EX, PX-15E0
Circuit diagram related to neutral safety relay
D85EX, PX-15E0 11
Failure code [D161KA] Back-up alarm relay: Disconnection 1
Action code Failure code Symptom Backup alarm relay: Disconnection

E01 D161KA of failure (Steering and transmission controller system)
Failure content • The voltage of the backup alarm relay circuit is inconsistent with the output state of the controller.
Controller's
• Stops ground output to backup alarm relay circuit.
action
Symptoms that
• The backup alarm does not turn on, or backup alarm turns on regardless of positions of steering,
appear on
directional and gear shift lever.
machine
• Output state (voltage) to backup alarm relay can be checked in monitoring mode.
(Code 70400: Backup alarm relay drive voltage)
General • Duplication of failure code: Turn starting switch ON + shift steering, directional and gear shift lever to
information neutral
a This failure code identifies a detected abnormality in primary side (coil side) of backup alarm relay,

If fuse is blown, it is highly possible that a defective harness ground-
1 Defective fuse FS2-3
ing, etc. has occurred in the circuit.
Defective backup alarm relay switch still OFF.
2
(internal disconnection) BKA (male) Resistance
Between (1) – (2) 200 – 400 z
harness Wiring harness between PTC2 (female) (18) Resis-
3 Max. 1 z
(disconnection or defective – BKA (female) (2) tance
contact of connectors) Wiring harnesses between BKA (female) (1) Resis-
Max. 1 z
Possible – FS2-3 outlet tance
when normal Defective harness grounding Between ground and wiring harness between Resis-
4 Min. 1 Mz
(contact with ground circuit) PTC2 (female) (18) – BKA (female) (2) tance
Between ground and wiring harnesses of Resis-
Min. 1 Mz
BKA (female) (1) – FS2-3 outlet tance
Hot short of wiring harness switch ON, PCCS lever in reverse position.
5
Voltage Max. 1V
PTC2 (female) (18) – BKA (female) (2)
switch ON.
6
Between (18) and At neutral 20 – 30 V
ground At reverse Max. 1V
12 D85EX, PX-15E0
Circuit diagram related to back-up alarm relay
D85EX, PX-15E0 13
Failure code [D161KB] Back-up alarm relay: Short circuit 1
Action code Failure code Symptom Backup alarm relay: Short circuit
E01 D161KB of failure (Steering and transmission controller system)
Failure content • Abnormal current flowed when backup alarm relay circuit is output.
Controller's
• Stops ground output to backup alarm relay circuit.
action
Symptoms that
appear on • Backup alarm does not turn on.
machine
• Output state (voltage) to backup alarm relay can be checked in monitoring mode.
(Code 70400: Backup alarm relay drive voltage)
General • Duplication of failure code: Turn starting switch ON + Shift steering, directional and gear shift lever
information (to reverse)
a This failure code identifies a detected abnormality in primary side (coil side) of backup alarm relay,

Defective backup alarm relay switch still OFF.
1
(internal disconnection) BKA (male) Resistance
Between (1) – (2) 200 – 400 z
causes and the Defective harness grounding switch still OFF.
2
when normal Min. 1 Mz
PTC2 (female) (18) – BKA (female) (2) tance
switch ON.
3
Between (18) and At neutral 20 – 30 V
ground At reverse Max. 1V
14 D85EX, PX-15E0
Circuit diagram related to back-up alarm relay
D85EX, PX-15E0 15
Failure code [D190KA] Engine controller ACC signal cutout relay:

Disconnection 1
Action code Failure code Symptom Engine controller ACC signal cutout relay: Disconnection
— D190KA of failure (Steering and transmission controller system)
• The voltage of the engine controller ACC signal cutout relay circuit is not inconsistent with the output
Failure content
state of the controller.
Controller's
• No particular action
action
Symptoms that
appear on • Engine cannot be stopped (option function) by steering and transmission controller.
machine
General a This failure code identifies a detected abnormality in primary side (coil side) of engine controller ACC
information signal cutout relay, but an abnormality in secondary side (contact side) can not be detected.

Defective engine controller switch still OFF.
1 ACC signal cutout relay
ACT (male) Resistance
Between (1) – (2) 200 – 400 z
2 Max. 1 z
(disconnection or defective – ACT (female) (2) tance
contact of connectors) Wiring harness between ACT (female) (1) – Resis-
Max. 1 z
starting switch ACC (270) tance
switch still OFF.
Possible
causes and the Between ground and wiring harness
Resis-
standard values Defective harness grounding between PTC2 (female) (19) – ACT (female) Min. 1 Mz
3 tance
when normal (contact with ground circuit) (2)
Resis-
between ACT (female) (1) – starting switch Min. 1 Mz
tance
ACC (270)
switch ON, when the stop signal is input.
Hot short of wiring harness
4 Between ground and wiring harness
(contact with 24 V circuit)
between PTC2 (female) (19) – ACT (female) Voltage Max. 1 V
(2)
switch ON.
Defective steering and PTC2 Stop signal Voltage
5
Between (19) and Input Max. 1 V
ground No input 20 – 30 V
16 D85EX, PX-15E0
Circuit diagram related to engine controller ACC signal cutout relay
D85EX, PX-15E0 17
Failure code [D190KB] Engine controller ACC signal cutout relay: Short
circuit 1
Action code Failure code Symptom Engine controller ACC signal cutout relay: Short circuit
— D190KB of failure (Steering and transmission controller system)
Failure content • Abnormal current flowed in the engine controller ACC signal cutout relay circuit.
Controller's
• Stops the ground output of the engine controller ACC signal cutout relay circuit.
action
Symptoms that
appear on • Engine cannot be stopped (option function) by steering and transmission controller.
machine
General a This failure code identifies a detected abnormality in primary side (coil side) of engine controller ACC
information signal cutout relay, but an abnormality in secondary side (contact side) can not be detected.

Defective engine controller switch still OFF.
1 ACC signal cutout relay
ACT (male) Resistance
Between (1) – (2) 200 – 400 z
causes and the Defective harness grounding
2
standard values (contact with ground circuit) Between ground and wiring harness Resis-
when normal between PTC2 (female) (19) – ACT (female) Min. 1 Mz
tance
(2)
switch ON.
Defective steering and PTC2 Stop signal Voltage
3
Between (19) and Input Max. 1V
ground No input 20 – 30 V
18 D85EX, PX-15E0
Circuit diagram related to engine controller ACC signal cutout relay
D85EX, PX-15E0 19
Failure code [D811KR] KOMTRAX controller CAN communication:

Defective communication 1
Action code Failure code KOMTRAX controller CAN communication: Defective communica-
Symptom
tion
— D811KR of failure
(Steering and transmission controller system)
• Steering and transmission controller cannot identify KOMTRAX controller with CAN communication
Failure content
circuit.
Controller's
action
Symptoms that
appear on • KOMTRAX LED information (Code: 20300) cannot be correctly displayed in monitoring mode.
machine
General
• Duplication of failure code: Turn starting switch ON and then select Code: 20300 in monitoring mode.
information

switch still OFF.
Wiring harness between S04 (female) (1)
(2)-PT2 (female) (32), S04 (female) (1) (2) –
EGC2 (female) (46) and S04 (female) (1) (2)
Resis-
– CA1 (female) (A) and among S04 (female) Max. 1 z
tance
Disconnection in wiring (1) (2) – CA2 (female) (A) – KOM1 (female)
harness (8) and between S04 (female) (1) (2) – SRV
1
(disconnection or defective (male) (3)
contact of connectors) Wiring harnesses between S04 (female) (3)
(4) – PTC2 (female) (22), S04 (female) (3)
(4) – EGC2 (female) (47), S04 (female) (3)
Resis-
(4) – CA1 (female) (B), S04 (female) (3) (4) – Max. 1 z
tance
CA2 (female) (B), S04 (female) (3) (4) –
KOM1 (female) (7) and S04 (female) (3) (4)
Possible
– SRV (male) (10)
causes and the
between S04 (female) (1) (2) – PTC2
(female) (32), S04 (female) (1) (2) – EGC2
(female) (46) and S04 (female) (1) (2) – CA1 Resis-
Min. 1 Mz
(female) (A) and among S04 (female) (1) (2) tance
– CA2 (female) (A) – KOM1 (female) (8) and
Defective harness grounding between S04 (female) (1) (2) – SRV (male)
2
(contact with ground circuit) (3)
(female) (47), S04 (female) (3) (4) – CA1 Resis-
Min. 1 Mz
(female) (B), S04 (female) (3) (4) – CA2 tance
(female) (B), S04 (female) (3) (4) – KOM1
(female) (7) and S04 (female) (3) (4) – SRV
(male) (10)
20 D85EX, PX-15E0

switch ON.
(female) (46) and S04 (female) (1) (2) – CA1
Voltage Max. 1V
(female) (A) and among S04 (female) (1) (2)
– CA2 (female) (A) – KOM1 (female) (8) and
Hot short of wiring harness between S04 (female) (1) (2) – SRV (male)
3
(contact with 24 V circuit) (3)
Possible Between ground and wiring harnesses
causes and the between S04 (female) (3) (4) – PTC2
standard values (female) (22), S04 (female) (3) (4) – EGC2
when normal (female) (47), S04 (female) (3) (4) – CA1
Voltage Max. 1V
(male) (10)
Defective CAN terminal switch still OFF.
4
resistance CA1 (male), CA2 (male) Resistance
Between (A)-(B) 100 – 140 z
Defective KOMTRAX con- When Causes 1 to 4 are not applicable, it can be suspected that
5 troller or defective steering KOMTRAX controller or steering and transmission controller is
and transmission controller defective. (Since this is an internal defect, it cannot be diagnosed.)
D85EX, PX-15E0 21
Circuit diagram related CAN communication
22 D85EX, PX-15E0
Failure code [DAFRKR] Monitor panel CAN communication: Defective

communication 1
Action code Failure code Symptom Monitor panel CAN communication: Defective communication
CALL E03 DAFRKR of failure (Monitor panel circuit)
Failure content • Monitor panel cannot identify steering and transmission controller with CAN communication circuit.
Symptoms that • System may not operate normally.
appear on • Once machine is stopped, engine speed is limited to medium (half).
machine • Once machine is stopped, travel is limited to F1 and R1.
General
information

switch still OFF.
– PT2 (female) (32), S04 (female) (1) (2) –
EGC2 (female) (46), S04 (female) (1) (2) –
Resis-
CA1 (female) (A), S04 (female) (1) (2) – CA2 Max. 1 z
tance
Disconnection in wiring (female) (A), S04 (female) (1) (2) – KOM1
harness (female) (8) and S04 (female) (1) (2) – SRV
1
Resis-
tance
Possible KOM1 (female) (7) and S04 (female) (3) (4)
causes and the – SRV (male) (10)
between S04 (female) (1) (2) – PT2 (female)
(32), S04 (female) (1) (2) – EGC2 (female)
Resis-
(46), S04 (female) (1) (2) – CA1 (female) (A), Min. 1 Mz
tance
S04 (female) (1) (2) – CA2 (female) (A), S04
(female) (1) (2) – KOM1 (female) (8) and
2 S04 (female) (1) (2) – SRV (male) (3)
(contact with ground circuit)
Min. 1 Mz
(male) (10)
24 D85EX, PX-15E0

switch ON.
(46), S04 (female) (1) (2) – CA1 (female) (A), Voltage Max. 1V
3 S04 (female) (1) (2) – SRV (male) (3)
Possible between S04 (female) (3) (4) – PTC2
causes and the (female) (22), S04 (female) (3) (4) – EGC2
standard values (female) (47), S04 (female) (3) (4) – CA1
when norma Voltage Max. 1V
(male) (10)
4
Between (A) – (B) 100 – 140 z
Defective monitor panel or When Causes 1 to 4 are not applicable, it can be suspected that
5 defective steering and trans- monitor panel or steering and transmission controller is defective.
mission controller (Since this is an internal defect, it cannot be diagnosed.)
D85EX, PX-15E0 25
26 D85EX, PX-15E0
Failure codes [DAQ0KT] and [DB30KT] Steering and transmission

controller: Abnormal controller memory information 1
Action code Failure code Steering and transmission controller: Abnormal controller memory
Symptom
DAQ0KT information
E01 of failure
DB30KT (Steering and transmission controller system)
Failure content • Information of ROM (non volatile memory) of steering and transmission controller is not normal.
Controller's
• Defaults the memory information value.
action
Symptoms that
appear on • Gear shift feeling of transmission may become worse.
machine
General • Both of DAQ0KT and DB30KT are displayed.
information • Duplication of failure code: turn ON the starting switch.

Possible
causes and the (Since this is an internal defect, it cannot be diagnosed.)
standard values Defective steering and trans- • Adjust once in adjustment mode (Code 0002).
1
when normal mission controller (It is no problem to keep using controller unless any visible trouble
symptom appears on machine.)
D85EX, PX-15E0 27
Failure code [DAQ1KK] [DB31KK] Main power source of steering and

transmission controller: Power source voltage drop and input 1
Action code Failure code Main power supply of steering and transmission controller: Power
Symptom
DAQ1KK source voltage drop and input
CALL E04 of failure
DB31KK (Steering and transmission controller system)
Failure content • Power source voltage of steering and transmission controller is below 17V.
• Monitor panel may not display normally.
Symptoms that
• Relay and solenoid may not be driven and therefore system may not operate properly.
appear on
machine
• Once machine is stopped, it can not travel any more.
• Both of DAQ1KK and DB31KK are displayed.
General • Battery charge state (voltage) can be checked in monitoring mode.
information (Code 03200: Battery voltage)

If fuse FS1-5 is blown, it is highly possible that a defective ground-
Defective circuit breaker When the circuit breaker is cut off, it is highly possible that a defec-
2
CB30 tive harness grounding has occurred in the circuit.
switch still OFF.
Disconnection in wiring Wiring harness between PTC3 (female) (1) Resis-
Max. 1 z
harness (11) – FS1-5 tance
3
(disconnection or defective Wiring harness between FS1-5 – battery Resis-
Possible relay BRB terminal tance
causes and the Wiring harness between PTC3 (female) (21) Resis-
Max. 1 z
standard values (31) (32) (33) and ground GND02 tance
switch still OFF.
Defective harness grounding Between ground and wiring harness Resis-
4 Min. 1 Mz
(contact with ground circuit) between PTC3 (female) (1) (11) – FS1-5 tance
Between ground and wiring harness Resis-
Min. 1 Mz
between FS1-5 – battery relay BRB terminal tance
switch ON.
Defective steering and trans-
5 PTC3 Voltage
mission controller
Between (1) (11) – (21) (31) (32)
20 – 30V
(33)
28 D85EX, PX-15E0
Circuit diagram related to steering and transmission power source
D85EX, PX-15E0 29
Failure code [DAQ2KK] [DB32KK] Load power source of steering and

Action code Failure code Load power supply of steering and transmission controller: Power
Symptom
DAQ2KK source voltage drop and input
CALL E04 of failure
• Power source voltage of load (relay, solenoid, etc.) on steering and transmission controller is below
Failure content
17V.
Symptoms that • Relay and solenoid may not be driven and therefore system may not operate properly.
machine • Once machine is stopped, it can not travel any more.
• Both of DAQ2KK and DB32KK are displayed.
General • Battery charge state (voltage) can be checked in monitoring mode.
information (Code 03200: Battery voltage)

If fuse FS2-2 is blown, it is highly possible that a defective ground-
Defective circuit breaker When the circuit breaker is cut off, it is highly possible that a defec-
2
CB105 tive harness grounding has occurred in the circuit.
switch still OFF.
Max. 1 z
harness (12) (22) – FS2-2 tance
3
(disconnection or defective Wiring harness between FS2-2 – battery Resis-
Possible relay BRC terminal tance
causes and the Wiring harness between PTC3 (female) (21) Resis-
Max. 1 z
standard values (31) (32) (33) and ground tance
switch still OFF.
4 Min. 1 Mz
(contact with ground circuit) between PTC3 (female) (2) (12) (22) – FS2-2 tance
Min. 1 Mz
between FS2-2 – battery relay BRC terminal tance
switch ON.
Defective steering and trans-
5 PTC3 Voltage
mission controller
Between (2) (12) (22) – (21) (31)
20 – 30 V
(32) (33)
30 D85EX, PX-15E0
Circuit diagram related to steering and transmission power source
D85EX, PX-15E0 31
Failure codes [DAQ5KK] and [DB35KK] Steering and transmission

controller sensor 5 V power source (1): Power source voltage drop and
input 1

Symptom Steering and transmission controller sensor 5 V power source(1):
DAQ5KK of failure Power source voltage drop and input
CALL E03
DB35KK
• Voltage of 5 V power source circuit of steering and transmission controller sensor is less than 4.5 V
Failure content or more than 5.5 V.
• Abnormal current flowed in 5 V power source circuit of steering and transmission controller sensor.
Controller's
• Stops output of 5 V power source circuit if abnormal voltage has flowed.
action
General • Both of DAQ5KK and DB35KK are displayed.

switch still OFF.
Defective brake potentiome- BRK (male) Resistance
1
ter (Internal short circuit) Between (C) – (A) 5 kz ± 20%
Sensor Between (C) and
Min. 1 Mz
ground
switch still OFF.
Defective fuel dial potentiom- DIAL (male) Resistance
2
eter (Internal short circuit) Between (1) – (3) 5 kz ± 15%
Sensor Between (1) and
Min. 1 Mz
ground
causes and the Defective forward and TL2 (male) Resistance
standard values 3 reverse potentiometer
when normal (Internal short circuit) Between (4) – (1) 3.2 kz ± 20%
Min. 1 Mz
ground
switch still OFF.
Defective steering TL2 (male) Resistance
4 potentiometer
(Internal short circuit) Between (5) – (8) 3.2 kz ± 20%
Min. 1 Mz
ground
switch still OFF.
Defective harness grounding Between ground and wiring harnesses

5
(contact with ground circuit) between PTC1 (female) (22) – TL2 (female) Resis-
(5), PTC1 (female) (22) – TL2 (female) (4), Min. 1 Mz
tance
PTC1 (female) (22) – DIAL (female) (1) and
PTC1 (female) (22) – BRK (female) (C)
32 D85EX, PX-15E0

switch ON.
Hot short of wiring harness Between ground and wiring harnesses

Possible 6 between PTC1 (female) (22) – TL2 (female)
causes and the (5), PTC1 (female) (22) – TL2 (female) (4), Voltage Max. 1V
standard values PTC1 (female) (22) – DIAL (female) (1) and
when normal PTC1 (female) (22) – BRK (female) (C)
Defective steering and switch ON.
7
transmission controller PTC1 Voltage
Between (22) – (21) 4.5 – 5.5 V
Circuit diagram related to steering and transmission controller sensor 5 V power source (1)
D85EX, PX-15E0 33
Failure code [DAQ6KK] [DB36KK] Steering and transmission controller

sensor 24 V power source: Power source voltage drop and input 1
Action code Failure code Steering and transmission controller sensor 24 V power source:
Symptom
DAQ6KK Power source voltage drop and input
CALL E03 of failure
• Voltage of 24 V power source circuit of steering and transmission controller sensor is less than 12 V
Failure content or more than 30 V.
Controller's
action
• Stops output of 24 V power source circuit if abnormal voltage has flowed.

If service code lights up steadily (reset display) when
Defective pitch angle sensor right connector is disconnected, the defect is internal. PT2
1
(internal short circuit) a Disconnect connector with starting switch OFF and connector
turn the switch ON to diagnose.
standard values 2
when normal between PTC1 (female) (16) – PT2 (female) Min. 1 Mz
tance
(C)
3
Between (16) – (21) 20 – 30V
Circuit diagram related to steering and transmission controller sensor 24 V power source
34 D85EX, PX-15E0
Failure codes [DAQ7KK] and [DB37KK] Steering and transmission

input 1

Symptom Steering and transmission controller sensor 5 V power source (2):
DAQ7KK of failure Power source voltage drop and input
E01
DB37KK
• Voltage of 5 V power source (2) circuit of steering and transmission controller sensor is less than 4.5
Failure content V or more than 5.5 V.
Controller's
• Stops output of 5 V power source (2) circuit if abnormal voltage has flowed.
action
Symptoms that
appear on • System may not operate normally.
machine

If service code lights up steadily (reset display) when
Defective work equipment oil
right connector is disconnected, the defect is internal. HHP
1 pressure sensor
a Disconnect connector with starting switch OFF and connector
(internal short circuit)
turn the switch ON to diagnose.
switch still OFF.
2
Possible between PTC3 (female) (34) – HHP (female) Min. 1 Mz
tance
causes and the (B)
when normal switch ON.
between PTC3 (female) (34) – HHP (female) Voltage Max. 1V
(B)
switch ON.
4 PTC3, PTC1 Voltage
Between PTC3 (34) –
4.5 – 5.5 V
PTC1(21)
36 D85EX, PX-15E0
Circuit diagram related to steering and transmission controller sensor 5 V power source (2)
D85EX, PX-15E0 37
Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller

model selection: Inconsistency in model select signal 1
Action code Failure code Steering and transmission controller model selection: Inconsistent
Symptom
DAQ9KQ model selection signal
CALL E04 of failure
DB39KQ (Steering and transmission controller system)
• Internal specification setting of steering and transmission controller is inconsistent with specification
Failure content setting signal.
(Steering and transmission controller cannot be recognized properly.)
Controller's
• Stops all outputs of steering and transmission controller.
action
• Restricts the operation of engine, transmission and brake.
Symptoms that • Machine does not operate at all.
General • Both of DAQ9KQ and DB39KQ are displayed.

It is normal if failure code lights up steadily (reset display) after
adjustment mode is carried out.
1 transmission
• Adjustment code 0002: Steering and transmission controller
controller adjustment
specification set
harness switch still OFF.
2 (Disconnection in wiring,
Possible defective contact of connec- Wiring harnesses between PTC3 (female) Resis-
Max. 1 z
tors) (30) – GND02 tance
causes and the
when normal Defective harness grounding switch still OFF.
3
Min. 1 Mz
between PTC3 (female) (40) – PL2 (18) tance
switch ON.
Defective steering and PTC3 Voltage
4
Between (30) and ground Max. 1V
Between (40) and ground 5 – 11 V
38 D85EX, PX-15E0
Circuit diagram related to steering and transmission controller model selection
D85EX, PX-15E0 39
Failure codes [DAQRKR] and [DB3RKR] Steering and transmission

controller CAN communication: Defective communication 1
Action code Failure code Steering and transmission controller CAN communication: Defective
Symptom
DBQRKR communication
CALL E03 of failure
DB3RKR (Steering and transmission controller system)
• Steering and transmission controller cannot identify monitor panel or engine controller with CAN
Failure content
communication circuit.
General • Both of DAQRKR and DB3RKR are displayed.

switch still OFF.
– PTC2 (female) (32), S04 (female) (1) (2) –
Resis-
tance
1
Resis-
tance
Resis-
tance
2 S04 (female) (1) (2) – SRV (male) (3)
Min. 1 Mz
(male) (10)
40 D85EX, PX-15E0

switch ON.
3 S04 (female) (1) (2) – SRV (male) (3)
Voltage Max. 1V
when normal (female) (B), S04 (female) (3) (4) – CA2
(male) (10)
4
Between (A) – (B) 100 – 140 z
Defective monitor panel or
When Causes 1 to 4 are not applicable, it can be suspected that
engine controller, or defec-
5 monitor panel or steering and transmission controller is defective.
tive steering and transmis-
sion controller
D85EX, PX-15E0 41
42 D85EX, PX-15E0
Failure code [DB2RKR] Engine controller CAN communication:

Defective communication 1
Action code Failure code Symptom Engine controller CAN communication: Communication disabled
CALL E03 DB2RKR of failure (Engine controller system)
• Engine controller cannot identify steering and transmission controller with CAN communication cir-
Failure content
cuit.
General
information

switch still OFF.
– PT2 (female) (32), S04 (female) (1) (2) –
Resis-
tance
1
Resis-
tance
Resis-
tance
2 S04 (female) (1) (2) – SRV (male) (3)
Min. 1 Mz
(male) (10)
44 D85EX, PX-15E0

switch ON.
3 S04 (female) (1) (2) – SRV (male) (3)
when normal Voltage Max. 1V
(male) (10)
4
Between (A) – (B) 100 – 140 z
Defective engine controller If no problem is found in causes 1 – 4, it can be suspected that
5 or defective steering and engine controller or steering and transmission controller is defec-
transmission controller tive. (Since this is an internal defect, it cannot be diagnosed.)
D85EX, PX-15E0 45
46 D85EX, PX-15E0

Abnormal controller memory information 1
a See DAQ0KT
Failure code [DB31KK] [DAQ1KK] Main power source of steering and

a See DAQ1KK
Failure code [DB32KK] [DAQ2KK] Load power source of steering and

a See DAQ2KK
Failure codes [DB35KK] and [DAQ5KK] Steering and transmission

input 1
a See DAQ5KK
Failure code [DB36KK] [DAQ6KK] Steering and transmission controller

sensor 24 V power source: Power source voltage drop and input 1
a See DAQ6KK
Failure codes [DB37KK] and [DAQ7KK] Steering and transmission

input 1
a See DAQ7KK
Failure codes [DB39KQ] and [DAQ9KQ] Steering and transmission

controller model selection: Inconsistent model selection signal 1
a See DAQ9KQ
Failure codes [DB3RKR] and [DAQRKR] Steering and transmission

controller CAN communication: Defective communication 1
a See DAQRKR
D85EX, PX-15E0 47
Failure code [DD12KA] Shift up switch: Disconnection 1
Action code Failure code Symptom Shift up switch: Disconnection

E02 DD12KA of failure (Steering and transmission controller system)
Failure content • 2 circuit signals of shift up switch circuit were turned OFF (OPEN) at the same time.
action • Recognizes that switch is not pressed.
Symptoms that
• Cannot shift up.
appear on
• Auto shift down function does not work.
machine
• As for two circuit signals of switch, NO is for an operation detection and NC is for an error detection.
General • The input state (ON or OFF) from shift up switch can be checked in monitoring mode.
information (Code 40905: Transmission-related controller input signal 1)
• Duplication of failure code: Turn starting switch ON +Operate shift up switch

switch still OFF.
Shift up switch
SFTU (male)
Defective shift up switch OFF (Release) ON (Press)
1
(internal disconnection) Resistance between
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
switch still OFF.
Max. 1 z
harness – SFTU (female) (3) tance
2
(disconnection or defective Wiring harness between PTC3 (female) (9) – Resis-
SFTU (female) (1) tance
Wiring harness between PTC1 (female) (4) – Resis-
Max. 1 z
Possible SFTU (female) (2) tance
standard values switch ON.
when normal
between PTC1 (female) (12) – SFTU Voltage Max. 1V
(female) (3)
between PTC3 (female) (9) – SFTU (female) Voltage Max. 1V
(1)
between PTC1 (female) (4) – SFTU (female) Voltage Max. 1V
(2)
switch ON.
Shift up switch
PTC1, PTC3
Defective steering and OFF (Release) ON (Press)
4
transmission controller Voltage between
Max. 1V 5 – 11 V
PTC1 (12) – PTC1 (4)
Voltage between
5 – 11 V Max. 1V
PTC3 (9) – PTC1 (4)
48 D85EX, PX-15E0
Circuit diagram related to shift up & shift down switch
D85EX, PX-15E0 49
Failure code [DD12KB] Shift up switch: Short circuit 1
Action code Failure code Symptom Shift up switch: Short circuit

E02 DD12KB of failure (Steering and transmission controller system)
Failure content • 2 circuit signals of shift up switch circuit were turned ON (CLOSE) at the same time.
Symptoms that
• Cannot shift up.
appear on
machine
• Duplication of failure code: Turn starting switch ON +Operate shift up switch

switch still OFF.
Shift up switch
SFTU (male)
Defective shift up switch OFF (Release) ON (Press)
1
(internal short circuit) Resistance between
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
switch still OFF.
Possible
Resis-
standard values Defective harness grounding between PTC1 (female) (12) – SFTU Min. 1 Mz
2 tance
when normal (contact with ground circuit) (female) (3)
Resis-
between PTC3 (female) (9) – SFTU (female) Min. 1 Mz
tance
(1)
switch ON.
Shift up switch
PTC1, PTC3
3
Max. 1V 5 – 11 V
PTC1 (12) – PTC1 (4)
Voltage between
5 – 11 V Max. 1V
PTC3 (9) – PTC1 (4)
50 D85EX, PX-15E0
D85EX, PX-15E0 51
Failure code [DD13KA] Shift down switch: Disconnection 1
Action code Failure code Symptom Shift down switch: Disconnection

E02 DD13KA of failure (Steering and transmission controller system)
Failure content • 2 circuit signals of shift down switch circuit were turned OFF (OPEN) at the same time.
Symptoms that
• Cannot shift down.
appear on
machine
• Duplication of failure code: Turn starting switch ON + Operate shift down switch

switch still OFF.
Shift down switch
SFTD (female)
Defective shift down switch OFF (Release) ON (Press)
1
(internal disconnection) Resistance between
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
switch still OFF.
Max. 1 z
harness – SFTD (male) (3) tance
2
(disconnection or defective Wiring harness between PTC1 (female) (18) Resis-
– SFTD (male) (1) tance
Max. 1 z
Possible SFTD (male) (2) tance
when normal
between PTC1 (female) (24) – SFTD (male) Voltage Max. 1V
(3)
(1)
(2)
switch ON.
Shift down switch
PTC1
4
Max. 1V 5 – 11 V
PTC1 (24) – PTC1 (4)
Voltage between
5 – 11 V Max. 1V
PTC1 (18) – PTC1 (4)
52 D85EX, PX-15E0
D85EX, PX-15E0 53
Failure code [DD13KB] Shift down switch: Short circuit 1
Action code Failure code Symptom Shift down switch: Short circuit
E02 DD13KB of failure (Steering and transmission controller system)
Failure content • 2 circuit signals of shift down switch circuit were turned ON (CLOSE) at the same time.
Symptoms that
• Cannot shift down.
appear on
machine
General • The input state (ON or OFF) from shift down switch can be checked in monitoring mode.
• Duplication of failure code: Turn starting switch ON + Operate shift down switch

switch still OFF.
Shift down switch
SFTD (female)
Defective shift down switch OFF (Release) ON (Press)
1
(internal short circuit) Resistance between
Max. 1 z Min. 1 Mz
(2) – (3)
Resistance between
Min. 1 Mz Max. 1 z
(2) – (1)
switch still OFF.
Possible
Resis-
standard values Defective harness grounding between PTC1 (female) (24) – SFTD (male) Min. 1 Mz
2 tance
when normal (contact with ground circuit) (3)
Resis-
between PTC1 (female) (18) – SFTD (male) Min. 1 Mz
tance
(1)
switch ON.
Shift down switch
PTC1
3
Max. 1V 5 – 11 V
PTC1 (24) – PTC1 (4)
Voltage between
5 – 11 V Max. 1V
PTC1 (18) – PTC1 (4)
54 D85EX, PX-15E0
D85EX, PX-15E0 55
Failure codes [DD14KA] and [DDQ2KA] Parking lock switch:

Disconnection 1
Symptom Parking lock switch: Disconnection
DD14KA of failure (Steering and transmission controller system)
CALL E03
DDQ2KA
Failure content • 2 circuit signals of parking lock switch circuit were turned OFF (OPEN) at the same time.
Controller's
• Recognizes that parking brake lever is in free position.
action
appear on • Once machine is stopped, travel is limited to F1 and R1.
machine • Engine can not start.
• Both of DD14KA and DDQ2KA are displayed.
• As for two circuit signals of switch, NC is for an operation detection and NO is for an error detection.
General
• The input state (ON or OFF) from parking lock switch can be checked in monitoring mode.
information
(Code 40910: Steering-related controller input signal 1)
• Duplication of failure code: Turn starting switch ON + operate parking brake lever.

switch still OFF.
Parking lever
NSW (male)
Defective parking lock switch Free position Lock position
1
(Internal disconnection) Resistance
Max. 1 z Min. 1 Mz
between (A) – (B)
Resistance
Min. 1 Mz Max. 1 z
between (A) – (C)
switch still OFF.
Max. 1 z
harness – NSW (female) (C) tance
2
NSW (female) (B) tance
Possible Max. 1 z
NSW (female) (A) tance
causes and the
Hot short circuiting in wiring Between ground and wiring harness between
Voltage Max. 1V
harness PTC2 (female) (15) – NSW (female) (C)
3
(a defective contact with 24 Between ground and wiring harness between
V circuit) Voltage Max. 1V
PTC2 (female) (5) – NSW (female) (B)
Voltage Max. 1V
PTC1 (female) (4) – NSW (female) (A)
switch ON.
Parking lever
PTC2, PTC1
Free position Lock position
Defective steering and Voltage between
4
transmission controller PTC2 (5) and 5 – 11 V Max. 1V
PTC1 (4)
Voltage between
PTC2 (15) and Max. 1V 5 – 11 V
PTC1 (4)
56 D85EX, PX-15E0
Circuit diagram related to parking brake switch
D85EX, PX-15E0 57
Failure codes [DD14KB] and [DDQ2KB] Parking lock switch: Short

circuit 1

Symptom Parking lock switch: Short circuit
DD14KB of failure (Steering and transmission controller system)
CALL E03
DDQ2KB
Failure content • 2 circuit signals of parking lock switch circuit were turned ON (CLOSE) at the same time.
Controller's
• Recognizes that parking brake lever is in free position.
action
appear on • Once machine is stopped, travel is limited to F1 and R1.
machine • Engine can not start.
• Both of DD14KB and DDQ2KB are displayed.
• As for two circuit signals of switch, NC is for an operation detection and NO is for an error detection.
General
• The input state (ON or OFF) from parking lock switch can be checked in monitoring mode.
information
(Code 40910: Steering-related controller input signal 1)
• Duplication of failure code: Turn starting switch ON + operate parking brake lever.

switch still OFF.
Parking lever
NSW (male)
Defective parking lock Free position Lock position
1
switch (internal short circuit) Resistance between
Max. 1 z Min. 1 Mz
(A) – (B)
Resistance between
Min. 1 Mz Max. 1 z
(A) – (C)
switch still OFF.
Possible Min. 1 Mz
causes and the Defective harness grounding NSW (female) (A) – PTC1 (female) (4) tance
2
Min. 1 Mz
when normal NSW (female) (B) – PTC2 (female) (5) tance
Min. 1 Mz
NSW (female) (C) – PTC2 (female) (15) tance
switch ON.
Parking lever
PTC2, PTC1
Free position Lock position
Defective steering and Voltage between
3
transmission controller PTC2 (5) and 5 – 11 V Max. 1V
PTC (4)
Voltage between
PTC2 (15) and Max. 1V 5 – 11 V
PTC1 (4)
58 D85EX, PX-15E0
Circuit diagram related to parking brake switch
D85EX, PX-15E0 59
Failure codes [DDQ2KA] and [DD14KA] Parking lock switch:

Disconnection 1
a See DD14KA
Failure codes [DDQ2KB] and [DD14KB] Parking lock switch: Short

circuit 1
a See DD14KB
60 D85EX, PX-15E0
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is

out of normal range 1
Action code Failure code Symptom Hydraulic oil temperature sensor: Input signal out of range
— DGS1KX of failure (Steering and transmission controller system)
Failure content • Hydraulic oil temperature sensor signal is out of normal range.
Controller's • Only memorizes the trouble. Does not turn on a particular alarm.
action • Recognizes that the hydraulic oil temperature is the maximum value.
Symptoms that
appear on • Hydraulic oil temperature on monitor panel is not displayed properly.
machine
• Hydraulic oil temperature state (temperature) can be checked in monitoring mode.
General
(Code 04401: Hydraulic oil temperature)
information
• Duplication of failure code: Turn starting switch ON or start engine.

Defective hydraulic oil tem- switch still OFF.
perature sensor SDS (male) Resistance
1
(internal disconnection and
short circuit) Between (1) – (2) 3.5 kz – 90 kz (10 – 100°C)
2 Max. 1 z
(disconnection or defective SDS (female) (1) tance
contact of connectors) Wiring harness between PTC1 (female) (21) Resis-
Max. 1 z
Possible – SDS (female) (2) tance
when normal Defective harness grounding
3
between PTC1 (female) (9) – SDS (female) Min. 1 Mz
tance
(1)
switch ON.
Hot short of wiring harness between PTC1 (female) (9) – SDS (female) Voltage Max. 1V
4
between PTC1 (female) (21) – SDS (female) Voltage Max. 1V
(2)
62 D85EX, PX-15E0
Circuit diagram related to hydraulic oil temperature sensor
D85EX, PX-15E0 63
Failure code [DGT1KA] Power train oil temperature sensor:

Disconnection 1
Action code Failure code Symptom Power train oil temperature sensor: Disconnection
E01 DGT1KA of failure (Steering and transmission controller system)
Failure content • The power train temperature sensor signal is lower than the specified value.
Controller's
• Nothing particular.
action
Symptoms that • Power train oil temperature on monitor panel is not displayed properly.
appear on • Fan speed is limited to half.
machine • Gear shift shock of transmission is large.
• Power train temperature state (temperature) can be checked in monitoring mode.
General
(Code 30100: Power train oil temperature)
information

switch still OFF.
Defective power train oil tem-
1 perature sensor 453 (male) Resistance
(Short circuit) Between (1) – (2) 3.5 kz – 90 kz (10 – 100°C)
switch still OFF.
Wiring harness between S04 (female) (12) – Resis-
Max. 1 z
Defective harness grounding 453 (female) (1) tance
Possible 2
(contact with ground circuit) Wiring harness between S03 (female) (3) – Resis-
standard values 453 (female) (2) tance
when normal Wiring harness between S03 (female) (4) – Resis-
Max. 1 z
453 (female) (2) tance
Hot short of wiring harness switch still OFF.
3
Voltage Max. 1V
S04 (female) (12) – 453 (female) (1)
switch ON.
4 Defective monitor panel
Voltage Max. 1V
S04 (female) (12) – 453 (female) (1)
5 Defective monitor panel Since this is an internal defect, it cannot be diagnosed.
64 D85EX, PX-15E0
Circuit diagram related to power train oil temperature sensor
D85EX, PX-15E0 65
Failure code [DGT1KX] Power train oil temperature sensor: Input signal
is out of normal range 1
Action code Failure code Symptom Power train oil temperature sensor: Input signal out of range
E01 DGT1KX of failure (Steering and transmission controller system)
Failure content • Power train temperature sensor signal is out of normal range.
Controller's
action
Symptoms that • Power train oil temperature on monitor panel is not displayed properly.
appear on • Fan speed is limited to half.
machine • Gear shift shock of transmission is large.
• Power train temperature state (temperature) can be checked in monitoring mode.
General
information

switch still OFF.
Defective power train oil tem-
1 perature sensor 453 (male) Resistance
(Short circuit) Between (1) – (2) 3.5 kz – 90 kz (10 – 100°C)
standard values 2
when normal between S04 (female) (12) – 453 (female) Min. 1 Mz
tance
(1)
switch ON.
between S04 (female) (12) – 453 (female) Voltage Max. 1V
(1)
66 D85EX, PX-15E0
Failure code [DH22KA] HSS and work equipment pump oil pressure
sensor: Disconnection 1
Action code Failure code Symptom HSS and work equipment pump oil pressure sensor: Disconnection
— DH22KA of failure (Steering and transmission controller system)
Failure content • Signal voltage of work equipment pump oil pressure sensor circuit is lower than the specified value.
Controller's
action
Symptoms that
appear on • Oil pressure of work equipment pump cannot be monitored.
machine
• Input state (voltage) from work equipment pump oil pressure sensor can be checked in monitoring
General mode.
information (Code 70701: Voltage of work equipment oil pressure sensor)

Defective sensor 5 V power Check if failure code [DAQ7KK] or [DB37KK] is displayed. If it is
1
supply circuit displayed, carry out troubleshooting for it first.
Defective work equipment switch ON.
2 pump oil pressure sensor
HHP Voltage
(internal defect)
Between (C) – (A) 0.5 – 6.0 V
switch still OFF.
Possible Disconnection in wiring Wiring harness between PTC3 (female) (34) Resis-
harness – HHP (female) (B) tance
standard values 3
when normal contact of connectors) Max. 1 z
HHP (female) (C) tance
Wiring harness between PTC1 (female) (21) Resis-
Max. 1 z
– HHP (female) (A) tance
switch still OFF.
4
between PTC1 (female) (1) – HHP (female) Min. 1 Mz
tance
(C)
68 D85EX, PX-15E0
Circuit diagram related to work equipment pump oil pressure sensor
D85EX, PX-15E0 69
Failure code [DH22KB] HSS and work equipment pump oil pressure
sensor: Short circuit 1
Action code Failure code Symptom HSS and work equipment pump oil pressure sensor: Short circuit
— DH22KB of failure (Steering and transmission controller system)
Failure content • Signal voltage of work equipment pump oil pressure sensor circuit is higher than the specified value.
Controller's
action
Symptoms that
appear on • Oil pressure of work equipment pump cannot be monitored.
machine
• Input state (voltage) from work equipment pump oil pressure sensor can be checked in monitoring
General mode.
information (Code 70701: Voltage of work equipment oil pressure sensor)

1
Defective work equipment switch ON.
2 pump oil pressure sensor
HHP Voltage
(internal defect)
Between (C) – (A) 0.5 – 6.0 V
Possible
when normal Between ground and wiring harness
Hot short of wiring harness between PTC1 (female) (1) – HHP (female) Voltage Max. 1V
3
(contact with 24 V circuit) (C)
between PTC3 (female) (34) – HHP (female) Voltage Max. 1V
(B)
Circuit diagram related to work equipment pump oil pressure sensor
70 D85EX, PX-15E0
Failure code [DK10KA] Fuel dial: Disconnection 1
Action code Failure code Symptom Fuel dial: Disconnection

CALL E03 DK10KA of failure (Steering and transmission controller system)
Failure content • Signal voltage of fuel dial circuit is lower than the specified value.
Controller's
• Continues to control with decelerator pedal potentiometer signal.
action
• Operation of engine and transmission is limited.
Symptoms that
appear on
machine
• Input state (voltage) from fuel dial can be checked in monitoring mode.
General
(Code 03000: Fuel dial voltage)
information

Defective sensor 5V power Check if failure code [DAQ5KK] or [DB35KK] is displayed. If it is
1
switch still OFF.
Defective fuel dial DIAL (male) Resistance
2 (internal disconnection and
Between (1) – (3) 4.0 – 6.0 kz
short circuit)
Between (1) – (2) 0.5 – 4.5 kz
Between (2) – (3) 0.5 – 4.5 kz
switch still OFF.
Max. 1 z
Possible harness – DIAL (female) (1) tance
3
– DIAL (female) (2) tance
when normal
Max. 1 z
switch still OFF.
4 Min. 1 Mz
(contact with ground circuit) PTC1 (female) (22) – DIAL (female) (1) tance
Min. 1 Mz
PTC1 (female) (20) – DIAL (female) (2) tance
switch ON.
5
Between (22) – (21) 4.6 – 5.4 V
Between (20) – (21) 0.5 – 4.5 V
72 D85EX, PX-15E0
Circuit diagram related to fuel dial
D85EX, PX-15E0 73
Failure code [DK10KB] Fuel dial: Short circuit 1
Action code Failure code Symptom Fuel dial: Short circuit

CALL E03 DK10KB of failure (Steering and transmission controller system)
Failure content • Signal voltage of fuel dial circuit is higher than the specified value.
Controller's
• Continues to control with decelerator pedal potentiometer signal.
action
• Operation of engine and transmission is limited.
Symptoms that
appear on
machine
• Input state (voltage) from fuel dial can be checked in monitoring mode.
General
(Code 03000: Fuel dial voltage)
information

1
switch still OFF.
Defective fuel dial DIAL (male) Resistance
Between (1) – (3) 4.0 – 6.0 kz
short circuit)
Between (1) – (2) 0.5 – 4.5 kz
Between (2) – (3) 0.5 – 4.5 kz
3
Possible
when normal Between ground and wiring harness
between PTC1 (female) (22) – DIAL (female) Voltage Max. 1V
(1)
(2)
(3)
switch ON.
5
Between (22) – (21) 4.6 – 5.4 V
Between (20) – (21) 0.5 – 4.5 V
74 D85EX, PX-15E0
Circuit diagram related to fuel dial
D85EX, PX-15E0 75
Failure code [DK30KA] Steering potentiometer (1): Disconnection 1
Action code Failure code Symptom Steering potentiometer (1): Disconnection

Failure content • Signal voltage of steering potentiometer (1) circuit is higher than the specified value.
Controller's
• Continues to control with signal of steering potentiometer (2) circuit.
action
Symptoms that
appear on
machine
• Input state (voltage) from steering potentiometer (1) can be checked in monitoring mode.
General
(Code 50300: Steering potentiometer (1) voltage)
information
• Duplication of failure code: Turn starting switch ON+(operate PCCS lever (steering))

1
switch still OFF.
Defective TL2 (male) Resistance

steering potentiometer (1) Between (5) – (8) 3.2 kz ± 20%
2
(internal disconnection and 1 – 6 kz
short circuit) Between (7) – (5)
(for steering to right and left)
6 – 1 kz
Between (7) – (8)
3 Max. 1 z
Possible (disconnection or defective – TL2 (female) (8) tance
causes and the contact of connectors) Wiring harness between PTC1 (female) (2) – Resis-
TL2 (female) (7) tance
when normal
switch ON.
between PTC1 (female) (2) – TL2 (female) Voltage Max. 1V
(7)
(5)
(8)
5
Between (2) – (21) 0.5 – 4.5 V
76 D85EX, PX-15E0
Circuit diagram related to steering potentiometer
D85EX, PX-15E0 77
Failure code [DK30KB] Steering potentiometer (1): Short circuit 1
Action code Failure code Symptom Steering potentiometer (1): Short circuit
Failure content • Signal voltage of steering potentiometer (1) circuit is lower than the specified value.
Controller's
action
Symptoms that
appear on
machine
General
information

1
switch still OFF.
Defective steering potenti- TL2 (male) Resistance

ometer (1) Between (5) – (8) 3.2 kz ± 20%
2
(internal disconnection and 1 – 6 kz
6 – 1 kz
Between (7) – (8)
Possible
switch still OFF.
causes and the
standard values Between ground and wiring harness
Resis-
when normal Defective harness grounding between PTC1 (female) (2) – TL2 (female) Min. 1 Mz
3 tance
Resis-
between PTC1 (female) (22) – TL2 (female) Min. 1 Mz
tance
(5)
4
– TL2 (female) (5) tance
5
Between (2) – (21) 0.5 – 4.5 V
78 D85EX, PX-15E0
D85EX, PX-15E0 79
Failure code [DK30KX] Steering potentiometer: Input signal is out of

normal range 1
Action code Failure code Symptom Steering potentiometer: Input signal out of normal range
CALL E04 DK30KX of failure (Steering and transmission controller system)
• Either failure code [DK30KA] or [DK30KB] and either failure code [DK31KA] or [DK31KB] occurred
Failure content
at the same time at steering potentiometer circuits 1 and 2.
action • Restricts the operation of engine, transmission and brake.
Symptoms that
appear on
machine
• Input state (voltage) from steering potentiometer can be checked in monitoring mode.
General (Code 50300: Steering potentiometer 1 voltage)
information (Code 50301: Steering potentiometer 2 voltage)
causes and the
standard values Diagnose the failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
when normal
Failure code [DK30KZ] Steering potentiometer: Disconnection or short

circuit (Double failure) 1
Action code Failure code Symptom Steering potentiometer: Disconnection or short circuit
CALL E04 DK30KZ of failure (Steering and transmission controller system)
• With starting switch ON, an abnormality existed in only one of the steering potentiometer circuit 1 or
Failure content 2. After that, either failure code [DK30KA] or [DK30KB] and either failure code [DK31KA] or
[DK31KB] occurred at the same time.
action • Restricts the operation of engine, transmission and brake.
Symptoms that
appear on
machine
causes and the
when normal
80 D85EX, PX-15E0
Failure code [DK30L8] Steering potentiometer: Inconsistent analog

signal 1
Action code Failure code Symptom Steering potentiometer: Inconsistent analog signal
CALL E03 DK30L8 of failure (Steering and transmission controller system)
Failure content • Total signal voltage of steering potentiometer circuits 1 and 2 is beyond the specified range.
Controller's
• Continues to control with the normal signal of either steering potentiometer circuit 1 or 2.
action
Symptoms that
appear on
machine
• Duplication of failure code: Turn starting switch ON +(operate PCCS lever (forward-reverse))
causes and the
when normal
D85EX, PX-15E0 81
Failure code [DK31KA] Steering potentiometer (2): Disconnection 1
Action code Failure code Symptom Steering potentiometer (2): Disconnection

Failure content • Signal voltage of steering potentiometer (2) circuit is lower than the specified value.
Controller's
action
Symptoms that
appear on
machine
General
information

Defective sensor power Check if failure code [DAQ5KK] or [DB35KK] is displayed. If it is
1
source circuit displayed, carry out troubleshooting for it first.
switch still OFF.

potentiometer (2) Between (5) – (8) 3.2 kz ± 20%
2
(internal disconnection and 6–1z
1–6z
Between (6) – (8)
Possible
causes and the harness Wiring harness between PTC1 (female) (22) Resis-
3 Max. 1 z
standard values (disconnection or defective – TL2 (female) (5) tance
when normal contact of connectors) Wiring harness between PTC1 (female) (19) Resis-
Max. 1 z
switch still OFF.
Resis-
Defective harness grounding between PTC1 (female) (19) – TL2 (female) Min. 1 Mz
4 tance
Resis-
tance
(5)
5
Between (19) – (21) 0.5 – 4.5 V
82 D85EX, PX-15E0
D85EX, PX-15E0 83
Failure code [DK31KB] Steering potentiometer (2): Short circuit 1
Action code Failure code Symptom Steering potentiometer (2): Short circuit
Failure content • Signal voltage of steering potentiometer (2) circuit is higher than the specified value.
Controller's
action
Symptoms that
appear on
machine
General
information

1
switch still OFF.

potentiometer (2) Between (5) – (8) 3.2 kz ± 20%
2
(internal disconnection and 1 – 6 kz (for steering to right and
left)
6 – 1 kz (for steering to right and
Between (6) – (8)
left)
switch ON.
Possible Between ground and wiring harness
causes and the between PTC1 (female) (19) – TL2 (female) Voltage Max. 1V
standard values (6)
when normal Hot short of wiring harness
(5)
(8)
4
5
Between (19) – (21) 0.5 – 4.5 V
84 D85EX, PX-15E0
D85EX, PX-15E0 85
Failure code [DK40KA] Brake potentiometer: Disconnection 1
Action code Failure code Symptom Brake potentiometer: Disconnection

E01 DK40KA of failure (Steering and transmission controller system)
Failure content • Signal voltage of brake potentiometer circuit is lower than the specified value.
Controller's
action
Symptoms that
appear on • Automatic shift-down does not function properly.
machine
• Input state (voltage) from brake potentiometer can be checked in monitoring mode.
General
(Code 50400: Brake potentiometer voltage value)
information
• Duplication of failure code: Turn starting switch ON + (operate brake pedal)

Defective sensor power Check if failure code [DAQ5KK] or [DB35KK] is displayed. If it is
1
source circuit displayed, carry out troubleshooting for it first.
• Defective brake potenti- switch still OFF.
ometer. (internal discon- BRK (male) Resistance
2 nection and short circuit)
Between (A) – (C) 4.0 – 6.0 kz
• Defective potentiometer
mounting Between (A) – (B) 1.5 – 4.5 kz (free – full stroke)
Between (B) – (C) 4.5 – 1.5 kz (free – full stroke)
Possible
3 Max. 1 z
standard values (disconnection or defective – BRK (female) (C) tance
when normal contact of connectors) Wiring harness between PTC1 (female) (3) – Resis-
Max. 1 z
BRK (female) (B) tance
switch still OFF.
4 Min. 1 Mz
(contact with ground circuit) PTC1 (female) (3) – BRK (female) (B) tance
Min. 1 Mz
PTC1 (female) (22) – BRK (female) (C) tance
5
Between (3) – (21) 1.5 – 4.5 V
Circuit diagram related to brake potentiometer
86 D85EX, PX-15E0
Failure code [DK40KB] Brake potentiometer: Short circuit 1
Action code Failure code Symptom Brake potentiometer: Short circuit

