Shop Manual: D85EX D85PX

SEN00060-02
Shop
Manual
D85EX-15E0
D85PX-15E0
BULLDOZER
SERIAL NUMBERS
D85EX-15E0 11001 and up

D85PX-15E0 1201 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2007 Komatsu

Printed in U.S.A.
Komatsu America Corp.
March 2007
This Page Intentionally left Blank
SEN00069-02
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
00 Index and foreword
Index
Composition of shop manual................................................................................................................ 2
Table of contents .................................................................................................................................. 4
D85EX, PX-15E0
SEN00069-02
Composition of shop manual
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 accordingly.
Section Title
Form Number
Shop Manual, contents binder, binder label and tabs
SEN00060-02

Index
Foreword and general information
SEN00061-02
SEN00069-02 q
SEN00070-00
01 Specification
Specification and technical data
SEN00062-00
SEN00071-00
10 Structure, function and maintenance standard

Engine and cooling system
Power train, Part 1
Power train, Part 2
Undercarriage and frame
Hydraulic system, Part 1
Work equipment
Cab and its attachments
Electrical system
SEN00063-00
SEN00293-00
SEN00295-00
SEN00297-00
SEN00298-00
SEN00299-00
SEN00300-00
SEN00302-00
SEN00305-00
SEN00306-00
SEN00308-00
20 Standard value table

Standard service value table
SEN00064-00
SEN00629-00
30 Testing and adjusting

Testing and adjusting, Part 1
SEN00065-00
SEN00630-00
SEN00631-00
SEN00632-00
40 Troubleshooting
General information on troubleshooting
Troubleshooting by failure code (Display of code), Part 1
Troubleshooting of electrical system (E-mode)
SEN00066-00
SEN00633-00
SEN00634-00
SEN00635-00
SEN00636-00
SEN00637-00
SEN00638-00
D85EX, PX-15E0
Troubleshooting of hydraulic and mechanical system (H-mode)

Troubleshooting of engine (S-mode)
SEN00069-02
SEN00639-00
SEN00640-00
50 Disassembly and assembly

General information on disassembly and assembly
Engine and cooling system, Part 1
Power train, Part 1
Power train, Part 2
Undercarriage and frame, Part 1
Hydraulic system
Work equipment
Electrical system
SEN00067-00
SEN01263