E01 DK40KB of failure (Steering and transmission controller system)
Failure content • Signal voltage of brake potentiometer circuit is higher than the specified value.
Controller's
action
Symptoms that
appear on • Automatic shift-down does not function properly.
machine
• Input state (voltage) from brake potentiometer can be checked in monitoring mode.
General
(Code 50400: Brake potentiometer voltage value)
information
• Duplication of failure code: Turn starting switch ON + (operate brake pedal)

1
• Defective brake potenti- switch still OFF.
ometer. (internal discon- BRK (male) Resistance
2 nection and short circuit)
Between (A) – (C) 4.0 – 6.0 kz
• Defective potentiometer
mounting Between (A) – (B) 1.5 – 4.5 kz (free – full stroke)
Between (B) – (C) 4.5 – 1.5 kz (free – full stroke)
switch ON.
Possible
causes and the Between ground and wiring harness between
Voltage Max. 1V
standard values Hot short of wiring harness PTC1 (female) (3) – BRK (female) (B)
3
when normal (contact with 24 V circuit) Between ground and wiring harness between
Voltage Max. 1V
PTC1 (female) (22) – BRK (female) (C)
Voltage Max. 1V
PTC1 (female) (21) – BRK (female) (A)
4
contact of connectors) Min. 1 z
– BRK (female) (A) tance
5
Between (3) – (21) 1.5 – 4.5 V
Circuit diagram related to brake potentiometer
D85EX, PX-15E0 87
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is

out of normal range 1
Action code Failure code Symptom Forward-reverse potentiometer: Input signal out of range
CALL E04 DK55KX of failure (Steering and transmission controller system)
• Either failure code [DK56KA] or [DK56KB] and either failure code [DK57KA] or [DK57KB] occurred
Failure content
at the same time at forward-reverse potentiometer circuits 1 and 2.
Symptoms that
appear on
machine
• Input state (voltage) from forward-reverse potentiometer can be checked in monitoring mode.
General (Code 50200: Forward-reverse potentiometer 1 voltage)
information (Code 50201: Forward-reverse potentiometer 2 voltage)
• Duplication of failure code: Turn starting switch ON + (operate PCCS lever (forward-reverse))
causes and the
when normal
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection

or short circuit (Double failure) 1
Action code Failure code Forward-reverse potentiometer: Disconnection or short circuit (dou-
Symptom
ble failure)
CALL E04 DK55KZ of failure
(Steering and transmission controller system)
• With starting switch ON, an abnormality existed in only one of the forward-reverse potentiometer cir-
Failure content cuit 1 or 2. After that, either failure code [DK56KA] or [DK56KB] and either failure code [DK57KA]
or [DK57KB] occurred at the same time.
Symptoms that
appear on
machine
causes and the
when normal
88 D85EX, PX-15E0
Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent

analog signal 1
Action code Failure code Symptom Forward-reverse potentiometer: Inconsistent analog signals
CALL E03 DK55L8 of failure (Steering and transmission controller system)
Failure content • Total signal voltage of forward-reverse potentiometer circuits 1 and 2 is beyond the specified range.
Controller's
• Continues to control with the normal signal of either forward-reverse potentiometer circuit 1 or 2.
action
Symptoms that
appear on
machine
causes and the
when normal
D85EX, PX-15E0 89
Failure code [DK56KA] Forward-reverse potentiometer (1):

Disconnection 1
Action code Failure code Symptom Forward-reverse potentiometer (1): Disconnection

Failure content • Signal voltage of forward-reverse potentiometer (1) circuit is lower than the specified value.
Controller's
• Continues to control with signal of forward-reverse potentiometer (2) circuit.
action
Symptoms that
appear on
machine
• Input state (voltage) from forward-reverse potentiometer (1) can be checked in monitoring mode.
General
(Code 50200: Forward-reverse potentiometer (1) voltage)
information

1
switch still OFF.
Defective forward-reverse
potentiometer (1) TL2 (male) Resistance
2
(Internal disconnection or Between (4) – (1) 3.2 kz ± 20%
short circuit) Between (3) – (4) 5.5 – 1.5 kz (forward – reverse)
Between (3) – (1) 1.5 – 5.5 kz (forward – reverse)
Possible harness Wiring harness between PTC1 (female) (22) Resis-

3 Max. 1 z
causes and the (disconnection or defective – TL2 (female) (4) tance
standard values contact of connectors) Wiring harness between PTC1 (female) (13) Resis-
Max. 1 z
when normal – TL2 (female) (3) tance
switch still OFF.
Resis-
4 tance
Resis-
tance
(4)
5
Between (13) – (21) 0.5 – 4.5 V
90 D85EX, PX-15E0
Circuit diagram related to forward-reverse potentiometer
D85EX, PX-15E0 91
Failure code [DK56KB] Forward-reverse potentiometer (1): Short

circuit 1
Action code Failure code Symptom Forward-reverse potentiometer (1): Short circuit
Failure content • Signal voltage of forward-reverse potentiometer (1) circuit is higher than the specified value.
Controller's
action
Symptoms that
appear on
machine
General
information

1
switch still OFF.
2
switch ON.
Possible between PTC1 (female) (13) – TL2 (female) Voltage Max. 1V
causes and the (3)
standard values Hot short of wiring harness
when normal (contact with 24 V circuit)
(4)
(1)
4
5
Between (13) – (21) 0.5 – 4.5 V
92 D85EX, PX-15E0
D85EX, PX-15E0 93
Failure code [DK57KA] Forward-reverse potentiometer (2):

Disconnection 1
Action code Failure code Symptom Forward-reverse potentiometer (2): Disconnection

Failure content • Signal voltage of forward-reverse potentiometer (2) circuit is lower than the specified value.
Controller's
action
Symptoms that
appear on
machine
General
information

1
switch still OFF.
2

3 Max. 1 z
causes and the (disconnection or defective – TL2 (female) (4) tance
standard values contact of connectors) Wiring harness between PTC1 (female) (7) – Resis-
Max. 1 z
when normal TL2 (female) (2) tance
switch still OFF.
Resis-
4 tance
Resis-
tance
(4)
5
Between (7) – (21) 0.5 – 4.5 V
94 D85EX, PX-15E0
D85EX, PX-15E0 95
Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit 1
Action code Failure code Symptom Forward-reverse potentiometer (2): Short circuit
Failure content • Signal voltage of forward-reverse potentiometer (2) circuit is higher than the specified value.
Controller's
action
Symptoms that
appear on
machine
General
information

1
switch still OFF.
2
switch ON.
Possible between PTC1 (female) (7) – TL2 (female) Voltage Max. 1V
causes and the (2)
standard values Hot short of wiring harness
when normal (contact with 24 V circuit)
(4)
(1)
4
5
Between (7) – (21) 0.5 – 4.5 V
96 D85EX, PX-15E0
D85EX, PX-15E0 97
SEN00636-00

© 2006 KOMATSU
All Rights Reserved
98
SEN00637-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit ................................................... 3
Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection ............................................... 4
Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range......... 5
Failure code [DLT3KA] Transmission output speed sensor: Disconnection......................................... 6
Failure code [DLT3KB] Transmission output speed sensor: Short circuit ............................................ 7
Failure code [DV00KB] Alarm buzzer: Short circuit ............................................................................. 8
Failure code [DW7BKA] Fan reverse solenoid: Disconnection ............................................................ 9
Failure code [DW7BKB] Fan reverse solenoid: Short circuit.............................................................. 10
Failure code [DW7BKY] Fan reverse solenoid: Hot short circuit.........................................................11
Failure code [DWN1KA] HSS EPC solenoid right: Disconnection ..................................................... 12
Failure code [DWN1KB] HSS EPC solenoid right: Short circuit......................................................... 13
Failure code [DWN1KY] HSS EPC solenoid right: Hot short circuit................................................... 14
Failure code [DWN2KA] HSS EPC solenoid left: Disconnection ....................................................... 15
D85EX, PX-15E0 1
Failure code [DWN2KB] HSS EPC solenoid left: Short circuit ........................................................... 16
Failure code [DWN2KY] HSS EPC solenoid left: Hot short circuit ..................................................... 17
Failure code [DWN5KA] Fan pump EPC solenoid: Disconnection..................................................... 18
Failure code [DWN5KB] Fan pump EPC solenoid: Short circuit ........................................................ 19
Failure code [DWN5KY] Fan pump EPC solenoid: Hot short circuit .................................................. 20
Failure code [DXA0KA] HSS and work equipment pump TVC solenoid: Disconnection ................... 21
Failure code [DXA0KB] HSS and work equipment pump TVC solenoid: Short circuit ....................... 22
Failure code [DXA0KY] HSS and work equipment pump TVC solenoid: Hot short circuit ................. 23
Failure code [DXH4KA] 1st clutch ECMV: Disconnection .................................................................. 24
Failure code [DXH4KB] 1st clutch ECMV: Short circuit...................................................................... 25
Failure code [DXH4KY] 1st clutch ECMV: Hot short circuit................................................................ 26
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ................................................................. 27
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit..................................................................... 28
Failure code [DXH5KY] 2nd clutch ECMV: Hot short circuit............................................................... 29
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection.................................................................. 30
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit ..................................................................... 31
Failure code [DXH6KY] 3rd clutch ECMV: Hot short circuit ............................................................... 32
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection.......................................................... 33
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit ............................................................. 34
Failure code [DXH7KY] Reverse clutch ECMV: Hot short circuit ....................................................... 35
Failure code [DXH8KA] Forward clutch ECMV: Disconnection.......................................................... 36
Failure code [DXH8KB] Forward clutch ECMV: Short circuit ............................................................. 37
Failure code [DXH8KY] Forward clutch ECMV: Hot short circuit ....................................................... 38
2 D85EX, PX-15E0

Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit 1

Symptom Pitch angle sensor: Short circuit
DKH1KA of failure (Steering and transmission controller system)
CALL E03
DKH1KX
Failure content • Signal voltage of pitch angle sensor is higher than specified value.
Controller's
• Cannot recognize pitch angle.
action
Symptoms that • Gear shift shocks become large.
• Both DKH1KA and DKH1KX are displayed
General • Input state (voltage) from pitch angle sensor can be checked in monitoring mode.
information (Code 60100: Voltage of pitch angle sensor)

1
Defective pitch angle sensor switch ON.
2
(internal defect) PT2 Voltage
Between (B) – (A) 0.15 – 4.85 V
switch ON.
Possible
standard values Hot short of wiring harness between PTC1(female) (8) – PT2 (female) Voltage Max. 1V
3
when normal (contact with 24 V circuit) (B)
between PTC1 (female) (21) – PT2 (female) Voltage Max. 1V
(A)
Disconnection in wiring har- a Prepare with starting switch OFF and diagnose with starting
ness switch still OFF.
4
– PT2 (female) (A) tance
Circuit diagram related to pitch angle sensor
D85EX, PX-15E0 3
Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection 1

Symptom Pitch angle sensor: Disconnection
DKH1KB of failure (Steering and transmission controller system)
CALL E03
DKH1KX
Failure content • Signal voltage of pitch angle sensor is lower than specified value.
Controller's
• Cannot recognize pitch angle.
action
Symptoms that • Gear shift shocks become large.
• Both DKH1KB and DKH1KX are displayed.
General • Input state (voltage) from pitch angle sensor can be checked in monitoring mode.
information (Code 60100: Voltage of pitch angle sensor)

1
Defective pitch angle sensor switch ON.
2
(internal defect) PT2 Voltage
Between (B) – (A) 0.15 – 4.85 V
Possible
3 Max. 1 z
standard values (disconnection or defective – PT2 (female) (C) tance
when normal contact of connectors) Wiring harness between PTC1 (female) (8) – Resis-
Max. 1 z
PT2 (female) (B) tance
switch still OFF.
4 Min. 1 Mz
(contact with ground circuit) PTC1(female) (8) – PT2 (female) (B) tance
Min. 1 Mz
PTC1 (female) (16) – PT2 (female) (C) tance
Circuit diagram related to pitch angle sensor
4 D85EX, PX-15E0
Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor:

Input signal out of range 1
a Refer to DKH1KA or DKH1KB
D85EX, PX-15E0 5
Failure code [DLT3KA] Transmission output speed sensor: Disconnection1
Action code Failure code Symptom Transmission output speed sensor: Disconnection
E01 DLT3KA of failure (Steering and transmission controller system)
Failure content • Signal is not input from transmission output speed sensor.
Controller's
• Assumes that transmission output speed is 0 rpm.
action
• Transmission speed cannot be monitored.
Symptoms that
• Traction force cannot be calculated.
appear on
• Automatic shift-down does not function properly
machine
• Transmission output speed can be checked in monitoring mode.
General
(Code 31400: Transmission speed)
information
• Duplication of failure code: Start engine and travel machine actually.

Defective transmission switch still OFF.
1 output speed sensor
TM1 (male) Resistance
Between (1) – (2) 400 – 1,000 z
2 Max. 1 z
(disconnection or defective – TM1 (female) (1) tance
Possible
standard values – TM1 (female) (2) tance
switch ON.
Hot short of wiring harness between PTC2 (female) (30) – TM1 (female) Voltage Max. 1V
3
between PTC2 (female) (29) – TM1 (female) Voltage Max. 1V
(2)
Circuit diagram related to transmission output speed sensor
6 D85EX, PX-15E0
Failure code [DLT3KB] Transmission output speed sensor: Short circuit1
Action code Failure code Symptom Transmission output speed sensor: Short circuit
E01 DLT3KB of failure (Steering and transmission controller system)
• Signal from transmission output speed sensor does not change even though the machine is
Failure content
traveling.
Controller's
• Assumes that transmission output speed is 0 rpm.
action
• Transmission speed cannot be monitored.
Symptoms that
• Traction force cannot be calculated.
appear on
• Automatic shift-down does not function properly.
machine
• Transmission output speed can be checked in monitoring mode.
General
(Code 31400: Transmission speed)
information
• Duplication of failure code: Start engine and travel machine actually.

Defective mounting of trans- Make adjustment according to Testing and adjusting “Adjusting
1
mission output speed sensor transmission speed sensor”.
switch still OFF.
Defective transmission
2 output speed sensor TM1 (male) Resistance
(internal short circuit) Between (1) – (2) 400 – 1,000 z
Possible Between (1) and ground Min. 1 Mz
causes and the
standard values
switch still OFF.
when normal
Resis-
Defective harness grounding between PTC2 (female) (30) – TM1 (female) Min. 1 Mz
3 tance
Resis-
between PTC2 (female) (29) – TM1 (female) Min. 1 Mz
tance
(2)
Circuit diagram related to transmission output speed sensor
D85EX, PX-15E0 7
Failure code [DV00KB] Alarm buzzer: Short circuit 1
Action code Failure code Symptom

Alarm buzzer: Short circuit (monitor panel circuit)
E02 DV00KB of failure
Failure content • Abnormal current flowed in the alarm buzzer circuit.
Controller's
• Stops the GND output for alarm buzzer circuit.
action
Symptoms that
appear on • Alarm buzzer does not sound.
machine
General • Duplication of failure code: Turn starting switch ON
information (When it is turned ON, buzzer sounds for 1 second).

Defective alarm buzzer switch still OFF.
1
(internal short circuit) 217 (male) Continuity
Between (2) – (1) Continue
Hot short of wiring harness switch ON.
2
Voltage Max. 1V
Possible 217 (female) (1) – S03 (female) (18)
when normal Defective harness grounding
3
between 217 (female) (1) – S03 (female) Min. 1 Mz
tance
(18)
switch ON.
S03 Alarm buzzer Voltage
4 Defective monitor panel
When stopping 20 – 30 V
Between (18) and
ground When turned ON
Max. 3V
(sounding)
Circuit diagram related to alarm buzzer
8 D85EX, PX-15E0
Failure code [DW7BKA] Fan reverse solenoid: Disconnection 1
Action code Failure code Symptom Fan reverse solenoid: Disconnection

E01 DW7BKA of failure (Steering and transmission controller system)
Failure content • Current does not flow when power is output to fan reverse solenoid circuit.
Controller's
• Stops outputting power to fan reverse solenoid circuit.
action
Symptoms that
appear on • The fan reversing function cannot be used.
machine
• Output state (ON/OFF) to fan reverse solenoid can be checked in monitoring mode.
General
(Code 40914: Steering-related controller output signal)
information
• Duplication of failure code: Turn starting switch ON and operate cleaning.

Defective fan reverse switch still OFF.
1 solenoid
FAR2 (male) Resistance
Between (1) – (2) 34 – 44 z
causes and the 2 Max. 1 z
(disconnection or defective – FAR2 (female) (1) tance
standard values contact of connectors) Wiring harness between PTC3 (female) (13) Resis-
– FAR2 (female) (2) tance
switch ON.
between PTC3 (female) (18) – FAR2 Voltage Max. 1V
(female) (1)
Circuit diagram related to fan reverse solenoid
D85EX, PX-15E0 9
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 1
Action code Failure code Symptom Fan reverse solenoid: Short circuit
E01 DW7BKB of failure (Steering and transmission controller system)
Failure content • Abnormal current flowed when power is output to fan reverse solenoid circuit.
Controller's
action
Symptoms that
appear on • The fan reversing function cannot be used.
machine
General
information
• Duplication of failure code: Turn starting switch ON and operate cleaning.

switch still OFF.
Defective fan reverse
1 solenoid FAR2 (male) Resistance
(internal short circuit) Between (1) – (2) 34 – 44 z
2
between PTC3 (female) (18) – FAR2 Min. 1 Mz
when normal tance
(female) (1)
switch still OFF.
Harness short
3 Between PTC3 (female) (18) – FAR2
(female) (1) and ST3. Wiring harness Min. 1 Mz
tance
between (female) (13) – FAR2 (female) (2)
10 D85EX, PX-15E0
Failure code [DW7BKY] Fan reverse solenoid: Hot short circuit 1
Action code Failure code Symptom Fan reverse solenoid: Hot short circuit
E02 DW7BKY of failure (Steering and transmission controller system)
Failure content • Current flows constantly to fan reverse solenoid circuit.
Controller's
action
Symptoms that
appear on • Fan remains in reverse.
machine
General
information

Defective fan reverse switch still OFF.
1 solenoid
FAR2 (male) Resistance
Between (1) – (2) 34 – 44 z
Possible
when normal 2 Between ground and wiring harness
between PTC3 (female) (18) – FAR2 Voltage Max. 1V
(female) (1)
Steering and transmission controller can be suspected to be defec-
3 tive if no problem is found in causes 1 – 2 (since this is an internal
defect, it cannot be diagnosed).
D85EX, PX-15E0 11
Failure code [DWN1KA] HSS EPC solenoid right: Disconnection 1
Action code Failure code Symptom HSS EPC solenoid right: Disconnection
CALL E03 DWN1KA of failure (Steering and transmission controller system)
Failure content • Current does not flow when power is output to HSS EPC solenoid right circuit.
Controller's
• Stops outputting to HSS EPC solenoid right circuit.
action
Symptoms that • Can not turn to the right.
• Output state (current) to HSS EPS solenoid right can be checked in monitoring mode.
General
(Code 50603: Right HSS solenoid output current value)
information
• Duplication of failure code: Turn starting switch ON and operate PCCS lever (for steering to right).

Defective HSS EPC solenoid switch still OFF.
1
right (internal disconnection) HSB (male) Resistance
Between (1) – (2) 5 – 15 z
Possible
standard values Disconnection in wiring switch still OFF.
when normal harness Wiring harness between PTC3 (female) (35) Resis-
2 Max. 1 z
(disconnection or defective – HSB (female) (1) tance
contact of connectors) Wiring harness between PTC3 (female) (3) – Resis-
Max. 1 z
HSB (female) (2) tance
Circuit diagram related to HSS EPC solenoid right
12 D85EX, PX-15E0
Failure code [DWN1KB] HSS EPC solenoid right: Short circuit 1
Action code Failure code Symptom HSS EPC solenoid right: Short circuit
CALL E03 DWN1KB of failure (Steering and transmission controller system)
Failure content • Abnormal current flowed when power was output to HSS EPC solenoid right circuit.
Controller's
action
Symptoms that • Can not turn to the right.
General
information
• Duplication of failure code: Turn starting switch ON and operate PCCS lever (for steering to right).

switch still OFF.
Defective HSS EPC solenoid HSB (male) Resistance
1
right (internal short circuit)
Between (1) – (2) 5 – 15 z
2
between PTC3 (female) (35) – HSB (female) Min. 1 Mz
when normal tance
(1)
switch still OFF.
Harness short
3 Wiring harness between PTC3 (female) (35)
– HSB (female) (1) and PTC3 (female) (3) – Min. 1 Mz
tance
HSB (female) (2)
D85EX, PX-15E0 13
Failure code [DWN1KY] HSS EPC solenoid right: Hot short circuit 1
Action code Failure code Symptom HSS EPC solenoid right: Hot short circuit
CALL E04 DWN1KY of failure (Steering and transmission controller system)
Failure content • Current flows constantly to HSS EPC solenoid right circuit.
Controller's
action
Symptoms that • Continues to turn to the right (Stop with pedal brake or parking brake)
General
information
Defective HSS EPC solenoid a Prepare with starting switch OFF and diagnose with starting
right switch still OFF.
1
(internal disconnection and HSB (male) Resistance
short circuit) Between (1) – (2) 5 – 15 z
Possible
between PTC3 (female) (35) – HSB (female) Voltage Max. 1V
(1)
3 tive if no problem is found in causes 1 – 2.
14 D85EX, PX-15E0
Failure code [DWN2KA] HSS EPC solenoid left: Disconnection 1
Action code Failure code Symptom HSS EPC solenoid left: Disconnection
CALL E03 DWN2KA of failure (Steering and transmission controller system)
Failure content • Current does not flow when power is output to HSS EPC solenoid left circuit.
Controller's
• Stops outputting to HSS EPC solenoid left circuit.
action
Symptoms that • Cannot turn to the left.
• Output state (current) to HSS EPS solenoid left can be checked in monitoring mode.
General
(Code 50602: Left HSS solenoid output current value)
information
• Duplication of failure code: Turn starting switch ON and operate PCCS lever (for steering to left).

Defective HSS EPC solenoid switch still OFF.
1 left
HSA (male) Resistance
Between (1) – (2) 5 – 15 z
Possible
2 Max. 1 z
(disconnection or defective – HSA (female) (1) tance
Max. 1 z
HSA (female) (2) tance
Circuit diagram related to HSS EPC solenoid left
D85EX, PX-15E0 15
Failure code [DWN2KB] HSS EPC solenoid left: Short circuit 1
Action code Failure code Symptom HSS EPC solenoid left: Short circuit
CALL E03 DWN2KB of failure (Steering and transmission controller system)
Failure content • Abnormal current flowed when power was output to HSS EPC solenoid left circuit.
Controller's
action
Symptoms that • Cannot turn to the left.
General
information
• Duplication of failure code: Turn starting switch ON and operate PCCS lever (for steering to left).

switch still OFF.
Defective HSS EPC solenoid HSA (male) Resistance
1
left (internal short circuit)
Between (1) – (2) 5 – 15 z
2
between PTC3 (female) (25) – HSA (female) Min. 1 Mz
when normal tance
(1)
switch still OFF.
Harness short
– HSA (female) (1) and PTC3 (female) (3) – Min. 1 Mz
tance
HSA (female) (2)
16 D85EX, PX-15E0
Failure code [DWN2KY] HSS EPC solenoid left: Hot short circuit 1
Action code Failure code Symptom HSS EPC solenoid left: Hot short circuit
CALL E04 DWN2KY of failure (Steering and transmission controller system)
Failure content • Current flows constantly to HSS EPC solenoid left circuit.
Controller's
action
Symptoms that • Continues to turn to the left (Stop with pedal brake or parking brake)
General
information
Defective HSS EPC solenoid a Prepare with starting switch OFF and diagnose with starting
left switch still OFF.
1
(internal disconnection and HSA (male) Resistance
Possible
between PTC3 (female) (25) – HSA (female) Voltage Max. 1V
(1)
D85EX, PX-15E0 17
Failure code [DWN5KA] Fan pump EPC solenoid: Disconnection 1
Action code Failure code Symptom Fan pump EPC solenoid: Disconnection
E01 DWN5KA of failure (Steering and transmission controller system)
Failure content • Current does not flow when power is output to fan pump EPC solenoid circuit.
Controller's
• Stops outputting power to fan pump EPC solenoid circuit.
action
Symptoms that
appear on • Fan speed is kept at maximum level
machine
• Output state (current) to fan pump EPC solenoid can be checked in monitoring mode.
General
(Code 31623, 31624: Cooling fan solenoid output current)
information

Defective fan pump solenoid switch still OFF.
1
(Internal disconnection) FAC (male) Resistance
Between (1) – (2) 15 – 25 z
Possible
2 Max. 1 z
(disconnection or defective – FAC (female) (1) tance
Max. 1 z
– FAC (female) (2) tance
Circuit diagram related to fan pump EPC solenoid
18 D85EX, PX-15E0
Failure code [DWN5KB] Fan pump EPC solenoid: Short circuit 1
Action code Failure code Symptom Fan pump EPC solenoid: Short circuit
E01 DWN5KB of failure (Steering and transmission controller system)
Failure content • Abnormal current flowed when power is output to fan pump EPC solenoid circuit.
Controller's
• Stops outputting power to fan pump EPC solenoid circuit.
action
Symptoms that
appear on • Fan speed is kept at maximum level
machine
General
information

switch still OFF.
Defective fan pump solenoid FAC (male) Resistance
1
(Internal short circuit)
Between (1) – (2) 15 – 25 z
2
between PTC3 (female) (36) – FAC (female) Min. 1 Mz
when normal tance
(1)
switch still OFF.
Harness short
– FAC (female) (1) and PTC3 (female) (23) – Min. 1 Mz
tance
FAC (female) (2)
D85EX, PX-15E0 19
Failure code [DWN5KY] Fan pump EPC solenoid: Hot short circuit 1
Action code Failure code Symptom Fan pump EPC solenoid: Hot short circuit
E02 DWN5KY of failure (Steering and transmission controller system)
Failure content • Current flows constantly to fan pump EPC solenoid circuit.
action • Stops outputting power to fan pump EPC solenoid circuit.
Symptoms that
• Fan speed is kept at minimum level.
appear on
• Overheat easily.
machine
General
information

Defective fan pump solenoid switch still OFF.
1 (Internal disconnection and
FAC (male) Resistance
short circuit)
Between (1) – (2) 15 – 25 z
Possible
between PTC3 (female) (36) – FAC (female) Voltage Max. 1V
(1)
20 D85EX, PX-15E0
Failure code [DXA0KA] HSS and work equipment pump TVC solenoid:
Disconnection 1
Action code Failure code Symptom HSS and work equipment pump TVC solenoid: Disconnection
E01 DXA0KA of failure (Steering and transmission controller system)
• Any current does not flow when power is output to HSS and work equipment pump TVC solenoid cir-
Failure content
cuit.
Controller's
• Stops outputting power to HSS and work equipment TVC solenoid circuit.
action
Symptoms that
appear on • When load is applied while engine is running at low speed, engine may tend to stall.
machine
• Output state (current) to HSS and work equipment pump TVC solenoid left can be checked in moni-
General toring mode.
information (Code 01300, 01301: Output current of TVC solenoid)

Defective HSS and work switch still OFF.
1 equipment pump TVC sole-
TVC (male) Resistance
noid (Internal disconnection)
Between (1) – (2) 9 – 19 z
Possible
2 Max. 1 z
(disconnection or defective – TVC (female) (1) tance
Max. 1 z
TVC (female) (2) tance
Circuit diagram related to and work equipment HSS pump TVC solenoid
D85EX, PX-15E0 21
Failure code [DXA0KB] HSS and work equipment pump TVC solenoid:
Short circuit 1
Action code Failure code Symptom HSS and work equipment pump TVC solenoid: Short circuit
E01 DXA0KB of failure (Steering and transmission controller system)
• Abnormal current flowed when power is outputted to HSS and work equipment pump TVC solenoid
Failure content
circuit.
Controller's
• Stops outputting power to HSS and work equipment TVC solenoid.
action
Symptoms that
appear on • When load is applied while engine is running at low speed, engine may tend to stall.
machine

switch still OFF.
Defective HSS and work
1 equipment pump TVC sole- TVC (male) Resistance
noid (Internal short circuit) Between (1) – (2) 9 – 19 z
2
between PTC3 (female) (17) – TVC (female) Min. 1 Mz
when normal tance
(1)
switch still OFF.
Harness short
3 Between wiring harness from PTC3 (female)
(17) to TVC (female) (1) and wiring harness Min. 1 Mz
tance
from PTC3 (female) (3) to TVC (female) (2)
Circuit diagram related to HSS and work equipment pump TVC solenoid
22 D85EX, PX-15E0
Failure code [DXA0KY] HSS and work equipment pump TVC solenoid:
Hot short circuit 1
Action code Failure code Symptom HSS and work equipment pump TVC solenoid: Hot short circuit
E01 DXA0KY of failure (Steering and transmission controller system)
Failure content • Current flows constantly to HSS and work equipment pump TVC solenoid circuit.
Controller's
• Stops outputting power to HSS and work equipment TVC solenoid circuit.
action
Symptoms that
• Large turning radius
appear on
• Work equipment speed is slow.
machine

Defective HSS and work switch still OFF.
1 equipment pump TVC sole-
TVC (male) Resistance
noid (Internal disconnection)
Between (1) – (2) 9 – 19 z
Possible
between PTC3 (female) (17) – TVC (female) Voltage Max. 1V
(1)
Circuit diagram related to HSS and work equipment pump TVC solenoid
D85EX, PX-15E0 23
Failure code [DXH4KA] 1st clutch ECMV: Disconnection 1
Action code Failure code Symptom 1st clutch ECMV: Disconnection

CALL E03 DXH4KA of failure (Steering and transmission controller system)
Failure content • Current does not flow when power is output to transmission 1st clutch solenoid circuit.
Controller's
• Stops outputting to transmission 1st clutch solenoid circuit.
action
Symptoms that • Auto shift down function does not work.
• Output state (current) to 1st clutch solenoid can be checked in monitoring mode.
General
(Code 31602, 31612: 1st clutch ECMV output current value)
information

Defective 1st clutch ECMV switch still OFF.
1
(internal disconnection) S1T (male) Resistance
Between (1) – (2) 5 – 25 z
Possible
when normal harness Wiring harness between PTC3 (female) (6) – Resis-
2 Max. 1 z
(disconnection or defective S1T (female) (1) tance
Max. 1 z
– S1T (female) (2) tance
24 D85EX, PX-15E0
Failure code [DXH4KB] 1st clutch ECMV: Short circuit 1
Action code Failure code Symptom 1st clutch ECMV: Short circuit
CALL E03 DXH4KB of failure (Steering and transmission controller system)
Failure content • Abnormal current flowed when power was output to transmission 1st clutch solenoid circuit.
Controller's
action
General
information

switch still OFF.
Defective 1st clutch ECMV S1T (male) Resistance
1
Between (1) – (2) 5 – 25 z
2
between PTC3 (female) (6) – S1T (female) Min. 1 Mz
when normal tance
(1)
switch still OFF.
Harness short
(6) to S1T (female) (1) and wiring harness Min. 1 Mz
tance
from PTC3 (female) (23) to S1T (female) (2)
D85EX, PX-15E0 25
Failure code [DXH4KY] 1st clutch ECMV: Hot short circuit 1
Action code Failure code Symptom 1st clutch ECMV: Hot short circuit
CALL E03 DXH4KY of failure (Steering and transmission controller system)
Failure content • Current flows constantly to transmission 1st clutch solenoid circuit.
Controller's
action
General
information

Defective 1st clutch ECMV switch still OFF.
S1T (male) Resistance
short circuit)
Between (1) – (2) 5 – 25 z
Possible
between PTC3 (female) (6) – S1T (female) Voltage Max. 1V
(1)
Circuit diagram related to transmission 1st clutch ECMV solenoid
26 D85EX, PX-15E0
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection 1
Action code Failure code Symptom 2nd clutch ECMV: Disconnection

Failure content • Current does not flow when power is output to transmission 2nd clutch solenoid circuit.
Controller's
• Stops outputting to transmission 2nd clutch solenoid circuit.
action
• Output state (current) to 2nd clutch solenoid can be checked in monitoring mode.
General
(Code 31603, 31613: 2nd clutch ECMV output current value)
information

Defective 2nd clutch ECMV. switch still OFF.
1
Between (1) – (2) 5 – 25 z
Possible
2 Max. 1 z
(disconnection or defective – S2T (female) (1) tance
Max. 1 z
D85EX, PX-15E0 27
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit 1
Action code Failure code Symptom 2nd clutch ECMV: Short circuit
Failure content • Abnormal current flowed when power was output to transmission 2nd clutch solenoid circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
Defective 2nd clutch ECMV. S2T (male) Resistance
1
Between (1) – (2) 5 – 25 z
2
when normal tance
(1)
switch still OFF.
Harness short
tance
28 D85EX, PX-15E0
Failure code [DXH5KY] 2nd clutch ECMV: Hot short circuit 1
Action code Failure code Symptom 2nd clutch ECMV: Hot short circuit
Failure content • Current flows constantly to transmission 2nd clutch solenoid circuit.
Controller's
action
General
information

Defective 2nd clutch ECMV. switch still OFF.
short circuit)
Between (1) – (2) 5 – 25 z
Possible
(1)
D85EX, PX-15E0 29
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection 1
Action code Failure code Symptom 3rd clutch ECMV: Disconnection

Failure content • Current does not flow when power is output to transmission 3rd clutch solenoid circuit.
Controller's
• Stops outputting to transmission 3rd clutch solenoid circuit.
action
• Output state (current) to 3rd clutch solenoid can be checked in monitoring mode.
General
(Code 31604, 31614: 3rd clutch ECMV output current value)
information

Defective 3rd clutch ECMV switch still OFF.
1
Between (1) – (2) 5 – 25 z
Possible
2 Max. 1 z
(disconnection or defective – S3T (female) (1) tance
Max. 1 z
30 D85EX, PX-15E0
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit 1
Action code Failure code Symptom 3rd clutch ECMV: Short circuit
Failure content • Abnormal current flowed when power was output to transmission 3rd clutch solenoid circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
Defective 3rd clutch ECMV S3T (male) Resistance
1
Between (1) – (2) 5 – 25 z
2
when normal tance
(1)
switch still OFF.
Harness short
tance
D85EX, PX-15E0 31
Failure code [DXH6KY] 3rd clutch ECMV: Hot short circuit 1
Action code Failure code Symptom 3rd clutch ECMV: Hot short circuit
Failure content • Current flows constantly to transmission 3rd clutch solenoid circuit.
Controller's
action
General
information

Defective 3rd clutch ECMV switch still OFF.
short circuit)
Between (1) – (2) 5 – 25 z
Possible
(1)
32 D85EX, PX-15E0
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection 1
Action code Failure code Symptom Reverse clutch ECMV: Disconnection

Failure content • Current does not flow when power is output to transmission reverse clutch solenoid circuit.
Controller's
• Stops outputting to transmission reverse clutch solenoid circuit.
action
Symptoms that
appear on
machine
• Output state (current) to reverse clutch solenoid can be checked in monitoring mode.
General
(Code 31606, 31616: Output current of reverse clutch ECMV)
information

Defective reverse clutch switch still OFF.
1 ECMV
SRT (male) Resistance
Between (1) – (2) 5 – 25 z
Possible
2 Max. 1 z
(disconnection or defective – SRT (female) (1) tance
Max. 1 z
– SRT (female) (2) tance
D85EX, PX-15E0 33
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit 1
Action code Failure code Symptom Reverse clutch ECMV: Short circuit
Failure content • Abnormal current flowed when power was output to transmission reverse clutch solenoid circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1 solenoid SRT (male) Resistance
(Internal short circuit) Between (1) – (2) 5 – 25 z
2
between PTC3 (female) (37) – SRT (female) Min. 1 Mz
when normal tance
(1)
switch still OFF.
Harness short
(37) to SRT (female) (1) and wiring harness Min. 1 Mz
tance
from PTC3 (female) (13) to SRT (female) (2)
34 D85EX, PX-15E0
Failure code [DXH7KY] Reverse clutch ECMV: Hot short circuit 1
Action code Failure code Symptom Reverse clutch ECMV: Hot short circuit
Failure content • Current flows constantly to transmission reverse clutch solenoid circuit.
Controller's
action
Symptoms that
appear on
machine
General
information
Defective reverse clutch a Prepare with starting switch OFF and diagnose with starting
ECMV switch still OFF.
1
(internal disconnection and SRT (male) Resistance
Possible
between PTC3 (female) (37) – SRT (female) Voltage Max. 1V
(1)
D85EX, PX-15E0 35
Failure code [DXH8KA] Forward clutch ECMV: Disconnection 1
Action code Failure code Symptom Forward clutch ECMV: Disconnection

Failure content • Current does not flow when power is output to transmission forward clutch solenoid circuit.
Controller's
• Stops outputting to transmission forward clutch solenoid circuit.
action
Symptoms that
appear on
machine
• Output state (current) to forward clutch solenoid can be checked in monitoring mode.
General
(Code 31608, 31622: Output current of forward clutch ECMV)
information

Defective forward clutch switch still OFF.
1 ECMV
SFT (male) Resistance
Between (1) – (2) 5 – 25 z
Possible
2 Max. 1 z
(disconnection or defective – SFT (female) (1) tance
Max. 1 z
– SFT (female) (2) tance
36 D85EX, PX-15E0
Failure code [DXH8KB] Forward clutch ECMV: Short circuit 1
Action code Failure code Symptom Forward clutch ECMV: Short circuit
Failure content • Abnormal current flowed when power was output to transmission forward clutch solenoid circuit.
Controller's
action
Symptoms that
appear on
machine
General
information

switch still OFF.
1 ECMV SFT (male) Resistance
(Internal short circuit) Between (1) – (2) 5 – 25 z
2
between PTC3 (female) (27) – SFT (female) Min. 1 Mz
when normal tance
(1)
switch still OFF.
Harness short
(Harness internal short)
(27) to SFT (female) (1) and wiring harness Min. 1 Mz
from PTC3 (female) (13) to SFT (female) (2)
D85EX, PX-15E0 37
Failure code [DXH8KY] Forward clutch ECMV: Hot short circuit 1
Action code Failure code Symptom Forward clutch ECMV: Hot short circuit
Failure content • Current flows constantly to transmission forward clutch solenoid circuit.
Controller's
action
Symptoms that
appear on
machine
General
information
Defective forward clutch a Prepare with starting switch OFF and diagnose with starting
ECMV switch still OFF.
1
(internal disconnection and SFT (male) Resistance
Possible
between PTC3 (female) (27) – SFT (female) Voltage Max. 1V
(1)
38 D85EX, PX-15E0
SEN00637-00

© 2006 KOMATSU
All Rights Reserved
40
SEN00638-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
Troubleshooting of electrical system
(E-mode)
Troubleshooting of electrical system (E-mode)............................................................................................... 3
Before troubleshooting of electrical system ......................................................................................... 3
Contents of troubleshooting table......................................................................................................... 5
E-1 Engine does not start..................................................................................................................... 6
E-2 The preheater does not operate. ................................................................................................... 9
E-3 The monitor panel does not light up at all when the starting switch is turned ON. ...................... 12
E-4 When the starting switch is turned ON, the monitor panel completely remains lighted and
does not go out. .......................................................................................................................... 14
E-5 When the starting switch is turned ON, the radiator coolant level caution lamp flashes. ............ 15
E-6 While the engine is running, the battery charge level caution lamp flashes. ............................... 16
E-7 While the engine is running, the emergency warning item flashes.............................................. 18
E-8 While the preheater is operating, the preheating pilot lamp does not light up............................. 20
E-9 The coolant temperature gauge does not indicate correctly. ....................................................... 22
E-10 Power train oil temperature gauge does not indicate correctly. ................................................. 24
D85EX, PX-15E0 1
E-11 Hydraulic oil temperature gauge does not indicate properly. ..................................................... 26
E-12 Fuel gauge does not indicate properly....................................................................................... 28
E-13 Gear speed and engine speed are not indicated properly. ........................................................ 29
E-14 The preset mode and service meter do not indicate properly.................................................... 29
E-15 The warning lamp does not flash or does not go out................................................................. 30
E-16 The alarm buzzer does not sound or does not stop. ................................................................. 32
E-17 Auto shift down does not operate or does not release. ............................................................. 34
E-18 Buzzer cancel switch does not work.......................................................................................... 36
E-19 The information switch does not work. ...................................................................................... 38
E-20 The manual mode does not operate or does not release. ......................................................... 40
E-21 The monitor panel cannot be set in the service mode or
cannot be set out of the service mode. ....................................................................................... 42
E-22 The back-up alarm does not sound. .......................................................................................... 44
E-23 The head lamp and rear lamp do not light up. ........................................................................... 46
E-24 The horn does not sound or does not stop. ............................................................................... 49
E-25 Malfunction of wipers ................................................................................................................. 50
E-26 Washer does not spray water .................................................................................................... 66
E-27 The air conditioner does not operate ......................................................................................... 71
E-28 KOMTRAX system does not operate normally. ......................................................................... 76
2 D85EX, PX-15E0
Troubleshooting of electrical system (E-mode) 1

Before troubleshooting of electrical system 1
Connection table of fuse box
a This wiring table shows apparatuses to which electric power is supplied through the fuse box and circuit
breaker. (A switching power source supplies power with the starting switch ON. Constant power source
supplies power with starting switch either ON or OFF.)
a When carrying out troubleshooting related to the electrical systems, firstly check the fuse or circuit
breaker to see whether the power is supplied normally or not.
Fuse box A [FS1]
Electric supply Fuse

Fuse No. Destinations of electric power distribution
source capacity (A)
1 30 Standby electric power supply
2 Switched electric 20 Horn, Electrical intake air heater, Air suspension seat
3 power supply 20 Head lamp
4 20 Rear lamp
Constant power Transmission and steering controller, Monitor panel,
5 20
source KOMTRAX
Fuse box B [FS2]

source capacity (A)
Constant power
1 20 Starting switch (B) (with 20 A circuit breaker in the subsequent circuit)
source
2 30 Steering and transmission controller (main electric power supply)
3 Switched electric 30 Backup alarm
4 power supply 30 Air conditioner (with 20 A circuit breaker in the subsequent circuit)
5 30 Starting switch (ACC), Engine controller
Cab fuse box C

source capacity (A)
1 10 Accessory electric power supply (12 V electric power supply)
2 20 Radio, Room lamp, Cigarette lighter, Additional light
3 Switched electric 20 Glass with heating wire
4 power supply 10 Rear wiper
5 10 Front wiper
6 10 Left and right door wipers
D85EX, PX-15E0 3
Fuse installation position and No.
Circuit breaker
No. Connector No. Capacity (A) Circuit Remarks
1 CB105 105 Main power source Installed in the
2 CB30H 30 Engine controller constant power source battery box
located at the left
3 CB105 105 Main power source for electrical intake air heater side of the opera-
4 CB30 30 Constant power source tor cab
5 CB1 20 Starting switch Installed in the
dash board air
6 CB2 20 Air conditioner conditioner filter
a Recovery operation of circuit breaker

Turn the starting switch OFF and push in reset button (7) which is pushed out. If the button returns
immediately after it is pushed in, carry out the troubleshooting and repair the defective part.
4 D85EX, PX-15E0

a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Trouble Problem that appears on machine

Related
Information related to detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting

<Described contents>
• Standard value in normal state required to judge the
assumed cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Causes by which a trouble A harness of an independent circuit abnormally comes into
and standard is assumed to be defected contact with one of another circuit.
value in normal (The order number indi-
state cates a serial number, not <Notes on troubleshooting>
a priority sequence.) (1) Method of indicating connector numbers and handling of T-
adapter
For troubleshooting, insert or connect T-adapter shown
3 below unless especially specified.
• When “male” or “female” is not indicated for a connector
number, disconnect the connector, and insert the T-
adapters in both the male and female.
• When “male” or “female” is indicated for a connector
number, disconnect connector, and insert the T-adapter
in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated in
the front.
• Connect the minus (–) lead to a pin or harness indicated
in the rear.
Related circuit diagram
This is the excerpted circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – No. of pins) (Color).
• “Connector No. and pin No.” from each branching/merging point: indi-
cate the ends of branch or source of merging within the parts of the
same wiring harness
• Arrow (io): Roughly indicates mounting place on machine.
D85EX, PX-15E0 5
E-1 Engine does not start. 1
Symptom of
• The starting motor does not turn and accordingly the engine does not start.
failure
• Since the engine starting circuit has the neutral safety function, the engine does not start unless the
parking lever is in the lock position and the travel and swing lever are in the neutral position.
• If “the monitor panel does not light up” or “the battery relay does not make operating noise” when
General turning the starting switch ON, the main electric power supply system can be suspected to be defec-
information tive. So, check the main electric power supply system.
• Before starting the troubleshooting, validate that the related failure code is not displayed.
(If the failure code [D130KA], [D130KB], [DD14KA], [DD14KB], [DDQ2KA] or [DDQ2KB] is displayed,
conduct troubleshooting for the displayed code first.)

Battery voltage Battery specific gravity
1 Insufficient battery capacity
Min. 24 V Min. 1.26
switch still OFF.
Defective starting switch Starting switch Switch position Resistance
2
Between 250 (B) and OFF Min. 1 Mz
280 (C) START Max. 1 z
switch ON.
Defective parking lever
switch Parking lever
3
(internal defect or defective Free position Lock position
adjustment) Monitor panel
Other than “P” is
“P” is displayed.
displayed.
nose.
Possible Defective neutral safety relay If the engine starts in accordance with the engine starting operation
causes and the 4
(internal disconnection) after the neutral safety relay (NSF) is replaced with another one
standard values
while the starting switch is set to OFF, the neutral safety relay is
when normal
defective.
Defective alternator switch ON.
5
(internal short circuit) Alternator Voltage
Between terminal R and ground Max. 1 V
nose.
Starting motor Voltage
Electric power supply: between
20 – 30 V
terminal ST/B and ground
Detective starting motor Charge: between ST (2) and
6 Max. 1 V
(internal defect) ground
Starting: between ST (1) and
20 – 30 V
ground
When each voltage of electric power supply, charging, and starting
is normal but the starting motor does not rotate, the starting motor is
defective.
6 D85EX, PX-15E0

switch still OFF.
Defective diode
7 Diagnose diode RSD (male)
• See the “Inspection procedure of diode” in the “Testing and
adjusting” section.
harness Wiring harness between 280 (C) – NSF Resis-
8 Max. 1 z
(disconnection or defective (female) (3) tance
contact of connectors) Wiring harness between NSF (female) (5) – Resis-
Possible Max. 1 z
ST (female) (1) tance
causes and the
Hot short of wiring harness Between ground and wiring harness

9 between alternator R terminal – ST (female)
(2), alternator R terminal – PTC1 (female) Voltage Max. 1V
(15) and alternator R terminal – S04 (female)
(9)
switch still OFF.
10 Min. 1 Mz
(contact with ground circuit) between 280 (C) – NSF (female) (3) tance
Min. 1 Mz
between NSF (female) (5) – ST (female) (1) tance
D85EX, PX-15E0 7
Circuit diagram related to engine start and charge
8 D85EX, PX-15E0
E-2 The preheater does not operate. 1
Symptom of
• The preheater does not operate.
failure
a This troubleshooting describes the procedures to be followed when the automatic and manual pre-
heating does not function to heat the electrical intake air heater mounting section.
(When only the preheating lamp does not light up, carry out the troubleshooting of “E-8 While the
preheater is operating, the preheating pilot lamp does not light up”)
• For preheating, both the “Automatic preheating function” and “Manual preheating function” are avail-
General able. When either function is performed, the preheating lamp comes on.
information • If “the monitor panel does not light up” or “the battery relay does not make operating noise” when
turning the starting switch ON, the main electric power supply system can be suspected to be defec-
tive. So, check the main electric power supply system.
(If the failure code [CA153], [CA154], [CA2555] or [CA2556] is displayed, firstly conduct this trouble-
shooting.)

switch still OFF.
1
Between 250 (B) – OFF Min. 1 Mz
255 (R1) HEAT (R1) Max. 1 z
Defective fuse If the fuse is burnt, it is highly possible that a defective grounding,
2
(FS1, FS2) etc. has occurred in the circuit.
Defective circuit breaker If the breaker is cutout, it is highly possible that a defective ground-
3
(CB105H) ing, etc. has occurred in the circuit.
switch ON.
Defective preheater relay
4 If preheating starts normally at the intake air temperature below
minus 5°C after the preheater relay RHR is replaced with another
one, the preheater relay RHR is defective.
Possible
a Prepare with the starting switch OFF and diagnose with the start-
causes and the
ing switch HEAT.
standard values
when normal Heater relay Voltage
Electric power supply: between
Defective heater relay 20 – 30V
5 terminal HT/B and ground
(internal defect)
Signal: between terminal HT/C
20 – 30V
and ground
When the both voltages of electric power supply and signal are nor-
mal and no operating noise is heard, the heater relay is defective.
switch still OFF.
Defective diode
6 Diagnose diode HDT (male)
• See the “Inspection procedure of diode” in the “Testing and
Defective electrical intake air switch still OFF.
7
heater (internal defect) Electrical intake air heater Continuity
Between terminals Continue
D85EX, PX-15E0 9

switch still OFF.
Wiring harnesses between starting switch
Resis-
255 (R1) – RHR (female) (3) and between Max. 1 z
Disconnection in wiring tance
starting switch 255 (R1) – HT/C
harness
8 Wiring harness between RHR (female) (5) – Resis-
(disconnection or defective Max. 1 z
FS1 (2) tance
contact of connectors)
Wiring harness between battery relay BRC Resis-
Max. 1 z
terminal – HT/B terminal tance
Possible Wiring harness between heater relay HT/A Resis-
Max. 1 z
causes and the terminal – electrical intake air heater tance
Resis-
between starting switch 255 (R1) – RHR (3) Min. 1 Mz
tance
and starting switch 255 (R1) – HT/C
9 Min. 1 Mz
(contact with ground circuit) between RHR (female) (5) – FS1 (2) tance
Min. 1 Mz
between battery relay BRC terminal – HT/B tance
Resis-
between heater relay HT/A – electrical intake Min. 1 Mz
tance
air heater terminal
10 D85EX, PX-15E0
Circuit diagram related engine preheat
D85EX, PX-15E0 11
E-3 The monitor panel does not light up at all when the starting switch is
turned ON. 1
• If “the battery relay does not make operating sound” when the starting switch is turned on, the main
Symptom of electric power supply system can be suspected to be defective. So, check the main electric power
failure supply system.
• The monitor panel does not light up at all when the starting switch is turned ON.
General • When the starting switch is turned ON, the gear speed indicator, multi-information section, gauge
information section, and lamp section light up for approximately 2 sec. and then go out.

When the fuse FS1-5 is blown, the circuit probably has a ground
fault.
switch still OFF.
Disconnection in wiring Wiring harness between S03 (female) (1) (2) Resis-
Max. 1 z
harness – starting switch 270 (ACC) tance
2
(disconnection or defective Wiring harness between S03 (female) (5) (6) Resis-
– fuse FS1-5 tance
Wiring harness between S03 (female) (3) (4) Resis-
Possible Max. 1 z
– GND02 tance
causes and the
standard values
switch still OFF.
when normal
Between ground wiring harness between
Defective harness grounding Resis-
3 S03 (female) (1) (2) – starting switch 270 Min. 1 Mz
(contact with ground circuit) tance
(ACC)
Min. 1 Mz
between S03 (female) (5) (6) and fuse FS1-5 tance
switch ON.
4 Defective monitor panel S03 Voltage
Between (1) (2) – (3) (4) 20 – 30 V
Between (5) (6) – (3) (4) 20 – 30 V
12 D85EX, PX-15E0
Circuit diagram related to electric power supply to monitor panel
D85EX, PX-15E0 13
E-4 When the starting switch is turned ON, the monitor panel
completely remains lighted and does not go out. 1
Symptom of • When the starting switch is turned ON, the monitor panel completely remains lighted and does not go
failure out.
General • When the starting switch is turned ON, the gear speed indicator, multi-information section, gauge
information section, and lamp section light up for approximately 2 sec. and then go out.
Possible Cause Standard value when normal and remarks for troubleshooting
causes and the
standard values 1 Defective monitor panel Since this is an internal defect, it cannot be diagnosed.
when normal
14 D85EX, PX-15E0
E-5 When the starting switch is turned ON, the radiator coolant level
caution lamp flashes. 1
Symptom of
• Radiator coolant level caution lamp flashes.
failure
General • Regarding basic check items, the caution lamp flashes if any abnormality is detected before engine
information starting.

Since the low radiator coolant level is detected, check the radiator
Radiator coolant level is too
coolant level.
1 low.
(The lamp flashes in case that the level is lower than the specifica-
tion.)
switch still OFF.
Defective radiator coolant WLD (male) Radiator coolant level Resistance
2
level sensor
When normal Max. 1 z
Between (1) – (2)
Possible When level is too low. Min. 1 Mz
causes and the
standard values
when normal
harness Wiring harness between S03 (female) (11) – Resis-
3 Max. 1 z
(disconnection or defective WLD (female) (1) tance
contact of connectors) Wiring harness between WLD (female) (2) Resis-
Max. 1 z
and ground GND03 tance
switch ON.
4 Defective monitor panel S03 Radiator coolant level Voltage
Between (11) and When normal Max. 1V
ground When level is too low. Min. approx. 7 V
Circuit diagram related to electric power supply to monitor panel
D85EX, PX-15E0 15
E-6 While the engine is running, the battery charge level caution lamp
flashes. 1
Symptom of
• The battery charge level caution lamp flashes.
failure
General • When any abnormality is detected during engine operating, the battery charge level caution lamp
information flashes.

Defective alternator nose.
1 (insufficient power genera- Alternator Engine speed Voltage
tion) Between terminal R Min. medium speed
20 – 30 V
and ground (half)
switch still OFF.
Disconnection in wiring Wiring harness between S04 (female) (9) – Resis-
Max. 1 z
harness alternator terminal AL/R tance
2
(disconnection or defective Wiring harness between alternator terminal Resis-
Possible Max. 1 z
contact of connectors) AL/E and ground tance
causes and the
standard values Wiring harness between PTC1 (female) (15) Resis-
Max. 1 z
when normal – alternator terminal AL/R tance
switch still OFF.
between S04 (female) (9) – alternator termi- Resis-
Min. 1 Mz
Defective harness grounding nal AL/R and S04 (female) (9) – PTC1 tance
3
(contact with ground circuit) (female) (15)
between PTC3 (female) (4) – starting switch Resis-
Min. 1 Mz
260 (BR) and PTC3 (female) (4) – SW (bat- tance
tery relay)
16 D85EX, PX-15E0
Circuit diagram related to engine start and charge
D85EX, PX-15E0 17
E-7 While the engine is running, the emergency warning item flashes. 1
Symptom of
(1) The engine oil pressure caution lamp flashes.
failure
• When any abnormality is detected during engine running, the engine oil pressure caution lamp
General
flashes and the alarm buzzer sounds.
information
• The engine oil pressure sensor signal is used to communicate with the engine controller.

Reduction of engine oil pres- Check the engine oil pressure, as the drop of engine oil pressure is
1 sure detected.
Possible (When system is normal) • Carry out the troubleshooting of “S-12 Oil pressure drops.”
causes and the
standard values If no problem is found in cause 1, the engine oil pressure sensor cir-
when normal Defective engine hydraulic cuit can be suspected to be defective. So, carry out the trouble-
2
system shooting of “Failure codes [CA135] and [CA141] Abnormal engine
oil pressure sensor.”
Symptom of
(2) The coolant temperature caution lamp flashes.
failure
• When any abnormality is detected while engine is running, the coolant temperature caution lamp
flashes and the alarm buzzer sounds.
• The coolant temperature caution lamp flashes or goes out in accordance with an indication on the
General
engine water temperature gauge.
information
• The input state (temperature) from the coolant temperature sensor can be checked in the monitoring
mode.
(Code 04104: Coolant temperature)

Since the coolant overheat is detected, check the coolant tempera-
Coolant overheats
1 ture. (At the coolant temperature over 105°C, the lamp flashes and
Possible (When system is normal)
the buzzer sounds. Over 102°C, just the lamp flashes.)
causes and the
standard values When the cause 1 is not the real cause, the coolant temperature
Defective coolant tempera-
when normal sensor circuit can be suspected to be defective. So, carry out the
2 ture sensor system
troubleshooting of “E-9 The coolant temperature gauge does not
(Engine controller circuit)
indicate correctly.”
18 D85EX, PX-15E0
Symptom of
(3) The power train oil temperature caution lamp flashes.
failure
• When any abnormality is detected while engine is running, the power train oil temperature caution
lamp flashes and the alarm buzzer sounds.
• The power train oil temperature caution lamp flashes or goes out in accordance with indication on
the power train oil temperature gauge.
General
• The input state (temperature) from the power train oil temperature sensor can be checked in the
information
monitoring mode.
(If the failure code [DGT1KA] or [DGT1KX] is displayed, firstly diagnose the displayed code.)

Since the power train oil overheat is detected, check the power train
Power train oil temperature
oil temperature.
1 overheat
Possible (At the oil temperature over 130°C, the lamp flashes and the buzzer
causes and the sounds. Over 120°C, just the lamp flashes.)
standard values If no problem is found in cause 1, the power train oil temperature
when normal Defective power train oil tem-
sensor circuit can be suspected to be defective. So, carry out the
2 perature sensor circuits
troubleshooting of “E-10 The power train oil temperature gauge
(Monitor panel circuit)
does not indicate correctly.”
Symptom of
(4) The hydraulic oil temperature caution lamp flashes.
failure
• When any abnormality is detected while engine is running, the hydraulic oil temperature caution
lamp flashes and the alarm buzzer sounds.
• The hydraulic oil temperature caution lamp flashes or goes out in accordance with indication on the
hydraulic oil temperature gauge.
General
• The input state (temperature) from the hydraulic oil temperature sensor can be checked at monitor-
information
ing mode.
(If the failure code [DGS1KX] is displayed, firstly diagnose the displayed code.)

Since the hydraulic oil overheat is detected, check the hydraulic oil
Hydraulic oil overheat
1 temperature. (At the hydraulic oil temperature over 110°C, the lamp
Possible (When system is normal)
flashes and the buzzer sounds. Over 100°C, just the lamp flashes.)
causes and the
standard values When the cause 1 is not the real cause, the hydraulic oil tempera-
Defective hydraulic oil tem-
when normal ture sensor circuit can be suspected to be defective. So, carry out
2 perature sensor circuit
the troubleshooting of “E-11 The hydraulic oil temperature gauge
(Monitor panel circuit)
does not indicate correctly.”
D85EX, PX-15E0 19
E-8 While the preheater is operating, the preheating pilot lamp does not
light up. 1
Symptom of
While the preheater is operating, the preheating pilot lamp does not light up.
failure
a This troubleshooting describes the procedures to be followed when the preheating lamp doe not light
up. (When the electrical intake air heater mounting section is not heated, carry out the troubleshoot-
General
ing of “E-2 The preheater does not operate.”)
information
• For preheating, both the “Automatic preheating function” and “Manual preheating function” are avail-
able. When either function is performed, the preheating lamp comes on.
Cause Standard value when normal and remarks for troubleshooting

1
(Disconnection or defective Wiring harness between S03 (female) (9) – Resis-
RHR (female) (3) tance
2
standard values (Contact with ground circuit) Between ground and wiring harness Resis-
between S03 (female) (9) – RHR (female) Min. 1 Mz
when normal tance
(3)
switch ON.
3 Defective monitor panel S03 Starting switch Voltage
ON Min. 1 V
Between (9) – ground
HEAT Min. 7 V
20 D85EX, PX-15E0
Circuit diagram related to engine preheat
D85EX, PX-15E0 21
E-9 The coolant temperature gauge does not indicate correctly. 1
(1) Although the coolant temperature is rising normally, the indication of the coolant temperature stays
Symptom of in white range (a).
failure (2) Although the coolant temperature is stabilized normally, the indication of the coolant temperature
rises to red range (c).
• Signals of the coolant temperature sensor are input into the engine controller and that information is
transmitted to the monitor panel through communication system.
General
information
mode.

Since the coolant temperature sensor circuit is supposed to be
Possible Defective coolant tempera-
1 defective, carry out the troubleshooting of failure codes [CA144]
causes and the ture sensor circuit
and [CA145].
standard values
when normal When the possible cause 1 is not the real cause, the monitor panel
2 Defective monitor panel is supposed to be defective. (As it is an internal defect, it cannot be
diagnosed.)
Symptom of (3) The coolant temperature does not match to the indication of coolant temperature gauge.
failure (4) The coolant temperature gauge does not match with the indication of coolant temperature monitor.
• Signals of the coolant temperature sensor are input into the engine controller and that information is
transmitted to the monitor panel through communication system.
General
information
mode.
Possible a Diagnose with starting switch ON or with engine started.

causes and the Caution lamp (d)
standard values 1 Defective monitor panel OFF Flashing
when normal
White range (a)
Red range (c)
Green range (b)
Coolant temperature gauge and caution lamp
22 D85EX, PX-15E0
E-10 Power train oil temperature gauge does not indicate correctly. 1
(1) Although the power train oil temperature is rising normally, the indication of the power train oil tem-
Symptom of perature stays in white range (a).
failure (2) Although the power train oil temperature is stabilized normally, the indication of the power train oil
temperature rises to red range (c).
monitoring mode.
General
information
• If an abnormality takes place in the power train oil temperature sensor circuit, the failure code
[DGT1KA] or [DGT1KX] may be displayed.

switch still OFF.
Defective power train oil Torque converter
temperature sensor 453 (male) Resistance
1 oil temperature
(internal disconnection or
short circuit) Between (1) – (2) 3.5 – 90 kz
Between (1) and 10 – 100°C
Min. 1 Mz
ground
2 Max. 1 z
(disconnection or defective 453 (female) (1) tance
contact of connectors) Wiring harness between 453 (female) (2) – Resis-
Max. 1 z
S03 (female) (3) tance
causes and the Defective grounding of wiring switch still OFF.
standard values 3 harness Between ground and wiring harness
when normal (contact with GND circuit) Resis-
between S04 (female) (12) – 453 (female) Min. 1 Mz
tance
(1)
switch ON.
4 between S04 (female) (12) – 453 (female) Voltage Max. 1V
(1)
Voltage Max. 1V
between 453 (female) (2) – S03 (female) (3)
switch still OFF.
Power train oil tem-
5 Defective monitor panel S04 (female) Resistance
perature
Between (12) and
10 – 100°C 3.5 kz – 90 kz
ground
24 D85EX, PX-15E0
(3) The power train oil temperature does not match with the indication of oil temperature gauge.
Symptom of
(4) The power train oil temperature gauge does not match with the indication of the power train oil tem-
failure
perature monitor.
General
monitoring mode.
information

when normal
White range (a)
Red range (c)
Green range (b)
Power train oil temperature gauge and caution lamp
D85EX, PX-15E0 25
E-11 Hydraulic oil temperature gauge does not indicate properly. 1
(1) Though the hydraulic oil temperature rises normally, the gauge indication does not rise from white
Symptom of range (a).
failure (2) Although the hydraulic oil temperature is stabilized normally, but gauge indication rises to red range
(c).
• Signals of the hydraulic oil temperature sensor are input to the steering and transmission controller
and the information is transmitted to monitor panel through communication system.
• When any abnormality occurred in the hydraulic oil temperature sensor system, the failure code
General
[DGS1KX] may be displayed.
information
• The input state (temperature) from the hydraulic oil temperature sensor can be checked in monitor-
ing mode.
(Code: 04401 hydraulic oil temperature)

Defective hydraulic oil tem- switch still OFF.
perature sensor SDS (male) Resistance
1
(internal disconnection and
short circuit) Between (1) – (2) 3.5 kz – 90 kz
2 Max. 1 z
(disconnection or defective SDS (female) (1) tance
Max. 1 z
– SDS (female) (2) tance
Defective grounding of wiring switch still OFF.
Possible
3 harness Between ground and wiring harness
causes and the Resis-
(contact with GND circuit) between PTC1 (female) (9) – SDS (female) Min. 1 Mz
when normal (1)
switch ON.
Hot short of wiring harness between PTC1 (female) (9) – SDS (female) Voltage Max. 1V
4
between PTC1 (female) (21) – SDS (female) Voltage Max. 1V
(2)
switch still OFF.
Defective steering and PTC1 (female) Resistance
5
Between (9) – (21) 3.5 kz – 90 kz
26 D85EX, PX-15E0
Circuit diagram related to hydraulic oil temperature sensor
Symptom of (3) Actual temperature of the hydraulic oil and the indication of the oil temperature gauge do not match.
failure (4) Indication of hydraulic oil temperature gauge and hydraulic oil temperature monitor do not match.
• The input state (temperature) from the hydraulic oil temperature sensor can be checked at monitor-
General
ing mode.
information

when normal
White range (a)
Red range (c)
Green range (b)
Hydraulic oil temperature gauge and caution lamp
D85EX, PX-15E0 27
E-12 Fuel gauge does not indicate properly. 1
Symptom of
Fuel gauge does not indicate properly.
failure
General • The input state (voltage signal) from the fuel level sensor can be checked in monitoring mode.
information (Code: 04200 fuel level sensor voltage)

switch still OFF.
Defective fuel level sensor
1 (Internal disconnection and 423 (male) Fuel level Resistance
short circuit) Between (1) – (2) Full Approx. 4 z
ground Empty Approx. 85 z
2 Max. 1 z
(Disconnection or defective 423 (female) (1) tance
contact of connectors) Wiring harness among 423 (female) (2) – Resis-
Possible Max. 1 z
S03 (female) (3), (4) – ground tance
causes and the
standard values
Defective grounding of wiring switch still OFF.
when normal
(Contact with GND circuit) Resis-
between S04 (female) (10) – 423 (female) Min. 1 Mz
tance
(1)
switch ON.
Hot short of wiring harness between S04 (female) (10) – 423 (female) Voltage Max. 1V
4
(Contact with 24 V circuit) (1)
between 423 (female) (2) – S03 (female) (3) Voltage Max. 1V
(4)
Circuit diagram related to fuel level sensor
28 D85EX, PX-15E0
E-13 Gear speed and engine speed are not indicated properly. 1
Symptom of
• Gear speed and engine speed are not indicated properly.
failure
General • Signals of gear speed and engine speed are sent and received through communication by steering
information transmission controller and engine controller.
causes and the
when normal
E-14 The preset mode and service meter do not indicate properly. 1
Symptom of
(1) While engine is running, the service meter does not advance.
failure
• The service meter accumulates time while the monitor panel is receiving engine run signals (alterna-
General tor signals).
information The display data of the preset mode and service meter is received from the S/T and T/M controller
through communication system.

Possible When the battery charge level caution lamp flashes during engine
Defective alternator signal
causes and the 1 operation, carry out the troubleshooting of "E-6 While engine is run-
circuit
standard values ning, battery charge level caution lamp flashes."
when normal Defective monitor panel
(Gauge or lamp module)
Symptom of
(2) Shift mode and service meter are not displayed at all.
failure
General • The display data are sent and received through communication by the steering and transmission
information controller.
causes and the
when normal
D85EX, PX-15E0 29
E-15 The warning lamp does not flash or does not go out. 1
Symptom of
• The warning lamp does not flash or does not go out.
failure
General
information
causes and the
when normal
30 D85EX, PX-15E0
E-16 The alarm buzzer does not sound or does not stop. 1
Symptom of
• The alarm buzzer does not sound or does not stop.
failure
General • When a short circuit occurs in the alarm buzzer system, the failure code [DV00KB] is displayed but
information no other failure codes are displayed.

a Prepare with the starting switch OFF, then carry out troubleshoot-
ing without turning the starting switch ON.
1
(Internal disconnection)
Between (B) – 270 OFF Min. 1 Mz
(ACC) ON(ACC) Max. 1 z
switch still OFF.
Defective alarm buzzer
2 (Internal disconnection and 217 (male) Continuity
short circuit) Between (2) – (1) Continue
Between (1), (2) – ground No continuity
Possible harness Wiring harness between S03 (female) (18) – Resis-
3 Max. 1 z
causes and the (Disconnection or defective 217 (female) (1) tance
standard values contact of connectors) Wiring harness between 217 (female) (2) – Resis-
starting switch 270 (ACC) tance
switch still OFF.
Defective grounding of wiring Resis-
between starting switch 270 (ACC) – 271 Min. 1 Mz
4 harness tance
(female) (2)
(Contact with GND circuit)
Resis-
between 217 (female) (1) – S03 (female) Min. 1 Mz
tance
(18)
switch ON.
Defective monitor panel S03 Alarm buzzer Voltage
5
(Gauge or lamp module) When stopping 20 – 30V
Between (18) –
ground When turned ON
Max. 3V
(sounding)
32 D85EX, PX-15E0
Circuit diagram related to alarm buzzer
D85EX, PX-15E0 33
E-17 Auto shift down does not operate or does not release. 1
Symptom of
• The auto shift down does not operate or does not release.
failure
General
information

switch still OFF.
Defective auto shift down
switch Auto shift down
1 ASD (male) Resistance
(Internal disconnection or switch
short circuit) OFF(0) Min. 1 Mz
Between (2) – (3)
ON(1) Max. 1 z
2 Max. 1 z
(disconnection or defective – ASD (female) (2) tance
Possible contact of connectors) Wiring harness between ASD (female) (3) Resis-
Max. 1 z
causes and the and ground tance
Defective grounding of wiring
(contact with GND circuit) between PTC2 (female) (37) – ASD (female) Voltage Max. 1V
(2)
switch ON.
Defective steering and Auto shift down
4 Between PTC2 (37) – Voltage
transmission controller switch
PTC3 (21), (31), (32),
OFF(0) 5 – 11 V
(33)
ON(1) Max. 1 V
Limitation of function by If no problem is found in causes 1 – 4, the steering and transmission
5
controller controller may be restricting the function because of other causes.
34 D85EX, PX-15E0
Circuit diagram related to auto shift down switch
D85EX, PX-15E0 35
E-18 Buzzer cancel switch does not work. 1
Symptom of
• Buzzer cancel switch does not work.
failure
General
information

switch still OFF.
Buzzer cancel
BUZ (male) Resistance
Defective buzzer cancel switch
1 switch (internal disconnec- OFF (Center) Min. 1 Mz
tion or short circuit) Between (1) – (2)
t (Right) Max. 1 z
OFF (Center) Min. 1 Mz
Between (1) – (3)
U (Left) Max. 1 z
switch still OFF.
Max. 1 z
harness – BUZ (female) (2) tance
2
– BUZ (female) (3) tance
Possible Wiring harness between BUZ (female) (1) – Resis-
Max. 1 z
causes and the GND01 tance
Resis-
Defective harness grounding between PTC2 (female) (36) – BUZ (female) Min. 1 Mz
3 tance
Resis-
between PTC2 (female) (26) – BUZ (female) Min. 1 Mz
tance
(3)
switch ON.
Steering and trans- Buzzer cancel
Voltage
mission controller switch
Defective steering and Between PTC2 (36) – OFF (Center) 5 – 11 V
4
transmission controller PTC3 (21), (31), (32),
(33) t (Right) Max. 1 V
Between PTC2 (26) – OFF (Center) 5 – 11 V
PTC3 (21), (31), (32),
(33) U (Left) Max. 1 V
36 D85EX, PX-15E0
Circuit diagram related to buzzer cancel switch
D85EX, PX-15E0 37
E-19 The information switch does not work. 1
Symptom of
• Information switch does not work.
failure
General
information

switch still OFF.
Information
CUR (male) Resistance
Defective information switch switch
1 (internal disconnection and OFF (Center) Min. 1 Mz
> (Right) Max. 1 z
OFF (Center) Min. 1 Mz
Between (1) – (3)
< (Left) Max. 1 z
switch still OFF.
Max. 1 z
harness – CUR (female) (2) tance
2
CUR (female) (3) tance
Wiring harness between CUR (female) (1) – Resis-
Possible Max. 1 z
GND01 tance
causes and the
Resis-
Defective harness grounding between PTC2 (female) (16) – CUR (female) Min. 1 Mz
3 tance
Resis-
between PTC2 (female) (6) – CUR (female) Min. 1 Mz
tance
(3)
switch ON.
Steering and trans-
Information
mission Voltage
switch
controller
4 Between PTC2 (16) – OFF (Center) 5 – 11 V
PTC3 (21), (31), (32),
(33) > (Right) Max. 1 V
Between PTC2 (6) – OFF (Center) 5 – 11 V

PTC3 (21), (31), (32),
(33) < (Left) Max. 1 V
38 D85EX, PX-15E0
Circuit diagram related to information switch
D85EX, PX-15E0 39
E-20 The manual mode does not operate or does not release. 1
Symptom of
• The manual mode or preset mode does not operate or does not release.
failure
General
information

switch still OFF.
Defective manual mode
1 switch MAM (male) Manual mode switch Resistance
(Internal disconnection) Manual (O) Min. 1 Mz
Between (2) – (3)
Preset (I) Max. 1 z
switch still OFF.
2 (disconnection or defective Max. 1 z
– MAM (female) (2) tance
contact)
Possible Wiring harness between MAM (female) (3) Resis-
Max. 1 z
causes and the and ground tance
3
between PTC2 (female) (10) – MAM Max. 1 Mz
tance
(female) (2)
switch ON.
Defective steering and PTC2 Manual mode switch Voltage
4
Between (10) and Manual (0) 5 – 11 V
ground Preset (I) Max. 1V
Limitation of function by If no problem is found in causes 1 – 4, the steering and transmission
5
controller controller may be restricting the function because of other causes.
40 D85EX, PX-15E0
Circuit diagram related to manual mode
D85EX, PX-15E0 41
E-21 The monitor panel cannot be set in the service mode or cannot be
set out of the service mode. 1
Symptom of
• The monitor panel cannot be set in the service mode or cannot be set out of the service mode.
failure
General
information

Since the buzzer cancel switch system can be suspected to be
Defective buzzer cancel
1 defective, carry out the troubleshooting of "E-18 Buzzer cancel
switch circuit
switch does not work."
Since the information switch system can be suspected to be defec-
Defective information switch
2 tive, carry out the troubleshooting of "E-19 Information switch does
circuit
not work".
When the fuse FS1 (5) is blown, the circuit probably has a ground
3 Defective fuse FS1 (5)
fault.
switch still OFF.
Defective service switch
4 (Internal short circuit or dis- S24 Service switch Resistance
connection) Between (1) – (2) OFF Min. 1 Mz
Between (5) – (4) ON Max. 1 z
switch still OFF.
Wiring harness between FS1 (5) outlet – S24 Resis-
Max. 1 z
Disconnection in wiring (1) tance
Possible harness Resis-
5 Wiring harness between S24(4) and ground Max. 1 z
causes and the (disconnection or defective tance
standard values contact of connectors) Wiring harness between S03 (female) (16) – Resis-
S24 (2) tance
Max. 1 z
S24 (5) tance
switch still OFF.
Defective harness grounding Resis- Max.
6 between FS1 (5) – S24 (1) and FS1 (5) –
(contact with ground circuit) tance 1 Mz
S03 (female) (5) (6)
Between ground and wiring harness Resis- Max.
between S24 (5) – PTC1 (female) (6) tance 1 Mz
7
(contact with 24 V circuit) Between ground and wiring harness
Voltage Max. 1V
between S24 (2) – S03 (female) (16)
switch ON.
8 Defective monitor panel S03 Service switch Voltage
Between (16) and OFF Max. 1 V
ground ON 20 – 30 V
42 D85EX, PX-15E0
standard values Defective steering and PTC1 Service switch Voltage
9
when normal transmission controller
Between (6) and OFF 5 – 11 V
ground ON Max. 1 V
Circuit diagram related to service switch
D85EX, PX-15E0 43
E-22 The back-up alarm does not sound. 1
Symptom of
• Back-up alarm does not turn on.
failure
• When a failure occurs on the primary side (coil side) of the back-up alarm relay, relevant failure code
General
[D161KA] or [D161KB] is displayed, but in case of failure on the secondary side (contact side), no
information
failure code is displayed.

If fuse is blown, it is highly possible that a defective harness ground-
1 Blown fuse (FS2-3)
switch ON.
Defective back-up alarm
2 relay If alarm sounds when the starting switch is turned on and the
(internal disconnection) machine is operated in reverse after the relay is replaced with
another relay while the starting switch is set to OFF, the back-up
alarm relay (BKA) is defective.
switch still OFF.
Wiring harness between FS2-3 – BKA Resis-
Max. 1 z
Possible Disconnection in wiring (female) (1) (3) tance
causes and the harness Wiring harness between BKA (female) (2) – Resis-
3 Max. 1 z
standard values (disconnection or defective PTC2 (female) (18) tance
when normal contact of connectors) Wiring harness between BKA (female) (5) – Resis-
Max. 1 z
back-up alarm positive (+) terminal tance
Wiring harness between back-up alarm neg- Resis-
Max. 1 z
ative (–) terminal – and GND03 tance
switch still OFF.
Between ground and wiring harness FS2-3 – Resis-
Defective harness grounding Min. 1 Mz
4 BKA (female) (1) (3) tance
Resis-
between BKA (female) (5) – back-up alarm Min. 1 Mz
tance
positive (+) terminal
Defective back-up alarm If no problem is found in causes 1 – 4, the back-up alarm can be
5
(internal defect) suspected to be defective.
44 D85EX, PX-15E0
Circuit diagram related to back-up alarm
D85EX, PX-15E0 45
E-23 The head lamp and rear lamp do not light up. 1
Symptom of
(1) Head lamp does not light up.
failure
General
information

Defective head lamp Since the head lamp can be suspected to be defective, check for
1
(burned-out bulb) burned-out bulb.
If the fuse is blown, the circuit probably has a defective grounding,
2 Defective fuse (FS1-3)
etc.
switch still OFF.
Defective head lamp switch FWL (male) Switch Resistance
3
OFF Min. 1 Mz
Between (2) – (3)
ON Max. 1 z
Defective left head lamp a Prepare with starting switch OFF and diagnose with starting
relay switch ON.
4
(internal disconnection and If the left head lamp becomes normal after replacing left head lamp
short circuit) relay (LMFL) with new one, the previous relay is defective.
Defective right head lamp a Prepare with starting switch OFF and diagnose with starting
Possible relay switch ON.
causes and the 5
(internal disconnection and If the right head lamp becomes normal after replacing right head
standard values short circuit) lamp relay (LMFR) with new one, the previous relay is defective.
when normal
switch still OFF.
Wiring harness between FS1 (3) – FWL Resis-
Max. 1 z
(female) (3) tance
Wiring harnesses between FWL (female) (2)
Resis-
– LMFR (female) (1) and FWL (female) (2) – Max. 1 z
tance
Disconnection in wiring LMFL (female) (1)
harness Wiring harnesses between FS1 (3) – LMFR Resis-
6 Max. 1 z
(disconnection or defective (female) (3) and FS1 (3) – LMFL (female) (3) tance
contact of connectors) Wiring harness between LMFR (female) (5) Resis-
Max. 1 z
– 203 (female) (1) tance
Wiring harness between LMFL (female) (5) – Resis-
Max. 1 z
Wiring harnesses between LMFR (female)
Resis-
(2) – GND03 and LMFL (female) (2) – Max. 1 z
tance
GND03
46 D85EX, PX-15E0

switch still OFF.
between FS1 (3) – FWL (female) (3), FS1 (3) Resis-
Min. 1 Mz
– LMFR (female) (3) and FS1 (3) – LMFL tance
(female) (3)
Possible
causes and the Between ground and wiring harnesses
standard values Defective harness grounding between FWL (female) (2) – LMFR (female) Resis-
7 Min. 1 Mz
when normal (contact with ground circuit) (1) and FWL (female) (2) – LMFL (female) tance
(1)
Resis-
between LMFR (female) (5) – 203 (female) Min. 1 Mz
tance
(1)
Resis-
between LMFL (female) (5) – 204 (female) Min. 1 Mz
tance
(1)
Symptom of
(2) The rear lamp and ripper point lamp do not light up.
failure
General
information

Defective rear lamp Since a defect of the rear lamp can be suspected, check for burned-
1
(burned-out bulb) out bulb directly.
Defective ripper point lamp Since a defect of the ripper point lamp can be suspected, check for
2
(burned-out bulb) burned-out bulb directly.
If the fuse is blown, the circuit probably has a defective grounding,
3 Defective fuse (FS1-4)
etc.
switch still OFF.
Defective rear lamp switch RWL (male) Switch Resistance
4
OFF Min. 1 Mz
Between (2) – (3)
Possible ON Max. 1 z
causes and the
standard values
switch still OFF.
when normal
Disconnection in wiring
Wiring harness between FS1-4 – RWL Resis-
harness Max. 1 z
(disconnection or defective
contact of connectors) Wiring harnesses between RWL (female) (2)
Resis-
– 224 (female) (1) and RWL (female) (2) – Max. 1 z
tance
226 (female) (1)
switch still OFF.
Defective harness grounding Min. 1 Mz
6 between FS1-4 – RWL (female) (3) tance
Resis-
between RWL (female) (2) – 224 (female) (1) Min. 1 Mz
tance
and RWL (female) (2) – 226 (female) (1)
D85EX, PX-15E0 47
Circuit diagram related to panel illumination, head lamp and rear lamp
48 D85EX, PX-15E0
E-24 The horn does not sound or does not stop. 1
Symptom of
• Horn does not sound or does not stop.
failure
General
information

If the fuse is burnt, it is highly possible that a defective grounding,
1 Blown fuse (FS1-2)
etc. has occurred in the circuit.
switch still OFF.
Defective horn switch
2 (internal short circuit and dis- Terminal (switch) Horn switch Resistance
connection) OFF Min. 1 Mz
265 – 266
ON Max. 1 z
harness Resis-
3 Wiring harness between FS1-2 – 266 Max. 1 z
Possible (disconnection or defective tance
causes and the contact of connectors) Wiring harness between 265 – 205 (female) Resis-
(1) tance
when normal
switch still OFF.
Defective grounding of wiring
4 harness Min. 1 Mz
between FS1-2 – 266 tance
(contact with GND circuit)
Min. 1 Mz
between 265 – 205 (female) (1) tance
5
(contact with 24 V circuit) Between ground and wiring harness
Voltage Max. 1 V
between 265 – 205 (female) (1)
Defective horn If no problem is found in causes 1 – 5, the horn can be suspected to
6
(internal defect) be defective.
Circuit diagram related to horn
D85EX, PX-15E0 49
E-25 Malfunction of wipers 1
Symptom of
(1) The front wiper does not operate. (Continuous operation is defective.)
failure
• When only the front wiper is defective
General • If fuse (5) in the cab is blown, intermittent operation of the all wipers becomes defective.
information • If all wipers do not operate, check circuit breaker (CB105).
• Diagnose with intermittent switch OFF and with wiper switch ON.

Defective circuit breaker When the circuit breaker is cut off, a defective grounding may have
1
(CB105) possibly occurred in the circuit.
Since fuse (5) in the cab is used for the front wiper circuit and inter-
Defective fuse (5)
2 mittent switch circuit, either circuit of those two probably have a
in cab
ground fault, etc.
switch ON.
Between CN23 (6) and ground Voltage 20 – 30 V
3 Defective front wiper motor a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Wiring harness between CN23 (female) (1) Resis-
Max. 1 z
and ground tance
switch still OFF.
Possible CN14 (male) Position of switch Resistance
4 Defective front wiper switch
causes and the
standard values ON Max. 1 z
Between (3) – (4)
when normal OFF Min. 1 Mz
• If the problem is eliminated by replacing the relay (CN27), (CN31)
or (CN33) with another one, the relay is defective.
Defective front wiper switch ON.
5
intermittent selector relay
Between CN29 (1) and ground Voltage Max. 1 V
Defective front wiper switch ON.
6
intermittent relay
50 D85EX, PX-15E0

switch still OFF.
Wiring harness between CN14 (female) (4) – Resis-
Max. 1 z
CN29 (female) (3) tance
Resis-
between CN14 (female) (4) – CN29 (female) Min. 1 Mz
tance
(3)
Max. 1 z
Resis-
tance
Possible Disconnection or short circuit (4)
causes and the with ground in wiring harness Wiring harnesses between fuse (5) – CN14
Resis-
standard values (Disconnection in wiring or (female) (2) (3), fuse (5) – CN23 (female) (3) Max. 1 z
7 tance
when normal defective contact of connec- and fuse (5) – CN28 (female) (3)
tors or contact with ground Between ground and wiring harnesses
circuit) between fuse (5)-CN14 (female) (2) (3), fuse Resis-
Min. 1 Mz
(5)-CN23 (female) (3) and fuse (5)-CN28 tance
(female) (3)
Max. 1 z
Resis-
tance
(6)
Max. 1 z
and ground tance
Max. 1 z
and ground tance
D85EX, PX-15E0 51
Symptom of
(2) Front wiper malfunctions in the intermittent mode.
failure
• When the ordinary operation is normal.
General
• When carrying out the troubleshooting, turn the wiper switch and intermittent switch ON.
information
• The wiper stops for about 5 seconds after a single wiping operation.

• If the ordinary operation is normal and the other wiper also mal-
functions in the intermittent mode, the intermittent switch is prob-
ably defective.
1 Defective intermittent switch switch still OFF.
CN11 (male) Position of switch Resistance
ON Max. 1 z
Between (1) – (2)
OFF Min. 1 Mz
Defective front wiper inter- a Prepare with starting switch OFF and diagnose with starting
2 switch ON.
mittent selector relay
Between CN29 (1) – ground Voltage 20 – 30 V
Possible • If the problem is eliminated by replacing the relay (CN26), (CN30)
causes and the or (CN32) with another one, the relay is defective.
standard values Defective front wiper inter-
when normal 3 a Prepare with starting switch OFF and diagnose with starting
mittent relay
switch ON.
switch still OFF.
Max. 1 z
Disconnection or short circuit Between ground and wiring harness
Resis-
with ground in wiring harness between CN11 (female) (2) – CN29 (female) Min. 1 Mz
tance
(Disconnection in wiring or (1)
4
defective contact of connec- Wiring harness between CN29 (female) (5) – Resis-
tors or contact with ground Max. 1 z
circuit)
Resis-
tance
(2)
Max. 1 z
ground tance
52 D85EX, PX-15E0
Circuit diagram related to wiper system
D85EX, PX-15E0 53
Symptom of
(3) The rear wiper does not operate (Continuous operation is defective)
failure
• When only the rear wiper is defective
General
• If all wipers do not operate, check circuit breaker (CB105).
information
• Diagnose with intermittent switch OFF and with wiper switch ON.

1
Since fuse (4) in the cab is used only for the rear wiper circuit, the
2 Defective fuse (4) in cab
rear wiper circuit probably has a ground fault, etc.
switch ON.
3 Defective rear wiper motor a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Max. 1 z
and ground tance
switch still OFF.
Possible 4 Defective rear wiper switch CN12 (male) Position of switch Resistance
causes and the ON Max. 1 z
standard values Between (3) – (4)
OFF Min. 1 Mz
when normal
Defective rear wiper switch ON.
5
Between CN33 (1) and ground Voltage Max. 1V
Defective rear wiper switch ON.
6
intermittent relay
54 D85EX, PX-15E0

switch still OFF.
Max. 1 z
Resis-
tance
(3)
Max. 1 z
Resis-
tance
(4)
Disconnection or short circuit Wiring harness between fuse (4) – CN12 Resis-
Possible Max. 1 z
with ground in wiring harness (female) (2) (3) tance
causes and the
standard values (Disconnection in wiring or Between ground and wiring harness Resis-
7 Min. 1 Mz
when normal defective contact of connec- between fuse (4) – CN12 (female) (2) (3) tance
tors or contact with ground Wiring harnesses between fuse (4) – CN32 Resis-
circuit) Max. 1 z
(female) (3) and fuse (4) – CN37 (female) (3) tance
Resis-
between fuse (4)-CN32 (female) (3) and fuse Min. 1 Mz
tance
(4)-CN37 (female) (3)
Max. 1 z
Resis-
tance
(1)
Max. 1 z
and ground tance
Max. 1 z
and ground tance
D85EX, PX-15E0 55
Symptom of
(4) Rear wiper malfunctions in the intermittent mode.
failure
General
information

ably defective.
ON Max. 1 z
Between (1) – (2)
OFF Min. 1 Mz
Defective rear wiper a Prepare with starting switch OFF and diagnose with starting
2 switch ON.
standard values Defective rear wiper
intermittent relay
switch ON.
switch still OFF.
Max. 1 z
Resis-
tance
4
defective contact in connec- Wiring harness between CN33 (female) (5) – Resis-
tor or contact with ground cir- Max. 1 z
cuit)
Resis-
tance
(2)
Max. 1 z
ground tance
56 D85EX, PX-15E0
D85EX, PX-15E0 57
Symptom of
(5) The right door wiper does not operate. (Continuous operation is defective.)
failure
• When only the right door wiper is defective (If fuse (6) in the cab is blown, the left door wiper does not
operate either.)
General
information
• When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch
ON.

Defective circuit breaker If the circuit breaker is cut off, a defective grounding may have pos-
1
(CB105) sibly occurred in the circuit.
Since fuse (6) in the cab is used for the right and left wiper system,
either circuit of those two probably has a ground fault, etc.
switch ON.
Between connector (3) just before motor and
Voltage 20 – 30 V
Defective right door wiper ground
3
motor a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Wiring harness between connector (1) just Resis-
Max. 1 z
before motor and ground tance
switch still OFF.
Possible Defective right door wiper CN13 (male) Position of switch Resistance
4
causes and the switch
Between (3) – (4)
Defective right door wiper switch ON.
5
Defective right door wiper switch ON.
6
intermittent relay
58 D85EX, PX-15E0

switch still OFF.
Max. 1 z
Resis-
tance
(3)
Max. 1 z
Resis-
tance
(4)
Wiring harnesses between fuse (6) – CN13
(female) (2) (3) and among fuse (6) – CN17 Resis-
Max. 1 z
(4) – connector (female) (4) just before motor tance
Possible Disconnection or short circuit – CN15 (female) (2) (3)
causes and the with ground in wiring harness
standard values (Disconnection in wiring or
7 between fuse (6) – CN13 (female) (2) (3) and
when normal defective contact of connec- Resis-
among fuse (6) – CN17 (4) – connector Min. 1 Mz
tors or contact with ground tance
(female) (4) just before motor – CN15
circuit)
(female) (2) (3)
Wiring harness between fuse (6) – CN30 Resis-
Max. 1 z
(female) (3) tance
Min. 1 Mz
between fuse (6) – CN30 (female) (3) tance
Wiring harness among connector (female)
Resis-
(3) just before motor – CN17 (3) – CN30 Max. 1 z
tance
(female) (5)
Between ground and wiring harness among
Resis-
connector (female) (3) just before motor – Min. 1 Mz
tance
CN17 (3) – CN30 (female)(5)
Max. 1 z
and ground tance
Wiring harness among connector (female) Resis-
Max. 1 z
(1) just before motor – CN17(1) – ground tance
D85EX, PX-15E0 59
Symptom of
(6) Right door wiper malfunctions in the intermittent mode.
failure
General
information

ably defective.
CN11 (female) Position of switch Resistance
ON Max. 1 z
Between (1) – (2)
OFF Min. 1 Mz
Defective right door wiper a Prepare with starting switch OFF and diagnose with starting
2 switch ON.
standard values Defective right door wiper
intermittent relay
switch ON.
switch still OFF.
Max. 1 z
Resis-
tance
4
cuit)
Resis-
tance
(2)
Max. 1 z
ground tance
60 D85EX, PX-15E0
D85EX, PX-15E0 61
Symptom of
(7) The left door wiper does not operate (continuous operation is defective.)
failure
• When only the left door wiper is defective (If fuse (6) in the cab is blown, the right door wiper does not
operate either.)
General
information
• When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch
ON.

Defective circuit breaker If the circuit breaker is cut off, a defective grounding may have pos-
1
(CB105) sibly occurred in the circuit.
Since fuse (6) in the cab is used for the right and left wiper system,
either circuit of those two probably has a ground fault, etc.
switch ON.
Between connector (3) just before motor and
Voltage 20 – 30 V
Defective left door wiper ground
3
motor a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Wiring harness between connector (1) just Resis-
Max. 1 z
before motor and ground tance
switch still OFF.
Possible Defective left door wiper CN15 (male) Position of switch Resistance
4
causes and the switch
Between (3) – (4)
Defective left door wiper switch ON.
5
Defective left door wiper switch ON.
6
intermittent relay
62 D85EX, PX-15E0

switch still OFF.
Max. 1 z
Resis-
tance
(3)
Max. 1 z
Resis-
tance
(4)
Wiring harnesses between fuse (6) – CN26
Resis-
(female)(3) and among fuse (6) – CN24 (4) – Max. 1 z
Disconnection or short circuit connector just before motor (female)(4) tance
Possible
causes and the with ground in wiring harness
standard values (Disconnection in wiring or
7 between fuse (6) – CN26 (female)(3) and Resis-
when normal defective contact of connec- Min. 1 Mz
among fuse (6) – CN24 (4) – connector just tance
tors or contact with ground
before motor (female)(4)
circuit)
Max. 1 z
(female) (2) (3) tance
Min. 1 Mz
between fuse (6) – CN15 (female) (2) (3) tance
Wiring harness among connector (female)
Resis-
(3) just before motor – CN24(3) – CN26 Max. 1 z
tance
(female) (5)
Between ground and wiring harness among
Resis-
connector (female) (3) just before motor – Min. 1 Mz
tance
CN24 (3) – CN26 (female) (5)
Max. 1 z
and ground tance
Wiring harness among connector (female) Resis-
Max. 1 z
(1) just before motor – CN24 (1) – ground tance
D85EX, PX-15E0 63
Symptom of
(8) Left door wiper malfunctions in the intermittent mode.
failure
General
information

ably defective.
ON Max. 1 z
Between (1) – (2)
OFF Min. 1 Mz
Defective left door wiper a Prepare with starting switch OFF and diagnose with starting
2 switch ON.
standard values Defective left door wiper
intermittent relay
switch ON.
switch still OFF.
Max. 1 z
Resis-
tance
4
cuit)
Resis-
tance
(2)
Max. 1 z
ground tance
64 D85EX, PX-15E0
D85EX, PX-15E0 65
E-26 Washer does not spray water 1
Symptom of
(1) Front washer does not spray water.
failure
• When the front wiper operates normally
General
(If the wiper does not operate either, carry out troubleshooting in “E-25 (1) The front wiper does not
information
operate.” first.)

switch still OFF.
Wiring harness between 362 (female) (2) Resis-
Max. 1 z
1 Defective front washer motor and ground tance
switch ON. (Switch position: W/I or W/II)
Between 362 (1) and ground Voltage 20 – 30 V
switch still OFF.
2 Defective front wiper switch CN14 (female) Position of switch Resistance
Possible
W/I or W/II Max. 1 z
causes and the Between (2) – (1)
standard values OFF Min. 1 Mz
switch still OFF.
Max. 1 z
(female) (2) tance
Disconnection or short circuit
with ground in wiring harness Between ground and wiring harness Resis-
Min. 1 Mz
(disconnection in wiring har- between fuse (5) – CN14 (female) (2) tance
3
ness or defective contact of Wiring harness among CN14 (female) (1) – Resis-
connectors or contact with Max. 1 z
19 (3) – 362 (female) (1) tance
ground circuit)
Between ground and wiring harness among Resis-
Min. 1 Mz
CN14 (female) (1) – 19 (3) – 362 (female) (1) tance
Max. 1 z
and ground tance
66 D85EX, PX-15E0
Circuit diagram related to washer system
D85EX, PX-15E0 67
Symptom of
(2) Rear washer does not spray water
failure
• When the rear wiper operates normally
General
(If the wiper does not operate either, carry out troubleshooting in “E-25 (3) The rear wiper does not
information
operate.” first.)

switch still OFF.
Max. 1 z
1 Defective rear washer motor and ground tance
switch still OFF.
2 Defective rear wiper switch CN12 (female) Position of switch Resistance
Possible
causes and the Between (2)-(1)
switch still OFF.
Max. 1 z
(female) (2) tance
Min. 1 Mz
3
19 (4) – 364 (female) (1) tance
ground circuit)
Min. 1 Mz
Max. 1 z
and ground tance
* For the electrical diagram of each system, see Symptom of failure (1).
68 D85EX, PX-15E0
Symptom of
(3) Left door washer does not spray water
failure
• When the left door wiper operates normally
(If the wiper does not operate either, carry out troubleshooting in “E-25 (7) The left wiper does not
General
operate.” first.)
information
• Since the left door wiper switch and right door wiper switch use fuse (6) jointly, if fuse (6) is blown,
both wipers do not operate.

switch still OFF.
Defective left door washer Max. 1 z
1 and ground tance
motor
switch still OFF.
Defective left door wiper CN15 (female) Position of switch Resistance
2
Possible switch
switch still OFF.
Max. 1 z
(female) (2) tance
Min. 1 Mz
3
19 (1) – 361 (female) (1) tance
ground circuit)
Min. 1 Mz
Max. 1 z
and ground tance
D85EX, PX-15E0 69
Symptom of
(4) Right door washer does not spray water
failure
• When the right door wiper operates normally
(If the wiper does not operate either, carry out troubleshooting in “E-25 (5) The right wiper does not
General
operate.” first.)
information
• Since the right door wiper switch and left door wiper switch use fuse (6) jointly, if fuse (6) is blown,
both wiper do not operate.

switch still OFF.
Defective right door washer Max. 1 z
1 and ground tance
motor
switch ON.
switch still OFF.
Defective right door wiper CN13 (female) Position of switch Resistance
2
Possible switch
switch still OFF.
Max. 1 z
(female) (2) tance
Min. 1 Mz
3
19 (2) – 363 (female) (1) tance
ground circuit)
Min. 1 Mz
Max. 1 z
and ground tance
70 D85EX, PX-15E0
E-27 The air conditioner does not operate 1
Symptom of
• Air does not blow out
failure
General
information

1 Defective fuse (FS2-4) If the fuse is burnout, the circuit probably has a ground fault, etc.
2
Defective blower main relay switch still OFF.
3
(coil side) CN-R1 (male) Resistance
Between (1) – (2) 240 ± 40 z
Defective blower main relay switch ON.
4
(contact side) CN-R1 Voltage
Between (8C) and ground 20 – 30 V
Defective blower Hi relay switch still OFF.
5
Between (1) – (2) 240 ± 40 z
Defective blower Hi relay switch ON.
6
Possible (contact side) It is normal if the motor rotates with the starting switch and the
causes and the blower Hi switch turned ON.
standard values
when normal
Defective blower Mi1 relay switch still OFF.
7
Between (1) – (2) 240 ± 40 z
Defective blower Mi1 relay switch ON.
8
(contact side) It is normal if the motor rotates with the starting switch and the
blower Mi switch turned ON.
Defective blower Mi2 relay switch still OFF.
9
Between (1) – (2) 240 ± 40 z
Defective blower Mi2 relay switch ON.
10
(contact side) It is normal if the motor rotates with the starting switch and the
blower Lo switch turned ON.
switch ON.
11 Defective blower motor
It is normal if the motor rotates with the starting switch and the
blower Lo switch turned ON.
D85EX, PX-15E0 71

switch still OFF.
Wiring harnesses between CN-R4 (female)
(14C) – AC1 (female) (14A), CN-R4 (female)
(14C) – CN-R (female) (S141), CN-R4 Resis-
Max. 1 z
(female) (14C) – CN-R2 (female) (14E) and tance
CN-R4 (female) (14C) – CN-R3 (female)
(14N)-ground
Wiring harness between CN-B (female) Resis-
Max. 1 z
(11B) – CN-R1(female) (11A) tance
Wiring harnesses between CN-B (female)
Disconnection or short circuit Resis-
(12A) – CN-R2 (female) (12B) and CN-B Max. 1 z
with ground in wiring harness tance
(female) (12A) – CN-R (female) (12C)
Possible 12 (disconnection in wiring or
Wiring harnesses between CB2 outlet – AC1
causes and the defective contact of connec-
(female) (1A),CB2 outlet – CN-R1 (female)
standard values tors) Resis-
(1D), CB2 outlet – CN-R2 (female) (1E), CB2 Max. 1 z
when normal tance
outlet – CN-R3 (female) (1N) and CB2 outlet
– CN-R4 (female) (1I)
Wiring harness between CN-R1 (female) Resis-
Max. 1 z
(2B) – AC1 (female) (2A) tance
Max. 1 z
Max. 1 z
Max. 1 z
Control panel can be suspected to be defective if no problem is
13 Defective control panel
Symptom of failure is When the cause cannot be identified, the symptom of failure may be
14
incorrect. incorrect. Carry out the troubleshooting of “It does not get cool.”
72 D85EX, PX-15E0
Symptom of
• It does not get cool.
failure
General
information

switch ON.
1 Defective pressure switch CN-P Blower switch Voltage
Between (6B) and
ON 20 – 30 V
ground
Defective compressor clutch switch still OFF.
2
relay (coil side) CN-R5 (male) Resistance
Between (1) – (2) 240 ± 40 z
a Prepare with starting switch OFF and diagnose starting switch
Defective compressor clutch and air conditioner switch ON.
3
relay (contact side) CN-R5 Voltage
Between (18A) and ground 20 – 30 V
Possible
causes and the
switch still OFF.
standard values 4 Defective thermistor
when normal CN-T (male) Resistance
Between (1) – (2) Max. 3,500 z
switch still OFF.
5 Defective blower resister
Blower resister Resistance
Between terminals 2.8 z ± 5 %
a Start the engine to diagnose.
Defective compressor
6 Since the compressor magnet clutch can be suspected to be defec-
magnet clutch.
tive, check it directly.
7 Defective compressor Since the compressor can be suspected to be defective, check it
directly.
Diagnose diode ACS (male).
Defective diode
8 • See the “Inspection procedure of diode” in the “Testing and
D85EX, PX-15E0 73

switch still OFF.
Wiring harnesses between CB2 outlet – AC1
(female) (1A), CB2 outlet – CN-R1 (female)
(1D), CB2 outlet – CN-R2 (female) (1E), CB2 Resis-
Max. 1 z
outlet – CN-R3 (female) (1N), CB2 outlet – tance
CN-R4 (female) (1I) and CB2 outlet – CN-R5
Disconnection in wiring (female) (1K)
Possible
harness (Disconnection in Wiring harnesses between CN-T (female)
causes and the 9 Resis-
wiring or defective contact of (13B) – AC1 (female) (13A) and CN-T Max. 1 z
connectors) (female) (13B) – CN-W (female) (13C)
when normal
Wiring harness between CN-T (female) (9B) Resis-
Max. 1 z
– AC1 (female) (9A) tance
Wiring harness between CN-P (female) (7B) Resis-
Max. 1 z
– CN-R5 (female) (7A) tance
Wiring harness between CN-P (female) (6B) Resis-
Max. 1 z
– AC1 (female) (6A) tance
Control panel can be suspected to be defective if no problem is
10 Defective control panel
74 D85EX, PX-15E0
Circuit diagram related to air conditioner
D85EX, PX-15E0 75
E-28 KOMTRAX system does not operate normally. 1
Symptom of
• KOMTRAX system does not operate properly.
failure
• If KOMTRAX system administrator makes request for checking system on machine side for trouble,
General
carry out the following troubleshooting.
information
• Even if KOMTRAX system has a trouble, it does not particularly appear on machine.

Defective specification Check the code 0021: KOMTRAX specification setting in adjust-
1
setting ment mode and set to “ACTIVE”.
switch still OFF.
Defective electric power
2 KOM1 Signal Voltage
supply
Between (39) (40) – Constant power
20 – 30 V
(37) (38) source
a Diagnose with starting switch ON and with the engine started.
LED(1) Normal condition
LED-C1 ON
Defective starting switch
nose.
3 ACC signal and alternator R
signal KOM1 Signal Voltage
Between (36) –
Starting switch ACC 20 – 30 V
(37) (38)
Between (28) –
Alternator R 20 – 30 V
(37) (38)
standard values Defective starting switch C
4 KOM1 Signal Voltage
when normal signal
Between (27) –
Starting switch C 20 – 30 V
(37) (38)
a Diagnose with starting switch ON.
LED-C4 ON
Defective CAN connecting
5 a Prepare with starting switch OFF and diagnose with starting
condition
switch still OFF.
KOM1 (female) Signal Resistance
Between (7) – (8) CAN 40 – 80 z
6 Number of mails not yet sent LED(7) Normal condition
7 segments 0–9
Defective GPS positioning Dot ON
7
status
It may take more than 1 minute from turning on the starting switch to
the completion of positioning even in an outdoor place where radio
wave can reach.
76 D85EX, PX-15E0
LED display section of KOMTRAX terminal KOM1 connector
CPU LED
1. LED-C1 (R signal and ACC signal status)
2. LED-C2 (starting output status)
3. LED-C3 (S-NET, C signal status)
4. LED-C4 (CAN status)
5. LED-C5 (download writing condition)
6. LED-C6 (download writing condition)
7-segment and dot for CPU
7. 7-segment (number of mails not yet sent)
8. Dot (GPS positioning in progress)
D85EX, PX-15E0 77
SEN00638-00

© 2006 KOMATSU
All Rights Reserved
78
SEN00639-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Contents of troubleshooting table......................................................................................................... 3
H-1 There is no travel power (no drawbar pull) .................................................................................... 4
H-2 Machine does not move (at 2nd or 3rd speed).............................................................................. 5
H-3 Machine does not move at any gear speed .................................................................................. 6
H-4 Machine travels only in one direction, forward or reverse ............................................................. 7
H-5 When gear is shifted or travel direction is changed, large time lag is made ................................. 8
H-6 Machine cannot be steered (Machine does not turn leftward or rightward) .................................. 9
H-7 Steering speed or power is low ..................................................................................................... 9
H-8 Brake does not work.................................................................................................................... 10
H-9 Overheat of power train oil ...........................................................................................................11
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor........ 12
H-11 All work equipment speeds are slow ......................................................................................... 13
H-12 All work equipments do not move ............................................................................................. 14
D85EX, PX-15E0 1
H-13 Blade lift speed is slow or lacks power ...................................................................................... 14

H-14 Blade tilt speed is slow or lacks power ...................................................................................... 15
H-15 Ripper lift speed is slow or lacks power..................................................................................... 15
H-16 Excessive hydraulic drift of blade lift.......................................................................................... 16
H-17 Excessive hydraulic drift of blade tilt.......................................................................................... 16
H-18 Excessive hydraulic drift of ripper lift ......................................................................................... 17
2 D85EX, PX-15E0
Troubleshooting of hydraulic and mechanical system (H-mode)1

a Troubleshooting lists contain the following information all together. Understand the contents carefully
and troubleshoot the machine.
Symptom of
Symptom of failure that has appeared in the machine
failure
General
Information related to troubles occurred or troubleshooting
information
Possible 2
Cause by which a trouble
causes and the <Described contents>
is assumed to be caused
standard values • Standard value when normal required to judge the possible
(The order number indi-
when normal cause
cates a serial number, not
• Remarks required to judge whether the cause is right or not
a priority sequence.)
3
D85EX, PX-15E0 3
H-1 There is no travel power (no drawbar pull) 1
Symptom of
• There is no travel power (no drawbar pull).
failure
General
• Check that the power train oil level is normal before troubleshooting.
information

a Prepare with the starting switch OFF, and diagnose by measuring
the torque converter stall speed according to item 5 of “Measur-
1 Defective engine ing engine speed” in Testing and adjusting.
Measurement conditions Engine speed
F3 stall 1,760rpm
The power train pump can be suspected to be defective; visually
2 Defective power train pump
check it.
a Prepare with the starting switch OFF, and then run the engine at
high idle for troubleshooting.
Internally defective torque Torque converter Torque converter
3 PCCS lever
converter inlet pressure outlet pressure
Max. 1.02 MPa 0.61 – 0.81 MPa
Full neutral
{Max. 10 kg/cm2} {6 – 8 kg/cm2}
Transmission main relief
PCCS lever
pressure
Full neutral Min. 2.81 MPa {Min. 29 kg/cm2}
Defective set pressure or
4 internal defect of transmis- a Prepare with starting switch OFF and diagnose with starting
Possible sion main relief valve switch still OFF.
causes and the Visually check that the free length of spring and the number of
standard values shims are normal and also that the spool rotates smoothly.
when normal • Free length of large spring: 128 mm
• Free length of small spring: 108 mm
• Number of shims: 6 pieces
low idle for troubleshooting.
Transmission clutch Clutch pressure
Defective operation of FWD Min. 1.96 MPa {Min. 20 kg/cm2}
5 transmission valve REV Min. 2.55 MPa {Min. 26 kg/cm2}
(ECMV)
1ST Min. 2.16 MPa {Min. 22 kg/cm2}
2ND Min. 2.35 MPa {Min. 24 kg/cm2}
3RD Min. 2.55 MPa {Min. 26 kg/cm2}
6 Defective brake valve
Parking lever Brake pressure
Free Min. 2.45 MPa {Min. 25 kg/cm2}
If any problem has been found in the troubleshooting for cause 6,
Defective parking lever and
7 improper adjustment of parking lever or brake pedal linkage can be
brake pedal linkage
suspected. Therefore check the adjustment directly.
Internally defective Since the transmission is suspected to be internally defective, check
8
transmission it directly.
4 D85EX, PX-15E0
H-2 Machine does not move (at 2nd or 3rd speed) 1
Symptom of
• Machine does not travel (at 2nd or 3rd speed)
failure
General
• Check that the transmission main relief pressure is normal before troubleshooting.
information
(See H-1 “There is no travel power”.)

1 PCCS lever
converter inlet pressure outlet pressure
Max. 1.02 MPa 0.61 – 0.81 MPa
Full neutral
{Max. 10 kg/cm2} {6 – 8 kg/cm2}
low idle for troubleshooting.
Defective operation of Transmission clutch Clutch pressure
Possible 2
transmission valve (ECMV)
causes and the 2ND Min. 2.35 MPa {Min. 24 kg/cm2}
standard values
when normal
Internally defective Since the transmission clutch (2nd or 3rd speed) can be suspected
3
transmission clutch to be internally defective, check it directly.
Defective operation of Since the defective operation of parking brake (dragging) can be
4
parking brake (dragging) suspected, inspect the linkage valves.
a Move to a flat ground (with a firm surface), and start the engine to
Defective operation of brake diagnose.
5
(dragging) If the machine does not move by low idle + F2 operation, the brake
is dragging (carry out troubleshooting "H-8 Brake does not work.").
Internally defective Since the transmission is suspected to be internally defective, check
6
transmission it directly.
D85EX, PX-15E0 5
H-3 Machine does not move at any gear speed 1
Symptom of
• Machine does not start at any gear speed.
failure
General
information

Defective power train Since the power train pump can be suspected to be defective,
1
pump check it directly.
PCCS lever
pressure
2 internal defect of transmis- a Prepare with starting switch OFF and diagnose with starting
sion main relief valve switch still OFF.
Visually check that the free length of spring and the number of
shims are normal and also that the spool rotates smoothly.
• Free length of large spring: 128 mm
• Free length of small spring: 108 mm
• Number of shims: 6 pieces
a Prepare with the starting switch OFF, and diagnose with the
engine running at low idle.
Possible (After checking that the transmission main relief pressure is nor-
causes and the mal.)
standard values Transmission clutch Clutch pressure
when normal Defective operation of
3 FWD Min. 1.96 MPa {Min. 20 kg/cm2}
REV Min. 2.55 MPa {Min. 26 kg/cm2}
Internally defective Since the transmission clutch can be suspected to be internally
4
transmission defective, check it directly.
a Move to a flat ground, and diagnose with the engine running at
high idle.
(After checking that the transmission main relief pressure is nor-
mal.)
Brake pedal Brake oil pressure (left and right)
5 Defective brake valve
Release Min. 2.45 MPa {Min. 25 kg/cm2}
Depress 0 {0}
When the oil pressure is abnormal, carry out troubleshooting "H-8
Brake does not work".
6 D85EX, PX-15E0
H-4 Machine travels only in one direction, forward or reverse 1
Symptom of
• Machine travels only in one direction, forward or reverse.
failure
General
information

Since the power train pump can be suspected to be defective,
1 Defective power train pump
check it directly.
PCCS lever
pressure
2 internal defect of transmis-
sion main relief valve a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
Possible
causes and the
standard values
when normal a Prepare with the starting switch OFF, and diagnose with the
(After checking that the transmission main relief pressure is nor-
Defective operation of mal.)
3
transmission valve (ECMV) Transmission clutch Clutch pressure
FWD Min. 1.96 MPa {Min. 20 kg/cm2}
Defective transmission clutch
4 the clutch seal can be suspected to be defective. Therefore check
seal
the clutch seal directly.
Internally defective Since the transmission clutch (forward or reverse) can be suspected
5
transmission clutch to be internally defective, directly check it.
D85EX, PX-15E0 7
H-5 When gear is shifted or travel direction is changed, large time lag is
made 1
Symptom of
• Time lag is excessive at shifting gear speed or shifting forward-reverse.
failure
General
information

Defective power train Since the power train pump can be suspected to be defective,
1
pump check it directly.
PCCS lever
pressure
2 internal defect of transmis-
sion main relief valve a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
a Prepare with the starting switch OFF, and diagnose with the
Possible (After checking that the transmission main relief pressure is nor-
causes and the mal.)
standard values
when normal Transmission clutch Clutch pressure
Defective operation of
3 FWD Min. 1.96 MPa {Min. 20 kg/cm2}
Defective transmission clutch
4 the clutch seal can be suspected to be defective. Therefore check
seal
the clutch seal directly.
Internally defective Since the transmission clutch can be suspected to be internally
5
transmission clutch defective, check it directly.
a Move the machine to a flat ground (with a firm surface), and start
Defective operation of brake the engine to diagnose.
6
(dragging) If the machine does not move by low idle + F2 operation, the brake
is dragging (carry out troubleshooting "H-8 Brake does not work.").
8 D85EX, PX-15E0
H-6 Machine cannot be steered (Machine does not turn leftward or

rightward) 1
Symptom of
• Machine cannot be steered. (Machine does not turn leftward or rightward.)
failure
General
• Check that the hydraulic oil level is normal before troubleshooting.
information

a Prepare with the engine started, and then run the engine at high
Incorrect set pressure or idle for troubleshooting.
Possible defective operation of self
1 PCCS lever Control circuit basic pressure
causes and the pressure reducing valve
standard values (PPC basic pressure) 3.78 – 4.46 MPa
Neutral
when normal {38.5 – 45.5 kg/cm2}
If an abnormal noise occurs in the HSS peripheral equipment, carry
Abnormal noise from HSS
2 out troubleshooting "Abnormal noise comes out around HSS and
peripheral equipment
work equipment pump or HSS motor."
H-7 Steering speed or power is low 1
Symptom of
• Steering speed or power is insufficient.
failure
General
information

a Prepare with the engine started, and then run the engine at high
idle for troubleshooting.
Incorrect set pressure or
1 defective operation of HSS PCCS lever HSS relief pressure
main relief valve Min. 38.2 – 41.7 MPa
Left or right stroke end
Possible {Min. 390 – 425 kg/cm2}
causes and the a Prepare with the engine started, and then run the engine at high
standard values Incorrect set pressure or idle for troubleshooting.
when normal defective operation of self
2 PCCS lever Control circuit basic pressure
pressure reducing valve
(PPC basic pressure) 3.78 – 4.46 MPa
Neutral
{38.5 – 45.5 kg/cm2}
If an abnormal noise occurs in the HSS peripheral equipment, carry
Abnormal noise from HSS
3 out troubleshooting "Abnormal noise comes out around HSS and
peripheral equipment
work equipment pump or HSS motor."
D85EX, PX-15E0 9
H-8 Brake does not work 1
Symptom of
• Brake does not work.
failure
General
information
(See “H-1 There is no travel power”.)

Defective operation of brake Brake pedal Brake oil pressure

1
valve Min. 2.45 MPa
When released
{Min. 25 kg/cm2}
Possible
causes and the When depressed 0 MPa {0 kg/cm2}
standard values If any problem has been found in the troubleshooting for cause 1,
when normal Improper adjustment of
2 the improper adjustment of the brake pedal linkage can be also sus-
brake pedal linkage
pected, directly check it.
3 Defective brake seal the brake seal can be also suspected to be improper. Therefore
check the brake seal directly.
A slip or wear of brake disc Slip or wear of the brake disc plate can be suspected; directly check
4
plate it.
10 D85EX, PX-15E0
H-9 Overheat of power train oil 1
Symptom of
• Power train oil overheats.
failure
• Check that the reading on the power train oil temperature gauge matches the actual oil temperature
General before troubleshooting. (If they do not match, carry out troubleshooting‚ “E-10 Power train oil temper-
information ature gauge does not indicate correctly.”)
(See “H-1 There is no travel power”.)

Since the engine cooling system can be suspected to be defective
1 Defective engine system or the engine output can be suspected to be increased, see the
engine section of shop manual.
Defective power train pump
The power train pump can be suspected to be defective or residual
2 or residual air in the suction
air in the suction circuit can be suspected, directly check them.
circuit
3 PCCS lever
Possible converter inlet pressure outlet pressure
causes and the
Max. 1.02 MPa 0.61 – 0.81 MPa
standard values Full neutral
{Max. 10 kg/cm2} {6 – 8 kg/cm2}
when normal
Defective operation of Since the transmission clutch can be suspected to be internally
4
transmission clutch (Slip) defective (slip), directly check it.
Defective operation of brake 1. Raise the machine with blade and ripper.
5 2. Run the engine at low idle and shift the gearshift lever in F3.
(dragging)
3. If the track shoes do not move, the brake dragging occurs.
(Carry out troubleshooting “H-8 Brake does not work”)
Defective operation of brake
6 If the machine cannot be stopped completely while performing F3
(Slip)
stall, the brake is slipping.
D85EX, PX-15E0 11
H-10 Abnormal sound comes out from around HSS and work equipment
pump or HSS motor 1
Symptom of
• Abnormal sound comes out around HSS and hydraulic pump or HSS motor.
failure
General
information

1 Inappropriate oil is used. The oil used can be suspected to be inappropriate, directly check it.
Clogged hydraulic oil tank The hydraulic oil tank strainer can be suspected to be clogged,
2
Possible strainer directly check it.
causes and the Since the air can be suspected to be inhaled in the suction circuit of
standard values 3 Air inhaled in suction circuit
the HSS and work equipment pump, directly check the pipes.
when normal
Internally defective HSS and Since the HSS and work equipment pump can be suspected to be
4
work equipment pump internally defective, directly check it.
Internally defective HSS Since the HSS motor can be suspected to be internally defective,
5
motor directly check it.
12 D85EX, PX-15E0
H-11 All work equipment speeds are slow 1
Symptom of
• Speed of all work equipments is slow.
failure
General
• Check that the oil level in the hydraulic tank is normal before troubleshooting.
information

Defective PTO
Since the PTO pump drive unit of the HSS and work equipment is
1 (pump drive unit of HSS and
assumed to be defective, directly check it.
work equipment)
Defective HSS and work Since the HSS and work equipment pump can be suspected to be
2
equipment pump defective, directly check it.
3 Work equipment control lever Unload pressure
unload valve
2.45 – 3.82 MPa
Full neutral
{25 – 39 kg/cm2}
Possible
causes and the a Prepare with the starting switch OFF, and then run the engine at
standard values high idle for troubleshooting.
when normal 4 defective operation of main Work equipment control lever Main relief pressure
relief valve 22.54 ± 1.18 MPa
Stroke end
{230 ± 12 kg/cm2}
Defective operation of self
5 pressure reducing valve Work equipment control lever Control circuit basic pressure
Full neutral
{38.5 – 45.5 kg/cm2}
Internally defective PPC
6 the PPC valve can be suspected to be internally defective. There-
valve
fore directly check the PPC valve.
D85EX, PX-15E0 13
H-12 All work equipments do not move 1
Symptom of
• All work equipments do not move.
failure
General
information

Defective PTO
Since the PTO pump drive unit of the HSS and work equipment is
1 (pump drive unit of HSS and
assumed to be defective, directly check it.
work equipment)
Defective HSS and work Since the HSS and work equipment pump can be suspected to be
2
equipment pump defective, directly check it.
3 Work equipment control lever Unload pressure
unload valve
Possible 2.45 – 3.82 MPa
causes and the Full neutral
{25 – 39 kg/cm2}
standard values
when normal a Prepare with the starting switch OFF, and then run the engine at
4 defective operation of main Work equipment control lever Main relief pressure
relief valve 22.54 ± 1.18 MPa
Stroke end
{230 ± 12 kg/cm2}
Defective operation of self
5 pressure reducing valve Work equipment control lever Control circuit basic pressure
Full neutral
{38.5 – 45.5 kg/cm2}
H-13 Blade lift speed is slow or lacks power 1
Symptom of
• Blade lift moves slowly or lacks power.
failure
General • Check for modifications to the blade.
information • If the hydraulic drift of blade lift is also excessive, carry out the troubleshooting of “H-16 Excessive
hydraulic drift of blade lift” first.

Defective operation of PPC
Possible 1 Blade control lever PPC valve output pressure
valve
causes and the 3.82 – 4.12 MPa
standard values Lift stroke end
{39 – 42 kg/cm2}
when normal
Defective operation of blade Since the operation of the blade lift control valve spool can be sus-
2
lift control valve (spool) pected to be defective, directly check it.
Residual air in blade lift Since the air can be suspected to reside in the blade lift cylinder,
3
cylinder bleed air and observe how the symptom changes.
14 D85EX, PX-15E0
H-14 Blade tilt speed is slow or lacks power 1
Symptom of
• Blade tilt speed or power is insufficient.
failure
information • If the hydraulic drift of blade tilt is also excessive, carry out the troubleshooting of “H-17 Excessive
hydraulic drift of blade tilt” first.

Possible 1 Blade control lever PPC valve output pressure
valve
causes and the 3.82 – 4.12 MPa
standard values Tilt stroke end
{39 – 42 kg/cm2}
when normal
Defective operation of Since the operation of the blade tilt control valve spool can be sus-
2
blade tilt control valve (spool) pected to be defective, directly check it.
Residual air in blade tilt Since the air can be suspected to reside in the blade tilt cylinder,
3
H-15 Ripper lift speed is slow or lacks power 1
Symptom of
• Ripper lift speed or power is insufficient.
failure
General • Check for modifications to the ripper.
information • If the hydraulic drift of ripper lift is also excessive, carry out the troubleshooting of “H-18 Excessive
hydraulic drift of ripper lift” first.

1 Ripper control lever PPC valve output pressure
valve
3.82 – 4.12 MPa
Lift stroke end
{39 – 42 kg/cm2}
Possible
causes and the Defective operation of ripper Since the operation of the ripper lift control valve spool can be sus-
2
standard values lift control valve (spool) pected to be defective, directly check it.
when normal Since the operation of the ripper lift control valve suction valve can
Defective operation of ripper be suspected to be defective, directly check it.
3 lift control valve a Also the judgement can be made by replacing the suction valve
(suction valve) on the head side and the bottom side with each others to observe
how the symptom changes.
Residual air in ripper lift Since the air can be suspected to reside in the ripper lift cylinder,
4
D85EX, PX-15E0 15
H-16 Excessive hydraulic drift of blade lift 1
Symptom of
• Excessive hydraulic drift of blade lift.
failure
information • Check for oil leak in the hydraulic circuit of the work equipment before troubleshooting.

a Prepare with the engine started, and diagnose with the engine
stopped.
If the hydraulic drift speed becomes faster when diagnosing in the
following procedure, the seal of the blade lift control valve spool is
Defective seal of blade lift defective.
1
Possible control valve (spool) 1. Tense the blade lift against the ground to push up the front of the
causes and the machine.
standard values 2. Stop the engine and release the work equipment lock lever.
when normal 3. Check symptoms when the blade control lever is shifted to the lift-
lowering position.
Defective seal of blade lift Since the seal of the blade lift cylinder can be suspected to be
2
cylinder defective, directly check it.
Raise the blade approximately 1,000 mm and check hydraulic drift
Defective fitting of quick drop
3 of the tip of blade cutting edge.
valve
• 300 mm/15 min
H-17 Excessive hydraulic drift of blade tilt 1
Symptom of
• Excessive hydraulic drift of blade tilt
failure

stopped.
following procedure, the seal of the blade tilt control valve spool is
Defective seal of blade tilt defective.
Possible 1
control valve (spool) 1. Tense the blade tilt against the ground to push up the right side of
causes and the the machine.
when normal 3. Check symptoms when the blade control lever is shifted to the
right-tilt position.
Defective seal of blade tilt high idle for troubleshooting.
2
cylinder Blade tilt cylinder Leakage from cylinder
Right tilt stroke end 16 cc/min
16 D85EX, PX-15E0
H-18 Excessive hydraulic drift of ripper lift 1
Symptom of
• Hydraulic drift of ripper lift is excessive.
failure
General • Check for modifications to the ripper.

stopped.
following procedure, the seal of the ripper lift control valve (Hi) spool
Defective seal of ripper lift is defective.
Possible 1
control valve (spool) 1. Tense the ripper lift against the ground to push up the rear of the
causes and the machine.
when normal 3. Check symptoms when the ripper control lever is shifted to the
lift-lowering position.
Defective seal of ripper lift high idle for troubleshooting.
2
cylinder Ripper lift cylinder Leakage from cylinder
Lower stroke end 16 cc/min
D85EX, PX-15E0 17
SEN00639-00

© 2006 KOMATSU
All Rights Reserved
18
SEN00640-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)............................................................................................................... 3
Method of using troubleshooting charts ............................................................................................... 3
S-1 Starting performance is poor.......................................................................................................... 6
S-2 Engine does not start..................................................................................................................... 8
S-3 Engine does not pick up smoothly............................................................................................... 12
S-4 Engine stops during operations ................................................................................................... 13
S-5 Engine does not rotate smoothly ................................................................................................. 14
S-6 Engine lacks output (or lacks power)........................................................................................... 15
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 16
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 17
S-9 Oil becomes contaminated quickly .............................................................................................. 18
S-10 Fuel consumption is excessive.................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) ....................................... 20
S-12 Oil pressure drops ..................................................................................................................... 21
S-13 Oil level rises (water, fuel in oil) ................................................................................................. 22
S-14 Coolant temperature becomes too high (overheating) .............................................................. 24
D85EX, PX-15E0 1
S-15 Abnormal noise is made. ........................................................................................................... 25

S-16 Vibration is excessive ................................................................................................................ 26
2 D85EX, PX-15E0
Troubleshooting of engine (S-mode) 1

Method of using troubleshooting charts 1
This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspection without using
troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
Questions:
Sections A + B in the right correspond to the items
were answers can be obtained from the user or
operator.
A is the basic content. B is the items that can be
obtained from the user or operator depending on
their level.
Check items:
Simple items checked by the serviceman to deter-
mine the causes. C in the chart to the right corre-
sponds to them.
Causes:
The contents to be determined after asking ques-
tions and checking items.
The serviceman determines causes of high proba-
bility from A, B, and C.
Troubleshooting:
The content for ultimately verifying whether the
determined causes are truly the defective factors
by using troubleshooting tools or making direct
checking starting with probable causes of higher
order.
This troubleshooting chart marks the content of the questions and check items with E, Q or w according to
their closer relationship with the causes.
E: A cause that can be referred to in relation to the question or check item.
Q: A cause that is related the question or check item.
w: A cause particularly probable among those marked with Q above.
a Count the priority level of each marking as w > Q when determining the cause.
Don't count E when determining the cause. The item with this marking may be counted, however, if no
difference is present than this and the cause cannot be determined.
D85EX, PX-15E0 3
<Example of troubleshooting> Exhaust smoke is black

Let us assume that the questions and check items were conducted when a defect of black exhaust gas is
detected. Now suppose that three symptoms have causal relationship with this problem: namely, [Exhaust
gas gradually became black], [Power was lost gradually], and [Dust indicator turned red].
4 D85EX, PX-15E0
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 6 causes.
Procedure for determining the causes from these relationship and leading to the troubleshooting will be
explained in step 1 to 3 in the following diagram.
D85EX, PX-15E0 5
S-1 Starting performance is poor. 1

General causes why starting performance is poor Cause
Defective electrical system
Cracked EGR cooler (Coolant in exhaust piping)

q
q Insufficient supply of fuel
Leaking or clogged fuel piping, entry of air

Insufficient intake of air
Clogged air breather hole of fuel tank cap

Defective contact of valve and valve seat
q
Defective alternator (generator section)

Defective alternator (regulator section)
q Improper selection of fuel
Stuck, seized supply pump plunger

Coolant in exhaust piping
Defective intake air heater system

q
Defective or deteriorated battery

Clogged feed pump gauze filter
a The common rail fuel injection system (CRI) recog-
Clogged air cleaner element

nizes the fuel injection timing electrically. Accordingly,
Clogged fuel filter, element

Worn piston ring, cylinder
even if the starting operation is carried out, the engine
may not start until the crankshaft revolves 2 turns at
Defective injector
maximum. This phenomenon does not indicate a trou-
ble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E E E
Became worse gradually Q Q w w Q Q
Starting performance
Engine starts easily when warm w w
Non-specified fuel is being used Q Q Q Q
Questions
Replacement of filters has not been carried out according to Operation and Main-
w w w Q Q
tenance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does
w
not indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is
w w
installed)
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly Q w
If air bleeding plug of fuel filter is removed, fuel does
w w
While engine is cranked not flow out
with starting motor If spill hose from injector is disconnected, little fuel
Check items
w
spills
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze
q
flows out (*1)
When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Troubleshooting
Inspect gauze filter of feed pump directly q

Carry out troubleshooting by failure code “Loss of pressure feed from supply
q
pump (*2)”
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change with some cylinders
When starting switch is turned to HEAT, intake air heater mount does not become
q
warm
Is voltage 20 – 30 V between alternator terminal R and terminal E Yes q
with engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are
q
low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 D85EX, PX-15E0
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out.
A little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent,
however, it is not a problem.
*2: Failure codes [CA559] and [CA2249]
D85EX, PX-15E0 7
S-2 Engine does not start 1

a) Engine does not turn Cause
Cracked EGR cooler (Coolant in exhaust piping)
Defective starting motor (safety relay section)

General causes why engine does not turn
q Internal parts of engine seized
Defective connection of battery terminal
Defective starting motor (motor section)

o See “S-4 Engine stops during operations“
q Coolant entered in cylinder, producing water hammer
q Defective electrical system
Defective starting circuit wiring

q Defective hydraulic pump
Broken flywheel ring gear
Defective hydraulic pump

Defective starting switch
Questions
Degree of use of machine Operated for long period EEE

Condition of horn when Horn does not sound Q Q w
starting switch is turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low Q w

When starting switch is
Makes grating noise w w
turned to START, starting
Soon disengages again w
pinion moves out, but
Makes rattling noise and does not turn w Q Q w
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows
Carry out troubleshooting in H-mode.

Carry out troubleshooting in E-mode.
q
out (*1)
Inspect flywheel ring gear directly q
When specific gravity of electrolyte and voltage of battery are measured, they are
q
Troubleshooting
low
There is not voltage (20 – 30 V) between battery relay
q
terminal M and terminal E
When terminal B and terminal C of starting switch are
Turn starting switch OFF, connected, engine starts q
connect cord, and carry out When terminal B and terminal C at safety relay outlet
troubleshooting at ON q
are connected, engine starts
Even if terminal B and terminal C at safety relay outlet
q
are connected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
—
8 D85EX, PX-15E0

D85EX, PX-15E0 9
b) Engine cranks but no exhaust smoke comes out. Causes
Defective operation of overflow valve (does not close)

General causes why engine cranks but no exhaust smoke
comes out:
q Fuel is not being supplied.

Supply of fuel is extremely small.
Clogged air breather hole in fuel tank cap

q
Wrong connection of supply pump PCV

Improper selection of fuel (particularly in winter)
Seized or abnormally worn feed pump

q
Stuck or seized supply pump plunger
Defective operation of flow damper

Broken supply pump shaft or key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Confirm recent repair history.
Questions
Degree of use of machine Operated for long period EEE

Exhaust smoke suddenly stopped coming out (when restarting). w Q w w w EE
Replacement of filters has not been carried out according to Operation
w w E Q
and Maintenance Manual.
When fuel tank is inspected, it is found to be empty. w
Air breather hole in fuel tank cap is clogged. w
Rust or water are observed when fuel tank is drained. Q Q Q Q Q
When fuel filter is removed, there is no fuel in filter. w w
Fuel is leaking from fuel piping. w
Check items
When priming pump is operated, it makes no reaction or it is heavy. w Q Q

If air bleeding plug of fuel filter is removed,
Q Q w Q
While engine is cranked fuel does not flow out.
with starting motor, When spill hose from injector is discon-
Q w w w w Q
nected, little fuel spills.

Inspect fuel filter directly. q
Inspect feed pump gauze filter directly q
Troubleshooting
Check feed pump directly. q

Carry out troubleshooting by failure code “Loss of pressure feed from
q q q q
supply pump (*1)”.
Carry out troubleshooting by failure code “Abnormal PCV1 (*2) or
q
Abnormal PCV2 (*3)”.
Inspect overflow valve directly. q
Engine can be started in reduced cylinder mode. q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Refill

10 D85EX, PX-15E0
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected).
Defective coolant temperature sensor or wiring harness

General causes why exhaust smoke comes out but engine
does not start:
Worn valve system (valve, rocker lever, etc.)
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system


q Insufficient intake of air
Defective intake air heater system

Improper selection of fuel
Clogged injector, defective spray

Worn piston ring or cylinder liner

q

Clogged fuel filter or strainer
Use of improper fuel

Degree of use of machine Operated for long period E E E E
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used. Q Q

Replacement of filters has not been carried out according to Operation and
w w w
Maintenance Manual.
More engine oil is required for refill than before. w
When engine is preheated or when temperature is low, preheating monitor
w
does not indicate properly (if monitor is installed).
Dust indicator is red (if indicator is installed). w
Air breather hole in fuel tank cap is clogged. Q
Rust or water are observed when fuel tank is drained. w w
When fuel filter is removed, there is no fuel in filter. w
Starting motor cranks engine slowly. w
When engine is cranked, abnormal noise comes out around cylinder head. w
If air bleeding plug of fuel filter is removed, fuel
Check items
Q w w
While engine is cranked with does not flow out.
starting motor, When spill hose from injector is disconnected, lit-
w
tle fuel spills.
w
ture of some cylinders is low.
Inspect air cleaner directly. q

Inspect valve system directly. q
When compression pressure is measured, it is found to be low. q
q
Troubleshooting
Inspect fuel filter and strainer directly.

q
pump (*1)”.
When injector unit is tested, spray condition is bad. q
When electrolyte specific gravity and voltage of battery are measured, they are
q
too low.
Coolant temperature gauge does not indicate properly (if coolant temperature
q
gauge is installed).
Intake air heater mount does not become warm during operation of preheating. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
D85EX, PX-15E0 11
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly: Causes
q Insufficient intake of air
Seized turbocharger or interference of turbocharger

q Defective condition of fuel injection

q Controller is controlling in derate mode.

(limiting injection rate (output) because of an error in
Defective operation of flow damper

(Excessive leakage from injector)
electrical system)
Clogged injector, defective spray


q EGR valve is stuck open.

(There is much EGR gas and intake of air is insuffi-
Improper valve clearance

cient.)
Stuck EGR valve

Degree of use of machine Operated for long period E E E E E E
Questions
Engine pick-up suddenly becomes worse. Q w Q Q Q

Non-specified fuel is being used. w w w w
w w w
Maintenance Manual.
More engine oil is required for refill than before. w
Rust and water are observed when fuel tank is drained. w w
When exhaust manifold is touched immediately after starting engine, tem-
Q w
perature of some cylinders is low
Blue under light load w
Color of exhaust gas is
Check items
Black w Q w w
When engine is cranked, abnormal noise comes out around cylinder head. w
When engine is running, interference noise comes out around turbocharger. w
High idle speed under no load is normal, but speed suddenly drops when
Q w w
load is applied.
Engine hunts (rotation is irregular). Q Q w Q
Blow-by gas is excessive. w

Carry out troubleshooting by failure code “Abnormal EGR valve servo (*1)”. q
When compression pressure is measured, it is found to be low. q q
q
Troubleshooting
Inspect valve clearance directly.

When turbocharger is rotated by hand, it is found to be heavy. q
Inspect fuel filter and strainer directly. q
Carry out troubleshooting by failure code “Loss of pressure feed from sup-
q
ply pump (*2)”.
When a specific cylinder is cut out for reduced cylinder mode operation,
q q
engine speed does not change with some cylinders.
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy

12 D85EX, PX-15E0
S-4 Engine stops during operations 1

General causes why engine stops during operations: Causes
q Seized parts inside engine
Broken valve system (valve, rocker lever, etc.)

Broken or seized piston or connecting rod

q Engine is overheating.
q Defective hydraulic pump

Broken or seized crankshaft bearing
Broken supply pump shaft or key

Leaking or clogged fuel piping
Broken or seized feed pump

Broken or seized gear train
Defective hydraulic pump

Degree of use of machine Operated for long period EE
Abnormal noise was heard and engine
w w w w Q w Q w
stopped suddenly.
Condition when engine
Questions
Engine overheated and stopped. w Q

stopped
Engine stopped slowly. w Q Q
There was hunting and engine stopped. w Q Q Q Q
Non-specified fuel is being used. Q Q Q Q
w w
and Maintenance Manual.
Fuel level monitor indicates low level (if monitor is installed). w
Rust or water are observed when fuel tank is drained. w w
Check items
Metal particles are observed when oil in oil pan is drained. w w Q Q

Does not turn at all w w
When engine is cranked Turns in opposite direction w
by hand Moves by amount of gear backlash w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine. w

Inspect piston and connecting rod directly. q
shooting in H-mode
Troubleshooting
Carry out trouble-
Inspect crankshaft bearing directly q

Inspect gear train directly. q
Check feed pump directly. q
q q
supply pump (*1)”.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Refill
Remedy
—
D85EX, PX-15E0 13
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly: Causes
q Air in fuel system
Defective operation of flow damper (Excessive leakage from injector)

q Defective speed sensor (Error at degree that it is not indicated)
q Defective EGR valve
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor or wiring harness

Defective Ne speed sensor or wiring harness
Defective operation of EGR valve

Low idle speed is set too low.

Degree of use of machine Operated for long period E E E
Occurs at a certain speed range Q Q Q Q
Questions
Occurs at low idle. w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and Main-
w w
tenance Manual.
Check items
Rust or water are observed when fuel tank is drained. Q Q

Troubleshooting

When a specific cylinder is cut out for reduced cylinder mode operation, engine
q q
speed does not change.
Carry out troubleshooting by failure code “Abnormal engine Ne speed sensor
q
(*2)“
Carry out troubleshooting by failure code “Abnormal engine Bkup speed sensor
q
(*3)“
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Clean
Clean
Refill
Remedy

*2: Failure code [CA689]
*3: Failure code [CA778]
14 D85EX, PX-15E0
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Cause
Defective charge air pressure sensor, wiring harness

q
Defective installation of charge air pressure sensor
Defective fuel temperature sensor, wiring harness

Seized turbocharger, interference of turbocharger
Clogged injector, defective spray (dirt in injector)

q Defective condition of fuel spray
Excessive wear of piston ring, cylinder liner
Defective drive of injector (signal, solenoid)

Clogged air breather hole of fuel tank cap

q There is overheating
o See “S-14 Coolant temperature becomes
Stuck, seized supply pump plunger

Air leakage from air intake piping

too high (Overheating)”.
Leaking, clogged fuel piping

q Controller is controlling in derate mode
Clogged fuel filter, strainer

(limiting injection rate (output) because of an
error in electrical system)
(air leakage)
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Non-specified fuel is being used Q Q
w
and Maintenance Manual
Engine oil must be added more frequently Q Q Q
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w
Output becomes insufficient after short stop of operation w
Black w w
Color of exhaust gas
When exhaust manifold is touched immediately after starting engine, tem-
w
perature of some cylinders is low
When engine is cranked, interference sound is generated around turbo-
w
Check items
charger
When engine is cranked, abnormal sound is generated around cylinder
w
head
High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when
w w Q
load is applied
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Inspect valve clearance directly q
Inspect fuel filter, strainer directly q
Troubleshooting
Inspect gauze filter of feed pump directly q

q
supply pump (*1)
When a cylinder is cut out for reduced cylinder mode operation, engine
q q
speed does not change
Inspect boost pressure sensor mount directly q
Carry out troubleshooting for “Charge pressure sensor too high. (*2)”
q
See *2 for code.
Carry out troubleshooting for “Fuel temperature sensor too high. (*3)”
q
See *3 for code.
Adjustment
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Remedy

D85EX, PX-15E0 15
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust gas color is black: Causes
Leakage of air between turbocharger and cylinder head

q
q Excessive fuel is supplied.
Seized turbocharger or interference of turbocharger

q Defective condition of fuel injection
Clogged fuel spill piping (on cylinder head side)

q Engine is overheating

o See “S-14 Coolant temperature becomes too

high (overheating).“

Controller is controlling in derate mode.
Improper fuel injection pressure

q
Improper fuel injection timing

(limiting injection rate (output) because of an error
Crushed or clogged muffler
Clogged or seized injector

in electrical system)
Abnormally worn injector

q EGR valve is stuck open.
(There is much EGR gas and intake of air is insuffi-
Stuck EGR valve

cient.)

Suddenly became black w Q Q Q
Questions
Color of exhaust gas is Gradually became black w Q Q Q

More oil is required for refill than before. w
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed. w
Leakage of air in piping between turbocharger and cylinder head or loose clamp w
Engine is running in low-temperature mode at normal temperature. Q Q Q
When exhaust manifold is touched immediately after starting engine, temper-
Q w
ature of some cylinders is low.
Check items

When engine is running, abnormal noise comes out around cylinder head. w
Pump relief speed is too high (excessive fuel is injected). Q Q
Exhaust noise is abnormal. Q w Q
Engine does not pick up smoothly and combustion is irregular. Q Q Q Q Q Q w
When spill hose from injector is disconnected, abnormally much fuel spills. w

Troubleshooting
Inspect valve clearance directly. q

When muffler is removed, exhaust gas color improves. q
q q
pump (*2)”.
When a specific cylinder is cut out for reduced cylinder mode operation,
q
engine speed does not change with some cylinders.
Inspect fuel spill piping (on cylinder head side) visually. q
Carry out troubleshooting by failure code “Abnormal coolant temperature
q
sensor (*3)”.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy

16 D85EX, PX-15E0
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive: Causes
q Abnormal combustion of oil
Turbocharger
Worn or damaged valve (stem, guide or seal)
Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
Dust sucked in from air intake system.

minutes continuously.)
Clogged breather or breather hose

q External leakage of oil
Oil leakage from EGR valve stem

q Wear of parts in lubrication system
Worn or damaged rear oil seal
Oil leakage from oil drain plug

Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Questions
Degree of use of machine Operated for long period EEEE E

Oil consumption suddenly increased. w Q
More oil is required for refill than before. Q w Q
Oil gets contaminated prematurely. Q Q w
Smear of oil is observed on the outside of engine. w w w w w
There are loose piping clamps in air intake system. w
Inside of turbocharger intake air outlet pipe has been smeared with
w
oil.
Inside of turbocharger exhaust gas outlet pipe has been smeared
Q w
Check items
with oil.
Oil has been mixed into the coolant. w
Oil level in damper chamber has risen. w
Exhaust gas color is blue under light load. Q w w
Excessive Q Q w w
Amount of blow-by gas
No w
When intake manifold is removed, dust is observed inside. q

When intake manifold is removed, excessive dirt is observed on the
q
inside.
Excessive play of turbocharger shaft q q
Troubleshooting
When EGR valve is removed, exhaust port is found to be smeared

q
with oil.
Inspect breather and breather hose visually. q
Inspect rear oil seal visually. q
A leakage has been detected during a pressure tightness test of the
q q
oil cooler.
Oil is leaking to the outside of the engine. q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
D85EX, PX-15E0 17
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Cause
q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Excessive wear of piston ring, cylinder liner
Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Worn EGR valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of use of machine Operated for long period EEEE
Questions
Non-specified fuel is being used Q

Engine oil must be added more frequently Q w
Oil filter clogging monitor indicates error even when oil temperature is high (if moni-
w Q
tor is installed)
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Color of exhaust gas

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

When EGR valve is removed, exhaust port is found to be dirty with oil q
Troubleshooting

See S-7
Check breather and breather hose directly q

Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
18 D85EX, PX-15E0
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive: Causes
q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Questions
Degree of use of machine Operated for long period EE E

Is excessive when compared with others of same model Q Q Q Q
Fuel consumption Gradually increased Q Q
Suddenly increased Q Q
Fuel is leaking to the outside of the engine. w
Combustion is irregular. w
Oil level rises and oil smells of diesel fuel. w w
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders are low.
Check items
Low idle speed is too high. Q

Hydraulic pump relief speed is high. Q
Black Q Q Q Q
White Q
Remove head cover and inspect visually. q

Inspect feed pump oil seal visually. q
Troubleshooting
Carry out troubleshooting by failure code “Loss of pressure feed from supply pump
q
(*1)”.
When a specific cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change with some cylinders.
When spill hose from injector is disconnected, the spill measures too much. q
Carry out troubleshooting by failure code “Abnormal coolant temperature sensor (*2)”. q
Confirm with monitoring function of monitor. q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy

D85EX, PX-15E0 19
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) 1
General causes why oil is in coolant: Causes
q Internal leakage in lubrication system
Damaged cylinder liner O-ring or holes caused by pitting

q Internal leakage in cooling system
Insufficient protrusion of cylinder liner

Broken cylinder head or head gasket
Broken oil cooler core or O-ring

Cracks inside of cylinder block
Questions
Degree of use of machine Operated for long period E E

Suddenly Q Q
Oil level rose
Gradually Q Q
Hard water is being used as coolant. Q Q
Oil level has risen and oil is milky. Q Q w
Check
items
Excessive air bubbles are trapped in the radiator and coolant spurts back. w w
A leakage has been detected during a pressure tightness test of the cylinder head. q
Troubleshooting
Inspect cylinder block and liner visually. q q

Inspect cylinder liner visually. q
A leakage has been detected during a pressure tightness test of the oil cooler. q
Replace
Replace
Replace
Replace
Correct
Remedy
20 D85EX, PX-15E0
S-12 Oil pressure drops 1

General causes why oil pressure drops: Causes
q Leakage, clogging or worn part in lubrication system
Defective oil pressure sensor or wiring harness

q Defective oil pressure control
Defective oil level sensor or wiring harness

Leaking, crushed, clogged hydraulic piping
q Improper selection of oil (improper viscosity)
q Deterioration of oil due to overheat
Clogged or broken pipe in oil pan
Defective oil pump relief valve
Leaking EGR hydraulic piping

Clogged strainer in oil pan
Defective EGR oil pump

Worn bearing journal
Coolant or fuel in oil

Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Degree of use of machine Operated for long period E E E E
Questions
Oil pressure monitor indicates oil pressure is too low (if monitor is installed) Q w
Non-specified oil is used. Q Q
w
Maintenance Manual.
Indicates pressure drop at low idle w Q Q
Oil pressure monitor Indicates pressure drop at low and high idle Q w w w Q Q Q
(if monitor is installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed). w w
Oil level in oil pan is low. w
External hydraulic piping is leaking or crushed. w w
Check items
Oil is milky or smells of diesel oil. w

Metal particles are observed when oil pan is drained. w
Metal particles are observed when oil filter is drained. w Q Q
Metal particles are observed in oil filter. q

Inspect oil pan strainer and pipe visually. q q
Oil pump rotation is heavy, or there is excessive play in oil pump. q
Troubleshooting
Valve or spring of oil pump relief valve is fatigued or damaged. q

See S-13.
Inspect oil filter visually q

Relief valve of EGR oil pump is damaged or oil leaks from it. q
Inspect EGR hydraulic piping visually. q
Carry out troubleshooting by failure code “Abnormal oil pressure sensor
q
(*1)“
If oil level sensor is replaced, oil pressure monitor indicates properly. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Refill
Remedy
—
D85EX, PX-15E0 21
S-13 Oil level rises (water, fuel in oil) 1

General causes why oil level rises: Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole) or defective seal
Defective seal of auxiliary equipment (pump or air compressor)

q Fuel in oil (smells of diluted diesel fuel)
a If oil in coolant, carry out troubleshooting for “S-11 Oil is in
Damaged cylinder liner O-ring or holes caused by pitting

coolant”.
Cracked EGR cooler (entry of coolant)

Broken cylinder head or head gasket
Internally defective supply pump

Broken oil cooler core or O-ring
Fuel leakage inside head cover
Cracks inside of cylinder block
Worn or damaged rear oil seal
Defective thermostat seat

Questions
Degree of use of machine Operated for long period EE E E

Fuel consumption has increased. w w
More coolant is required for refill than before. Q Q w
Oil has been mixed into the coolant. Q Q Q w
Oil smells of diesel fuel. w w
Oil is milky. Q Q w
After engine is started, drops of water come from muffler. Q Q
When engine is running at low idle with the radiator cap removed, excessive bub-
w Q
bles come out or coolant spurts back.
Check items
Exhaust gas color is white. Q Q

Water pump drain hole (breather hole) is clogged. w
When water pump drain hole (breather hole) is cleaned, coolant comes out. w
Oil level in clutch or damper chamber of machine has lowered. w
Oil level in hydraulic tank of machine has lowered. w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze
q
flows out (*1).
Troubleshooting
Remove head cover and inspect visually. q

Inspect cylinder block and liner visually. q q
Inspect rear oil seal visually. q
A leakage has been detected during a pressure tightness test of the oil cooler. q
Remove water pump and inspect visually. q
Remove thermostat cover and inspect visually. q
Remove supply pump and inspect visually. q
Directly check seal of auxiliary equipment. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
22 D85EX, PX-15E0

D85EX, PX-15E0 23
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too high Cause
q Lack of cooling air (deformation, damage of fan)
Broken O-ring of cylinder liner, holes caused by pitting

q Drop in heat dissipation efficiency
q Problem in coolant circulation system
q Rise in hydraulic oil temperature
External water leakage from EGR cooler
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Broken cylinder head, head gasket
Defective operation of thermostat
Slipping fan belt, worn fan pulley

Clogged, crushed radiator fins
Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of use of machine Operated for long period EEE EE
Questions
Suddenly overheated Q Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Coolant temperature Rises quickly Q w
gauge (if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is
Q w
installed)
Engine oil level has risen and oil is milky w Q
Fan belt tension is low w
When fan belt is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard on applicable machine side are
w w
clogged with dirt or mud
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Inspect EGR cooler for leakage of coolant directly q

When compression pressure is measured, it is found to be low q
Inspect cylinder liner directly q
q
Troubleshooting
Inspect oil cooler directly

Temperature difference between upper and lower tanks of radiator is large q
When operation of thermostat is carried out, it does not open at cracking tem-
q
perature
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is fount to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
24 D85EX, PX-15E0
S-15 Abnormal noise is made. 1

General causes why abnormal noise comes out. Causes
Abnormality due to defective parts
Improper fuel injection timing (abnormal coolant temperature sensor)

q
q Abnormal combustion
q Air sucked in from air intake system
a Judge if the noise is an internal noise or an external
Internally defective muffler (partition plate out of position)

noise, before starting troubleshooting.
Leakage of air between turbocharger and cylinder head
Deformed fan, loose fan belt or interference of fan belt

a The engine is operated in the low-temperature mode
Interference of turbocharger or seized turbocharger

while it is not warmed up sufficiently.
Accordingly, the engine noise becomes a little larger.
Excessive wear of piston ring or cylinder liner

This does not indicate abnormality, however.
Broken valve system (valve, rocker lever)

a When the engine is accelerated, it is operated in the
Removed or seized gear train bushing

acceleration mode and its sound becomes a little larger
Cracked or leaking EGR gas piping

for up to about 3 seconds. This does not indicate abnor-
mality, however.
Improper gear train backlash
Clogged or seized injector

Dirt caught in injector

Degree of use of machine Operated for long period E
Questions
Gradually Q Q
Abnormal noise appeared
Suddenly Q Q Q Q
Non-specified fuel is being used. Q
More oil is required for refill than before. w
Metal particles are observed when oil in oil filter is drained. w w
Air leaks between turbocharger and cylinder head. w
When engine is running, abnormal noise comes out around EGR gas piping. w
When engine is running, abnormal noise comes out around cylinder head. w w
When engine is running, beating noise comes out around muffler. w
Check items

Q
ture of some cylinders is low.
Black Q w Q
Engine does not pick up smoothly and combustion is irregular. w
Abnormal noise is loud during acceleration. Q Q Q Q

Inspect EGR gas piping visually. q
When muffler is removed, abnormal noise disappears. q
Troubleshooting
Inspect valve clearance directly. q

Inspect gear train directly. q q
Inspect fan and fan belt visually. q
When a specific cylinder is cut out for reduced cylinder mode operation, engine
q q
speed does not change with some cylinders.
Abnormal noise comes out only when engine is started. q
Confirm with monitoring function of monitor. q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Remedy
D85EX, PX-15E0 25
S-16 Vibration is excessive 1

General causes why vibration is excessive: Causes
q Defective parts (abnormal wear, breakage, etc.)
Misalignment between engine and devices on the machine side

q Misalignment with chassis side
q Abnormal combustion
a If abnormal noise comes out and vibration is excessive, also carry out
troubleshooting for "S-15 Abnormal noise is made"
Worn main bearings or connecting rod bearings
Loose engine mounting bolts, broken cushions

Stuck valve system (valve, rocker lever, etc.)
Broken parts inside the damper

Improper gear train backlash
Worn camshaft bushing
Questions
Degree of use of machine Operated for long period E E E

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Metal particles are observed when oil in oil filter is drained. w w
Metal particles are observed when oil pan is drained. w w
Oil pressure is low when running at low idle. Q Q
Check items
Vibration occurs when running at a medium speed. Q Q

Vibration follows engine speed. Q Q Q Q
Exhaust gas color is black. w

Inspect main bearings and connecting rod bearings visually. q
Troubleshooting
Inspect gear train directly. q

Inspect camshaft bushing visually. q
Confirm with monitoring function of monitor. q
Inspect engine mounting bolts and cushions visually. q
When alignment is checked, radial runout or facial runout is detected. q
Inspect inside of damper directly. q
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
26 D85EX, PX-15E0
SEN00640-00

© 2006 KOMATSU
All Rights Reserved
28
SEN01263-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
General information on disassembly and assembly ....................................................................................... 2
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 4
Special tool list ..................................................................................................................................... 7
Sketch of special tool ..........................................................................................................................11
D85EX, PX-15E0 1
SEN01263-00 50 Disassembly and assembly
General information on disassembly and assembly 1

How to read this manual 1 Removal
q The [Removal] section contains procedures
and precautions for implementing the work,
1. Removal and installation of assemblies
know how and the amount of oil or coolant to
Special tools
be drained.
q Special tools which are deemed neces-
q Various symbols used in the Removal Section
sary for removal or installation of parts are
are explained and listed below.
k: This mark indicates safety-related precau-
described as A1,•••X1 etc. and their part
names, part numbers and quantities are
tions that must be followed when imple-
described in the special tool list.
menting the work.
q Also the following information is described
a: Know-how or precautions for work
in the special tool list.
[*1] : This mark shows that there are instructions or
1) Necessity precautions for installing parts.
t : Special tools that cannot be substi-
6: This mark shows the amount of oil or coolant
tuted and should always be used
to be drained.
(installed).
4: Weight of part or component
q : Special tools that will be useful if avail-
able and are substitutable with com-
mercially available tools.
2) Distinction of new and existing special Installation
tools q Except where otherwise instructed, installation
N: Tools newly developed for this of parts is done in the reverse order of
model. They respectively have a removal.
new part number. q Instructions and precautions for installing parts
R: Tools with upgraded part numbers. are shown with [*1] mark in the Installation sec-
They are remodeled from already tion, identifying which step the instructions are
available tools for other models. intended for.
Blank: Tools already available for other q Marks shown in the Installation section stand
models. They can be used without for the following.
any modification. k: Precautions related to safety in execution
3) Circle mark Q in sketch column: of work.

q The sketch of the special tool is pre- a : This mark gives guidance or precautions
sented in the section of "Sketches of when doing the procedure.
special tools". 2 : Type of coating material
q Part No. of special tools starting with 3 : Tightening torque
5
* *** ****
79 T- - :
means that they can not be supplied
: Quantity of oil or coolant to be added
from Komatsu in Japan (i.e. locally Sketches of special tools

made parts). q Various special tools are illustrated for the con-
venience of local manufacture.
a General tools that are necessary for
removal or installation are described as
[1],[2]•••etc. and their part names, part
numbers and quantities are not described.
2 D85EX, PX-15E0
2. Disassembly and assembly of assemblies Disassembly

Special tools q In Disassembly section, the work procedures,
q Special tools which are deemed neces- precautions and know-how for carrying out
sary for removal or installation of parts are those procedures, and quantity of the oil and
described as A1,•••X1 etc. and their part coolant drained are described.
names, part numbers and quantities are q The meanings of the symbols used in Disas-
described in the special tool list. sembly section are as follows.
q Also the following information is described k: This mark indicates safety-related precau-
in the special tool list. tions that must be followed when imple-
1) Necessity menting the work.
t : Special tools that cannot be substi- a : Know-how or precautions for work
tuted and should always be used 6: Quantity of oil or coolant drained
(installed).
q : Special tools that will be useful if avail-
able and are substitutable with com-
mercially available tools. Assembly
2) Distinction of new and existing special q In Assembly section, the work procedures, pre-
tools cautions and know-how for carrying out those
N : Tools newly developed for this procedures, and quantity of the oil and coolant
model. They respectively have a added are described.
new part number. q The meanings of the symbols used in Assem-
R : Tools with upgraded part numbers. bly section are as follows.
They are remodeled from already k: Precautions related to safety in execution
available tools for other models. of work
Blank : Tools already available for other a : This mark gives guidance or precautions
models. They can be used without when doing the procedure.
any modification. 2 : Type of coating material
3) Circle mark Q in sketch column: 3 : Tightening torque
q The sketch of the special tool is pre- 5 : Quantity of oil or coolant to be added
sented in the section of "Sketches of
special tools". Sketches of special tools
q Part No. of special tools starting with
q Various special tools are illustrated for the con-
* *** ****
79 T- - :
means that they can not be supplied
venience of local manufacture.
from Komatsu in Japan (i.e. locally
made parts).
a General tools that are necessary for

removal or installation are described as
[1], [2]•••etc. and their part names, part
numbers and quantities are not described.
D85EX, PX-15E0 3
Coating materials list 1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resis-
ThreeBond tant, vibration-resistant, impact-resistant seal-
419-15-18131 100 g Tube
1207B ant.
• Used to seal transfer case, etc.
4 D85EX, PX-15E0
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used to lubricate sliding portions.
disulfide lubricant
LM-G 09940-00051 60 g Can

Molybdenum
(to prevent squeaking)

• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various • General purpose type.
SYG2-160LI
SYGA-160CNLI
SYG2-400CA
SYG2-350CA
• Used for bearings used at normal temperature
G2-CA SYG2-400CA-A Various Various
under light load in contact with water or steam.
SYG2-160CA
SYGA-160CNCA
Grease
Molybdenum SYG2-400M 400 g x 10 Bellows-type

disulfide grease SYG2-400M-A 400 g x 20 container • Used for parts under heavy load.
LM-G (G2-M) SYGA-16CNM 16 kg Can
Hyper White SYG2-400T-A • Seizure resistance and heat resistance higher
400 g Bellows-type
Grease G2-T, SYG2-16CNT than molybdenum disulfide grease.
container
G0-T (*) SYG0-400T-A (*) • Not conspicuous on machine since color is
16 kg Can
*: For cold district SYG0-16CNT (*) white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass
SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
D85EX, PX-15E0 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• “S” is used for high-temperature season
SUNSTAR
(April – October) and “W” for low-tempera-
PENGUINE
Polyethylene ture season (November – April) as adhe-
SEAL 580 417-926-3910 320 ml
container sive for glass.
SUPER “S” or
“W”
Adhesive
facture)
• Used as adhesive for glass.
Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Adhesive for cab glass

Sikaflex 256HV container
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
TOSSEAL 381
facture)
6 D85EX, PX-15E0
Special tool list 1
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity:t: Cannot be substituted, should always be installed (used).
q: Extremely useful if available, can be substituted with commercially available part.
a New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other
models.
Blank: Tools already available for other models, used without any modification.
a Tools marked Q in the Sketch column are tools introduced in special sketches (See Sketches of special
tools).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
1 795-630-5500 Standard puller t 1

A1 2 01010-81080 Bolt t 2 Removal of fuel supply pump
3 01643-31032 Washer t 2
795T-521-1140 Push tool t 1 Q
790-101-5221 Grip t 1
A2 Installation of engine front seal
• 01010-81225 • Bolt t 1
• 01050-31640 • Bolt t 3
Engine assembly 795-931-1210 Push tool t 1
1 • 01050-31625 • Bolt t 3
A3 • 01050-31645 • Bolt t 3 Installation of engine rear seal
795-931-1220 Push tool t 1
2
• 01050-31645 • Bolt t 3
A4 790-331-1120 Wrench t 1 Tightening of cylinder head bolt
Removal, installation of nozzle
A5 795T-471-1550 Wrench t 1 Q
tip
791-612-1100 Installer t 1
Damper assembly B 790-101-4200 Puller (294kN {30ton}) t 1 Press fitting of bearing
790-101-1102 Hydraulic pump t 1
Removal, installation of snap
TORQFLOW D1 791-415-1300 Puller assembly t 1
ring of carrier
transmission
assembly D2 799-301-1600 Oil leak tester t 1 Operation check of piston
Removal, installation of brake

E1 791T-422-1320 Hanger t 1 Q
assembly
Removal, installation of bearing
E2 790-302-1500 Wrench set q 1
nut
HSS case assembly
E3 796-730-2300 Wrench assembly t 1
Check of bevel gear rotating
795-630-1810 or torque
E4 Torque wrench q 1
purchased tool
D85EX, PX-15E0 7
New/Remodel
Necessity
Symbol
Sketch
Q'ty
790-337-1032 Lifting tool t 1

J1 791T-627-2110 Plate t 1 N Q Slinging of final drive assembly
01643-32060 Washer t 6
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
J2 Removal of sprocket hub bearing
791-546-1110 Adapter t 2
790-201-2690 Plate t 1
790-101-2102 Puller t 1
790-431-1031 Block t 1
Final drive assembly
791-520-4140 Screw t 1
791-112-1180 Nut t 2
01643-32460 Washer t 2 Press fitting of sprocket hub
J3
791T-627-2130 Plate t 1 N Q bearing inner race
791T-627-2120 Push tool t 1 N Q
790-101-2102 Puller t 1
J4 791-580-1510 Installer t 1 Press fitting of floating seal
790-101-5201 Push tool KIT t 1
• 790-101-5281 • Plate t 1
J5 Press fitting of oil seal
• 790-101-5221 • Grip t 1
• 01010-51225 • Bolt t 1
Press fitting of floating seal of
L1 791-530-1510 Installer t 1
idler assembly
Idler assembly
L2 791-601-1000 Oil pump t 1 Adding oil
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
Recoil spring Disassembly, assembly of recoil
M1 791T-630-2610 Spacer t 1 N Q
assembly spring assembly
790-101-1300 Cylinder t 1
Press fitting of floating seals of
N1 791-651-1510 Installer t 1 track roller and carrier roller
Track roller and
assemblies
carrier roller
assemblies
N2 791-601-1000 Oil pump t 1 Adding oil
8 D85EX, PX-15E0
New/Remodel
Necessity
Symbol
Sketch
Q'ty
794-650-3000 Remover and installer t 1

790-101-1300 Cylinder assembly t 1 Disassembly, assembly of track
R1
790-105-2300 Jack assembly t 1 (Master link type)
791-650-3500 Remover and installer t 1
791-675-5542 Adapter t 1
791-675-5571 Adapter t 1
Disassembly, assembly of track
R2 790-101-1300 Cylinder assembly t 1 (Lubricated type)
790-105-2300 Jack assembly t 1
Hydraulic pump
790-101-1102 t 1
Track shoe assembly
assembly R3 791-646-7531 Push tool t 1 Removal of track pin plug
R4 791-660-7460 Pin brush t 1 Cleaning of track pin plug
791-646-7900 Plug push tool t 1
• 790-434-1210 • Bar 1
• 790-434-1220 • Guide 1
R5 Installation of track pin plug
• 791-646-7523 • Bar 1
• 791-646-7590 • Guide 1
R6 791-632-1060 Installer t 1 Installation of track link seal
R7 790-701-3000 Seal checker t 1 Check of sealing of track link
R8 791-601-1000 Oil pump t 1 Adding track link oil
790-502-1003 Cylinder repair stand t 1 Disassembly, assembly of
U1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder
Removal, installation of hydrau-
U2 790-102-3802 Wrench t 1
lic cylinder head
790-302-1310 Socket t 1 Removal, installation of nut
790-302-1350 Socket (Blade lift)
U3
(Blade tilt)
790-302-1340 Socket t 1 (Ripper lift)
Press fitting of cylinder head
• 790-101-5021 • Grip 1
bushing
Hydraulic cylinder • 01010-50816 • Bolt 1 (Blade lift)
U4
assembly • 790-201-1791 • Push tool 1 (Blade tilt)
(Ripper lift)
• 790-201-1821 • Push tool 1
(Ripper tilt)
• 790-201-1811 • Push tool 1
Press fitting of cylinder head
• 790-101-5021 • Grip 1
dust seal
• 01010-50816 • Bolt 1 (Blade lift)
U5
• 790-201-1610 • Plate 1 (Blade tilt)
(Ripper lift)
• 790-201-1630 • Plate 1
(Ripper tilt)
• 790-201-1620 • Plate 1
U6 790-720-1000 Expander t 1 Installation of piston ring
D85EX, PX-15E0 9
New/Remodel
Necessity
Symbol
Sketch
Q'ty
796-720-1660 Ring t 1
07281-01159 Clamp t 1 Installation of piston ring
796-720-1680 Ring t 1 (Blade lift)
Hydraulic cylinder
U7 (Blade tilt)
assembly 07281-01589 Clamp t 1 (Ripper lift)
796-720-1670 Ring t 1 (Ripper tilt)
07281-01279 Clamp t 1
Operator's cab Removal, installation of operator's
X1 793-498-1210 Lifter (Suction cup) t 1
assembly cab glass (stuck glass)
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump t 1
Adding air conditioner refrigerant
Air compressor X2 799-703-1110 Vacuum pump t 1
(R134a)
799-703-1120 Vacuum pump t 1
799-703-1401 Gas leak detector t 1
10 D85EX, PX-15E0
Sketch of special tool 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A2: Push tool
A5: Wrench
D85EX, PX-15E0 11
E1: Hanger
J1: Plate
12 D85EX, PX-15E0
J3: Plate
J3: Plate
D85EX, PX-15E0 13
M1: Spacer
14 D85EX, PX-15E0
SEN01263-00

© 2006 KOMATSU
All Rights Reserved
16
SEN01264-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Engine and cooling system, Part 1
Engine and cooling system, Part 1 ................................................................................................................. 2
Removal and installation of fuel supply pump assembly...................................................................... 2
Removal and installation of cylinder head assembly ........................................................................... 8
Removal and installation of fuel injector assembly ............................................................................ 20
Removal and installation of engine front seal .................................................................................... 25
Removal and installation of engine rear seal ..................................................................................... 27
Removal and installation of engine oil pan......................................................................................... 31
D85EX, PX-15E0 1
Engine and cooling system, Part 1 1

Removal and installation of fuel 4. Open engine left side cover (2).
supply pump assembly 1
5. Remove side cover (3).
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part number Part name
1 795-630-5500 Standard puller t 1

A1 2 01010-81080 Bolt t 2
3 01643-31032 Washer t 2
Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X2 799-703-1110 t 1
(220 V) 6. Remove the air conditioner compressor as fol-
Vacuum pump lows.
799-703-1120 t 1 1) Disconnect air conditioner wirings (4) and
(240 V)
(5).
2) Disconnect air conditioner hoses (6) and
(7). [*1]
a Before disconnecting the air condi-
Removal tioner hoses, collect the new Freon
k
gas (R134a).
Disconnect the cable from the negative (–)
3) Remove the compressor belt and com-
terminal of the battery.
pressor (8).
4) Remove compressor mounting bracket
1. Release the residual pressure from the fuel sys-
(9).
tem. For details, see Testing and adjusting,
“Releasing residual pressure from fuel system”.
2. Close the fuel supply valve of the fuel tank.
3. Open engine undercover (1).
2 D85EX, PX-15E0
7. Disconnect fuel supply pump wiring connec- 12. Remove fuel supply pump assembly as follows.
tors PCV1 (10), PCV2 (11), and G (12). 1) Remove cover (1).
2) Rotate the crankshaft forward and set
8. Disconnect fuel return hose (13). [*2] intermediate point (a) between stamped
“2/5 TOP” and “3/4 TOP” on damper (2) to
pointer (3) (stamped 1/6 TOP comes
almost directly under).
a Make sure at this point that the forc-
ing tap of the drive gear is aligned to
the bolt hole at the top of cover (1).
(If not, rotate the crankshaft 1 more
turn.)
a At this point, the key of the shaft is
turned clockwise by 15° from the top.
9. Remove high-pressure pipe clamp (14) and 2

high-pressure pipes (15). [*3]
10. Disconnect lubrication tube (16). [*4]
3) Remove mounting nut (4) and then remove

washer (5).
a Use a magnet or the like in this opera-
tion so that washer (5) may not be
inadvertently dropped into the case.
11. Disconnect fuel filter tubes (17) and (18), hose

(19). [*5]
D85EX, PX-15E0 3
4) Remove pump mounting bolts (6) and Installation

bracket (7). q Carry out installation in the reverse order to
a Leave bolts (6) tightened by 2 – 3 removal.
threads to prevent the pump from fall-
ing down. [*1]
5) Install tool A1-1 with A1-2 and A1-3 and a Install each hose so that it will not be twisted.
then screw in the center bolt of A1-2 to a When installing the air conditioner hoses, take
remove the gear from the shaft. care that dirt, dust, water, etc. will not enter
6) Remove remaining bolts and then remove them.
fuel supply pump assembly (8). a When tightening each joint of the air condi-
a Leave tools A1-1, A1-2 and A1-3 in tioner hose, check that O-ring (43) is fitted to it.
the installed condition. a Apply sufficient compressor oil (Showa-Shell
Suniso 4G or 5G) to each O-ring.
3 Tightening torque of air conditioner refrigerant

piping
16 × 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 × 1.5 19.6 – 24.5 Nm {2.0 – 2.5 kgm}
24 × 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
q Charging air conditioner circuit refrigerant

gas
Using tool X2, charge the air conditioner circuit
with air conditioner refrigerant gas (R134a).
[*2]
3 Fuel return hose: 54 – 93 Nm {5.5 – 9.5 kgm}
4 D85EX, PX-15E0
[*3] 4) Install bracket (6).

k Do not correct the high-pressure pipe by 3 Mounting bolt (supply pump side):
bending before installing it. 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
a Leave the cylinder block side mount-
k Be sure to use the genuine high-pressure ing bolt in temporarily tightened state
pipe clamp and observe the tightening (it is to be tightened permanently in
torque. the following Step 2).
k Install the high-pressure pipe and wiring

harness at least 10 mm apart from each
other.
a When installing each high-pressure pipe,
check the taper seal of its joint (Part (a): Part of
2 mm from the end) for visible lengthwise slit
(b) and spot (c) and check part (d) (End of
taper seal: Part of 2 mm from the end) for
stepped-type wear caused by fatigue which
your nail can feel. If there is any of those
defects, it can cause fuel leakage. In this
case, replace the high-pressure pipe.
a Install the fuel supply pump and the high-pressure

pipe between it and common rail according to the 5) Make sure that match marks (A to C) of
following procedure. drive gears and idler gears are matched.
1. Installation of fuel supply pump assembly

1) Set fuel supply pump assembly (3) and
then tighten it temporarily using 4 mount-
ing bolts (5).
a Tighten it permanently according to
Step 2 described below.
2 Mounting bolt: Adhesive (LT-2)
2) Set the assembly by aligning (C) mark to
(C) mark of camshaft gear (2) while align-
ing the key groove of supply pump drive
gear (1) to the woodruff key of the shaft.
3) Fit the washer and then tighten them
using gear mounting nut (4).
3 Gear mounting nut:
127 – 147 Nm {13 – 15 kgm}
D85EX, PX-15E0 5
2. Installation of high-pressure pipe between

fuel supply pump and common rail
1) Tighten high-pressure pipes (3) and (4) by
hand first, and then tighten them perma-
nently.
3 Sleeve nut
(Pump side):
39.2 – 49 Nm {4 – 5 kgm}
(Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
2) Tighten supply pump mounting bolts (2)
permanently.
3) Tighten the cylinder block side mounting
bolt of bracket (1) permanently.
4) Install the splash prevention cover on both
ends of the high-pressure pipe.
a Face the common rail side slit down-
ward and the supply side slit toward
the cylinder block.
5) Tighten lubrication tube (12) by hand.
6) Tighten and install clamp (10) by hand
first, and then tighten it permanently.
7) Tighten and install brackets (6) and (5) by
hand first, and then tighten them perma-
nently.
8) Tighten and install bracket (8) and clamp
(9) by hand first, and then tighten them
permanently.
3 Clamp (9) mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
9) Tighten and install clamp (11) by hand
first, and then tighten it permanently.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
10) Tighten lubrication tube (12) permanently.
3 Joint bolt:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
11) Tighten and install clamp (7) by hand first,
and then tighten it permanently.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
6 D85EX, PX-15E0
[*4]
3 Joint bolt on supply pump side:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
3 Joint bolt on engine side:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*5]
3 Fuel hose (24):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Eyebolts (21), (22), and (23):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
q Checking for fuel leakage

Check for fuel leakage. For details, see Testing
and adjusting, “Checking fuel system for leak-
age”.
q Bleeding air
Bleed air from the fuel circuit. For details, see
Testing and adjusting, “Bleeding air from fuel
circuit”.
D85EX, PX-15E0 7
Removal and installation of

cylinder head assembly 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q’ty
A4 790-331-1120 Wrench (angle) q 1
Removal
k Disconnect the cable from the negative (–)
a Since the air hose band (MIKALOR clamp)
cannot be reused, use new one. See [*1],
[*2].
1. Remove the engine hood assembly. For details,

see “Removal and installation of engine hood
assembly”.
2. Drain the coolant.

6 Coolant: Approx. 53 l
4. Disconnect air hose (2). [*1]

a Make marks at the hose end and tube to
show the original insertion position of the
hose (See the figure below).
5. Remove the air hose, tube, and bracket

assembly (3). [*2]
a Make marks at the hose end and tube to
show the original insertion position of the
hose (See the figure below).
8 D85EX, PX-15E0
6. Disconnect dust indicator hose (3A). 12. Disconnect wiring harness clamps (9).
7. Disconnect air hose (4). [*3] 13. Disconnect terminal HT/A (10) (black).
8. Remove band (5). [*4] 14. Disconnect terminal (11) (green) and terminal
HT/B (12) (black).
9. Remove air cleaner assembly (6).
15. Remove heat insulation cover and bracket

10. Remove the mounting bolts and lift off muffler assembly (13).
assembly (7).
4
16. Disconnect harness clamps (14).
Muffler assembly: 33 kg
11. Remove air cleaner bracket (8).
D85EX, PX-15E0 9
17. Disconnect hose clamp (15). 25. Disconnect blow-by hose (24).
18. Disconnect fuel hoses (16) and (17). 26. Remove turbocharger lubrication tube (25). [*8]
19. Remove filter and bracket assembly (18).
20. Disconnect heater terminal (19). [*5]
27. Remove exhaust tube (26). [*9]
28. Disconnect turbocharger drain tube (27).
21. Remove tube and clamp assembly (20). [*6] 29. Temporarily sling turbocharger and exhaust
manifold assembly (28).
22. Remove filter and bracket assembly (21).
23. Disconnect 2 tubes (22). [*7]
24. Remove filter and bracket assembly (23). [*7]
30. Lift off turbocharger and exhaust manifold

assembly (28). [*10]
4 Turbocharger and exhaust manifold
assembly: 40 kg
10 D85EX, PX-15E0
31. Remove bracket (29). 37. Disconnect 6 injector connectors (35).
32. Disconnect EGR tube (30). 38. Disconnect wiring harness and bracket assem-
bly (36).
33. Remove connector (31).
4 Connector: 25 kg
34. Remove air housing (32).
35. Disconnect air hose (33). [*11]
39. Disconnect 6 clamps (37). [*12]
40. Remove 6 bellows (38) and 6 bellows (39). [*12]
41. Remove high-pressure pipe assembly (40). [*12]
42. Lift off air intake manifold (41).

4
36. Remove bracket (34).
Air intake manifold: 25 kg
D85EX, PX-15E0 11
43. Remove the air conditioner compressor. For 48. Disconnect 2 capture nuts (45).
details, see “Removal and installation of fuel a The capture nuts are so installed that they
supply pump assembly”. (Do not remove the will not fall.
air conditioner hoses.)
49. Loosen locknut (46) and adjustment screw (47).
44. Using the pulley mounting bolt, set intermedi-
ate point (L) between stamps 2.5 TOP and 3.4 50. Remove mounting bolts (48) and rocker arm
TOP of damper (D) to pointer (P). and shaft assembly (49).
a Rotate the crankshaft. For details, see
Testing and adjusting, “Testing and adjust-
ing valve clearance”.
51. Remove 12 push rods (50).
45. Remove spill tube (42).
46. Remove air vent tube (43).
47. Remove cylinder head cover (44).
52. Remove holder mounting bolts (51) and then

remove holder (52) and fuel injector assembly
(53) together.
a Never hold the solenoid valve unit at the
top of the injector with pliers, etc.
12 D85EX, PX-15E0
53. Remove 12 crossheads (54). Installation

54. Remove rocker arm housing (55). q Cylinder head assembly
1. Check that the cylinder head mounting surface
55. Remove cylinder head assembly (56). and the inside of the cylinder are free from dirt
and foreign matter and then set cylinder head
gasket (100).
a When installing the gasket, check that the
grommet is fitted normally.
2. Check the following items of the cylinder head

mounting bolts. If any bolt is out of the stan-
dard, do not use it but replace it.
1) The number of tightening times of the bolt
(indicated by the number of punch marks)
must be 5 or less.
2) Using limit of stem length (a) of bolt:
Below 171.4 mm.
D85EX, PX-15E0 13
3. Using sling [1], lift up cylinder head assembly

(56) and set it on the cylinder block.
4 Cylinder head assembly: 20 kg
a When not using tool A4, make marks (b)

on the cylinder head and bolt with paint
and then tighten the bolt by 90 – 120°
(Target: 120°).
4. Tighten the cylinder head assembly mounting
1] Make a punch mark (c) on the mount-
bolts in the order of 1 – 6 and then tighten aux-
ing bolt head to indicate the number
iliary bolt 7.
2 Mounting bolt (1 – 6 in following figure):
of tightening times.
a When a new bolt is used, do not
Molybdenum disulfide grease (LM-P) or
make a punch mark on its head.
engine oil (EO30).
3 Mounting bolt (1 – 6 in following figure)
1st time: 98.1 ± 9.8 Nm {10 ± 1 kgm}
2nd time:
166.6 – 176.4 Nm {17 – 18 kgm}
(Target: 176.4 Nm {18 kgm})
3rd time: Using tool A4, tighten by 90 –
120° (Target: 120°).
3 Auxiliary bolt (7 in following figure):
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
14 D85EX, PX-15E0
5. Fit the gasket to cylinder head assembly (56) q Fuel injector assembly
and install rocker arm housing (55). 6. Install gasket (103) and O-rings (104) and
3 Mounting bolt: (105) to fuel injector assembly (53).
58.8 – 73.5 Nm {6 – 7.5 kgm} 2 O-ring: Engine oil (EO30)
q Crosshead
1) Set crosshead (54), loosen locknut (101),
and return adjustment screw (102).
2) Hold the rocker arm contacting surface of
crosshead (54) lightly with the finger to
keep crosshead (54) in contact with the
valve stem on the push rod side.
3) Tighten adjustment screw (102) until cross-
head (54) touches the other valve stem.
4) After adjustment screw (102) touches the
valve stem, tighten it further by 20° and
tighten locknut (101) under this condition.
2 Crosshead guide and top of crosshead:
Engine oil (EO30)
3 Locknut: 58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
7. Insert holder (52) in fuel injector assembly (53)
and insert inlet connector (106) in the rocker
housing, directing it to the hole to insert the
high-pressure pipe.
8. Install spherical washer (107) to bolt (51) and

temporarily tighten holder (52).
a Check that the holder is inserted firmly to
the end.
2 Spherical part of washer:
Engine oil (EO30)
9. Permanently tighten bolt (51) of holder (52).

3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
10. Install the 12 push rods.
D85EX, PX-15E0 15
q Rocker arm and shaft assembly 15. Fit the O-ring and install cylinder head cover
11. Set rocker arm and shaft assembly (49). (44).
a When installing the rocker arm shaft, direct a When installing the O-ring, do not twist it.
its larger mounting hole end down and its 3 Mounting bolt:
ball plug (108) end forward of the engine. 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
12. Check that the ball of adjustment screw (47) is 16. Fit the gaskets to both sides, and install air
fitted in push rod socket (109) and tighten vent tube (43).
mounting bolts (48). 3 Joint bolt:
a Before installing, clean the oil holes. 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm} 17. Fit the gaskets to both sides, and install spill
tube (42).
13. Adjust the valve clearance. For details, see 3 Joint bolt:
Testing and adjusting, “Testing and adjusting 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
valve clearance”.
3 Locknut (46):
58.8 – 73.5 Nm {6 – 7.5 kgm}
q Fuel injector wiring harness

14. Tighten 2 capture nuts (45) of the wiring har-
ness into injector assembly (53).
3 Capture nut:
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
q Intake manifold
18. Tighten the mounting bolts in the numeric
order shown below.
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
16 D85EX, PX-15E0
q Carry out the rest of installation in the reverse [*2]

order to removal. a Use a new MIKALOR clamp.
a For the photos corresponding to the Nos., see a Set the hose to the original (marked) position.
“Removal”. (For the insertion depth of air hose: see the
table below.)
[*1] a Set the bridge (BR) at the bottom of clamp bolt
a Use a new MIKALOR clamp. and it will be lapped over band (BD) by at least
a Set the hose to the original (marked) position. min. 5 mm.
(For the insertion depth of air hose: see the 2 Threads of clamp bolt: Lubricating oil:
table below.) THREEBOND, PANDO 18B
a Set the bridge (BR) at the bottom of clamp bolt a Do not use an impact wrench.
and it will be lapped over band (BD) by at least q When reusing the hose
min. 5 mm. a Set the clamp to its original position.
2 Threads of clamp bolt: Lubricating oil: 3 MIKALOR clamp: Min. 6 Nm (0.6 kgm}
THREEBOND, PANDO 18B q When using a new hose
a Do not use an impact wrench. a Tighten until band gap (BDG) is as shown in
q When reusing the hose the table below.
a Set the clamp to its original position.
3 MIKALOR clamp: Min. 6 Nm (0.6 kgm}
Insertion depth of Band gap
q When using a new hose MIKALOR clamp
air hose (mm) (BDG) (mm)
a Tighten until band gap (BDG) is as shown in
the table below. MC1 60 7 – 10
MC2 80 17 – 20
Insertion depth of Band gap
MIKALOR clamp MC3 80 17 – 20
air hose (mm) (BDG) (mm)
MC5 60 7 – 10 MC4 55 17 – 20
MC6 80 17 – 20
[*3]
3 Air hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*4]
3 Air cleaner band:
9.8 – 11.8 Nm {1 – 1.2 kgm}
D85EX, PX-15E0 17
[*5] [*11]
3 Heater terminal: a Use a new MIKALOR clamp.
5.88 – 7.48 Nm {0.6 – 0.8 kgm} a Set the hose to the original (marked) position.
(Insertion depth of air hose: 80 mm)
[*6] a Set the bridge (BR) at the bottom of clamp bolt
3 Joint bolt on filter (upper) side of tube and and it will be lapped over band (BD) by at least
clamp assembly (20): min. 5 mm.
24.5 – 34.3 Nm {2.5 – 3.5 kgm} 2 Threads of clamp bolt: Lubricating oil:
3 Joint bolt on fuel supply pump (lower) side of THREEBOND, PANDO 18B
tube and clamp assembly (20): a Do not use an impact wrench.
14.8 – 19.6 Nm {1.5 – 2.0 kgm} q When reusing the hose
3 Sleeve nut on engine controller (lower) side a Set the clamp to its original position.
3 MIKALOR clamp: Min. 6 Nm {0.6 kgm}
of tube and clamp assembly (20):
84 – 132 Nm {8.5 – 13.5 kgm} q When using a new hose
a Tighten until band gap (BDG) is 17 – 20 mm.
3 Clamp of tube and clamp assembly (20):
27 – 34 Nm {2.8 – 3.5 kgm}
[*7]
q Filter and bracket assembly (23) and tube (22)
1. Finger tighten filter and bracket assembly (23).
2. Finger tighten tube (22).
3. Permanently tighten (22).
4. Permanently tighten filter and bracket assem-

bly (23).
[*8]
3 Sleeve nut: 40 – 44 Nm {4.1 – 4.5 kgm}
[*9]
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
[*10]
q Exhaust manifold
Tighten bolts [1], [2], and [3] first and then
tighten the other bolts.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
18 D85EX, PX-15E0
[*12] 4. Installation procedure for clamps and brackets.

q High-pressure pipe assembly 3 Mounting bolt of clamp and bracket
k Do not bend the high-pressure pipe to col- (Permanently tightening):
lect before installing. 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
k Be sure to use the genuine high-pressure 1) Finger tighten 6 clamps (110) and 6 brack-
pipe clamps and observe the tightening ets (37).
torque. 2) Permanently tighten clamps (110) and
brackets (37) in order.
a When installing each high-pressure pipe, 3) Finger tighten 4 hollow clamps (111).
check the taper seal of its joint (Part (a): Part of 4) Finger tighten clamp (112) to bracket (34)
2 mm from the end) for visible lengthwise slit and then permanently tighten it.
(b) and spot (c) and check part (d) (End of 5) Permanently tighten bracket (34).
taper seal: Part at 2 mm from the end) for 6) Permanently tighten 4 hollow clamps (111).
stepped-type wear caused by fatigue which
your nail can feel. If there is any of those
defects, it can cause fuel leakage. In this
case, replace the high-pressure pipe.
1. Finger tighten high-pressure pipe assembly

(40).
a Loosen all of the high-pressure pipe clamps.
2. Permanently tighten high-pressure pipe assem-

bly (40).
3 Sleeve nut (on both sides):
39.2 – 49 Nm {4 – 5 kgm}
3. Install 6 bellows (38) and 6 bellows (39) each

to each high-pressure pipe. k Check that each high-pressure pipe and
a When installing each bellows, take care of wiring harness are at least 10 mm apart
the direction of the slit. from each other.
q Fuel injector side: To be directed down.
q Common rail side: q Refilling with coolant
To be dir ec ted to cylinder block Add coolant through the coolant filler to the
(upper) side. specified level. Run the engine to circulate the
a The bellows are installed so that fuel will not coolant through the system. Then, check the
spout over the hot parts of the engine and coolant level again.
5
catch fire when it leaks for some reason.
Coolant: Approx. 53 l
D85EX, PX-15E0 19
Removal and installation of fuel 7. Remove turbocharger lubrication tube clamp

injector assembly 1 plates (6).
Removal 8. Disconnect wiring harness clamps (7).

terminal of the battery. 9. Disconnect tubes (8) at the inlet and outlet of
the engine oil filter and remove filter and
1. Remove the engine hood. For details, see bracket assembly (9).
“Removal and installation of engine hood
assembly”.
2. Remove the engine side cover.
3. Disconnect dust indicator hose (1) from the

dust indicator.
4. Loosen the hose clamp and disconnect hose

(2). [*1]
5. Remove band (3) and air cleaner assembly

(4).
[*2]
10. Remove common rail cover (10).
6. Remove the 4 mounting bolts and bracket (5).

11. Remove 6 splash prevention covers (11) on
the common rail side.
20 D85EX, PX-15E0
12. Remove 6 clamps (12) and 6 splash preven- 17. Remove the injector.
tion covers (13) on the injector side. Remove holder mounting bolt (26) of injector
(24) and then remove injector (24) and holder
13. Remove spill tube (19). (25) together.
a Never hold the solenoid valve unit at the
top of the injector with pliers etc. [*6]
14. Remove aerial clamps (14), (15), (16), and (17)

and 6 high-pressure pipes (18). [*3]
15. Remove head cover (20). [*4]
16. Disconnect the injector wiring harness.

1) Fully loosen 2 capture nuts (22) at the
head of injector (21).
a Loosen the nuts alternately.
2) Loosen bolt (23) of the wiring harness
holder. [*5]
D85EX, PX-15E0 21
Installation [*3]
q Carry out installation in the reverse order to a Install high-pressure pipes between the fuel
removal. injector and common rail according to the fol-
lowing procedure.
k Do not bend the high-pressure pipes before 1) Install high-pressure pipes (3), (4), (5), (6),
using them. (7) and (8).
k Be sure to use the genuine high-pressure a Mounting angle of the high-pressure
pipe clamps and tighten them to the speci- injection pipe is adjusted before the
fied torque. installation of the injector.
k Install the high-pressure pipes and wiring 3 Sleeve nut (on both sides):
harness at least 10 mm apart. 39.2 – 49 Nm {4 – 5 kgm}
2) Tighten bracket (9) and clamp (10) by
a When installing each high-pressure pipe, hand first, and then tighten them perma-
check the taper seal of its joint (Part (a): Part of nently.
2 mm from the end) for visible lengthwise slit 3 Mounting bolt:
(b) and spot (c) and check part (d) (End of 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
taper seal: Part of 2 mm from the end) for 3) Install clamps (11), (12), (13) and (14) by
stepped-type wear (fatigue) which your nail tightening them by hand.
can feel. If any of those defects may cause fuel 4) Install 6 each of the splash prevention
leakage, replace the high-pressure pipe. covers (15) and (16).
Direct the slit on the injector side down-
ward and that on the common rail side
toward the cylinder block.
[*1]
3 Hose clamp: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
3 Band clamp: 9.8 – 11.76 Nm {1.0 – 1.2 kgm}
22 D85EX, PX-15E0
5) Install bracket (17). 2) Insert holder (2) to injector (1). Continue

3 Clamp tightening torque: from that state, insert inlet connector (5) to
11.8 – 14.7 Nm {1.2 – 1.5 kgm} the high-pressure pipe insertion hole
6) Tighten clamps (11), (12), (13), and (14) through the rocker housing.
permanently.
3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3) Fit the ball washer to bolt (3) and tighten

holder (2) temporarily.
2 Spherical part of washer:
[*4] Engine oil (EO30)
3 Head cover mounting bolt: 4) Locate high-pressure sleeve (4) to inlet
9.8 ± 1 Nm {1.0 ± 0.1 kgm} connector (5) and then tighten them tem-
porarily.
[*5] a Tighten the common rail side sleeve
3 Wiring harness capture nut: nut temporarily, too.
2.0 – 2.4 Nm {0.2 – 0.24 kgm} 5) Tighten holder (2) with bolt (3) perma-
nently.
[*6] a Tighten bolt (3) while pulling the tube
a Install the fuel injector assembly according to of the high-pressure pipe in the oppo-
the following procedure. site direction of the injector.
1) Install gasket (6) and O-rings (7) and (8) to 3 Holder mounting bolt:
injector (1). 58.8 – 73.5 Nm {6.0 – 7.5 kgm}

2 O-ring: Engine oil (EO30) 6) After tightening the holder, remove the
high-pressure sleeve from the inlet con-
nector and then install the other injectors
in order according to the above procedure.
D85EX, PX-15E0 23
q Checking for fuel leakage

Check for fuel leakage. For details, see Testing
and adjusting, “Releasing residual pressure
from fuel system”.
q Bleeding air
Bleed air from the fuel circuit. For details, see
Testing and adjusting, “Bleeding air from fuel
circuit”.
24 D85EX, PX-15E0
Removal and installation of 4. Remove alternator belt (7) and air compressor
engine front seal 1 belt (8).
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
795T-521-1140 Push tool t 1

790-101-5221 Grip t 1 Q
A2
• 01010-81225 • Bolt t 1
• 01050-31640 • Bolt t 3
5. Remove 6 pulley mounting bolts (9) and (10)

Removal and pulley (11).
k Disconnect the cable from the negative (–) a One of mounting bolts (10) has a different
terminal of the battery. diameter. [*3]
1. Open undercover (1).
6. Remove front seal (12). [*4]
2. Loosen alternator assembly mounting bolts

(2), nuts (3) and (4) of the adjustment bolts,
and bolt (5) of the adjustment bolt guide. [*1]
3. Loosen the 4 mounting bolts of the air com-

pressor assembly and adjustment bolt (6). [*2]
D85EX, PX-15E0 25
Installation
[*1]
q Strain the belt according to the following proce-
dure.
1) Loosen mounting bolt (2), nut (3), and bolt
(4).
2) Strain the belt with nut (3).
3) Tighten mounting bolt (2), nut (3), and bolt
(4).
a Tension of belt: 13 mm (When pressed
with finger to about 58.8 N {6 kg})
[*2]
a Tension of belt: 16 – 20 mm (When pressed ii) Evenly push in the metallic ring of seal (12)
with finger to about 98 N {10 kg}) with both hands, getting over the large diam-
eter side of the internal plastic cylinder.
[*3] iii) After pushing in seal (12), remove internal
3 Mounting bolt (9): plastic cylinder (13).
245 – 309 Nm {25 – 31.5 kgm} a When removing, take care not to
3 Mounting bolt (10): damage the seal lip.
157 – 196 Nm {16 – 20 kgm}
[*4]
4) Procedure for installing front seal (12)
a Before installing the seal, check the
rims of the crankshaft end, sliding
faces of the lip, and housing for flaw,
burr, sharp fin, rust, etc.
a When installing the seal, do not apply
oil, grease, etc. to the shaft. Wipe oil
thoroughly from the shaft.
a Never remove the internal plastic cyl-
inder of the spare seal before install-
ing the seal.
iv) Tighten the bolt of tool A2 evenly until the
end of tool A2 touches the end of crank-
shaft (14) to press fit seal (12).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool, etc.
a After press fitting the seal, remove the
red sealant layer on its periphery.
+1
a Seal driving dimension (a): 16 +0 mm
i) Put the large inside diameter side (b) of

internal plastic cylinder (13) to the end of
crankshaft (14).
a Take care not to mistake the direction
of the plastic internal cylinder.
2 Lip: Lithium grease (G2-LI)
26 D85EX, PX-15E0
Removal and installation of 3. Lift off flywheel assembly (1).

engine rear seal 1 4 Flywheel assembly: 58 kg
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
795-931-1210 Push tool t 1

1 • 01050-31625 • Bolt t 3
A3 • 01050-31645 • Bolt t 3
795-931-1220 Push tool t 1
2
• 01050-31645 • Bolt t 3
4. Remove rear seal (2). [*2]

Removal
1. Remove the damper assembly. For details,

see “Removal and installation of damper
assembly”.
2. Using eyebolt [1], sling the flywheel assembly

temporarily and remove the 6 mounting bolts.
[*1]
D85EX, PX-15E0 27
Installation q Procedure for installing standard seal (A)

q Carry out installation in the reverse order to a Before installing the seal, check the rims
removal. of the crankshaft end, sliding faces of the
lip, and housing for flaw, burr, sharp fin,
[*1] rust, etc.
a Apply clean lubricating oil (EO30-CD) all over a When installing the seal, do not apply oil,
the threads, seats, and washers of the bolts. grease, etc. to the shaft. Wipe oil thor-
a Tighten the 6 flywheel mounting bolts in the oughly from the shaft.
order of 1 – 6 as shown in the following figure. a Never remove the internal plastic cylin-
a Tighten each mounting bolt twice. der (3) of the spare seal before installing
3 Mounting bolt: the seal.
1st tightening torque:
147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd tightening torque:
289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
1) Put the large inside diameter side (b) of

internal plastic cylinder (3) to the end of
crankshaft (4).
[*2] of the plastic internal cylinder.
q Procedure for installing rear seal (2)
a Before installing the Teflon seal (lay-down
lip seal), check the shaft for wear. Then,
install the “standard seal (A)” or the “seal
with sleeve (B)” according to the check
result.
If the shaft is still glossy (If the wear depth
felt with a finger cushion is 10 µm or less)
and it does not have a flaw, install the
“standard seal (A)”. In other cases, install
the “seal with sleeve (B)”.
28 D85EX, PX-15E0
2) Evenly push in the metallic ring of seal (2)

with both hands, getting over the large
diameter side of the internal plastic cylin-
der.
3) After pushing in seal (2), remove internal
plastic cylinder (3).
a When removing, take care not to
damage the seal lip.
1) Set seal with sleeve (2) to tool A3-2.

of the seal.
2 Internal cylinder of sleeve:
4) Tighten the bolt of tool A3-1 evenly until

the end of tool A3-1 touches the end of
crankshaft (4) to press fit seal (2).
a When press fitting the seal, take care
not to damage the lip on the damper
side with the tool, etc.
2) Put the sleeve of the seal to the end of the

crankshaft and tighten the bolt of tool A3-2
evenly until the end of tool A3-2 touches
the end of crankshaft (4) to press fit seal
with sleeve (2).
q Procedure for installing seal with sleeve (B)

a Before installing the seal, check the rims
of the crankshaft end, sliding faces of the
lip, and housing for flaw, burr, sharp fin,
rust, etc.
a When installing the seal, do not apply oil,
grease, etc. to the shaft. Wipe oil thor-
oughly from the shaft.
a Handle the seal and sleeve as an assem-
bly. Never separate them from each other.
D85EX, PX-15E0 29
3) Remove tool A3-2 and install tool A3-1.

4) Tighten the bolt of tool A3-1 evenly until the
end of tool A3-1 touches the end of crank-
shaft (4) to press fit seal with sleeve (2).
30 D85EX, PX-15E0
Removal and installation of 5. Disconnect oil hoses (6) and (7) of the power
engine oil pan 1 train oil cooler.
Removal
1. Open undercovers (1), (2) and (3).
6. Disconnect hoses (8), (9), and (10) between

the power train oil cooler and radiator.
2. Drain the engine oil. [*1]

6 Engine oil: Approx. 44 l
a Remove the engine oil level gauge.
3. Drain the radiator coolant.

4. Open both engine side covers (4) and remove

both side covers (5). 7. Disconnect the aeration hose at the top of the
power train oil cooler.
8. Disconnect hoses (11) and (12) between the

power train oil cooler and engine.
9. Disconnect tube assembly (13) from the front

of the oil pan.
a Take care of the spacer.
10. Loosen mounting bolt (14) and remove power

train oil cooler (15).
D85EX, PX-15E0 31
11. Disconnect fuel return circuit block (16) on the 14. Set jack [1] under damper (20) to push up the
left side of the engine. damper.
12. Disconnect universal joint assembly (17). [*3] 15. Push up the damper until clearance (a) of both
rear engine mounts (18) and (19) is 25 mm.
a This work must be performed to prevent
the main cap of No. 6 engine cylinder from
interfering with the oil pan when the oil
pan is pulled out.
13. Remove the mounting bolts of both rear engine

mounts (18) and (19).
16. Remove the mounting bolts of engine oil pan

(21). [*4]
32 D85EX, PX-15E0
17. Pull oil pan (21) forward until it can pass main Installation
cap (22) of No. 6 engine cylinder. q Carry out installation in the reverse order to
removal.
[*1]
3 Drain plug: 127.4 – 176.4 Nm {13 – 18 kgm}
[*2]
Length of spacer: (L) = 98.5 mm (2 pieces)
[*3]
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
[*4]
2 Mating face of oil pan:
18. Pull out oil pan (21) forward and remove.
4 Oil pan: 26 kg q Refilling with coolant
Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
q Refilling with oil

Tighten the drain plug and add oil through the
engine oil filler to the specified level. Run the
engine to circulate the oil through the system.
Then, check the oil level again.
5 Oil pan: Approx. 44 l
D85EX, PX-15E0 33
SEN01264-00

© 2006 KOMATSU
All Rights Reserved
34
SEN01265-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Engine and cooling system, Part 2
Engine and cooling system, Part 2 ................................................................................................................. 2
Removal and installation of engine assembly ...................................................................................... 2
Removal and installation of radiator assembly..................................................................................... 6
Removal and installation of fan drive assembly ................................................................................... 9
Removal and installation of fan motor assembly.................................................................................11
Removal and installation of fuel tank assembly ................................................................................. 12
Removal and installation of damper assembly................................................................................... 14
Removal and installation of engine hood assembly ........................................................................... 16
D85EX, PX-15E0 1
Engine and cooling system, Part 2 1

Removal and installation of 5. Open undercovers (1), (2) and (3).
engine assembly 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
799-703-1200 Service tool KIT t 1

Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X2 799-703-1110 t 1
(220 V)
6. Remove engine side covers (4) and plates (5)
Vacuum pump
799-703-1120 t 1 on both sides.
(240 V)
Removal
a For the method of changing the fuel injection

amount adjustment after the engine assembly
or engine controller is replaced, ask your
Komatsu distributor.
1. Drain the coolant.

7. Disconnect wirings (6), (7), (8), (9), and (10).
2. Remove the engine hood assembly. For details, 8. Remove external air suction tube (11).
assembly”.
3. Remove the radiator assembly. For details, see

“Removal and installation of radiator assembly”.
4. Close the fuel supply valve of the fuel tank.
2 D85EX, PX-15E0
9. Disconnect engine ground wire (12). 13. Disconnect fuel supply hose (18).
10. Disconnect fuel return hoses (13) and (14). 14. Disconnect air conditioner refrigerant pipings
(19) and (20). [*1]
a Before disconnecting the pipings, collect
the new Freon gas (R134a).
11. Disconnect starting motor wiring (15).
12. Disconnect heater hoses (16) and (17).

15. Remove both hood mounting brackets (21) and
(22).
D85EX, PX-15E0 3
16. Remove universal joint assembly (23). [*2] 20. Remove 2 bolts each from both sides of rear
engine mount (28).
17. Disconnect tubes (24) and (25) at the outlet

and inlet of the power train oil filter. 21. Lift off engine assembly (34).
a Cover the flange to prevent dirt from a Before lifting off the engine assembly,
entering it. check that all the wires and pipes are dis-
connected.
4
18. Remove power train oil filter (26) and mounting
Engine assembly: 1,465 kg
bracket together.
19. Remove 2 bolts each from both sides of front

engine mount (27).
4 D85EX, PX-15E0
Installation
q Carry out installation in the reverse order to
removal.
a For the method of changing the fuel injec-
tion amount adjustment after the engine
assembly or engine controller is replaced,
ask your Komatsu distributor.
[*1]
a Install each hose so that it will not be twisted.
a When installing the air conditioner hoses, take
care that dirt, dust, water, etc. will not enter
them.
a When tightening each joint of the air condi-
tioner hose, check that O-ring (43) is fitted to it.
a Apply sufficient compressor oil (Showa-Shell
3 Tightening torque of air conditioner refriger-

ant piping
16 × 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 × 1.5 19.6 – 24.5 Nm {2.0 – 2.5 kgm}
24 × 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
[*2]
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
q Charging air conditioner with refrigerant gas

with new Freon gas (R134a).
D85EX, PX-15E0 5
Removal and installation of 5. Disconnect hoses (4), (5), and (6) for the
radiator assembly 1 power train oil cooler from the bottom of the
radiator.
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
799-703-1200 Service tool KIT t 1

Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
X2 799-703-1110 t 1
(220 V)
Vacuum pump
799-703-1120 t 1
(240 V)
799-703-1401 Gas leak detector t 1 6. Disconnect the aeration hose from the top of
the power train oil cooler.
7. Disconnect wiring connector (7) of the radiator

Removal coolant level sensor, remove clamp (8), and
k Disconnect the cable from the negative (–) separate wiring harness (9) from the radiator.
1. Remove the fan drive assembly. For details,

see “Removal and installation of fan drive
assembly”.

assembly”.
3. Remove undercovers (1) and (2).
4. Drain the radiator coolant.

6 D85EX, PX-15E0
8. Disconnect hose (10) of the reserve circuit and 14. Disconnect bypass valve outlet hose (19) of
remove tank (11). the hydraulic oil cooler circuit.
9. Remove the corrosion resistor and mounting

bracket (12) together and disconnect the hose
clamp.
10. Disconnect radiator upper hose (13) and air

cooler upper hose (14). [*1]
11. Disconnect aeration hose (15).
15. Remove 2 mounting bolts (20) of radiator lower

bracket.
a The lower bracket is between the fan and
radiator.
12. Disconnect air cooler lower hose (16). [*1]
16. Sling the radiator assembly temporarily and

remove 2 mounting bolts (21) on each side.
13. Disconnect hoses (17) and (18) at the inlet and

outlet of the air conditioner condenser. [*2]
D85EX, PX-15E0 7
17. Lift off the radiator assembly (22). [*2]

4 Radiator assembly: Approx. 242 kg
them.
Installation
removal.
[*1]
a Use a new MIKALOR clamp. 3 Tightening torque of air conditioner refriger-
a Set the hose to the original (marked) position. ant piping
(Insertion depth of air hose: 80 mm)
a Set the bridge (BR) at the bottom of clamp bolt
and it will be lapped over band (BD) by at least 16 × 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
min. 5 mm. 22 × 1.5 19.6 – 24.5 Nm {2.0 – 2.5 kgm}
2 Threads of clamp bolt: Lubricating oil: 24 × 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
THREEBOND, PANDO 18B
a Do not use an impact wrench.
q When reusing the hose q Refilling with coolant
a Set the clamp to its original position. Add coolant through the coolant filler to the
3 MIKALOR clamp: Min. 6 Nm (0.6 kgm} specified level. Run the engine to circulate the
q When using a new hose coolant through the system. Then, check the
a Tighten until band gap (BDG) is 7 – 10 mm. coolant level again.
q Charging air conditioner with refrigerant gas

with new Freon gas (R134a).
8 D85EX, PX-15E0
Removal and installation of fan 4. Disconnect fan motor solenoid wiring connec-
drive assembly 1 tor (3).
Removal
1. Drain the hydraulic oil.

6 Hydraulic tank:
D85EX-15E0; Approx. 120 l
D85PX-15E0; Approx. 106 l
2. Remove the mounting bolt and open fan guard

(1).
5. Disconnect 3 fan motor hoses (4), (5) and (6).

a Plug the hoses to prevent dirt from enter-
ing them.
6. Remove 2 lower mounting bolts of the fan drive

assembly and spring (7).
3. Remove fan net (2).
7. Sling the fan drive assembly temporarily and

remove 3 upper mounting bolts (8).
D85EX, PX-15E0 9
8. Lift off fan drive assembly (9).

4 Fan drive assembly: 73 kg
Installation
removal.

Add oil to the specified level. Run the engine to
circulate the oil through the system. Then,
check the oil level again.
5 Hydraulic tank:
q Bleeding air
Bleed air from the piping. For details, see Test-
ing and adjusting, “Bleeding air from work
equipment cylinders”.
10 D85EX, PX-15E0
Removal and installation of fan Installation

motor assembly 1 q Carry out installation in the reverse order to
removal.
Removal
[*1]
1. Remove the fan drive assembly. For details, see a Tighten the nut to 142.2 Nm {14.5 kgm}. Then,
“Removal and installation of fan drive assembly”. align the holes on the front and back sides of
the lock plate by retightening the nut by the
2. Remove mounting bolt (1) and lock plate (2). minimum angle.
3 Mounting nut:
3. Remove nut (3). [*1] 132.4 – 156.9 Nm {13.5 – 16 kgm}
4. Using puller [1], remove fan (4).
5. Remove the 4 mounting bolts and fan motor

assembly (5).
D85EX, PX-15E0 11
Removal and installation of fuel 5. Disconnect fuel level sensor wiring connector
tank assembly 1 423 (5).
Removal
1. Remove rear cover (1).
6. Disconnect 2 fuel return hoses (6) and (7).
2. Close fuel supply valve (2).
3. Disconnect fuel supply hose (3).
7. Remove 6 fuel tank mounting bolts (8).
4. Remove operator seat rear cover (4).
12 D85EX, PX-15E0
8. Lift off fuel tank assembly (9).

4 Fuel tank assembly:
215 kg (When empty)
618 kg (When full)
Installation
removal.
D85EX, PX-15E0 13
Removal and installation of 7. Remove rubber cover (3).

damper assembly 1
Removal

assembly”.
2. Remove the operator's cab assembly. For details,

see “Removal and installation of operator's cab
assembly”.
3. Remove the floor frame assembly. For details,

see “Removal and installation of floor frame 8. Loosen clamp (4) of damper oil level detection
assembly”. pipe.
9. Disconnect breather hose (5) and remove oil

level detection pipe (6) and breather hose
5. Drain the oil from the damper chamber. together.
a Move the oil level detection pipe aside.
6 Oil in damper chamber: Approx. 1.5 l
6. Remove universal joint assembly (2). [*1]
14 D85EX, PX-15E0
10. Using a eyebolt, sling damper cover assembly Installation

(7) temporarily and remove the mounting bolts. q Carry out installation in the reverse order to
[*2] removal.
11. Using 2 forcing screws, lift off damper cover [*1]

assembly (7). [*3] 3 Mounting bolt:
a Lower the damper cover assembly to the 98.1 – 122.6 Nm {10 – 12.5 kgm}
floor.
4 Damper cover assembly: 57 kg [*2]
3 Damper cover assembly mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
[*3]
a When installing the damper assembly,
degrease the shaft spline and apply dry lubri-
cant (A) and leave it as it is for 2 – 3 minutes.
Then, apply extreme pressure lithium grease
containing molybdenum (B) to the shaft spline.
Molybdenum disul- • Sumiko lubricant: Rocol Dry
A
fide dry lubricant Splay or equivalent
Extreme pressure • Kyodo Yushi: Morilex No. 2
B lithium grease con- • Showa-Shell: Letinax AM
taining molybdenum • Nippon oil: Moritex
12. Using a eyebolt, sling damper assembly (8) tem-

porarily and remove the mounting bolts. [*4] [*4]
3 Damper assembly mounting bolt:
13. Using 2 guide bolts, lift off damper assembly (8). 98.1 – 122.6 Nm {10 – 12.5 kgm}
a Lift up the damper assembly, and then
lower it to the floor. q Refilling with oil
4 Damper assembly: 74 kg Add oil through the oil filler of the damper
assembly to the specified level. Run the
engine to circulate the oil through the system.
Then, check the oil level again.
5 Oil in damper chamber: Approx. 1.6 l
3 Drain plug: 58.8 – 78.5 Nm {6 – 8 kgm}
D85EX, PX-15E0 15
Removal and installation of 4. Loosen the clamp and disconnect air condi-
engine hood assembly 1 tioner duct hose (5).
Removal
1. Remove radiator top cover (1).
5. Remove 2 mounting bolts (6) on the rear side

of the engine hood.
2. Remove mounting bolt (2) on the front side of

the engine hood and remove plate (3).
6. Lift off engine hood assembly (7).

4 Engine hood assembly: 155 kg
3. Open both engine side covers (4).
Installation
removal.
16 D85EX, PX-15E0
SEN01265-00

© 2006 KOMATSU
All Rights Reserved
18
SEN01266-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Power train, Part 1
Power train, Part 1 .......................................................................................................................................... 2
Removal and installation of power train unit assembly ........................................................................ 2
Disconnection and connection of power train unit assembly ............................................................... 7
Disassembly and assembly of PTO assembly ....................................................................................11
Disassembly and assembly of torque converter assembly ................................................................ 17
Disassembly and assembly of TORQFLOW transmission assembly................................................. 21
D85EX, PX-15E0 1

Removal and installation of power 7. Remove work equipment valve cover (2).
train unit assembly 1
Removal
1. Drain the oil.

6 Power train case: Approx. 90 l
6 Hydraulic tank:

see “Removal and installation of engine hood 8. Disconnect 2 ripper hoses (3).
assembly”. a Secure the ripper assembly.
3. Remove the operator's cab assembly. For details, 9. Disconnect 2 blade tilt hoses (4).
assembly”. 10. Disconnect 2 HSS motor hoses (5).
a Disconnect these hoses from the HSS
4. Remove the floor frame assembly. For details, motor, too.
see “Removal and installation of floor frame
assembly”. 11. Disconnect main hoses (6) of the HSS and
work equipment pump.
5. Remove the fuel tank assembly. For details,
see “Removal and installation of fuel tank
assembly”.
6. Remove power train undercover (1).
2 D85EX, PX-15E0
12. Disconnect breather hose (7) and oil level detec- 18. Disconnect pump pressure sensor connector
tion pipe lower tube (8) from the steering case. HHP (17).
13. Remove clamp (9) and oil level detection pipe 19. Remove wiring harness clamp (18) and wiring
assembly (10). harness assembly (19).
14. Remove ripper hose clamp (11) and move the 20. Disconnect main hoses (6) of HSS and work
hose toward the ripper. equipment pump.
15. Remove blade lift hose clamp (12) and clamp

bracket (13).
21. Remove hose clamp bracket (20) and discon-

nect LS pressure hose (21) of the HSS and
work equipment pump.
16. Disconnect tank return hose (14) of the drain
merge block and pressure reducing valve
return hose (15).
22. Disconnect power train pump discharge hose

(22).
17. Remove pump suction tube clamp (16).
D85EX, PX-15E0 3
23. Disconnect torque converter outlet hose (23) 26. Remove cover (29).
and transmission lubrication inlet hose (24).
27. Remove right floor frame mount (30).
24. Disconnect fan pump discharge hose (25) and

EPC valve basic pressure input hose (26). 28. Remove left floor frame mount (31).
29. Remove centralized oil pressure pickup pipe

block (32).
25. Remove 2 wiring harness clamps (27) on the left

side of chassis and wiring harness assembly
(28).
30. Remove universal joint assembly (33). [*1]
4 D85EX, PX-15E0
31. Remove the mounting bolts and the left and

right covers (34) of the final drive shaft.
35. Remove left mount mounting bolts (40) and right

mount mounting bolts (41) on the front side.
32. Pull out drive shaft (35) according to the follow-
ing procedure.
Using forcing screw [1], pull out the drive shaft
until the spline on the steering case side
comes off.
a If the shaft is difficult to pull out, raise the
shoe grouser with a jack and find out a posi-
tion where the shaft is pulled out easily.
a Pull out the drive shaft on the opposite
side similarly.
36. Lift off the power train unit assembly (42). [*3]
a Before lifting off the power train unit
assembly, check that all the wires and
pipes are disconnected.
4 Power train unit assembly: 1,850 kg
33. Remove cover (36) of the steering case bevel

gear shaft.
34. Remove cap (37) and loosen coupling clamp

(38) and move seal (39) outward. [*2]
a Work on the opposite side similarly.
D85EX, PX-15E0 5
Installation
removal.
[*1]
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
[*2]
a Clamp the peak of the coupling seal securely
and set the clamp threads in parallel with the
cap mounting seat.
[*3]
a When installing the power train unit assembly,
take care extremely not to damage seal (39).

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Power train case: Approx. 90 l
5 Hydraulic tank:
3 Hydraulic tank drain plug:
58.8 – 78.5 Nm {6 – 8 kgm}
6 D85EX, PX-15E0
Disconnection and connection of 7. Remove hoses (10), (11), and (12) and suction
power train unit assembly 1 tubes (13) and (14).
Disconnection
1. Remove the drain plugs of the steering case and

transmission case to drain the oil from the cases.
2. Remove parking brake rod (1).

a Do not loosen nut (2) but remove bracket
(3). [*1]
3. Remove brake rod (4). [*2]
4. Remove 9 oil pressure pickup hoses (5).
5. Remove wires (6).

a The wiring connectors are TMV, TVC, 8. Remove suction tube (15).
HHP, 453, TMI, and FAC.
6. Disconnect hoses (7), (8), and (9).
D85EX, PX-15E0 7
9. Lift off HSS motor assembly (16). 12. Lift off HSS and work equipment pump assem-
bly (19).
10. Lift off fan drive pump assembly (17).

13. Remove scavenging pump assembly (20).
11. Remove tandem pump assembly (18).

14. Remove the left and right mount assemblies (21).
15. Remove blocks (22) and (23).
16. Remove lubrication tube (25).
8 D85EX, PX-15E0
17. HSS assembly 4) Sling PTO assembly (28) temporarily and

1) Set the power train assembly on blocks [1] remove the mounting bolts.
and [2]. 5) Sling PTO assembly (28) to separate it
2) Sling HSS assembly (26) temporarily. from transmission assembly (27).
3) Remove the mounting bolts and separate a The torque converter assembly will
HSS assembly (26) from transmission be left on the transmission side.
assembly (27). 4 PTO assembly: 300 kg
4 HSS assembly: 750 kg
19. Remove 8 mounting bolts. Using eyebolt [4], lift

18. PTO assembly off torque converter assembly (33).
1) Set the power train assembly on block [3]
with PTO assembly (28) up.
2) Remove coupling (29) and retainer (30). [*3]
3) Remove sleeves (31) and (32).
D85EX, PX-15E0 9
Connection
q Carry out connection in the reverse order to
disconnection.
[*1] [*2]
a Bend the cotter pin securely.
[*3]
q Fit oil seal (34) to retainer (30).
2 Oil seal fitting face:
a Apply the gasket sealant thinly to the
inside surface of the housing hole and
wipe off projected part.
2 Oil seal lip surface: Grease (G2-LI)
10 D85EX, PX-15E0
Disassembly and assembly of 2. Cover assembly (left)

PTO assembly 1 1) Remove the mounting bolts. Using forcing
screws [1], remove cover assembly (left) (8).
Disassembly
1. Cover assembly (right)

1) Remove the mounting bolts. Using forcing
screws [1] and guide bolt [2], remove
cover assembly (right) (3).
2) Remove snap ring (26) and spacer (27).

3) Drive out gear assembly (9) from cover (10).
2) Drive out gear assembly (4) from cover (5).

3) Remove bearing (6) from gear (7).
4) Remove snap ring (28) and inner race (29).
D85EX, PX-15E0 11
5) Remove snap ring (31) from cover (30), 2) Remove the mounting bolts on the shaft
and then remove bearing (32). side. Using forcing screws [3] and [4],
remove shaft (14).
6) Remove snap ring (34) from PTO case

(33), and then remove bearing (35). 3) Remove bearing (16) and spacer (17)
from gear (15).
a When reusing bearing, do not change
its combination with the outer race.
4) Remove outer race (18) from gear (15).
3. Idle gear
1) Remove the mounting bolts and plate (13).
4. Cover
Remove cover (20) on the opposite side of
cover assembly (right).
12 D85EX, PX-15E0
5. Scavenging pump drive gear Assembly

1) Remove snap ring (21). a Clean the all parts and check them for dirt or
2) Drive out gear (22) from the snap ring side. damage before installing.
a Drop engine oil onto the rotating parts of each
bearing and rotate it several turns.
a Check that the snap rings are fitted in the
grooves.
1. Outer race of input shaft bearing

1) Install snap ring (24) to the PTO and
torque converter case.
2) Press fit outer race (25).
a Do not press the snap ring with an
excessive force.
3) Remove snap ring (36) and bearing (23).
2. Scavenging pump drive gear

1) Install bearing (23) to the case.
2) Install snap ring (36).
6. Outer race of input shaft bearing

Remove snap ring (24), and then remove outer
race (25) from the PTO and torque converter
case.
D85EX, PX-15E0 13
3) Install gear (22) to bearing (23). 5) Install gear (15).

4) Install snap ring (21). 6) Install bearing (16).
a Press fit the inner race side to the shaft.
3. Idle gear
1) Install shaft (14). 7) Install plate (13) and tighten the mounting
3 Mounting bolt: bolts.
98 – 122.5 Nm {10 – 12.5 kgm} 2 Mounting bolt: Adhesive (LT-2)
2) Install bearing (16). 3 Mounting bolt:

98 – 122.5 Nm {10 – 12.5 kgm}
3) Install spacer (17).

4) Install outer race (18) to gear (15). 4. Cover assembly (left)
1) Install bearing (35) to case (33).
14 D85EX, PX-15E0
3) Install bearing inner race (29) to the gear. 9) Install cover assembly (8), meshing it with
4) Install snap ring (28). the idle gear.
10) Tighten the mounting bolts.
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
5) Install bearing (32) to cover (30).

5. Cover assembly (right)

1) Install bearing (6) to gear (7).
2) Install gear assembly (4) to cover (5).
7) Install gear assembly (9) to cover (10).

8) Install spacer (27) and snap ring (26).
3) Install cover assembly (3), meshing it with

the idle gear.
4) Tighten the mounting bolts.
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
D85EX, PX-15E0 15
6. Cover
Install cover (20).
16 D85EX, PX-15E0
Disassembly and assembly of 3. Case assembly

torque converter assembly 1 1) Remove snap ring (8).
2) Remove spacer (9).
Disassembly
1. Case and turbine assembly

Remove 30 bolts (2) from underside. Using eye-
bolt [1], remove case and turbine assembly (1).
3) Using puller [3], disconnect case assem-

bly (10) from turbine (11).
2. Gear and input shaft

1) Remove mounting bolts (3).
2) Using forcing screw [2], remove gear and
input shaft (4).
4. Stator
1) Remove mounting bolts (12) and stator (15).
D85EX, PX-15E0 17
2) Remove snap ring (14) and race (13). Assembly

a Clean the all parts and check them for dirt or
damage before installing.
a Drop engine oil onto the rotating parts of each
bearing and rotate it several turns.
a Check that the snap rings are fitted in the
grooves.
a Apply grease (G2-LI) thinly to each seal ring.
1. Pump assembly
1) Press fit bearing (21) to cage (20) and
install snap ring (22).
5. Pump assembly
1) Remove pump assembly (16) from stator
shaft (17).
2) Install cage assembly (18) to pump (23)

and tighten mounting bolts (19).
3 Mounting bolt:
58.9 – 73.6 Nm {6 – 7.5 kgm}
2) Remove mounting bolts (19), and then pull

case assembly (18) out of pump assembly
(23).
18 D85EX, PX-15E0
3) Install seal ring (24) to stator shaft (17). 3) Install stator (15) and tighten bolts (12).
a Apply grease (G2-LI) to the seal ring 2 Mounting bolt: Adhesive (LT-2)
and put the openings opposite to 3 Mounting bolt:
each other. 58.9 – 73.6 Nm {6 – 7.5 kgm}
Install pump assembly (16) to stator shaft
(17).
a Press the inner race side of the bear-
ing to press fit.
a After press fitting the bearing, drop
engine oil a little onto it and rotate
pump assembly (16) at least 10 turns.
3. Case
1) Install bearing (25) and case (26).
2. Stator
1) Install race (13).
2) Press the inner race side of the bearing to

install case assembly (10) to the boss of
turbine (11).
D85EX, PX-15E0 19
3) Install spacer (9). 5. Case and turbine assembly

4) Install snap ring (8). 1) Using eyebolts [1] and matching the case
groove to the drain plug, install case and
turbine assembly (1) and tighten 30
mounting bolts (2).
3 Mounting bolt:
49 – 58.8 Nm {5 – 6 kgm}
2) Install the drain plug.
3 Mounting bolt:
9.8 – 12.74 Nm {1.0 – 1.3 kgm}
4. Gear and input shaft

1) Press fit bearing (6) to input shaft (4).
3) Install gear and input shaft (4) to case

assembly (10) and tighten bolts (3).
3 Mounting bolt:
98 – 122.5 Nm {10 – 12.5 kgm}
20 D85EX, PX-15E0
Disassembly and assembly of 3) Disconnect 10 ECMV connectors (4).

TORQFLOW transmission 4) Remove cover (131) and wiring harness
(130) together.
assembly 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
1 791-415-1300 Puller assembly t 1

D
2 799-301-1600 Oil leak tester t 1
Disassembly
a Store the removed discs and plates on a level
place so that they will not be warped. 5) Remove control valve assembly (6).
1. Relief valve assembly

Remove relief valve assembly (1).
2. Control valve assembly

1) Remove cover (2).
3. Transmission case
1) Remove 9 tie rods (132) tightened together
with the case and 2 case clamp bolts
(marked with a).
2) Using eyebolt [1], remove sleeve (3).
D85EX, PX-15E0 21
2) Using eyebolt [2], lift off transmission case 2) Disassemble the input shaft/front plate/
(7). No. 1 carrier assembly according to the
i) Remove snap ring (10), No. 2 sun
gear (11), and snap ring (12).
ii) Remove snap ring (13), No. 1 sun
gear (14), and collar (15).
4. Tie bolts
Remove 4 remaining tie bolts (8)
iii) Remove snap ring (17).

iv) Drive out the input shaft from the
torque converter side and remove
front cover (18).
v) Remove collar (133)
5. Input shaft/Front plate/No. 1 carrier assembly

1) Using eyebolt [3], remove input shaft/front
plate/No. 1 carrier assembly (9).
vi) Remove snap ring (19), then remove

input shaft (20) by driving it out to the
torque converter side.
22 D85EX, PX-15E0
vii) Remove snap ring (21) and No. 1 ring 8. No. 2 piston
gear (22). Remove No. 2 piston (43).
9. Guide pin
Remove guide pin (44).
10. No. 2 discs, plates, and springs

1) Remove springs (45).
2) Remove discs (46) and plates (47).
viii) Pull out shaft (23) and remove thrust

washer (24), gear (25), bearing (26),
and ball (27).
a Take care not to lose the ball.
11. No. 2 housing and No. 2 carrier assembly

1) Using tool D1, push up No. 3 carrier (48)
and remove snap ring (49) from groove.
2) Using eyebolts, remove No. 2 housing and
No. 2 carrier assembly (50).

7. No. 1 housing assembly

1) Using eyebolts, remove No. 1 housing
assembly (41).
2) Remove piston (42) from the housing.
D85EX, PX-15E0 23
3) Disassemble No. 2 housing and No. 2 car- vi) Remove snap ring (49) which was
rier assembly according to the following removed in step 11-1).
procedure. vii) Remove snap ring (63) and ring gear
i) Remove snap ring (51) and pull No. 2 (64).
carrier assembly (52) out of No. 2
housing (53).
12. No. 3 discs and plates

Remove springs (140), discs (68), and plates
ii) Remove spacer (54) from No. 2 car- (69).
rier assembly (52).
iii) Remove No. 2 ring gear (56). 13. No. 3 ring gear
iv) Pull out shaft (57) and remove thrust Remove No. 3 ring gear (70).
washer (58), gear (59), bearing (60),
and ball (61). 14. No. 3 and No. 4 carriers assembly
v) Remove seal ring (133). 1) Remove No. 3 and No. 4 carriers (71).
24 D85EX, PX-15E0
2) Disassemble No. 3 and No. 4 carriers 15. No. 3 housing

assembly according to the following proce- 1) Remove No. 3 housing (86).
dure. 2) Remove No. 3 piston (87).
i) Remove seal ring (72).
ii) Drive pin (73) into shaft (74). 16. No. 4 discs, plates, and springs
iii) Drive out shaft (74) from No. 3 carrier 1) Remove springs (88).
side. 2) Remove discs (89) and plates (90).
iv) Remove thrust washer (76), No. 4
planetary gear (77), and bearing (78).
a Pull the pin out of the shaft.
17. No. 5 carrier and No. 4 ring gear assembly

2) Remove No. 5 carrier and No. 4 ring gear
v) Drive out shaft (79) and remove thrust assembly (92).
washer (80), No. 3 planetary gear
(81), bearing (82), and ball (83).
vi) Remove snap ring (84) and bearing
(85).
D85EX, PX-15E0 25
3) Disassemble No. 5 carrier and No. 4 ring 18. No. 4 housing assembly
gear assembly according to the following 1) Remove No. 4 housing assembly (101).
procedure. 2) Remove No. 4 piston (102).
i) Drive out shaft (93) and remove thrust
washer (94), gear (95), bearing (96), 19. Guide pin
and ball (97) from carrier (100). Remove guide pin (103).
ii) Remove snap ring (98), then remove

No. 4 ring gear (99) from carrier (100).
21. No. 5 ring gear

Remove No. 5 ring gear (107).
22. No. 5 piston

Remove No. 5 piston (108).
23. Collar
1) Remove snap ring (109).
2) Remove collar (110).
24. No. 4 sun gear

Remove No. 4 sun gear (111).
25. No. 5 sun gear

1) Remove No. 5 sun gear (112).
26 D85EX, PX-15E0
26. Cage (For fixing No. 5 carrier)

2) Using forcing screws [6], remove cage
(114).
27. Output shaft

2) Push out shaft (117) with a press.
a Since the shaft falls, receive it with
wood blocks, etc.

4) Remove bearing (137) from case (116).
D85EX, PX-15E0 27
Assembly 2) Using the push tool, install shaft assembly

(117) to case (116).
q Precautions for assembly a Push the outer race side of the bear-
a Clean the all parts and check them for dirt ing with a press to install the shaft
or damage before installing. assembly.
a Coat the sliding surfaces of each part with
engine oil before installing.
a Install the seal ring (a) of each piston with
the pressure receiving side (b) directed to
the housing (c) as shown in the figure.
a Apply grease (G2-LI) to each metallic seal
ring and install it evenly.
1. Output shaft
1) Press fit the bearing (137) to shaft (117)
and install snap ring (120).
2. Cage (For fixing No. 5 carrier)

1) Using the push tool, press fit bearing (124)
to cage (125).
28 D85EX, PX-15E0
2) Install seal rings (138) and (139). 7. Guide pin

2 Seal ring: Grease (G2-LI) Install guide pin (103).
3) Install cage (114) to case (116).
a Press fit the inner race side of the 8. No. 5 discs, plates, and springs
bearing. 1) Install discs (105) and plates (106).
4) Install snap ring (113). a Discs: 3 pieces, Plates: 2 pieces
2) Install springs (104).
a Free length of spring: 59 mm
9. No. 4 housing
1) Install the seal ring and No. 4 piston (102).
2) Install No. 4 housing (101).
a Check that spring (104) is fitted to the
groove.
3. No. 5 sun gear

2) Install No. 5 sun gear (112).
4. No. 4 sun gear

1) Install No. 4 sun gear (111).
2) Install collar (110).
10. No. 5 carrier and No. 4 ring gear assembly
5. No. 5 ring gear 1) Assemble No. 5 carrier assembly accord-
Install No. 5 ring gear (107). ing to the following procedure.
i) Set No. 4 ring gear (99) to carrier
6. No. 5 piston (100) and install snap ring (98).
Install the seal ring and No. 5 piston (108).
D85EX, PX-15E0 29
ii) Install bearing (96) to gear (95) and fit 11. No. 4 discs, plates, and springs
thrust washers (94) to both sides, and Install No. 4 discs (89), plates (90), and springs
then set them to carrier (100). (88).
iii) Install ball (97) and shaft (93). a Discs: 3 pieces, Plates: 2 pieces
a Free length of spring: 59 mm
12. No. 3 housing assembly

1) Install the seal ring and No. 3 piston (87).
2) Install No. 3 housing (86).
a Check that springs (88) are fitted in
the grooves.
2) Using guide bolt [9], install No. 5 carrier

and No. 4 ring gear assembly (92).
3 Mounting bolt:
66.1 ± 7.4 Nm {6.75 ± 0.75 kgm}
13. No. 3 and No. 4 carrier assembly

1) Assemble No. 3 and No. 4 carrier assem-
bly according to the following procedure.
i) Press fit bearing (85) and install snap
ring (84).
ii) Install bearing (82) to No. 3 planetary
gear (81) and fit thrust washers (80)
to both sides, and then set them to
the carrier.
iii) Install ball (83) and shaft (79).
30 D85EX, PX-15E0
iv) Install bearing (78) to No. 4 planetary 17. No. 2 housing and No. 2 carrier assembly
gear (77) and fit thrust washers (76) 1) Assemble No. 2 housing according to the
to both sides, and then set them to following procedure.
the carrier. i) Press fit bearing (68) to No. 2 housing
v) Install shaft (74), matching its pin hole (53) and install snap ring (70).
to the pin hole of the carrier.
vi) Check that the pin holes are matched
to each other and drive in pin (73).
vii) Install seal ring (72).
ii) Set ring gear (64) to No. 2 carrier (55)

and install snap ring (63).
2) Matching the sun gear to the ring gear,

install No. 3 and No. 4 carrier assembly (71).
a Take care that your fingers will not be
caught.
14. No. 3 ring gear

Install No. 3 ring gear (70).
a Install the ring gear with the notched side
of the external teeth down.
15. Guide pin

Install guide pin (44).
16. No. 3 discs and plates iii)Install bearing (60) to gear (59) and fit
1) Install No. 3 discs (68) and plates (69). thrust washers (58) to both sides,
a Discs: 3 pieces, Plates: 2 pieces then set them to the carrier.
2) Install springs (140). iv) Install ball (61) and shaft (57).
a Free length of spring: 59 mm a After assembling the 2 gear sets,
install snap ring (49).
D85EX, PX-15E0 31
v) Install the seal ring. 4) Install sleeve (67).

vi) Install No. 2 ring gear (56). a When installing the sleeve, install it to
vii) Install spacer (54). the bolt hole marked * in the figure
a Install the spacer with the cut with the slit (d) side down.
inside end directed to the carrier. 5) Install spring (66) and valve (65).
viii) Install No. 2 housing (53) to carrier

assembly (52).
a Press fit the inner race side of
the housing bearing.
ix) Install snap ring (51).
18. No. 2 discs and plates

Install No. 2 discs (46) and plates (47).
a Discs: 6 pieces, Plates: 5 pieces
19. No. 2 clutch springs

Install springs (45).
2) Using eyebolts, install No. 2 housing and a Free length of spring: 77 mm
No. 2 carrier assembly (50).
3) Using tool D1, push up No. 3 carrier (48) 20. No. 2 piston
and install snap ring (49). Install the seal ring and No. 2 piston (43),
matching the spring to the spring groove.
32 D85EX, PX-15E0
21. No. 1 housing assembly iii) Set No. 1 ring gear (22) to No. 1 car-
1) Fit the seal ring and install No. 1 piston rier and install snap ring (21).
(42) to housing (41).
2) Using eyebolts, install No. 1 housing assem-
bly (41), matching it to No. 2 piston.
a Press the housing and hit the dowel pin.
iv) Install snap ring (38) to input shaft

(20), and then press fit bearing (39).
22. Input shaft and No. 1 carrier assembly

1) Assemble the input shaft and No. 1 carrier
assembly according to the following pro-
cedure.
i) Install bearing (26) to gear (25) and fit
thrust washers (24) to both sides, and
then set them to the carrier.
ii) Install ball (27) and shaft (23).
v) Install input shaft (20) to No. 1 carrier

assembly (34), and then install snap
ring (19).
D85EX, PX-15E0 33
vi) Install collar (15). 24. Front plate

vii) Install No. 1 sun gear (14). 1) Fit seal ring (31) and install collar (32) to
viii) Install snap rings (13) and (12). No. 1 carrier (33).
ix) Install No. 2 sun gear (11) and snap
ring (10).
2) Install the following parts to the front plate.

i) Press fit bearing (28) and install snap
2) Sling and install input shaft and No. 1 car- ring (29).
rier assembly (34), meshing No. 2 sun ii) Install seal ring (30).
gear with No. 1 planetary gear.
3) Using eyebolts [3], install front plate (18),

23. No. 1 discs, plates, and springs matching it to the guide pin and spring.
Install discs (36), plates (37), and springs (35). 4) Press fit the inner race side of bearing (28)
a Disc: 5 pieces, Plates: 5 pieces to No. 1 carrier (33) and install snap ring
a Free length of spring: 77 mm (17).
a Check that the spring is fitted to the
cover.
34 D85EX, PX-15E0
25. Tie bolts 27. Transmission case

Install 4 tie bolts (8). Fit the O-ring and install transmission case (7),
3 Tie bolt: 166.7 ± 9.8 Nm {17 ± 1 kgm} using eyebolts [2]. Then, install the remaining 9
tie bolts and 2 case clamping bolts.
3 Tie bolt: 166.7 ± 9.8 Nm {17 ± 1 kgm}
26. Operation check of piston

Using tool D2, check the operating condition
and stroke of each piston. 28. Control valve
1) Place the transmission on its side.
Piston Standard stroke (mm)
2) Fit the O-ring and install control valve
No.1 5 assembly (6).
No.2 6 3 Mounting bolt:
No.3 3 49 ± 4.9 Nm {5 ± 0.5 kgm}

No.4 3
No.5 3
D85EX, PX-15E0 35
3) Install cover (131) and wiring harness

together.
2 Cover: Gasket sealant (LG-6)
2 1 bolt marked with *:
4) Connect 10 ECMV connectors (4).
5) Fit the O-ring and install sleeve (3), using

eyebolts [1].
6) Install cover (2).

2 Cover: Gasket sealant (LG-6)
29. Relief valve

Install relief valve assembly (1).
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
36 D85EX, PX-15E0
SEN01266-00

© 2006 KOMATSU
All Rights Reserved
38
SEN01267-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Power train, Part 2
Power train, Part 2 .......................................................................................................................................... 2
Disassembly and assembly of HSS assembly ..................................................................................... 2
Removal and installation of final drive assembly ............................................................................... 21
Disassembly and assembly of final drive assembly ........................................................................... 23
D85EX, PX-15E0 1

Disassembly and assembly of 2) Remove 5 sleeves (24) and 2 sleeves (25)
HSS assembly 1 from the HSS case.
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
1 791T-422-1320 Hanger t 1 Q
2 790-302-1500 Wrench set q 1
E 3 796-730-2300 Wrench t 1
Commercially
4 available or Torque wrench q 1
795-630-1810
q Disassembly of cover assembly
1) Input gear assembly
i) Remove snap ring (12).
Disassembly
1. Brake valve assembly

Remove brake valve assembly (4).
ii) Pull out gear assembly (6) and cage

(7) as a unit with puller [2], then
remove gear assembly (6) from cage
(7).
2. Cover assembly
a Take care not to lose ball (8).
1) Using eyebolts [1], remove cover assem-
bly (5).
2 D85EX, PX-15E0
iii) Remove bearing (10) from gear (9). iv) Remove bearing (17) and spacer
(17a) from gear (15).
2) Intermediate gear assembly

i) Remove tube (11). 3) Left carrier drive gear
i) Remove bolt (19) and holder (20).
ii) Remove gear (22).
ii) Remove the bolt and holder (13).

iii) Drive out shaft (14) from the bolt side
and remove gear (15). iii) Using gear puller [3], push out shaft
a Take care not to lose the ball. (21).
D85EX, PX-15E0 3
iv) Remove snap ring (23), then remove 3. Brake and carrier assembly
bearing (28) from cover (32). 1) Remove the mounting bolts, and then
v) Remove outer race (29) from cover remove brake assembly (34) with tool E1.
(32). a Do not remove 4 hexagon socket
head bolts.
vi) Remove bearing (26) from shaft (21).

q Disassembly of brake assembly
1) Remove flange (36).
2) Remove snap ring (37) and spacer (38).
4) Remove the plug, spring (30), and valve

(31).
3) Set puller [4], loosen 4 hexagon socket

head bolts (40) and remove cover (41).
a The inner race side of the bearing
comes out.
a Do not remove bolts (40) until cover
(41) comes off.
4 D85EX, PX-15E0
4) Remove bearing (60) from cover (41). 10) Remove discs (46), plates (47), and
springs (48) from drum (45).
5) Remove spring (42).

6) Using eyebolts [5], remove piston (43). 11) Remove snap ring (59) and bearing (57).
a Pry up the bearing from the notch of
the hub.
7) Push up and remove cage (51), taking

care not to damage the disc.
8) Remove seal rings (53) and (27) from 12) Remove 18 mounting bolts, and then
cage (51). remove hub (39) from hub (54).
9) Using eyebolts [7], remove drum (45),
discs, and plates as a unit.
D85EX, PX-15E0 5
13) Remove bushing (60) from hub (39). 3) Drive roll pin (65) into the shaft.
14) Remove snap ring (58), and then remove 4) Pull out shaft (66) and remove gear (52),
stopper (56) from the hub. thrust washer (67), and bearing (69).
a Pull roll pin (65) out of the shaft.
q Disassembly of carrier assembly

1) Turn over the hub and carrier assembly 5) Remove bushing (91) from carrier (90).
and remove bolts (89), and then remove
carrier assembly (64) from hub (54). 4. Sun gear
1) Remove snap ring (70) and collar (73).
2) Remove hub (92) from carrier assembly

(64), then remove snap ring (50) and ring 2) Using gear puller [8], remove sun gear
gear (52). (72) and bearing (98).
6 D85EX, PX-15E0
3) Using the bearing race puller, remove 3) Disassembly of bevel pinion assembly
bearing (74). i) Remove bolt (97), plate (99), and pin
4) Remove collar (71). (100).
a Perform this work for only right side of
the machine.
ii) Secure the pinion with a press and

remove nut (101) with tool E2.
iii) Using push tools [11], remove bevel
5. Bevel pinion assembly pinion (102) from cage (103).
1) Remove the mounting bolts.
2) Using guide bolts [9] and forcing screws
[10], remove bevel pinion assembly (95)
and shim (96).
a Check the quantity and thickness of
the shims and store them.
iv) Remove bearing (104).

v) Remove outer races (105) and (107)
from cage (103).
D85EX, PX-15E0 7
vi) Remove bearing (106) and spacer 4) Sling bevel gear (79), remove mounting
(108) from bevel pinion (102). nut (80), and pull out bevel gear shaft
assembly (81) to the right side of the
machine.
6. Bevel gear shaft and bevel gear assembly

1) Sling bevel gear and shaft assembly (75)
temporarily. 5) Remove bearing (78) from bevel gear
2) Remove cage assemblies (76) and (86). shaft (82).
a Check the thickness, quantity, and 6) Remove bolts (83).
positions of shims (77). 7) Remove outer race (84) from cage (76).
a Since both cages are different from
each other, make marks on them.
8) Remove seal ring (85) from bevel gear

shaft (81).
3) Move bevel gear and shaft assembly (75)
to the left end and remove bearing (78)
with puller [12].
a Remove only the bearing on the left
side of the machine.
8 D85EX, PX-15E0
Assembly 2. Bevel gear shaft and bevel gear assembly

1) Install bolt (83) to bevel gear shaft (82)
q Precautions for assembly 2) Heat bearing (78) with a bearing heater,
a Clean the all parts and check them for dirt etc. and install it to the right side of the
or damage before installing. bevel gear shaft by shrink fit.
a Drop engine oil onto the rotating parts of a If the bearing temperature is raised
each bearing and rotate it several turns. too high, the hardness of the heat-
a Coat the sliding parts with engine oil before treated part lowers. Accordingly, do
installing. not raise the bearing temperature
a Apply grease (G2-LI) to each piston seal more than 120°C.
ring and install it evenly, with the pressure a After installing the bearing, drop
receiving side directed to the housing. engine oil onto its rotating parts and
2 Rotary seal ring: Fix each seal ring rotate it several turns.
with grease (G2-LI) and install it a Check that the clearance at the bear-
very carefully not to catch it in the ing end is 0.03 mm or less.
parts. 3) Install outer race (84) to cages (76) and
a Check that the snap rings are fitted in the (86).
grooves.
4) Install seal ring (85) to bevel gear shaft

1. Suction tube (81).
Install suction tube (55).
D85EX, PX-15E0 9
5) Insert bevel gear shaft (81) in bevel gear 7) Install cages (76) and (86) to bevel gear
(79) slung at the center of the case from and shaft assembly (75).
the right side of the machine. a Since both cages are different from
a Tighten mounting nut (80) temporarily. each other, take care not to mistake
them.
a Install shims (77) of the thickness and
quantity recorded when removed.
q Standard shim thickness: 1.5 mm
q Varieties of shim thickness: 0.2 mm,
0.3 mm, 0.5 mm
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
8) Tighten the bevel gear mounting nut per-
manently.
a Place a plastic hammer, etc. between
the bevel gear and case to lock them.
3 Mounting nut:
245 – 309 Nm {25 – 31.5 kgm}
6) Heat bearing (78) with a bearing heater,
etc. and install it to the left side of the
bevel gear shaft by shrink fit.
a If the bearing temperature is raised
too high, the hardness of the heat-
treated part lowers. Accordingly, do
not raise the bearing temperature
more than 120°C.
a After installing the bearing, drop
engine oil onto its rotating parts and
rotate it several turns.
a Check that the clearance at the bear-
ing end is 0.03 mm or less.
10 D85EX, PX-15E0
9) Adjusting pre-load ii) Using the push tool, press fit outer
a Adjust the pre-load with the bevel pin- races (105) and (107) to cage (103).
ion assembly removed. iii) Place bevel pinion (102) on the press
i) Rotate the bevel gear and shaft stand and set cage (103).
assembly several turns to fit the bear-
ing.
ii) Install tool E3 to the end of bevel gear
shaft (81) and measure the rotation
torque with a torque wrench E4.
q Standard rotation torque:
10.3 – 14.7 Nm {1.05 – 1.5 kgm}
If the rotation torque is lower than the
standard value, reduce the quantity of
shims (77) in step 7. If the former is
higher, increase the latter.
iv) Press fit bearing (104) to cage (103)

with the press.
v) Secure the pinion with the press and
tighten locknut (101) with tool E2.
2 Locknut: Adhesive (LT-2)
3 Locknut:
392 – 441 Nm {40 – 45 kgm}
vi) After tightening the nut, return it until
1 of 8 pin holes on it is matched to 1
of 5 pin holes on the pinion shaft.
a Return the nut by 0 – 9°.
3. Bevel pinion assembly a Tighten the nut, while turning the
1) Assembly of bevel pinion cage.
i) Using the push tool, press fit bearing a After tightening the nut, check
(106) to bevel pinion (102) and install that the bevel pinion rotates
spacer (108). smoothly.
D85EX, PX-15E0 11
vii) Install pin (100) and plate (99), and 4. Adjusting backlash and tooth contact
then tighten bolt (97). 1) Adjusting backlash
3 Bolt: Apply the probe of dial gauge [13] to the
11.8 – 14.7 Nm {1.2 – 1.5 kgm} tooth tip at the end of the bevel gear at
right angles. Fix the bevel pinion and
move the bevel gear forward and back-
ward, and read the value at this time.
a Standard backlash: 0.2 – 0.28 mm
a Measure the backlash diagonally at 3
or more places.
q If the measured backlash is out of the
standard range, adjust it according to
the following procedure.
2) Using guide bolt [9], install shims (96) and

bevel pinion assembly (95).
a Install shims of the thickness and
quantity recorded when removed.
q Standard shim thickness: 2 mm
q Varieties of shim thickness: 0.2 mm,
0.3 mm, 1.0 mm
a Adjust the backlash by increasing or

decreasing the thickness of both
shims. Do not change the total thick-
ness of both shims, however, so that
the pre-load will not change. (If the
thickness of the shim on one side is
increased, decrease the thickness of
the other side, and vice versa.)
q When backlash is too small
Decrease the thickness of the shim
on the right side of the chassis and
increase the thickness on the left side
by the same quantity. (Move the bevel
gear in direction (A).)
12 D85EX, PX-15E0
q When backlash is too large Check that there is not a strong con-
Decrease the thickness of the shim tact at the tips (A) or roots (B) of the
on the left side of the machine body teeth of both small end (C) and large
and increase the thickness on the end (D).
right side by the same quantity. a If the bevel gear and bevel pinion are
(Move the bevel gear in direction (B).) adjusted in this way, their teeth come
in contact with each other correctly
when they are loaded.
2) Adjusting tooth contact

Testing
i) Apply red lead thinly to the tooth sur- Adjusting
faces of the bevel gear and turn the If the tooth contact pattern is not proper,
bevel gear in the forward and reverse adjust the tooth contact according to the
directions, then check the tooth con- following procedure.
tact pattern on the bevel gear. i) If the bevel pinion is too far from the
center line of the bevel gear, the con-
tact is at the small end of the bevel
gear tooth faces curved outward and
at the large end of the bevel gear
tooth faces curved inward.
q In this case, adjust the tooth contact
Adjust the thickness of the shims on
the bevel pinion side to move the
bevel pinion in direction (A).
Move the bevel gear in direction (B),
then check the tooth contact pattern
and backlash again.
ii) The tooth contact must be as follows

(The standard distance is measured
from the tooth tip of the bevel pinion.)
a) Center of tooth contact: 20 – 40%
of face width (from small end)
b) Width of tooth contact: 30 – 50%
of face width
c) Center of tooth contact: 35 – 65%
of tooth depth
d) Width of tooth contact: 60 – 80%
of tooth depth
D85EX, PX-15E0 13
ii) If the bevel pinion is too close to the 4) Install sun gear (72).
center line of the bevel gear, contact 5) Install bearing (98) with the push tool.
is at the large end of the bevel gear a Press fit the inner race and outer race
tooth faces curved outward and the simultaneously.
small end of the bevel gear tooth
faces curved inward.
q In this case, adjust the tooth contact
Adjust the thickness of the shims on
the bevel pinion side to move the
bevel pinion in direction (A).
Move the bevel gear in direction (B),
then check the tooth contact pattern
and backlash again.
a Do not change the total thickness of
the shims on both sides.
iii) When adjustment is finished, tighten
the mounting bolts of the cage and
bevel pinion assembly to the speci- 6) Install collar (73) and snap ring (70).
fied torque.
3 Mounting bolts of cage and bevel 6. Brake and carrier assembly
pinion assembly: q Assembly of carrier assembly
98 – 123 Nm {10 – 12.5 kgm} 1) Install bushing (91) to carrier (90).
2) Install bearing (69) to gear (52). Fit thrust

5. Sun gear washers (67) to top and bottom of the
1) Install snap ring (93) to the shaft. bearing, then set them to the carrier.
a Perform this work for only right side of 3) Install shaft (66), matching the inside of
the machine. the thrust washers and bearing to the
2) Install collar (71). shaft hole of the carrier.
3) Install bearing (74) with the push tool. a Match the roll pin hole accurately.
4) Install roll pin (65).
14 D85EX, PX-15E0
5) Set hub (92) to ring gear (52) and install 3) Install hub (39) to hub (54) with 18 mount-
snap ring (50). ing bolts.
6) Install hub (92) to carrier assembly (64). 3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
7) Install hub and carrier assembly (64) to

hub (54) and tighten bolts (89). 4) Install bearing (57) to hub (39).
3 Mounting bolt: 5) Install snap ring (59).
59 – 74 Nm {6 – 7.5 kgm}
6) Set brake drum (45) to hub (39).

q Assembly of brake assembly 7) Install discs (46), plates (47), and springs
1) Install stopper (56) to the hub, then install (48).
snap ring (58).
2) Install bushing (60) to hub (39).
D85EX, PX-15E0 15
8) Install seal rings (27) and (53) and cage 11) Install spring (42).
(51). 12) Install guide bolt [14] to cage (51).
a Roughly match the oil holes on the 13) Install bearing (60) to cover (41).
cage to the 4 oil holes on the drum.
a Press fit the cage to the outer race
side of the bearing.
14) Using eyebolts [15] and matching to the

guide bolt, set cover (41).
a Check that the spring is fitted to both
9) Install the seal ring to piston (43). of the piston and case.
10) Install piston (43), aligning counter bore 15) Compressing the spring with forcing
(b) having “assembly match mark (a)” with screws [17] and nuts [16], press fit the
“13.5-drill” (c) and opposite side (d) having inner race side of the bearing to the hub
the drilled hole of the hydraulic circuit. assembly.
16) Install spacer (38) and snap ring (37).

17) Install flange (36).
16 D85EX, PX-15E0
18) Remove the bolts and nuts used to com- 2) Left carrier drive gear
press the spring, then install 4 bolts (40). i) Press fit bearing (26) to shaft (21).
19) Brake and carrier assembly ii) Install outer race (29) to cover (32).
i) Equalize the projection of the seal iii) Press fit bearing (28) to cover (32),
rings from the shaft on the carrier then install snap ring (23).
side.
ii) Using tool E1, install brake and car-
rier assembly (34).
iv) Using puller [18], press fit shaft (21)

to the inner race side of bearing (28).
a Replace the bolt with one having
7. Cover assembly different length.
q Assembly of cover assembly
1) Install valve (31) and spring (30) to the
cover, then install the plug.
D85EX, PX-15E0 17
v) Install gear (22). iii) Install holder (13) and tighten bolt
vi) Install holder (20) and tighten bolt (12).
(19). 3 Mounting bolt:
3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
98 – 123 Nm {10 – 12.5 kgm}
iv) Install tube (11).

3) Intermediate gear assembly
i) Install bearing (17) and spacer (17a)
to gear (15).
4) Input gear assembly

i) Install bearing (10) to gear (9).
ii) Press fit shaft (14) to the inner race

side of bearing (17). Fit ball (16) half-
way and press fit completely.
a Before the shaft enters the cover,
position the ball accurately.
18 D85EX, PX-15E0
ii) Install gear assembly (6). 2) Using eyebolts [1], install cover assembly
iii)Install cage (7) and ball (8), matching (5).
them to the hole for ball (8). 2 Mating face of cover:
iv) Install snap ring (12). Gasket sealant (LG-6)
a Apply gasket sealant to both mating
faces of the case and cover.
a Apply gasket sealant to each mating
face without breakage.
q Installation of cover assembly

1) Install 2 sleeves (25) and 5 sleeves (24) to
the HSS case.
8. Brake valve assembly

Install brake valve assembly (4).
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
D85EX, PX-15E0 19
9. Adjustment and installation of speed sensor

1) Remove the locknut from speed sensor
(109) and apply LG-5 to its threads gener-
ously.
2) Screw the speed sensor into mounting
cover (110), and then install the cover to
the HSS case.
3) Screw the speed sensor until its tip
touches bevel gear (111), and then return
it by 1/2 – 1 turn.
4) Remove the speed sensor and cover
together and tighten locknut (112).
a Tighten the locknut so that the speed
sensor will not move.
3 Locknut: 49 – 68.8 Nm {5 – 7 kgm}
5) Install cover (110) and insert connector
(113) in the holder.
2 Mating faces of cover and HSS case:
a Install the cover so that the speed
sensor will be on the right side.
20 D85EX, PX-15E0
Removal and installation of final 4. Remove cover (4).

drive assembly 1
5. Using forcing screw [2], pull out drive shaft (6).
Special tools a If the shaft cannot be pulled out, set a jack
and move the sprocket forward or in
New/Remodel
reverse until the shaft can be pulled out.
Necessity
a Pull out the shaft until it comes in contact
Symbol
Sketch
Q'ty
Part number Part name with the sprocket.
790-337-1032 Lifting tool t 1

J1 791T-627-2110 Plate t 1 N Q
01643-32060 Washer t 6
Removal
1. Expand the track shoe assembly. For details,

see “Expanding track shoe assembly”.
2. Raise the chassis with a jack or the ripper and

set stand [1] under the frame.
6. Remove the 2 final drive bolts, install tool J1, and

sling the final drive assembly temporarily. [*1]
3. Remove guards (2) and (3).
D85EX, PX-15E0 21
7. Remove inside mounting bolts (7) of the final Installation

drive assembly. [*2] q Carry out installation in the reverse order to
removal.
[*1]
3 Tool mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
[*2]
3 Mounting bolt:
784 – 980 Nm {80 – 100 kgm}
[*3]
3 Mounting bolt:
784 – 980 Nm {80 – 100 kgm}
8. Remove the mounting bolts and lift off final

drive assembly (8). [*3]
4 Final drive assembly: 1,000 kg
22 D85EX, PX-15E0
Disassembly and assembly of

final drive assembly 1
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
790-431-1031 Block t 1
791-520-4140 Screw t 2
790-101-2360 Plate t 2
791-112-1180 Nut t 2
2
791-546-1110 Adapter t 2 3. Shaft
790-201-2690 Plate t 1 Using eyebolts, remove shaft (3).
790-101-2102 Puller t 1
790-431-1031 Block t 1
791-520-4140 Screw t 1
J 791-112-1180 Nut t 2
01643-22460 Washer t 2
3
791T-627-2130 Plate t 1 N Q
791T-627-2120 Push tool t 1 N Q
790-101-2102 Puller t 1
4 791-580-1510 Installer t 1
790-101-5201 Push tool kit t 1
4. Sprocket hub assembly
790-101-5281 Plate t 1
5 1) Remove the mounting bolts and plate (4).
790-101-5221 Grip t 1
01010-51225 Bolt t 1
Disassembly
1. Draining oil
Remove the drain plug and drain the oil from
the final drive case.
6 Final drive case: Approx. 26 l
2. Wear guard and plate

1) Set the final drive assembly on a block
with the sprocket side up.
2) Remove wear guard (1) and plate (2).
D85EX, PX-15E0 23
2) Using tool J2, disconnect sprocket hub 5. Cover assembly

assembly (5) and bearing (6). 1) Remove floating seal (10).
3) Using eyebolts (3), remove sprocket hub a Store the floating seal in a safe place
assembly (5). so that it will not be damaged.
4) Remove floating seal (7) and 2 bearing

outer races (8). 3) Using eyebolts, sling cover assembly (12)
a Store the floating seal in a safe place temporarily. Using 3 forcing screws [2],
so that it will not be damaged. remove the cover assembly.
5) Turn over the sprocket hub assembly and 4) Using puller [1], pull out bearing (15) and
remove sprocket (9). remove spacer (16).
24 D85EX, PX-15E0
5) Turn over the cover assembly and remove 3) Pull out planetary gear shaft (23) and
6 lock plates (17). remove planetary gear (24) and bearings
6) Remove ring (18) and ring gear (19). (25A) and (25B).
a Take care of spacer (25D) between
the bearings.
6. Carrier assembly
1) Using 3 eyebolts, remove carrier assembly
(20). 4) Remove 2 bearing outer races (25C).
2) Remove bolts (21) and holder (22). 7. Hub and case assembly
1) Remove thrust (26) and sun gear (27).
D85EX, PX-15E0 25
2) Remove gear mounting bolt (28). 5) Using tool J2, remove hub assembly (31)
and bearing (32A).
3) Using eyebolts, remove gear (29).

6) Using eyebolts, remove hub assembly (31).
4) Remove the mounting bolts and plate (30).

7) Remove 2 bearing outer races (32C) from
hub (33).
26 D85EX, PX-15E0
8) Remove collar (35) and bearing (32B) 2) Remove shim (39).

from case (34). a Check the thickness and quantity of
the inserted shims, then store them.
9) Remove oil sump plate (36) from case (34).

3) Remove outer race (41) and oil seal (42)
from cage (40).
8. Cage assembly
1) Remove the mounting bolts of cage assem-
bly (37). Using forcing screw [2], remove the 4) Remove outer race (43) and oil seal (44)
cage assembly from case (34). from case (34).
D85EX, PX-15E0 27
9. Gear assembly 2) Using tool J5, press fit bearing outer race
1) Remove gear assembly (45). (43) to case (34).
2) Using puller [3], remove bearings (47) and q Press fitting force for outer race:
(48) from gear (49). 1 – 14 kN {0.1 – 1.4 tons}
3) Using push tool [4], press fit bearings (47)

Assembly and (48) to gear (49).
a Clean the all parts and check them for dirt or q Press fitting force for bearing:
damage before installing. 6 – 17 kN {0.6 – 1.7 tons}
a Coat sliding surfaces of each part with engine 4) Install gear assembly (45).
oil before installing. a Lower and install the gear assembly
slowly so that the oil seal lip will not
1. Gear assembly be damaged.
1) Using tool J5, install oil seal (44) to case
(34).
a When installing the oil seal, take care
of its direction.
a Apply gasket sealant thinly to the
inside of the housing hole and wipe
off the projected part.
2 Oil seal lip: Grease (G2-LI)
2 Oil seal fitting surface:
28 D85EX, PX-15E0
2. Cage assembly 3) Install the O-ring to cage assembly (37)

1) Using tool J5, install oil seal (42) to cage and adjust shim (39).
(40).
a When installing the oil seal, take care
of its direction.
a Apply gasket sealant thinly to the
inside of the housing hole and wipe
off the projected part.
2 Oil seal lip: Grease (G2-LI)
2 Oil seal fitting surface:
4) Adjustment of shim
q Adjust the clearance of the pinion
bearing according to the following
procedure.
i) Tighten mounting bolts (B), (C), (E),
and (F) of cage (40) evenly.
3 Mounting bolt: 20 Nm {2 kgm}
ii) Under this condition, measure clear-
ances (a) and (b) between cage (40)
2) Using tool J5, press fit bearing outer race and case (34) with feeler gauges.
(41) to cage (40). iii) Set shim thickness (c) from the total
q Press fitting force for bearing: of clearances (a) and (b), referring to
1 – 14 kN {0.1 – 1.4 tons} Table 1.
iv) Install selected shim (39) to cage (40)
and tighten the 6 mounting bolts of
cage (40) evenly.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
D85EX, PX-15E0 29
Table 1 3. Hub and case assembly

a + b (mm) Number of shims to be used Total
1) Install oil sump plate (36) to case (34).
thickness a When installing the plate, press it
Larger of shims against faces (a) and (b) of the case.
Below t = 0.15 t = 0.5 t = 1.0
than (mm)
2.95 3.05 5 1 1.75
3.05 3.15 2 1 1 1.80
3.15 3.25 9 1 1.85
3.25 3.35 6 1 1.90
3.35 3.45 3 1 1 1.95
3.45 3.55 2 2.00
3.55 3.65 7 1 2.05
3.65 3.75 4 1 1 2.10
3.75 3.85 1 2 2.15
3.85 3.95 8 1 2.20
3.95 4.05 5 1 1 2.25
4.05 4.15 2 2 2.30
4.15 4.25 9 1 2.35
4.25 4.35 6 1 1 2.40
4.35 4.45 3 2 2.45
4.45 4.55 1 2 2.50
4.55 4.65 7 1 1 2.55
4.65 4.75 4 2 2.60
4.75 4.85 1 1 2 2.65
4.85 4.95 8 1 1 2.70
4.95 5.05 5 2 2.75
5.05 5.15 2 1 2 2.80
5.15 5.25 9 1 1 2.85
5.25 5.35 6 2 2.90
5.35 5.45 3 1 2 2.95
5.45 5.55 3 3.00 2) Using tool J5, press fit bearing (32B) to
5.55 5.65 7 2 3.05
case (34).
q Press fitting force for bearing:
5.65 5.75 4 1 2 3.10
13 – 26 kN {1.3 – 2.6 tons}
5.75 5.85 3 3 3.15 3) Install collar (35).
5.85 5.95 8 2 3.20
5.95 6.05 5 1 2 3.25
6.05 6.15 2 3 3.30
6.15 6.25 9 3 3.35
6.25 6.35 6 1 2 3.40
6.35 6.45 3 3 3.45
6.45 6.55 1 3 3.50
6.55 6.65 7 1 2 3.55
6.65 6.75 4 3 3.60
6.75 6.85 1 1 3 3.65
6.85 6.95 8 1 2 3.70
6.95 7.05 5 3 3.75
7.05 7.15 2 1 3 3.80
7.15 7.25 9 1 2 3.85
30 D85EX, PX-15E0
4) Using tool J5, press fit 2 bearing outer 8) Install plate (30).
races (32C) to hub (33). 2 Mounting bolt: Adhesive (LT-2)
q Press fitting force for outer race: 3 Mounting bolt:
2 – 15 kN {0.2 – 1.5 tons} 230 – 289 Nm {23.5 – 29.5 kgm}
5) Using eyebolts, set hub assembly (31) to 9) Using eyebolts, install gear (29).
the shaft.
6) Set bearing (32A) to the shaft.
10) Tighten gear mounting bolts (28).

7) Using tool J5, press fit bearing (32A) to 3 Mounting bolt:
case (34). 230 – 289 Nm {23.5 – 29.5 kgm}
13 – 26 kN {1.3 – 2.6 tons}
D85EX, PX-15E0 31
11) Install sun gear (27) and thrust (26). 3) Set the planetary gear assembly to the
carrier and press fit shaft (23).
a Aligning the holes of the bearing and
spacer with each other, press fit the
shaft gradually.
4. Carrier assembly
a Since each bearing of the planetary gear
is an assembly, match the identification
marks of the inner race, outer race, and
spacer when assembling. 4) Install bolt (21) and holder (22).
1) Using tool J5, press fit bearing outer race 2 Mounting bolt: Adhesive (LT-2)
(25C) to planetary gear (24). 3 Mounting bolt:
q Press fitting force for bearing: 230 – 289 Nm {23.5 – 29.5 kgm}
10 – 35 kN {1.0 – 3.6 tons}
5) Using 3 eyebolts, install carrier assembly

2) Install bearings (25A) and (25B) and (20).
spacer (25D) to planetary gear (24).
32 D85EX, PX-15E0
5. Cover assembly 5) Tighten mounting bolts (11).

1) Install ring gear (19) and ring (18) and 3 Mounting bolt:
secure them with 6 lock plates (17). 455 – 565 Nm {46.5 – 58 kgm}
2) Install spacer (16). 6) Using tool J4, press fit floating seal (10).
3) Using tool J3, press fit bearing (15). a Degrease the O-ring and O-ring fitting
q Press fitting force for bearing: surfaces thoroughly and dry them
24 – 52 kN {2.4 – 5.3 tons} before installing.
a After installing the floating seal, check
that its slant is less than 1 mm.
4) Using eyebolts, install the O-ring to cover

assembly (12), and then install them to the
case assembly. 6. Sprocket hub assembly
a Check that the mating faces of the 1) Using tool J5, press fit bearing outer race
case and cover are free from bruise, (8).
rust, oil, grease, dirt, and water. q Press fitting force for bearing:
2 Mounting bolt: 15 – 35 kN {1.5 – 3.6 tons}
D85EX, PX-15E0 33
2) Install sprocket (9) to the sprocket hub. 6) Using tool [3], press fit bearing (6).
3 Mounting bolt: a Press fit the bearing, turning the
931 – 1,127 Nm {95 – 115 kgm} sprocket hub assembly.
24 – 52 kN {2.4 – 5.3 tons}
3) Using tool J4, press fit floating seal (7).

a Degrease the O-ring and O-ring fitting
surfaces thoroughly and dry them 7) Install plate (4) and secure it with the
before installing. mounting bolts.
a After installing the floating seal, check 2 Mounting bolt: Adhesive (LT-2)
that its slant is less than 1 mm. 3 Mounting bolt:
230 – 289 Nm {23.5 – 29.5 kgm}
4) Using eyebolts, install sprocket hub

assembly (5) to the cover assembly. 7. Shaft
a Check that the sliding surfaces of the Install the O-ring to the sprocket hub assembly
floating seal are free from dirt and side. Using eyebolts, install shaft (3).
apply engine oil to them thinly. 3 Mounting bolt:
5) Set bearing (6). 824 – 1,030 Nm {84 – 105 kgm}
34 D85EX, PX-15E0
8. Wear guard and plate

1) Install plate (2).
3 Mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
2) Install wear guard (1)
3 Mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}

Tighten the drain plug and add oil through the
oil filler.
a After installing the final drive assembly to
the chassis, check the oil level finally.
5 Final drive case: Approx. 26 l
3 Oil filler plug and drain plug:
127 – 176 Nm {13 – 18 kgm}
3 Oil level gauge plug:
58.8 – 76.4 Nm {6 – 8 kgm}
D85EX, PX-15E0 35
SEN01267-00

© 2006 KOMATSU
All Rights Reserved
36
SEN01268-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Undercarriage and frame, Part 1
Undercarriage and frame, Part 1 .................................................................................................................... 2
Removal and installation of track frame assembly ............................................................................... 2
Removal and installation of idler assembly .......................................................................................... 5
Disassembly and assembly of idler assembly...................................................................................... 7
Removal and installation of recoil spring assembly ............................................................................11
Disassembly and assembly of recoil spring assembly ....................................................................... 13
Removal and installation of track roller assembly .............................................................................. 17
Disassembly and assembly of track roller assembly.......................................................................... 18
Removal and installation of carrier roller assembly............................................................................ 21
Disassembly and assembly of carrier roller assembly ....................................................................... 22
D85EX, PX-15E0 1
Undercarriage and frame, Part 1 1

Removal and installation of track 5. Remove guards (3) and (4).
frame assembly 1
Removal
1. Remove the blade assembly. For details, see

“Removal and installation of blade assembly”.

3. Raise the chassis with a jack or the ripper and

set stand [1] under the frame to float the rear
part of the chassis.
6. Remove cover (5) of the equalizer bar.
4. Set a hydraulic jack under the center of the

equalizer bar to raise the front part of the chas- 7. Temporarily sling the track frame assembly to
sis and set stand [2] under the frame to float be removed.
the front part.
a After floating the chassis, set the hydraulic
jack and ripper again as auxiliary supports.
2 D85EX, PX-15E0
8. Remove pin lock plate (6) and pull out pin (7). q Right track frame assembly
a If the equalizer bar hole and track frame 1) Remove cover (10). [*3]
hole are not aligned, the pin cannot be
removed easily. Adjust the hanging height
of the track frame properly.
k If the track frame assembly on the
opposite side is floated before the pin
is pulled out, support it on a block, etc.
2) Remove spacer (11). [*4]

a Receive the oil flowing out of the pivot
case with an oil pan, etc.
6 Pivot case: Approx. 8 l
3) Remove washer (12).
9. Removal of track frame assembly a Remove seal (13) and washer (12)
q Left track frame assembly together.
1) Remove cover (8). [*1]
10. Lift off track frame assembly (13).

4
2) Remove spacer (9). [*2]
Track frame assembly:
a Receive the oil flowing out of the pivot
D85EX-15E0; 2,160 kg
case with an oil pan, etc.
D85PX-15E0; 2,270 kg
6 Pivot case: Approx. 8 l
D85EX, PX-15E0 3
Installation
removal.
[*1] [*2] [*3] [*4]

3 Mounting bolt: 54 – 123 Nm {5.5 – 12.5 kgm}

Add oil through the oil filler at the upper section.
a The oil level must be 20 mm from the top
of the pivot shaft.
5 Pivot shaft case: Approx. 8 l
3 Oil filler plug:
127 – 176 Nm {13 – 18 kgm}
4 D85EX, PX-15E0
Removal and installation of idler 6. Remove spring (6) and seat (7).
assembly 1
Removal
k Never stand in front of the idler assembly to
prevent danger.


3. Loosen mounting bolts (2) of support (1) and

spring seat clamping bolts and remove plate (3). 7. Remove yoke (8).
4. Pass wires through the hanging holes of idler 8. Lift off idler assembly (4).
assembly (4). Sling idler assembly (4) and
slide it out forward along the top of the track
frame.
4 Idler assembly: 300 kg
5. Remove guide plate (5).
D85EX, PX-15E0 5
Installation
removal.
a Install the idler assembly to the chassis
with the oil filler plug on the left side of the
chassis.
a Adjustment of shims
Adjust the shims so that clearance (A)
between idler support (1) and guide plate
(5) will be 2 mm at every point.
q Standard thickness of shims:
(a) = 8 mm
(b) = 4 mm
a Select shims (a) and (b) so that
the total thickness of them ((a) +
(b)) will be 12 mm.
a Set at least 4 pieces of the 1-mm
thick shim on the (a) side and at
least 2 pieces on the (b) side.
6 D85EX, PX-15E0
Disassembly and assembly of 6. Using push puller [1], pull support (8) out of
idler assembly 1 idler (7).
Special tools 7. Remove floating seal (9) from support (8).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
1 791-530-1510 Installer t 1
L
2 791-601-1000 Oil pump t 1
Disassembly
1. Remove the oil filler plug and drain the oil.

6 Idler: 0.33 – 0.37 l 8. Sling idler (7) and pull it out of shaft and sup-
port assembly (10).
2. Set idler (1) to a block. a When hanging the idler with sling rope [2],
prevent sling rope [2] from opening with
3. Remove the spring seat mounting bolts and wires or ropes [3].
plate (2).
a Record the number of the removed shims. 9. Remove floating seals (11) and (12) from idler
(7).
4. Remove support mounting bolts (3).
a Record the number of the removed shims.
5. Remove nut (4) and drive out bolt (5) from the
nut side.
D85EX, PX-15E0 7
10. Remove floating seal (13) from shaft and sup- Assembly
port assembly (10).
1. Using push tool [4], press fit 2 bushings (18) to
idler (7).
q Press fitting force for bushing:
14.9 – 148.7 kN {1.5 – 15.2 tons}
11. Remove nut (14) and drive out bolt (15) from
the nut side.
12. Similarly to step 6, using push puller [1], pull

shaft (17) out of support (16). 2. Install the O-ring to shaft (17), and then install
them to support (16).
a When installing shaft (17), match its
groove to the groove of the support.
a Install the shaft with the opposite end of
the oil filler ahead.
3. Drive bolt (15) and tighten nut (14).

3 Mounting nut:
157 – 255 Nm {16 – 26 kgm}
13. Remove 2 bushings (18) from idler (7).
8 D85EX, PX-15E0
4. Using tool L1, install floating seal (13) to shaft 6. Sling idler (7) and install it to shaft support
and support assembly (10), and then install the assembly (10).
O-ring to shaft (17).
a Degrease the O-ring and O-ring fitting sur-
faces thoroughly and dry them before
installing.
a After installing the floating seal, check that
its slant is less than 1 mm.
5. Using tool L1, install floating seal (12) to idler

(7).
installing.
7. Using tool L1, install floating seal (11) to idler

(7).
installing.
D85EX, PX-15E0 9
8. Refill the idler with oil.

a The idler may be refilled with oil at this
time. For the ordinary method of refilling
with oil, see “Refilling with oil”.
5 Idler: Approx. 0.33 – 0.37 l
3 Oil filler plug:
157 – 255 Nm {16 – 26 kgm}
9. Using tool L1, install floating seal (9) to support

(8).
installing.
its slant is less than 1 mm. 14. Refilling with oil
q Ordinary method of refilling with oil
Remove plug (20) from shaft (17), add oil
through the oil filler, and tighten plug (20).
3 Oil filler plug:
157 – 255 Nm {16 – 26 kgm}
10. Install support (8) to idler (7).

a When installing shaft (17), match its
groove to the groove of the support.
11. Drive bolt (5) and tighten nut (4).

3 Mounting nut:
157 – 255 Nm {16 – 26 kgm} q Filling with oil by evacuation
1) Remove plug (20) from shaft (17).
2) Using tool L2, add oil through the oil filler
and tighten plug (2).
3 Oil filler plug:
157 – 255 Nm {16 – 26 kgm}
12. Set the shim and install support mounting bolts

(3).
13. Set the shim and install spring seat clamping

bolts (2).
10 D85EX, PX-15E0
Removal and installation of recoil 6. Remove spring (6) and seat (7).
spring assembly 1
Removal
k Never stand in front of the idler assembly to
prevent danger.


3. Loosen mounting bolts (2) of support (1) and

spring seat clamping bolts and remove plate (3).
7. Slide idler assembly (4) further and install
wires on spring case (8) side, and then slide
the assembly forward to remove.
4 Idler and recoil spring assembly: 640 kg
4. Pass wires through the hanging holes of idler

assembly (4). Sling idler assembly (4) and
slide it out forward along the top of the track
frame.
5. Remove guide plate (5). 8. Set idler and recoil spring assembly (9).
k Take measures to prevent the idler assem-
bly from leaning for safety.
4 Idler assembly: 300 kg
D85EX, PX-15E0 11
9. Remove the mounting bolts and yoke (10).

4 Recoil spring assembly: 350 kg
Installation
removal.
a Install the idler assembly to the chassis
with the oil filler plug on the left side of the
chassis.
a When installing the idler and recoil spring
assembly to the chassis, check it through
the lubricator adjustment window.
12 D85EX, PX-15E0
Disassembly and assembly of q If cylinder (18) is not broken and shaft end nut
recoil spring assembly 1 (21) is not lost, disassemble the yoke and piston
assembly according to the following procedure.
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
M1 791T-630-2610 Spacer t 1 N Q
790-101-1300 Cylinder t 1
3. Remove holder (14) from recoil spring case

Disassembly (13).
k Never stand in front or in the rear of the
1. Remove yoke and piston assembly (2) from recoil spring assembly to prevent danger.
recoil spring assembly (1).
4. Disassembly of holder
2. Disassembly of yoke and piston assembly 1) Remove cover (15) from holder (14).
1) Remove snap ring (3), ring (4), packing 2) Remove seal (16) and bushing (17) from
(5), and ring (6). holder (14).
2) Remove bolt (7), plate (8), and washer (9).
3) Using push tool (12) and a press, pull pis-
ton (11) out of yoke (10).
D85EX, PX-15E0 13
5. Remove lock plate (19) form cylinder (18), and 9. Take recoil spring (23) and cylinder (18) out of
then remove lubricator (20). recoil spring case (13).
10. Remove bushing (24) from cylinder (18).
11. Remove seal (25) and bushing (24) from recoil

spring case (13).
6. Set recoil spring assembly (1) to tool M1.

k Set the spring securely since its
installed load is large.
a Installed load of spring: 23.2 kN {23,200 kg}
q When cylinder (18) is broken or shaft end nut

(21) is lost, if mounting bolt (26) of holder (14)
is removed, recoil spring (23) flies forward.
Accordingly, disassemble according to the fol-
lowing procedure in this case.
k Never stand in front or in the rear of the
recoil spring assembly to prevent danger
until holder (14) and recoil spring case (13)
are separated and the recoil spring is taken
out and safety is confirmed.
7. Apply hydraulic pressure to tool M1 slowly to

compress the spring, tighten nut (21) until
spacer (22) can be removed, and remove the
spacer.
8. Remove nut (21) and reduce the hydraulic

pressure slowly to release the spring.
14 D85EX, PX-15E0
1) Set recoil spring assembly (1) to tool M1. 3. Install recoil spring (23) and cylinder (18) to
k Set the spring securely since its recoil spring case (13) temporarily and set tool
installed load is large. M1.
a Installed load of spring: k Set the spring securely since its
23.2 kN {23,200 kg} installed load is large.
2) Apply hydraulic pressure slowly to secure a Installed load of spring:
recoil spring assembly (1). 227.5 kN {23.2 tons}
a When compressing the spring, align it with
the other parts by using lever block [1], etc.
so that the threads will not be damaged.
a Installed length of spring: 651 mm
3) Remove mounting bolt (26) of holder (14)

under the condition in step 2).
4) Reduce the hydraulic pressure slowly to
release the spring.
4. Install nut (21) and spacer (22).
Assembly
1. Using the push tool, press fit bushing (24) to

recoil spring case (13) and install seal (25).
19.6 – 29.4 kN {2.0 – 3.0 tons}
2 Bushing: Grease (G2-LI)
2. Using the push tool, press fit bushing (24) to

cylinder (18).
19.6 – 29.4 kN {2.0 – 3.0 tons}
2 Bushing: Grease (G2-LI)
5. Reduce the hydraulic pressure slowly to elimi-

nate the spring tension, and then remove recoil
spring assembly (1) from tool M1.
D85EX, PX-15E0 15
6. Install lubricator (20) to cylinder (18), and then 9. Assembly of yoke and piston assembly
install lock plate (19). 1) Using push tool [2] and a press, press fit
piston (11) to yoke (10).
q Press fitting force for yoke:
392 kN {40 tons}
2) Install washer (9) and plate (8) and tighten
bolt (7).
a Bend washer (9) securely.
3) Install ring (6), packing (5), ring (4), and
snap ring (3).
2 Packing and ring: Grease (G2-LI)
7. Assembly of holder
1) Press fit bushing (17) to holder (14) and
install seal (16).
19.6 – 29.4 kN {2.0 – 3.0 tons}
2 Bushing and oil seal: Grease (G2-LI)
2) Install cover (15) to holder (14).
10. Install yoke and piston assembly (2) to recoil

spring assembly (1).
8. Install holder (14) to recoil spring case (13).
16 D85EX, PX-15E0
Removal and installation of track 8. Remove the mounting bolts of track roller
roller assembly 1 assembly (8).
Removal
1. Loosen the track shoe assembly. For details,

2. Remove 2 retainers (1) in the track frame and

the 5 nuts of guard tension bolts (2). [*1]
3. Remove the 5 mounting bolts and track roller

guard (3). [*2]
4. Remove the mounting bolts and rear roller

guard (4). [*3]
9. Start the engine and raise the chassis by oper-
ating the blade or ripper or by using a hydraulic
jack and leave the track roller assembly on the
track link.
k When raising the chassis, be sure to
apply the brake and lock the work
equipment control lever. After raising
the chassis, set a block on the track
link to prevent danger.
10. Pull out and remove controller assembly (8).

a Take care of the key on the inside.
4 Track roller assembly:
Single flange; 72 kg
5. Remove guard tension bolt (2). Double flange; 80 kg
a Take care of the guide spacer on the inside.
6. Remove 2 retainers (5) on the outside of the Installation

track frame, and then remove the 5 mounting q Carry out installation in the reverse order to
bolts and track roller guard (6). [*4] removal.
a Install the track roller assembly with the oil
7. Remove the mounting bolts and rear roller filler plug on the outside of the chassis.
guard (7). [*5]
[*1] [*2] [*3] [*4] [*5]
3 Mounting bolt:
750 – 829 Nm {76.5 – 84.5 kgm}
q Adjust the track shoe assembly tension. For

details, see “Adjusting track shoe assembly
tension”.
D85EX, PX-15E0 17
Disassembly and assembly of 5. Remove collar (3), floating seal (5), (6) and O-
track roller assembly 1 ring on the opposite side, similarly to steps 2) –
4).
Special tools
6. Remove mounting bolt (8) of bushing (7).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
1 791-651-1510 Installer t 1
N
2 791-601-1000 Oil pump t 1
Disassembly

6 Idler: 0.26 – 0.29 l
7. Set track roller assembly (1) on a block and
2. Set track roller assembly (1) on the block [1]. push the end of shaft (9) to pull out bushing (7)
Using push puller [2], push in collar (3) and and remove the O-ring.
then remove ring (4) and collar (3).
8. Turn over track roller assembly (1) and set it on

3. Remove floating seal (5) from collar (3). the block and push the end of shaft (9) to pull
out bushing (7) and remove the O-ring on the
4. Remove floating seal (6) and O-ring from track opposite side.
roller assembly (1).
18 D85EX, PX-15E0
Assembly 5. Install mounting bolt (8) of bushing (7).

a Clean the all parts and check them for dirt or 3 Initial torque: 49 ± 10 Nm {5 ± 1 kgm}
damage before installing. a After tightening, retighten by 90° ± 5°

2 Mounting bolt:
1. Set track roller (10) on a block. Molybdenum disulfide (LM-P)
2. Install the O-ring to bushing (7) and press fit

them to track roller (10).
a When installing the bushing, match it to
the bolt hole of the track roller.
2 Periphery of bushing:
Gear oil (GO140)
6. Using tool N1, install floating seal (5) to bush-

ing (7) and collar (3).
a Clean and degrease the O-ring and O-ring
fitting surfaces thoroughly and dry them
before installing.
3. Turn over track roller (10) and set it on the
block and insert shaft (9).
4. Install the O-ring to bushing (7) and using the

push tool [3], press fit them to track roller (10).
a When installing the bushing, match it to
the bolt hole of the track roller.
2 Periphery of bushing:
Gear oil (GO140)
7. Install the O-ring to shaft (9).

a Take care not to damage the O-ring.
2 Up to collar mounting portion of shaft:
Molybdenum disulfide (LM-P)
D85EX, PX-15E0 19
8. Set track roller assembly (1) on the block [1].

Using push puller [2], push in collar (3) and
install ring (4).
9. Turn over track roller assembly (1) and set it on

the block, and then perform steps 7 – 8 on the
opposite side.
10. Using tool N2, add oil through the oil filler and
tighten the oil filler plug.
5 Track roller: Approx. 0.26 – 0.29 l
3 Oil filler plug:
157 – 255 Nm {16 – 26 kgm}
20 D85EX, PX-15E0
Removal and installation of Installation

carrier roller assembly 1 q Carry out installation in the reverse order to
removal.
Removal
q Adjust the track shoe assembly tension. For
1. Loosen the track shoe assembly. For details, details, see “Adjusting track shoe assembly
see “Expanding track shoe assembly”. tension”.
2. Using hydraulic jack [1], raise the track shoe.
3. Remove mounting bolts (3) of carrier roller

assembly (2).
4. Sling carrier roller assembly (2) and remove it

from support (4).
4 Carrier roller assembly: 39 kg
D85EX, PX-15E0 21
Disassembly and assembly of 5. Using tool [2], remove nut (4).

carrier roller assembly 1
6. Using puller [3], remove the fitted part of the
Special tools bearing. Then, using eyebolts, remove bearing
(5) and carrier roller (6) together.
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
1 791-651-1510 Installer t 1
N
2 791-601-1000 Oil pump t 1
Disassembly

6 Idler: 0.47 – 0.53 l
7. Remove outer race (7) of the bearing from car-
2. Set carrier roller assembly (1) on a block [1]. rier roller (6).
3. Remove the mounting bolts, cover (2), and O- 8. Using puller [4], remove collar (8) and bearing
ring. inner race (9) together from shaft (11).
4. Remove ring (3).
9. Remove floating seal (10) from collar (8).
22 D85EX, PX-15E0
10. Using push tool [5], remove ring (12) from shaft 3. Set carrier roller (6) and bearing inner race (9)
(11). to shaft (11).
11. Remove floating seal (13) from ring (12). 4. Using push tool [8], press fit bearing inner race
(9).
Assembly 5. Using tool [2], tighten nut (4).

a Clean the all parts and check them for dirt or 3 Nut: 98 Nm {10 kgm}
damage before installing. a After nut (4) is tightened, if its hole is not
matched to the hole on the shaft side,
1. Using push tool [6], press fit bearing inner race loosen it until the holes are aligned.
(9) to shaft (11).
6. Install ring (3).
2. Using push tool [7], press fit bearing outer race a Check that the end play (clearance between
(7) to carrier roller (6). the bearing and nut) is 0 – 0.22 mm.
7. Install the O-ring and cover (2).
D85EX, PX-15E0 23
8. Using tool N1, install floating seal (10) to collar 11. Using push tool [9], press fit ring (12) to carrier
(8). roller assembly (1).
a Clean and degrease the O-ring and O-ring q Press fitting force for ring:
fitting surfaces thoroughly and dry them 40 – 73 kN {4.1 – 7.4 tons}
before installing. a Press fit the ring so that distance (b)
a After installing the floating seal, check that between the shaft end and ring top will be
its slant is less than 1 mm. 120 ± 0.2 mm.
a After press fitting the ring, check that its
9. Fit the O-ring to collar (8) and install them to car- slant from the shaft is less than 0.4 mm.
rier roller (6), matching them to the dowel pin.
a Take care not to damage the O-ring.
12. Using tool N2, add oil through the oil filler and
tighten the oil filler plug.
5
10. Using tool N1, install floating seal (13) to ring
Carrier roller: Approx. 0.47 – 0.53 l
(12).
a Clean and degrease the O-ring and O-ring 3 Oil filler plug:
fitting surfaces thoroughly and dry them 157 – 255 Nm {16 – 26 kgm}
before installing.
24 D85EX, PX-15E0
SEN01268-00

© 2006 KOMATSU
All Rights Reserved
26
SEN01269-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Undercarriage and frame, Part 2
Undercarriage and frame, Part 2 .................................................................................................................... 2
Expansion and installation of track shoe assembly.............................................................................. 2
Whole disassembly and assembly of track shoe ................................................................................. 6
Removal and installation of pivot shaft assembly............................................................................... 25
Removal and installation of equalizer bar assembly .......................................................................... 26
Disassembly and assembly of equalizer bar assembly...................................................................... 28
D85EX, PX-15E0 1
Undercarriage and frame, Part 2 1

Expansion and installation of Expansion of track shoe assembly
track shoe assembly 1 (Ordinary)
a If any abnormality is not detected by “Check
Check before expanding track shoe before expanding track shoe assembly”, per-
assembly form the following procedure.
k Since it may be very dangerous to expand
the track shoe assembly, check the follow- 1. Set master link (3) in position.
ing items in advance. a Set the master link above the idler (a little
k Do not loosen the lubricator more than 1 after the center of the idler).
turn. If the grease is not discharged well, a Set blocks [1] and [2] between the front
move the machine forward and in reverse. side of the idler and carrier roller so that
the mating part of the master link will not
1. Remove cover (1) and loosen lubricator (2) of open until the master bolt is pulled out.
the adjustment cylinder to discharge the
grease.
k Do not loosen the lubricator more than
1 turn.
2. After the shoe is loosened, perform “Expansion

of track shoe assembly (Ordinary)”.
3. If the track shoe is not loosened by the above

work, perform “Expansion of track shoe assem-
bly (When track frame has internal trouble)”.
a The track frame may have an internal trou-
ble (damage of the recoil spring or recoil
spring set bolt, fall of the shaft end nut, etc.)
2 D85EX, PX-15E0
2. Loosen the track shoe. [*1] 4. Sling the front end of the master link and move
k Do not loosen lubricator (2) more than the machine slowly forward and in reverse to
1 turn. expand track shoe assembly (7).
a If the track shoe is not loosened after the a Length of track shoe: Approx. 10.5 m
lubricator is loosened, move the machine
forward and in reverse.
3. Remove track shoe (6). [*2]

a Loosen the 4 bolts by 1 – 2 turns each and
check that they rotate lightly, and then pull
them out. Do not pull them out one by one
without checking their looseness.
a If the bolts are loosened forcibly while they
are still tight, the threads of them and
master link (3) may be damaged.
D85EX, PX-15E0 3
Expansion of track shoe assembly 3. Remove idler guide (10).

(When track frame has internal trouble) a Be sure to remove the idler guide at this
a If any abnormality is detected by “Check time. If the track shoe is expanded without
before expanding track shoe assembly”, per- removing the idler guide, the idler guide
form the following procedure. moves forward and is pressed against the
k If the track shoe is removed while the track track frame. If the idler guide is removed
frame has an internal trouble, it may spring at this time, the idler yoke assembly will
back. Even if the track shoe is removed, the jump forward.
idler may jump out, and that can cause a seri-
ous result. Accordingly, expand the track
shoe according to the following procedure.
1. Loosen the track shoe. [*1]

k Do not loosen lubricator (2) more than
1 turn.
a If the track shoe is not loosened after the
lubricator is loosened, move the machine
forward and in reverse.
a Check that the all grease has been dis-
charged.
4. Remove track shoe (6) and disconnect master

link (3). [*2]
a Loosen the 4 bolts by 1 – 2 turns each and
check that they rotate lightly, and then pull
them out.
5. Move the machine slowly in reverse to expand

track shoe assembly (7).
2. Move the machine slowly forward against large

block [1] or a wall (or the blade of another
machine of the similar size of the machine to be
repaired, if available) to press the track shoe on
the idler side. When the recoil spring and track
shoe are distorted, stop and apply the brake.
At this time, set the master link between the
idler and front carrier roller.
a For safe work, apply lever block [2]
between the carrier roller support and link.
4 D85EX, PX-15E0
Installation
expansion (ordinary).
[*1]
a Adjust the track shoe tension. For details, see
Testing and adjusting, “Testing and adjusting
track shoe tension”.
[*2]
a Tighten the shoe mounting bolts for the master
link in the following order.
2 Shoe bolt: Lubricant containing molyb-
denum disulfide (LM-P)
3 Shoe bolt (Master link):
q Single shoe:
Initial torque: 343 ± 39 Nm {35 ± 4 kgm}
–00
Retightening angle: 180° –20
q Swamp shoe:
Initial torque: 343 ± 39 Nm {35 ± 4 kgm}
–00
a Tighten the all 4 bolts with fingers until the
master link mating faces are fitted.
a If the bolts are tightened forcibly before the
master link mating faces are fitted, the threads
of them and master link may be damaged.
D85EX, PX-15E0 5
Whole disassembly and assembly a If a shoe bolt is turned forcibly while its
of track shoe 1 torque is not 0, it and link will adhere to
each other and they will need to be
Special tools repaired.
a When moving the shoe assembly, take
New/Remodel
care not to damage the master link.
Necessity
a If it is obliged to cut a shoe nut with gas,
Symbol
Sketch
Q'ty
Part No. Part name keep the seal temperature below 80°C to
prevent thermal deterioration of the seal
and take measures to prevent the spatters
791-650-3000
Remover and
t 1
from entering through the clearances
installer among the links.
Cylinder
1 790-101-1300 t 1
assembly
790-105-2300 Jack assembly t 1
Remover and
791-650-3500 t 1
installer
791-675-5542 Adapter t 1
791-675-5571 Adapter t 1
2
Cylinder
790-101-1300 t 1
assembly
R 790-105-2300 Jack assembly t 1
3 791-646-7531 Push tool t 1
4 791-660-7460 Pin puller t 1 2. Disassembly of link
1) Set the link assembly on a link press and
hit it with a hammer so that the bushing
• 790-434-1210 • Bar 1 will be fitted to the jaw [1].
5 • 790-434-1220 • Guide 1 a If the link tread, outside of the bush-
791-646-7523 Bar t 1 ing, etc. are worn, adjust the height of
jaw [1] or guide plate to align both dis-
791-646-7590 Guide t 1
assembling jigs [2] and [3] with the
6 791-632-1060 Installer t 1 pin and bushing so that the link hole
7 790-701-3000 Seal checker t 1 will not be damaged when the link is
8 791-646-8002 Lubricator t 1 assembled.
a If the pin and bushing are not aligned
well, the link hole may be damaged
a For the whole disassembly of the track shoe, and the pin and bushing may be bro-
see “Guidance for reusable parts, Undercar- ken during disassembly work.
riage, Lubricated track” and “Guidance for
reusable parts, Undercarriage, Reversing pro-
cedure for lubricated track”.
Whole disassembly
1. Removal of shoe
Sling the shoe assembly and set it with the
shoe up on the floor and remove the shoe by
using a shoe bolt impact wrench.
a If a shoe bolt is not loosened after it is
unscrewed by 1 turn (If its torque is not
reduced to 0), loosen the other bolts first,
and it will be removed smoothly.
6 D85EX, PX-15E0
a Using tool R1, drive the small plug of 4) Return the right cylinder and take out the
the pin inward after the disassembly links, pins, bushings, and spacers on both
work so that the workplace will not sides and feed the next 1 set of the link
become dirty. assembly to the jaw.
a If the bushing ends and sealing sur-
faces are damaged, oil will leak.
Accordingly, handle them carefully.
2) Operate the left cylinder to pull out the pin

and bushing from the left link simulta-
neously.
a Check the pulling out force of the pin 3. Inspection
and bushing to see if press fitting Check the parts for the following items to see if
force for them necessary for reversed they can be used for a lubricated track or a
reassembly is obtained. grease-filled track, then examine them gener-
ally and determine to use them for a lubricated
track or grease-filled track.
a For judgment of reuse of the parts, see
“Guidance for reusable parts, Undercar-
riage, Lubricated track”.
1) Check the parts visually for damage. If a

part seems to be damaged, check it by
dye penetrant test or magnaflux inspec-
tion. If it has any crack, it cannot be used
again. Discard it.
3) Return the left cylinder and operate the

right cylinder to pull out the pin and bush-
ing from the right link simultaneously.
D85EX, PX-15E0 7
2) Measure the outside diameter of the press Whole assembly

fitting parts of the pin and bushing and the a For the whole assembly of the track shoe, see
inside diameter of the pin and bushing fit- “Guidance for reusable parts, Undercarriage,
ting parts of the link with a micrometer and Reversing procedure for pin bushing”.
a cylinder gauge to see if the allowable fit-
ting allowance is obtained. When using When recycling for lubricated track
the pin, bushing, and link for a lubricated 1. Preparation work
track, however, secure the standard fitting 1) Cleaning seal assembly
allowance between the pin and link. Remove the seal assembly from the link
a If the allowable fitting allowance is not and divide it into the seal ring and load
obtained, replace the parts with new ring, then clean them.
ones. a Since the seal ring (1) and load ring
a For the dimensional criteria, see “Main- (2) are deteriorated easily by the
tenance standard”. cleaning liquid, clean them quickly.
After cleaning them, wipe off the
cleaning agent from them.
a Precautions for storage

1) Store the seal without removing it from the
link so that the counterbore portion will not 2) When reusing the pin, chamfer its end cor-
be rusted and take care not to damage the ners smoothly with a grinder. Remove the
seal lip. nodules sticking to the press fitting parts
2) Apply rust-preventive oil to the pin and with the grinder, too.
bushing fitting parts, shoe mating surface, a If the ends are worn and sharpened,
and master link mating surface of the link. they may scuff the press fitting parts
3) When storing, apply rust-preventive oil to and cause oil leakage.
the all surfaces of the pin, bushing, and
spacer. Take care not to damage the ends
of the bushing in particular.
8 D85EX, PX-15E0
3) If the link, pin, bushing, and spacer are dirty, 5) Installation of seal assembly
clean them. Remove the nodules sticking to Clean the counterbore portion (d) of the
the link and bushing with the grinder. link carefully and push in the seal to the
a Since these parts rust easily, clean bottom by using tool R6.
them just before assembling them. a If oil is sticking to the counterbore
a Do not polish the bushing ends. If portion of the link or seal assembly,
they are polished, oil may leak. the seal will turn and its sealing per-
4) If the large plug was pulled out, drive it in formance will lower. Accordingly, do
by using tool R5. not apply any oil. When inserting the
a In this case, clean the pin hole in seal in the counterbore portion, take
advance by using tool R4. care that oil does not stick to the seal
and counterbore portion.
i) Insert the plug (3) through the plug

insertion window into the guide hole. 6) Adjust the dimensions of the press fitting
ii) Push the bar with the hand until the jig of the link press to keep the projection
plug stops. of the pin and bushing constant and keep
iii) Push the plug with the bar to press the installed dimensions of the seal within
the guide against the pin (4). the standard range.
iv) Drive in the bar with a hammer. a For the standard dimensions, see
a Driving distance (a) from pin end: 6 ± “Dimensions table of press fitting jig
2 mm of link press”.
a If the chamfered part of the pin hole a If the pin end (part (P)) or the sides of
has been worn, chamfer it with a the link (parts (Q) and (R)) are worn,
small-sized grinder (grindstone tip add the dimensions of the worn parts
angle: 45° – 60°) so that the plug will when adjusting the standard dimen-
not be damaged. sions so that the projections of the
a Coat the plug with GO90 and drive it pins and bushings on both sides will
with the small diameter end ahead. be even.
D85EX, PX-15E0 9
7) Adjust the relief pressure of the link press

so that the pressing force of the press will
not exceed the standard value.
a If the pressing force is too strong, the
spacer will be pressed forcibly against
the bushing. As a result, the spacer
may be broken and bushing may be
worn abnormally.
a Final pressing force for pin and bushing:
588 kN {60 tons}
Final pressing force C 1.8 × Average
press fitting force
(Adjust the relief pressure of the link
press to set the final pressing force.)
2. Assembly of link 3) Using the shoe bolt hole pitch gauge,

1) Apply oil (GO90) to the mating surfaces of press fit the master links until the distance
the pin and bushing with a clean brush between the shoe bolt holes of both links
and assemble them, then set them before is the standard value.
the jaw of the link press. a Remove the all steel chips caused by
a When reusing (reversing) the bush- press fitting of the bushing with com-
ing, set the worn outside surface of pressed air.
the bushing on the shoe fitting side of 4) Turn over the master links and check that
the link (set the bushing with the worn they are press fitted in parallel.
outside surface up on the link press).
5) Measure the projections of the bushing on

2) Press fit the master links on both bushing both sides with a depth gauge.
sides to the bushing with the shoe fitting a Adjust the press fitting jig of the link
faces up. press so that the projections on both
a At this time, use the master links on sides will be even.
the pin side as supports.
a Press fitting force for bushing:
68 – 108 kN {7 – 8 tons}
10 D85EX, PX-15E0
6) Send the master links and set the next pin a Press fitting force for pin and bushing:
and bushing. 274 – 363 kN {28 – 37 tons}
a When reusing a pin, install it so that
its side hole (e) will be on the link
tread side similarly to a new one. If it
is not installed so, its strength may be
lowered. Accordingly, indicate the
direction of the side hole (e) on the
end face to prevent a mistake.
9) Using the spacer [4] for fine adjustment,

press fit the pin and bushing until the pin
end is fitted to the bottom of the receiving
jig.
a Adjust the depth of the receiving jig
hole so that the projections of the pin
on both sides will be even.
7) Set the right link and install the spacer to
the pin.
a Check that the seal surface and bush-
ing end are free from dirt and apply oil
(GO90) to them with a clean cloth or
brush.
a When installing the spacer, wipe it
with a clean cloth.
10) Set the left link and install the spacer to

the pin.
a Apply oil similarly to the right link.
8) Set the right jig on the receiving side and

the left one on the pushing side and press
fit the pin and bushing simultaneously.
a If the pin and bushing have play when
they are press fitted, the seal may
come off the link. To prevent this,
press fit smoothly. If the seal comes
off the link, stop press fitting and set
the seal to the link correctly, then start
press fitting again.
D85EX, PX-15E0 11
11) Set the left jig on the receiving side and 13) Using a shoe bolt hole pitch gauge, mea-
the right one on the pushing side and sure the distance between the shoe bolt
press fit the left link. holes and check that the result is within
a When press fitting, take care that both the standard range.
seals and spacers will not come off. a If the distance between the shoe bolt
a Press fitting force for link: holes is longer than the standard
274 – 363 kN {28 – 37 tons} range, disassemble and check for
abnormality, then press fit again.
a If the distance between the shoe bolt
holes is shorter than the standard
range and the shoe cannot be
installed, the spacer or bushing end
may be worn more than the allowable
limit. In this case, disassemble and
replace the parts.
12) Press fit until the link, spacer, and bushing

are fitted together.
a Actually, you cannot see from outside
if the above parts are fitted. Accord-
ingly, control the hydraulic pressure of
the link press. Set the relief pressure
to a proper level and heighten the
hydraulic pressure to that level.
For setting of the relief pressure, see 14) After each link is assembled, bleed air
“Preparation work”. from the pin by using tool R7 and check
a Check that adjacent 2 links can turn the sealing performance.
around each other. a Keep the degree of vacuum inside the
pin at 91 – 95 kPa {680 – 710 mmHg}
for 5 seconds and check that the
pressure does not change.
If the pressure changes, disassemble
and check the seal. If the seal is free
from abnormality, assemble again.
12 D85EX, PX-15E0
15) Using tool R7, supply oil (GO90) until the

oil supply pressure rises to 196 – 294 kPa
{2 – 3 kg/cm2}.
a In a cold or very cold district, supply
Komatsu genuine oil (150-19-19270
or 195-32-61990) having better low-
temperature characteristics instead of
GO90.
a If the oil pressure is heightened too
much, it has bad effects on the seal.
Take care.
17) Assemble the master link on the pin side

at last.
a Check that the master links on both
sides are press fitted in parallel.
3. Installation of shoe
1) Set the link assembly on the bed and
install the shoe with a shoe bolt impact
wrench and a torque wrench.
a When reusing (reversing) the bush-
ing, set the worn outside surface of
a Supply oil (d) to oil level (a) so that the bushing on the shoe fitting side of
depth (L) of the hole of pin (c) will be the link (set the bushing with the worn
in the following range when the link outside surface up on the link press).
assembly is left with small plug side 2 Shoe bolt: Lubricant containing
(b) up (with the link assembly on its molybdenum disulfide (LM-P)
side) for 30 minutes. 3 Shoe bolt (Regular link):
Dimension L: 35 – 60 mm q Single shoe:
Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
Retightening angle: 120° ± 10°
q Swamp shoe:
Initial torque:
539 ± 49 Nm {55 ± 5 kgm}
Retightening angle: 120° ± 10°
16) After supplying oil, drive in the small plug

into the specified position, using tool R3.
a Apply GO90 around the small plug.
a Drive in the small plug to the following
depth.
Driving depth from end: 2.5 ± 1 mm
D85EX, PX-15E0 13
2) When installing a 2-piece shoe, place the When recycling for grease-filled track
assembled 2-piece shoes on a level place 1. Preparation work
in 1 line with the shoe side up. 1) Cleaning seal assembly
3) Pull pin-side master link (1) and bushing- Remove the seal assembly from the link
side master link (2) together and set them and divide it into the seal ring and load
to each other by the mating faces. ring, then clean them.
4) Place and fit shoe (3) to mating surface of a Since the seal ring and load ring are
the links. deteriorated easily by the cleaning liq-
5) Check that master bolt (4) can be tight- uid, clean them quickly. After cleaning
ened easily with the fingers, then connect them, wipe off the cleaning agent
the links with the master bolts. from them.
2 Master bolt: Lubricant containing
molybdenum disulfide (LM-P)
3 Master bolt (Master link)
q Single shoe:
Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
–00
q Swamp shoe:
Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
–00
2) When reusing the pin, chamfer its end cor-

ners carefully with a grinder so that it will
be press fitted smoothly.
a Tighten the bolts in the order of 1 – 4.
3) Drive in the large and small plugs by using

tools R3 and R5.
i) Insert each plug through the plug
insertion window into the guide hole.
a Apply oil to the plug.
ii) Push the bar with the hand until the
plug stops.
iii) Push the plug with the bar to press
the guide against the pin.
14 D85EX, PX-15E0
iv) Drive in the bar with a hammer.

a Driving distance (a) from pin end:
Small plug: 2.5 ± 1 mm
Large plug: 6.0 ± 2 mm
a If the plugs were not pulled out
when the shoe was disassem-
bled, reuse them as they are.
7) Adjust the dimensions of the press fitting

jig of the link press to keep the projection
of the pin and bushing constant and keep
the installed dimensions of the seal within
the standard range.
a For the standard dimensions, see
“Dimensions table of press fitting jig
of link press”.
a If the pin end (part (P)) or the sides of
the link (parts (Q) and (R)) are worn,
add the dimensions of the worn parts
when adjusting the standard dimen-
sions so that the projections of the
pins and bushings on both sides will
be even.
4) If the outside of the pin, surfaces of the

spacer, and ends and inside of the bush-
ing are dirty, clean them.
5) Apply grease to the outside of the pin and
surfaces of the spacer.
6) Installation of seal assembly
Clean the counterbore portion of the link
carefully and push in the seal to the bot-
tom by using tool R6.
a If grease is sticking to the counter-
bore portion of the link or seal assem-
bly, the seal will turn and its sealing
performance will lower. Accordingly,
do not apply any oil.
D85EX, PX-15E0 15
2. Assembly of link 3) Using the shoe bolt hole pitch gauge,

1) Apply lithium grease (G2-LI) to the mating press fit the master links until the distance
surfaces of the pin and bushing and between the shoe bolt holes of both links
assemble them, then set them before the is the standard value.
jaw of the link press. a Remove the all steel chips caused by
a When reusing (reversing) the bush- press fitting of the bushing with com-
ing, set the worn outside surface of pressed air.
the bushing on the shoe fitting side of 4) Turn over the master links and check that
the link (set the bushing with the worn they are press fitted in parallel.
outside surface up on the link press).
5) Measure the projections of the bushing on

2) Press fit the master links on both bushing both sides with a depth gauge.
sides to the bushing with the shoe fitting a Adjust the press fitting jig of the link
faces up. press so that the projections on both
a At this time, use the master links on sides will be even.
the pin side as supports.
68 – 108 kN {7 – 8 tons}
16 D85EX, PX-15E0
6) Send the master links and set the next pin 8) Using a shoe bolt hole pitch gauge, mea-
and bushing. sure the distance between the shoe bolt
a When reusing a pin, install it so that holes. When the distance is in the stan-
its side hole will be on the link tread dard range, stop press fitting.
side similarly to a new one. If it is not
installed so, its strength may be low-
ered. Accordingly, indicate the direc-
tion of the side hole on the end face
to prevent a mistake.
a If the outside of the pin is worn, install
it so that the un-worn surface will be
on the traction side. In this case,
install the pin so that its side hole will
be on the link tread side.
9) Assemble the master link on the pin side

at last.
a Check that the master links on both
sides are press fitted in parallel.
7) Set both links and operate both pushing

jigs to press fit the pin and bushing simul-
taneously.
a If the pin and bushing have play when
they are press fitted, the seal may
come off the link. To prevent this,
press fit smoothly. If the seal comes
off the link, stop press fitting and set
the seal to the link correctly, then start
press fitting again.
a Final pressing force for pin and bushing:
588 kN {60 tons}
Final pressing force C 1.8 × Average
press fitting force
(Adjust the relief pressure of the link
press to set the final pressing force.)
D85EX, PX-15E0 17
3. Installation of shoe 2) When installing the assembled 2-piece

1) Set the link assembly on the bed and track shoes, place them on a level place in
install the shoe with a shoe bolt impact 1 line with the shoe side up.
wrench and a torque wrench. 3) Pull pin-side master link (1) and bushing-
a When reusing (reversing) the bush- side master link (2) together and set them
ing, set the worn outside surface of to each other by the mating faces.
the bushing on the shoe fitting side of 4) Place and fit shoes (3) to the mating sur-
the link (set the bushing with the worn face of the links.
outside surface up on the link press). 5) Check that master bolt (4) can be tight-
2 Shoe bolt: Lubricant containing ened easily with the fingers, then connect
molybdenum disulfide (LM-P) the links with the master bolt.
3 Shoe bolt (Regular link): 2 Master bolt: Lubricant containing
q Single shoe: molybdenum disulfide (LM-P)
Initial torque: 3 Master bolt (Master link)
343 ± 39 Nm {35 ± 4 kgm} q Single shoe:
Retightening angle: 120° ± 10° Initial torque:
q Swamp shoe: 343 ± 39 Nm {35 ± 4 kgm}
–00
Initial torque: Retightening angle: 180° –20
539 ± 49 Nm {55 ± 5 kgm} q Swamp shoe:
Retightening angle: 120° ± 10° Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
–00
a Tighten the bolts in the order of 1 – 4.
18 D85EX, PX-15E0
Dimensions table of fitting jig of link press
Adjusting Precaution
Adjust the dimensions of the press fitting jig of the 1. The link receiving faces of jaw (5) must be ver-
link press to keep the projection of the pin and tical.
bushing constant and keep the installed dimen-
sions of the seal within the standard range. 2. Replaceable wear plate (6) shown below is
a If the pin end (part (P)) or the sides of the link desirable.
(parts (Q) and (R)) are worn, add the dimen-
sions of the worn parts when adjusting the
standard dimensions so that the projections of
the pins and bushings on both sides will be
even.
Unit: mm
Dimensions of jig
a b c
4 2.0 47.9
D85EX, PX-15E0 19
Disassembly of 1 link in the field 6. Apply high pressure to jack R2-7 gradually to
k Only how to use the tools is explained disconnect the link.
below.
For details of disassembly and assembly,
see “Whole disassembly (or assembly) of
track shoe”.
1. Using screw R2-4 and nut R2-3, install frame

R2-1 to the cylinder.
2. Using the screw, install adapter R2-5 to frame

R2-1.
3. Set extension R2-2 and pusher R2-6.
4. Apply hydraulic pressure to the hydraulic cylin-

der to pull out the 2 pins.
Assembly of 1 link in the field
1. Assemble the link sub-assembly.

1) Set tool R2-8 on the tread side of the link
and press fit bushing (1).
69 – 108 kN {7 – 11 tons}
5. Install jack R2-7 and spacer [1] of the following

size to the tread side of the link.
a If an electric pump is used, unnecessarily
high hydraulic pressure may be applied.
Accordingly, be sure use a hand pump.
Size of spacer:
Outside diameter 55 mm × Thickness 51 mm 2) Set tool R2-9 to the end of link (on the pin
side) and press fit pin (2).
a Set the pin with its side hole (a)
directed toward tread (b) of the link.
a Pressing force for ping:
206 – 255 kN {21 – 26 tons}
20 D85EX, PX-15E0
2. Set the link (3) to which link sub-assembly will 5. Connection of link
be connected. 1) Set lever block [2].
2) Install jack R2-7 and spacer [1] on the
tread side of the link and apply hydraulic
pressure to the jack until the link tip opens
by 6 – 8 mm.
3) Operate lever block [2] to align the link
hole and bushing hole, and then connect
the link with guide R2-11.
3. Set link (4) on the opposite side and support it

with tool R2-10.
4) After connecting the link with guide R2-11,

remove jack R2-7.
4. Set tool R2 as in the procedure for removing

the pin. Using tool R2-1, press fit the pin to link
sub-assembly (5).
a Pressing force for ping:
206 – 255 kN {21 – 26 tons}
D85EX, PX-15E0 21
6. Press fitting of pin Disassembly of master link

1) Using screw R2-4 and nut R2-3, install
frame R2-1 to the cylinder. 1. Removal of track shoe assembly
2) Using the screw, install adapter R2-5 to Remove the track shoe assembly from the
frame R2-1. chassis.
3) Set extension R2-2 and press fit pin (6).
a Set the pin with its side hole directed 2. Removal of master link
toward the tread of the link. 1) Cutting and removal of master link on
a Pressing force for ping: bushing side with gas
412 – 510 kN {42 – 52 tons} Cut the parts marked VVV with gas and
remove the hatched parts. Pull out master
links (8) and (9) by moving them in the
directions of white arrow. Furthermore,
remove pins (11) and (12) from regular link
(10) by pressing them with a press in the
directions of black arrow.
Special tool : Gas cutting machine
: Tool R
4) Remove adapter R2-5 and set adapter

R2-11 in the large hole.
5) Set pusher R2-12 to extension R2-2.
6) Apply the specified final pressing force to
the 2 link connecting parts to install.
2) Removal of master link on pin side

Cut the parts marked VVV with gas and
remove the hatched parts. Remove pin
(13) from link (14) by pressing it with a
press in the direction of white arrow, and
then remove pin (13) and link (15) from
bushing (16) simultaneously.
Special tool : Gas cutting machine
: Tool R
22 D85EX, PX-15E0
Assembly of master link 2) Set spacer (3) and seal assembly (4) to
the counterbore of the link at the connect-
1. Assembly of link on bushing side ing section.
1) Press fit master link (1) on the bushing
side to bushing (2) with a press.
a Press fit both master links in parallel.
a Do not damage the mating faces of the
master links and end of the bushing.
Unit: mm
L1 146
L2 182.8
D1 25 drill
D2 22 × 2.0
3) Align the holes of the pin and bushing (7)

and connect with guide pin R2-11.
2. Installation of link on bushing side

1) Expand the central part of the link tread
with tool R2-7 as shown in the figure
(Expand the link tip by 6 – 8 mm).
(a): 5 mm 4) Press fit pin (5) with tool R2 and install
master link (1) on the bushing side.
a Direct the side hole of the pin toward
the link tread.
D85EX, PX-15E0 23
5) Install the shoe to the link at the connect- 2) Pass bushing (8) and pin (9), set master
ing section. links (10) on the pin side from both sides,
6) Drive in large plug (6) with tool R5, add oil and press fit them with tool R2.
with tool R8, and drive in small plug (7) 3) Drive in large plug (11) with tool R5, add
with R5. oil with tool R8, and drive in small plug
a Press fit both master links in parallel (12) with R5.
(on bushing side and pin side).
a Do not damage the mating faces of the
master links and end of the bushing.
a The end play of the connecting sec-
tion (the play of the links before and
after the pin in the thrust direction)
must be 0 – 0.13 mm.
a Take care extremely that dirt or sand
will not stick to the seal, spacer, ends
of bushing, and mating face of the
tapped hole.
4. Connection of master link

1) Place the assembled 2-piece track shoes on
a level place in 1 line with the shoe side up.
2) Pull pin-side master link (13) and bushing-
side master link (14) together and set
them to each other by the mating faces.
3) Place and fit the shoes to the mating sur-
face of the links.
4) Check that master bolt (15) can be tight-
ened easily with the fingers, then connect
the links with the master bolt (15).
3. Installation of link on pin side 2 Master bolt: Lubricant containing
1) Set spacer (3) and seal assembly (4) to molybdenum disulfide (LM-P)
the counterbore of the master link. 3 Master bolt (Master link)
q Single shoe:
Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
–00
q Swamp shoe:
Initial torque:
343 ± 39 Nm {35 ± 4 kgm}
–00
24 D85EX, PX-15E0
Removal and installation of pivot Installation

shaft assembly 1 q Carry out installation in the reverse order to
removal.
Removal
[*1]
1. Remove the track frame assembly. For details, 2 Mounting bolt: Adhesive (LT-2)
see “Removal and installation of track frame 3 Mounting bolt:
assembly”. 823 – 1,029 Nm {84 – 105 kgm}
2. Remove the mounting bolts of pivot shaft assem- [*2]

bly (1) (Leave 2 – 3 of them, however). [*1] a Install the seal according to the following pro-
cedure.
3. Sling pivot shaft assembly (1) temporarily and 1) Reverse the seal (2) so that the relief let-
pull it out, using forcing screw [1]. ters (a) will be on the inside.
4
2) Install the reversed seal (2) to the shaft
Pivot shaft assembly: 100 kg
(1).
2 Seal: Oil (EO-30)
4. Remove seal (2) from pivot shaft assembly (1).

[*2]
a Use tool [2] to press fit ring (4).
q Press fitting of force:
23.2 – 42.7 kN {2.37 – 4.35 tons}
a Check that press fitting dimension (a) of the
seal from the shaft end is proper.
q Press fitting dimension (a): 412 ± 1mm
D85EX, PX-15E0 25
Removal and installation of

equalizer bar assembly 1
Removal
1. Remove engine undercover (1) and power

train undercover (2).
5. Remove grease hose (8).
6. Remove lock plate (9). [*3]
2. Set a hydraulic jack under the center of the

equalizer bar to raise the front part of the chas-
sis and set stand [1] under the frame to float
the front part.
7. Set jack [2] at the center of equalizer bar cen-

ter pin (10).
3. Remove 2 bolts (4) and cover (5). [*1]
4. Remove lock plate (6) and side pin (7). [*2]

a If the equalizer bar hole and track frame
hole are not aligned, the pin cannot be
removed easily. Adjust the hanging height
of the track frame properly.
a Repeat steps 3 and 4 to remove the pin on
the opposite side.
k If the track frame assembly on the
opposite side is floated before the pin
is pulled out, support it on a block, etc.
26 D85EX, PX-15E0
8. Using tool [3], pull out center pin (10). [*4] Installation
9. Lower and remove equalizer bar (13) by oper- removal.
ating jack [2].
4 Equalizer bar assembly: [*1]
3 Mounting bolt:
D85EX-15E0; 158 kg
D85PX-15E0; 204 kg 319 – 608 Nm {32.5 – 62 kgm}
[*2]
k When aligning the pin holes, never insert

your fingers in them.
a Before installing the side pin, adjust the hang-
ing height on the track frame to align the hole
of the equalizer bar with the hole on the track
frame side.
a Direct the grease hole of the pin forward.
2 Equalizer bar side bushing:
Grease (G2-LI)
3 Mounting bolt:
54 – 123 Nm {5.5 – 12.5 kgm}
[*3]
3 Mounting bolt:
147 – 309 Nm {15 – 31.5 kgm}
[*4]
kWhen aligning the pin holes, never insert
a Before installing the center pin, adjust the jack
[2] to align the hole of the equalizer bar with
the hole on the track frame side.
2 Equalizer bar bushing and main frame bushing:
Grease (G2-LI)
D85EX, PX-15E0 27
Disassembly and assembly of 3. Center bushing

equalizer bar assembly 1 Remove center bushing (5) from equalizer bar
(4).
Disassembly
1. Remove the equalizer bar. For details, see

“Removal and installation of equalizer bar”.
2. Side bushing
1) Remove seal (1).
2) Remove ring (2).
3) Using tool [1], remove spherical bushing

(3) from equalizer bar (4).
28 D85EX, PX-15E0
Assembly 3) Install ring (2) on the opposite side.

4) Using the press, press fit seal (1).
1. Center bushing a Press fitting force for seal:
Using a press, press fit center bushing (5) to 57.8 – 161.7 kN {5.9 – 16.5 tons}
equalizer bar (4). 2 Periphery of spherical bushing:
a Press fitting force for center bushing: Lubricant containing molybde-

57.8 – 161.7 kN {5.9 – 16.5 tons} num disulfide (LM-P)
2 Periphery of spherical bushing: 2 Between spherical bushing and seal:
Lubricant containing molybdenum Grease (G2-LI)

disulfide (LM-P)
2. Side bushing
1) Install ring (2) to one side of equalizer bar
(4).
2) Using the press, press fit spherical bush-
ing (3) to equalizer bar (4).
a Press fitting force for spherical bushing:
49 – 118 kN {5 – 12 tons}
2 Periphery of spherical bushing:
Lubricant containing molybdenum
disulfide (LM-P)
D85EX, PX-15E0 29
SEN01269-00

© 2006 KOMATSU
All Rights Reserved
30
SEN01270-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Hydraulic system
Hydraulic system............................................................................................................................................. 2
Removal and installation of work equipment control valve assembly .................................................. 2
Disassembly and assembly of work equipment control valve assembly .............................................. 5
Removal and installation of HSS and work equipment pump assembly .............................................. 6
Removal and installation of power train and lubricating oil pump assembly ........................................ 8
Removal and installation of fan pump assembly .................................................................................. 9
Removal and installation of scavenging pump assembly................................................................... 10
Removal and installation of HSS motor assembly ..............................................................................11
Disassembly and assembly of hydraulic cylinder assembly............................................................... 12
D85EX, PX-15E0 1
Hydraulic system 1
Removal and installation of work 5. Disconnect the following hoses.
equipment control valve assembly1 q (6): Hydraulic tank return hose
q (7): Fan motor drain hose
Removal q (8): Cooler return hose
terminal of the battery. 6. Remove hose clamp plate (9).
k Lower the work equipment to the ground.
Referring to Testing and adjusting, “Releasing
residual pressure in work equipment cylin-
der”, release the residual pressure in the pip-
ing and lock the work equipment lock lever.
a Plug the disconnected pipes and hoses to pre-
vent foreign matter from entering them.
a Put tags to the disconnected pipes and hoses
to prevent a mistake in re-connecting them.
1. Drain the oil.

6 Hydraulic tank:
7. Disconnect the right PPC hoses. [*1]
2. Remove covers (1) and (2) from the right side q (11): Ripper lift cylinder RAISE hose cou-
of the chassis. pler (Port PA4) • Color band: Black
q (12): Blade lift cylinder LOWER hose cou-
pler (Port PA3) • Color band: Black
q (13): Blade tilt cylinder LEFT tilt hose cou-
pler (Port PA2) • Color band: Yellow
8. Disconnect hose (14) for the right of the HSS

(Port PA1).
3. Disconnect solenoid connector HSA (3) for the

left of the HSS and solenoid connector HSB (4)
for the right of the HSS.
4. Remove PPC hose clamp (5).
2 D85EX, PX-15E0
9. Disconnect the left PPC hoses. [*2] 11. Disconnect the following 8 work equipment
q (15): Ripper lift cylinder LOWER hose hoses.
coupler (Port B4) • Color band: None q (19): Ripper lift RAISE hose (Port A4)
q (16): Blade lift cylinder RAISE hose cou- q (20): Ripper lift LOWER hose (Port B4)
pler (Port B3) • Color band: None q (21): Blade lift RAISE hose (Port A3)
q (17): Blade tilt cylinder RIGHT tilt hose q (22): Blade lift LOWER hose (Port B3)
coupler (Port B2) • Color band: q (23): Blade tilt RIGHT hose (Port A2)
Green q (24): Blade tilt LEFT hose (Port B2)
q (25): HSS motor LEFT hose (Port A1)
q (26): HSS motor RIGHT hose (Port B1)
12. Disconnect drain hose (27).
13. Disconnect main hose (28).
10. Disconnect hose (18) for the left of the HSS

(Port PB1).
14. Disconnect LS hose (29).
D85EX, PX-15E0 3
15. Remove 4 work equipment control valve

mounting bolts (30).
16. Lift off work equipment control valve assembly

(31).
4 Work equipment control valve assembly:
125 kg

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic tank:
Installation
q Carry out installation in the reverse order to q Bleeding air
removal. Bleed air from the piping. For details, see Test-
ing and adjusting, “Bleeding air from work
[*1] [*2] equipment cylinders”.
q The connecting positions of the PPC hoses are
indicated by their band colors. When installing
them, check their band colors.
a Positions of PPC ports of work equipment
control valve assembly
q PA4 (Ripper lift cylinder RAISE port)
q PA3 (Blade lift cylinder LOWER port)
q PA2 (Blade tilt cylinder LEFT tilt port)
q PA1 (Port for right of HSS)
q PB4 (Ripper lift cylinder LOWER port)
q PB3 (Blade lift cylinder RAISE port)
q PB2 (Blade tilt cylinder RIGHT tilt port)
q PB1 (Port for left of HSS)
a Positions of ports of work equipment con-
trol valve assembly
q A4 (Ripper lift RAISE port)
q B4 (Ripper lift LOWER port)
q A3 (Blade lift LOWER and FLOAT port)
q B3 (Blade lift RAISE port)
q A2 (Blade tilt LEFT port)
q B2 (Blade tilt RIGHT port)
q A1 (HSS motor RIGHT port)
q B1 (HSS motor LEFT port)
q TS (Drain port)
q P1 (Main port)
q LS (LS port)
4 D85EX, PX-15E0

work equipment control valve
assembly 1
a Only the precautions for assembling the work

equipment control valve assembly are
described in this section.
a For the tightening torque of each part, see “Struc-
ture, function and maintenance standard”.
Assembly
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with
engine oil before installing.
a When assembling the suction valve, check that
the spring is installed normally in the sleeve.
a When assembling a relief valve or a plug,
check that the cut part of the backup ring is
closed and apply grease (G2-LI) to the periph-
ery of the backup ring.
a After installing the main relief valve assembly,
adjust it, referring to Testing and adjusting,
“Testing and adjusting work equipment hydrau-
lic pressure”.
D85EX, PX-15E0 5
Removal and installation of HSS 7. Disconnect oil pressure sensor connector HHP
and work equipment pump (4) and disconnect wiring harness clamp (5).
assembly 1 8. Disconnect TVC valve solenoid connector TVC
(6).
Removal
9. Remove hose clamp bracket (7).
10. Disconnect pump hoses.
1. Drain the oil.
q (8): Discharge hose
6 Hydraulic tank: q (9): LS pressure hose
D85EX-15E0; Approx. 120 l q (10): Drain hose

assembly”.
3. Remove the operator's cab assembly. For

details, see “Removal and installation of opera-
tor's cab assembly”.

assembly”.

11. Remove 4 suction tube mounting bolts (11).
12. Remove 1 pump lower mounting bolt (12).
6. Remove cover (2) and floor frame mount

bracket (right side) (3).
6 D85EX, PX-15E0
13. Sling the pump assembly temporarily and Installation

remove mounting bolts (13). q Carry out installation in the reverse order to
removal.

Add oil through the oil filler to the specified
through the system. Then, check the oil level
again.
5 Hydraulic tank:
q Bleeding air
Bleed air from the HSS and work equipment
pump. For details, see Testing and adjusting,
14. Lift off pump assembly (14). “Bleeding air from HSS and work equipment
pump”.
4 Pump assembly: 113 kg
D85EX, PX-15E0 7
Removal and installation of power Installation

train and lubricating oil pump q Carry out installation in the reverse order to
assembly 1 removal.
Removal

assembly”.
2. Remove the operator's cab assembly. For

details, see “Removal and installation of opera-
tor's cab assembly”.

assembly”.
4. Remove tube clamp (1).
5. Disconnect the pump hose and tubes.

q (2): Power train pump discharge hose
q (3): Lubricating oil pump discharge tube
q (4): Pump suction tube
6. Sling pump assembly (5) temporarily, remove

the 2 mounting bolts, and then lift off pump
assembly (5).
8 D85EX, PX-15E0
Removal and installation of fan 8. Disconnect EPC valve connector FAC (4).
pump assembly 1
9. Disconnect pump hoses.
Removal q (5): Discharge hose
k Disconnect the cable from the negative (–) q (6): EPC valve basic pressure input hose
terminal of the battery. q (7): Drain hose
1. Drain the oil.

6 Hydraulic tank:

assembly”.
3. Remove the operator's cab assembly. For details,

assembly”.
4. Remove the floor frame assembly. For details, 10. Sling the pump assembly temporarily and
see “Removal and installation of floor frame remove mounting bolts (8).
assembly”.
11. Lift off pump assembly (9).
6. Remove tube clamp U-bolt (2).
7. Remove 4 suction tube mounting bolts (3). Installation

removal.

Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
5 Hydraulic tank:
q Bleeding air
Bleed air from the fan pump. For details, see
Testing and adjusting, “Bleeding air from fan
pump”.
D85EX, PX-15E0 9
Removal and installation of 5. Remove 2 mounting bolts (4) and scavenging

scavenging pump assembly 1 pump assembly (5).
Removal
Installation
removal.

2. Drain the power train oil. Add oil through the oil filler to the specified
6 Power train case: Approx. 100 l through the system. Then, check the oil level
again.
3. Disconnect suction tube (2). 5 Power train case: Approx. 100 l
4. Disconnect discharge hose (3).
10 D85EX, PX-15E0
Removal and installation of HSS Installation

motor assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Remove the fuel tank assembly. For details,

see “Removal and installation of fuel tank
assembly”.
2. Disconnect the motor hoses.

q (1): Main hose (Port PA)
q (2): Main hose (Port PB)
q (3): Drain hose
3. Sling motor assembly (4) temporarily, remove

the 2 mounting bolts, and then lift off motor
assembly (4).
4 Motor assembly: 42 kg
D85EX, PX-15E0 11
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1
1. Cylinder tube
Special tools q Blade lift cylinder
1) Remove 2 clamps (1).
New/Remodel
2) Remove cylinder tube (2).
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
Cylinder head repair

790-502-1003 t 1
1 stand
2 790-102-3802 Wrench t 1
790-302-1310 Socket Blade lift t 1
3 790-302-1350 Socket Blade tilt t 1
790-302-1340 Socket Ripper lift t 1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
4 • 790-201-1791 Blade lift 1 q Ripper lift cylinder
• 790-201-1821 • Push Blade tilt 1 1) Remove 2 U-bolt clamps (3).
tool Ripper lift 1
2) Remove 2 cylinder tubes (4) and (5).
• 790-201-1811 3) Remove bracket (6).
Ripper tilt 1
U
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
5 • 790-201-1610 Blade lift 1
• 790-201-1630 Blade tilt 1
• Plate
Ripper lift 1
• 790-201-1620
Ripper tilt 1
6 790-720-1000 Expander t 1
796-720-1660 Ring t 1
Blade lift
07281-01159 Clamp t 1
796-720-1680 Ring t 1
7 Blade tilt
07281-01589 Clamp t 1
796-720-1670 Ring t 1
Ripper lift
07281-01279 Clamp t 1
12 D85EX, PX-15E0
2. Piston rod assembly 3. Piston assembly

q Blade lift and ripper lift cylinders q Blade lift cylinder
1) Set the cylinder assembly to tool U1. 1) Set piston rod assembly (11) to tool U1.
2) Using a hydraulic pump or a power wrench,
disconnect head assembly (7) from the cyl-
inder with tool U2.
3) Pull piston rod assembly (8) out of cylinder
(9).
a Put an oil pan, etc. under the cylinder
to receive oil.
2) Using tool U3, remove nut (12) from the

cylinder.
3) Remove collar (13) and sleeve (14), and
then remove piston assembly (15) from
piston rod (16).
4) Remove retainer (17) and sleeve (18).
q Blade tilt cylinder

1) Remove the mounting bolts and disconnect
head assembly (10).
2) Pull piston rod assembly (11) out of cylinder
(12).
a Put an oil pan, etc. under the cylinder
to receive oil.
5) Disassemble the piston assembly accord-

ing to the following procedure.
i) Remove 2 wear rings (19).
ii) Remove piston ring (20) from the piston.
a Do not remove 6 seats (21) and 3 pis-
ton valves (22).
D85EX, PX-15E0 13
q Blade tilt and ripper lift cylinders 2) Disassemble the head assembly accord-
1) Set piston rod assembly (23) to tool U1. ing to the following procedure.
2) Using tool U3, remove nut (24) from the i) Remove O-ring (29) and backup ring
cylinder. (30).
3) Remove piston assembly (25) from piston ii) Remove snap ring (31) and dust seal
rod (23). (32).
iii) Remove packing (33) and bushing (34).
4) Remove wear ring (26) and piston ring

(27) form the piston assembly.
4. Head assembly
1) Remove head assembly (7) or (10) from
piston rod (8) or (11).
14 D85EX, PX-15E0
Assembly 2) Fit the O-ring and install head assembly

a Take care not to damage the packings, dust (7) or (10) to piston rod (8) or (11).
seals, O-rings, etc.
a Clean the all parts. After installing them, cover
the piping ports and pin holes to prevent dirt
from entering.
1. Head assembly
1) Assemble head assembly (7) according to
the following procedure.
i) Using tool U4, press fit bushing (34).
ii) Install packing (33).
iii) Using tool U5, install dust seal (32).
iv) Install snap ring (31).
v) Install O-ring (29) and backup ring (30).
a When installing the backup ring,
warm it in water at 50 – 60°C.
2. Assembly of piston assembly
1) Set piston ring (27) to tool U6 and turn the
handle 8 – 10 times to expand the piston
ring.
2) Remove piston ring (27) from tool U6 and
install it to the piston.
3) Using tool U7, shrink piston ring (27).
4) Install wear ring (26).
D85EX, PX-15E0 15
3. Piston assembly q Blade tilt and ripper lift cylinders

Set piston rod (11) to tool U1. 1) Set piston rod assembly (23) to tool U1.
2) Install piston assembly (25) to piston rod
(23).
3) Using tool U3, tighten nut (24) onto the
cylinder.
2 Piston rod: Adhesive (LT-2)
3 Mounting nut:
Blade tilt cylinder:
5.20 ± 0.52 kNm {530 ± 53 kgm}
Ripper lift cylinder:
3.97 ± 0.40 kNm {405 ± 40.5 kgm}
q Blade lift cylinder

1) Install retainer (17) and sleeve (18).
2) Install piston assembly (15) to piston rod
(16), and then install sleeve (14) and col-
lar (13).
3) Using tool U3, tighten nut (12) onto the
cylinder.
2 Piston rod: Adhesive (LT-2)
3 Mounting nut:
2.16 ± 0.22 kNm {220 ± 22 kgm}
4. Piston rod assembly
q Blade lift and ripper lift cylinder
1) Set cylinder (9) to tool U1.
2) Insert piston rod assembly (8) in cylinder
(9).
a Push in the piston rod to the stroke end.
2 Sealing part: Grease (G2-LI)
3) Using a hydraulic pump or a power
wrench, install head assembly (7) to the
cylinder with tool U2.
3 Head assembly:
Blade lift cylinder:
785 ± 78.5 Nm {80 ± 8.3 kgm}
Ripper lift cylinder:
1.03 ± 0.10 Nm {105 ± 10.5 kgm}
16 D85EX, PX-15E0
q Blade tilt cylinder

1) Set cylinder (12) to tool U1.
2) Insert piston rod assembly (11) in cylinder
(12).
a Push in the piston rod to the stroke end.
2 Sealing part: Grease (G2-LI)
3) Tighten the mounting bolts of head
assembly (10).
3 Head assembly:
250 ± 25 Nm {25.5 ± 2.5 kgm}
D85EX, PX-15E0 17
SEN01270-00

© 2006 KOMATSU
All Rights Reserved
18
SEN01271-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Removal and installation of blade assembly ........................................................................................ 2
Disassembly and assembly of ripper assembly ................................................................................... 4
D85EX, PX-15E0 1
Work equipment 1
Removal and installation of blade
assembly 1
Removal
k Lower the work equipment horizontally to
the ground and set blocks [1] to the right
and left straight frames securely.
4. Similarly, disconnect the lift cylinder assembly

on the opposite side from the blade.
k Release the residual pressure in the work
equipment cylinders. For details, see Test-
ing and adjusting, “Releasing residual
pressure in work equipment cylinders”.
1. Remove cap (1) of the lift cylinder assembly. [*1] 5. Remove left and right covers (4).
a Check the quantity and thickness of the
shims.
6. Disconnect 2 tilt hoses (5) from the right straight

frame.
2. Sling lift cylinder assembly (2) temporarily. a Make distinction marks to the hoses and plug
Run the engine and retract the piston fully. them so that dirt will not enter the piping.
3. Using blade (3), fix lift cylinder assembly (2) to

the radiator guard.
a Bind the piston rod with wires, etc. so that
it will not come out.
2 D85EX, PX-15E0
7. Remove left and right trunnion caps (6). [*2]

a Adjust height (b) and width (c) of both straight
8. Remove blade assembly (7). [*2] frames to the following values with blocks [1],
a Run the engine and move the machine etc.
slowly in reverse to disconnect the blade q Height (b) of trunnion: 535 mm
assembly from the trunnion. q Width of frame (c): 2,762 mm
4 Blade assembly:
Straight tiltdozer; D85EX-15E0: 3,305 kg
D85PX-15E0: 3,343 kg
Semi-tiltdozer; D85EX-15E0: 3,575 kg
Installation
removal.
[*1]
a Adjust clearance (a) at the cap mating sur-
faces to the following value with the shim and
check that the trunnion turns smoothly.
q Standard clearance (a): 0.2 – 0.5 mm q Refilling with oil (Hydraulic tank)
q Standard shim thickness: 4 mm Add oil through the oil filler to the specified level.
a After installing the blade, adjust the blade tilting Run the engine to circulate the oil through the
distance. For details, see Testing and adjust- system. Then, check the oil level again.
ing, “Adjusting blade”.
q Bleeding air
Bleed air from the work equipment cylinders.
For details, see Testing and adjusting, “Bleed-
ing air from work equipment cylinders”.
1) Remove cover (10).
D85EX, PX-15E0 3

ripper assembly 1
For D85EX-15E0
Disassembly
1. Set jacks [2] under the respective centers stand

[1] of the arm and beam of the ripper assembly.
k Lower the blade and apply and lock the
brake securely.
6. Sling beam (6) temporarily and remove the

lock bolt of the pin.
7. Remove pin (7) and beam (6).

a Remove the beam on the opposite side
similarly.
4 Beam (with 3 shanks): 1,580 kg
2. Sling link (1) temporarily and remove the lock

bolt of the pin.
3. Remove pin (2) and link (1).

a Remove the pin and link on the opposite
side similarly.
4 Link: 56 kg
8. Remove stands [1] and set them under left and

right sides of the arm.
4. Sling lift cylinder assembly (3) temporarily and

2 disconnect hoses (4).
5. Remove the lock bolt of the pin, and then

remove the pin (5).
a Lower the lift cylinder assembly onto the
arm, inserting a block between them.
a Remove the pin on the opposite side simi-
larly.
4 D85EX, PX-15E0
9. Sling lift cylinder assembly (3) temporarily and 11. Sling arm (9) and remove stand [1].
remove the lock bolt of pin (8).
12. Pull out pin (8) and remove arm (9).

10. Pull out pin (8) and remove lift cylinder assembly a Pull out pin (8) to a position at which you
(3). can remove arm (9).
a Pull out pin (8) to a position at which you
4 Arm: 345 kg
can remove the lift cylinder assembly.
a Remove the lift cylinder assembly on the
opposite side.
4 Lift cylinder assembly: 87 kg
13. Sling bracket (10) temporarily and remove 4

bolt (11), 2 nuts (12), and bracket (10).
a Remove the bracket on the opposite side
similarly.
4 Bracket: 107 kg
D85EX, PX-15E0 5
Assembly 4. Sling lift cylinder assembly (3) and install it to

arm (9).
1. Sling and install bracket (10) and secure it with a Lower the lift cylinder assembly onto the
4 bolts (11) and 2 nuts (12). arm, inserting a block between them.
a Install the bracket on the opposite side
similarly.
3 Bolt: 225 ± 25 Nm {23 ± 2.6 kgm}
Nut: 225 ± 25 Nm {23 ± 2.6 kgm}
5. Insert pin (8) and tighten the lock bolt.
2. Sling arm (9) and install pin (8) to bracket (10).

a Insert pin (8) to a position to install arm (9).
a Install the arm on the opposite side similarly.
6. Remove stands [1] and set them under the

center of arm (9).
3. Set stands [1] under both sides of arm (9).
6 D85EX, PX-15E0
7. Sling beam (6) and install it to arm (9). 10. Connect lift cylinder hose (4).
8. Insert pin (7) and tighten the lock bolt. 11. Sling lift cylinder assembly (3) temporarily.
k When aligning the pin holes, never
insert your fingers in them. 12. Run the engine and extract the piston rod to
a Install the beam on the opposite side simi- align the pin holes.
larly. k When aligning the pin holes, never insert
13. Install pin (5) and tighten the lock bolt.

a Install the lift cylinder assembly on the
opposite side similarly.
9. Set jack [2] at the center of the beam.
14. Sling link (1), align the pin holes, install pin (2),
and tighten the lock bolt.
a Install the link on the opposite side simi-
larly.
D85EX, PX-15E0 7
15. Run the engine, raise the ripper assembly, and

remove stands [1] from under the arm and jack
[2] from the center of the beam.
q Bleeding air
a Bleed air from the work equipment cylin-
ders. For details, see Testing and adjust-
ing, “Bleeding air from work equipment
cylinders”.
a Supply grease (G2-LI) to each connecting
pin.
8 D85EX, PX-15E0
SEN01271-00

© 2006 KOMATSU
All Rights Reserved
10
SEN01272-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Cab and its attachments
Cab and its attachments ................................................................................................................................. 2
Removal and installation of ROPS guard assembly ............................................................................ 2
Removal and installation of operator’s cab assembly .......................................................................... 3
Removal and installation of operator’s cab glass (Stuck glass) ........................................................... 9
Removal and installation of floor frame assembly.............................................................................. 18
D85EX, PX-15E0 1
Cab and its attachments 1

Removal and installation of ROPS Installation
guard assembly 1 q Carry out installation in the reverse order to
removal.
Removal
[*1]
1. Sling ROPS guard (1) temporarily. 3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
2. Remove mounting bolts (2). [*1]
3. Lift off ROPS guard (1).

4 ROPS guard: 371 kg
2 D85EX, PX-15E0
Removal and installation of 5. Remove rear cover (5).

operator’s cab assembly 1
Removal
1. Remove the ROPS guard. For details, see

“Removal and installation of ROPS guard”.
2. Remove floor mat (1).
6. Remove right cover (6).
3. Remove the mounting bolts of left cover (2).
7. Remove both foot rests (7) and cover (8).
4. Turn over cover (2), disconnect cigarette lighter

connector CIG (3) and accessory socket connec-
tor ACC (4), and remove cover (1). [*1]
D85EX, PX-15E0 3
8. Remove hot and cool box (9). 11. Open battery case cover (13).
9. Remove dashboard mounting bracket (10). 12. Disconnect 4 washer hoses (14). [*2]
13. Disconnect connectors (15), (16) and (17). [*3]

a After disconnecting the connectors and
hoses, pull out grommet (18) in the operator’s
cab.
10. Disconnect antenna connectors KOM2 and

KOM3 (12) from KOMTRAX controller (11).
4 D85EX, PX-15E0
14. Remove mounting bolts (19) in the operator’s Installation

cab. q Carry out installation in the reverse order to
a Remove 5 bolts in the rear and 4 respec- removal.
tive bolts on both sides.
[*1] [*3]
a When connecting the connectors, take care
not to mistake their Nos.
[*2]
a After connecting the windshield washer hose
and connector, securely install the grommet to
the through hole of the cab.
Arrangement of seals
15. Remove 4 respective mounting bolts (20) at

both doors of the operator’s cab.
16. Lift off operator's cab assembly (21).

a When lifting off the operator’s cab assembly,
check that all the wire are disconnected.
4 Operator’s cab assembly: 410 kg
q Installation of seals to air conditioner box

1) Remove dirt, oil, and grease from the top of
the floor frame to apply gasket sealant (32).
2) Apply the gasket sealant to the top of the
floor frame.
q For the parts to apply the gasket seal-
ant, see view (Z) above. (Hunting of
position (A))
2 (32): Threebond 1207B
3) Fit seal (30) to the guide plate of the air
conditioner box.
2 Inside of seal: Adhesive (LT-1A)
a Pull down seal (30) to press the gas-
ket sealant applied in 2).
a Fill the clearance between seal (30)
and floor frame with adhesive (LT-1A).
D85EX, PX-15E0 5
4) Apply grease (G2-LI) to the outside of seal 8) Cut seal (22) flush with seal (23). (See figure
(30) (sealing face against the cab). P.)
a Apply grease so that the cab will slip q Fit part (k) (the joint) to eliminate
well and the seal will not be moved or clearance.
deformed when the cab is installed. 9) Seal (31) to the groove first, and then stick
seal (23). (See section A – A.)
q Installation of seals of operator's cab mating

faces
1) Sling the operator’s cab assembly.
2) Remove dirt, oil, and grease from the seal
fitting surfaces.
k Do not stand under the operator’s
cab.
3) Referring to the figure, stick seals (22),
(23), (24), (25), and (31).
4) Stick the seals in the order of (22), (31),
(23), (24), and (25).
5) Fit end part (h) of seal (22) to the air con-
ditioner box to eliminate clearance.
6) Fit part (j) (the joint) to eliminate clearance.
7) Use the excessive part of seal (22) as seal
(24).
a Cab seen from bottom
6 D85EX, PX-15E0
q When installing the operator’s cab, obey the

following points.
1) Lower the operator’s cab assembly onto
the floor frame slowly.
a Since the reaction force of the seal
sponge is large, lower the operator's
cab assembly slowly.
a Check that the air conditioner duct
seal on the cab side is tightly in con-
tact with the air conditioner duct on
the dashboard side and there is not
clearance.
a Since the clearance between the air
conditioner duct on the cab side and
the monitor is narrow, lower the oper-
ator's cab assembly carefully.
2) Tighten the mounting bolts temporarily.
3) Check that the seal between air condi-
tioner bracket (17) and cab (18) is fitted
securely.
4) Check that there is not clearance at joint
(a) of the seal and floor frame.
5) Check that clearance (e) between cab-side

air conditioner duct (26) and monitor (27) is
even on both sides. At the same time, check
that cab-side air conditioner duct seal (f) is
fitted to faces (C) on both sides of dash-
board-side air conditioner duct (28) without
deviating to the right or left.
a If clearance (e) between the cab-side
air conditioner duct and monitor is not
even, loosen the mounting screws of
the cab-side air conditioner duct and
move the duct so that the clearance
will be even. Similarly correct the
deviation of the cab and air condi-
tioner to the right or left, if necessary.
6) Tighten the mounting bolts of the dash-
board mounting bracket.
7) Measure the internal pressure. For details,
see “Testing and adjusting operator ’s
cab”.
D85EX, PX-15E0 7
q Parts to be installed before operator’s cab is

mounted
1) Install open lock stopper mounting grip (29).
2) Install cab mounting L-plate (10) to the cab

temporarily.
8 D85EX, PX-15E0
Removal and installation of operator’s cab glass (Stuck glass) 1
* Among the panes of window glass of the oper- (1) : Front window glass
ator’s cab, the 3 panes of (1) and (2) on both (2) : Left door window glass
sides are stuck. In this section, the procedure : Right door window glass
for replacing the stuck glass is explained. (3) : Both-sided adhesive tape
(4) : Trim seal
(5) : Door handle
D85EX, PX-15E0 9
Special tools (The following figure shows the operator’s cab of a

wheel loader.)
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
Lifter
X 1 793-498-1210 t 2
(Suction cup)
Removal
a Remove the window glass to be replaced
1. Using seal cutter [1], cut the adhesive between

broken window glass (6) and operator’s cab a If the window glass is broken finely, it may
(metal sheet) (7). be removed with knife [4] and a screw-
driver.
a Widening the cut with a screwdriver, cut
the adhesive and both-sided adhesive
tape with knife [4].
(The following figure shows the operator’s cab of a

wheel loader.)
a If a seal cutter is not available, make holes on

the adhesive and both-sided adhesive tape
with a drill and pass a fine wire (piano wire,
etc.) [2] through the holes. Grip the both ends
of the wire with pliers [3], etc. (or hold them by
winding them onto something) and move the
wire to the right and left to cut the adhesive
and both-sided adhesive tape. Since the wire 2. Remove the window glass.
may be broken by the frictional heat, apply
lubricant to it.
10 D85EX, PX-15E0
Installation 3. Stick both-sided adhesive tape (3) along the

inside edges of the front window glass sticking
1. Using a knife and scraper [5], remove the section and both door window glass sticking
remaining adhesive and both-sided adhesive sections.
tape from the metal sheets (glass sticking sur- a Do not remove the release tape of the
faces) of the operator’s cab. both-sided adhesive tape on the glass
a Remove the adhesive and both-sided adhe- sticking side before sticking the glass.
sive tape to a degree that they will not affect a When sticking the both-sided adhesive
adhesion of the new adhesive. Take care tape, do not touch the cleaned surface as
not to scratch the painted surfaces. long as possible.
(If the painted surfaces are scratched, adhe- a Take care that the both-sided adhesive
sion will be lowered.) tape will not float at each corner of the
window frame.
(The following figure shows the operator’s cab of a a Do not lap the finishing end of both-sided
wheel loader.) adhesive tape (3) over the starting end but
make clearance (a) of about 5 mm
between them.
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (7) and window glass (8) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
D85EX, PX-15E0 11
4. Install trim seals (4) to both door window 5. Position the new window glass.
glasses (2). 1) Using tool X1, set the window glass to the
sticking position. Check the clearance
between the window glass and the opera-
tor’s cab on the right, left, upper, and lower
sides, and then adjust it evenly.
a Position front window glass (1) from
inside of operator’s cab (7). Adjust it
so that the difference between black
coated part and the metal sheet of
operator’s cab (7) will be even on the
right, left, upper, and lower sides.
a When positioning each door window
glass (2), align handle holes (d) of
door (9) (on the glass side and door
metal sheet side) first.Then, adjust
the door window glass so that the
a Install each trim seal (4) so that its finish- positional relationship between it and
ing end and starting end will be jointed at door metal sheet will be even all
position (c) and dimension (b) between around the window.
the corner and position (c) will be 90 mm.
2) After positioning the glasses, stick tapes
[6] between front window glass (1) and
operator’s cab (7) and the right, left, and
lower parts of each door window glass (2)
and each door (9), and then draw position-
ing line (e).
3) Cut the tapes between window glasses (1)
and (2) and operator’s cab (7) with a knife,
and then remove the window glasses.
a Do not remove the tapes left on the
window glasses and operator’s cab
before installing the window glasses.
12 D85EX, PX-15E0
1) Break aluminum seal (11) of the outlet of

adhesive cartridge (10) and install the
nozzle.
6. Apply adhesive.
2 Adhesive: Sikaflex 256HV manufactured
by Sika Japan
a Do not use primer. 2) Cut the tip of the adhesive nozzle (12) so
a The using limit of the adhesive is 6 months that dimensions (f) and (g) will be as follows.
after the date of manufacture. Do not use q Dimension (f) : 10 mm
the adhesive after this limit. q Dimension (g): 15 mm
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
3) Set adhesive cartridge (10) to caulking

gun [7].
a An electric caulking gun is more efficient.
D85EX, PX-15E0 13
4) Remove release tape of the both-sided a Apply adhesive (13) to dimensions (h) and
adhesive tape (3a) on the glass side. (j) of both-sided adhesive tape (3) of oper-
ator’s cab (7).
q Dimension (h): 10 mm
q Dimension (j) : 15 mm
a Apply adhesive (13) higher than both-
sided adhesive tape (3).
a Apply the adhesive evenly.
5) Apply adhesive (13) to the outside of both-

sided adhesive tape (3) of the operator’s
cab.
7. Install the front window glass.

1) Using tool X1, match front window glass
(1) to line (e) on positioning tapes [6]
drawn in step 5 and install it to operator’s
cab (7).
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking the window glass, press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
14 D85EX, PX-15E0
3) Mask front window glass (1) and opera-

tor’s cab (7) with masking tapes [8].
4) Fill the clearance between front window
glass (1) and operator’s cab (7) with caulk-
ing material (14) all around the window.
2 Caulking material:
SEKISUI SILICONE SEALANT
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable period.
8. Install both door window glasses.

1) Using tool X1, match both door window
glasses (2) to lines (e) on positioning
tapes [6] drawn in step 5 and install them
to both doors (9).
a Since the window glass cannot be
removed and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after
applying the adhesive.
2) After sticking each window glass, press all
5) After applying caulking material (14) to around it until it is stuck to the both-sided
front window glass (1), form it with the fin- adhesive tape.
gers as shown in the following figure. a Press the corners of each window
a Use rubber spatula [9] to form the glass firmly.
caulking material around the handrail,
etc. where it is difficult to form with the
fingers.
D85EX, PX-15E0 15
a If adhesive (13) is projected from the

trim seals (4) of stuck door window
glasses on both sides, remove it with
rubber spatula [9].
9. Fix the window glasses.

1) Using styrene foam blocks [10] and rubber
bands [11], fix the front window glass to fit
it completely.
a You may use sealing tapes to fix the
3) Fill the clearance between each door win- front window glass.
dow glass and trim in the range of dimen-
sion (k). (The figure shows the operator's cab of a hydraulic
i) Mask the range of dimension (k) of excavator.)
each door window glass.
ii) Fill clearance (m) between each door
window glass (2) and trim seal (4)
with caulking material.
a The usable period of the following
caulking material is 6 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
a Apply the caulking material to joint (c)
of the trim seal, too.
2 Caulking material:
SEKISUI SILICONE SEALANT
16 D85EX, PX-15E0
2) Immediately after sticking both door win-

dow glasses, install door handles (5), and
lock the doors to fix the glasses.
10. After installing the window glasses, remove the

primer and adhesive from them and the opera-
tor’s cab.
a Using white gasoline, wipe off the adhesive
before it is dried up.
a When cleaning the glasses, do not give an
impact to them.
11. Protect the stuck window glasses.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humid-
ity of 60%).
2) After applying the adhesive, wait for at
least 24 hours, before operating the
machine actually.
D85EX, PX-15E0 17
Removal and installation of floor 4. Disconnect turnbuckle (2) of the brake linkage.
frame assembly 1 [*1]
a Before disconnecting turnbuckle (2), check
Special tools the pressing stroke of the brake.
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name

Vacuum pump
799-703-1100 t 1
(100 V)
Vacuum pump
799-703-1110 t 1
X2 (220 V)
Vacuum pump
799-703-1120 t 1
(240 V)
Gas leak
799-703-1401 t 1
detector
5. Remove rear cover (3).
Removal
k Lower the work equipment to the ground
safely and release the residual pressure in
the piping. For details, see Testing and
adjusting, “Releasing residual pressure in
work equipment cylinder”.

assembly”.
6. Disconnect fuel level sensor wiring connector
2. Remove the operator's cab assembly. For details, 423 (4).
see “Removal and installation of operator’s cab
assembly”.
18 D85EX, PX-15E0
7. Disconnect accumulator hose (5).
10. Disconnect 2 drain hoses from the drain merge

8. Disconnect 6 PPC hoses from the work equip- block.
ment control valve. [*2] (13): Ripper control valve drain hose
q Right-hand PPC hoses: (14): Blade control valve hose
(6) : Ripper lift cylinder RAISE hose
Coupler (Port PA4), Color band: Black
(7) : Blade lift cylinder LOWER hose
Coupler (Port PA3), Color band: Black
(8) : Blade tilt cylinder LEFT TILT hose
Coupler (Port PA2), Color band: Yellow
q Left-hand PPC hoses:
(9) : Ripper lift cylinder LOWER hose
Coupler (Port B4), Color band: Not used
(10): Blade lift cylinder RAISE hose
Coupler (Port B3), Color band: Not used
(11): Blade tilt cylinder RIGHT TILT hose
Coupler (Port B2), Color band: Green
9. Remove PPC hose clamp (12).

11. Disconnect centralized connectors (15), (16),
(17), (18) and (19).
12. Remove cover (20) on the dashboard side.
D85EX, PX-15E0 19
17. Remove bracket (26) for tool.
13. Disconnect air conditioner hoses (21) and (22).

[*3] 18. Disconnect battery relay terminals (27), (28),
a Before disconnecting the air conditioner (29) and (30).
hose, collect the refrigerant (R134a).
19. Disconnect intermediate connector (31).
14. Disconnect heater hoses (24).
a Close the heater hose valve on the engine
side.
a Stop the disconnected hoses with wooden
plugs, etc.
15. Remove cover (25) on the dashboard side.
20. Disconnect intermediate connectors (32), (33)

and (34).
21. Disconnect intermediate connectors (35), (36)

and (37).
22. Remove intermediate connector mounting

16. Open battery case cover (23). bracket (38).
20 D85EX, PX-15E0
23. Remove parking brake lock lever cable assembly 27. Lift off floor frame assembly (43).
(39). [*4] a When lifting off the floor frame assembly,
check that all the wires have been discon-
nected.
4 Floor frame assembly: 440 kg
24. Remove bracket (40) on the left side of the

rear section.
25. Remove 4 rear mounting bolts (41) on each

side.
26. Remove 2 front mounting bolts (42) on each

side.
D85EX, PX-15E0 21
Installation q Charging air conditioner circuit refrigerant gas

q Carry out installation in the reverse order to Using tool X2, charge the air conditioner circuit
removal. with air conditioner refrigerant gas (R134a).
[*1] [*4]
a Adjust the brake pedal. For details, see Testing
and adjusting, “Adjusting brake pedal and
parking brake lever”.
[*2]
a The connecting points of the PPC hoses are
indicated by their band colors. When connect-
ing each hose, check its band color.
q PPC ports of work equipment control valve
assembly
Ports for right side:
(6) PA4 (Ripper lift cylinder RAISE port)
(7) PA3 (Blade lift cylinder LOWER port)
(8) PA2 (Blade tilt cylinder LEFT TILT port)
Ports for left side:
(9) PB4 (Ripper lift cylinder LOWER port)
(10) PB3 (Blade lift cylinder RAISE port)
(11) PB2 (Blade tilt cylinder RIGHT TILT port)
[*3]
them.
3 Tightening torque of air conditioner refrig-

erant piping
16 × 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 × 1.5 19.6 – 24.5 Nm {2.0 – 2.5 kgm}
24 × 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
22 D85EX, PX-15E0
SEN01272-00

© 2006 KOMATSU
All Rights Reserved
24
SEN01273-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up

Electrical system
Electrical system ............................................................................................................................................. 2
Removal and installation of engine controller ...................................................................................... 2
Removal and installation of steering and transmission controller ........................................................ 4
Removal and installation of KOMTRAX terminal ................................................................................. 5
D85EX, PX-15E0 1
Electrical system 1
Removal and installation of 3. Disconnect air conditioner piping clamps (3)
engine controller 1 and (4).
Removal 4. Remove cover (5).

1. Open the engine left side cover (1).
5. Remove bracket (6).
6. Disconnect wiring harness connectors (7), (8),

and (9).
2 D85EX, PX-15E0
7. Remove controller (10). Installation

a Ground wire (11) is installed together with q Carry out installation in the reverse order to
the controller. removal.
[*1]
a Check that there is no dust in connectors (7),
(8) and (9) before connecting.
D85EX, PX-15E0 3
Removal and installation of 3. Remove the 4 mounting bolts and take out
steering and transmission steering and transmission controller assembly
(3).
controller 1
4. Disconnect wiring connectors PTC1 (4), PTC2
Removal
k
(5), and PTC3 (6) and remove steering and
Disconnect the cable from the negative (–)
transmission controller assembly (3). [*1]
a Disconnect each connector by loosening
one screw of the center of wiring harness.
1. Remove operator’s seat assembly (1).
4 Operator’s seat assembly: 70 kg
Installation
2. Remove left side cover (2). q Carry out installation in the reverse order to
removal.
[*1]
3 Mounting screw: 2.82 Nm {0.288 kgm}
4 D85EX, PX-15E0
Removal and installation of 3. Remove the 4 mounting bolts and KOMTRAX

KOMTRAX terminal 1 terminal assembly (5).
Removal
1. Remove operator’s seat assembly (1).

4 Operator’s seat assembly: 70 kg
Installation
removal.
[*1]
3 Mounting screw: 2.82 Nm {0.288 kgm}
2. Disconnect wiring connectors KOM1 (2), KOM2

(3), KOM3 (4). [*1]
a To disconnect wiring connector KOM1 (2),
loosen the central screw of the wiring har-
ness.
D85EX, PX-15E0 5
SEN01273-00

© 2006 KOMATSU
All Rights Reserved
6
SEN00072-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
90 Diagrams and drawings 1

Hydraulic diagrams and drawings
Hydraulic diagrams and drawings................................................................................................................... 2
Power train hydraulic circuit diagram ................................................................................................... 2
Hydraulic circuit diagram...................................................................................................................... 3
D85EX, PX-15E0 1
SEN00072-00 90 Diagrams and drawings
Hydraulic diagrams and drawings 1

Power train hydraulic circuit diagram 1
2 D85EX, PX-15E0
Hydraulic circuit diagram 1 Hydraulic circuit diagram (1/2)
(1/2) D85EX, PX-15E0
D85EX, PX-15E0 SEN00072-00

3
90 Diagrams and drawings SEN00072-00
Hydraulic circuit diagram 1

Hydraulic circuit diagram (2/2)
(2/2) D85EX, PX-15E0
D85EX, PX-15E0 5
SEN00072-00

© 2005 KOMATSU
All Rights Reserved
8
SEN00073-00
D85EX-15E0
D85PX-15E0

D85EX-15E0 11001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical diagrams and drawings ................................................................................................................... 3
Electrical circuit diagram ...................................................................................................................... 3
D85EX, PX-15E0 1
D85EX, PX-15E0
1
Electrical circuit diagram 1
3
SEN00073-00

© 2005 KOMATSU
All Rights Reserved

D85ex15 Sen00060-02

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SEN00060-02

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual................................................................................................................ 2

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00060-02

00 Index and foreword SEN00061-02

10 Structure, function and maintenance standard SEN00063-00

20 Standard value table SEN00064-00

30 Testing and adjusting SEN00065-00

Troubleshooting of hydraulic and mechanical system (H-mode) SEN00639-00

50 Disassembly and assembly SEN00067-00

90 Diagrams and drawings SEN00068-01

Foreword and general information SEN00070-00

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

Testing and adjusting, Part 3 SEN00632-00

Troubleshooting by failure code (Display of code), Part 3 SEN00636-00

Failure code [DK10KA] Fuel dial: Disconnection ............................................................................ 72

Troubleshooting of electrical system (E-mode) SEN00638-00

Troubleshooting of engine (S-mode) SEN00640-00

50 Disassembly and assembly

Undercarriage and frame, Part 1 SEN01268-00

90 Diagrams and drawings

D85EX, PX-15E0 Bulldozer

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Foreword and general information (Rev. 2005/09)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-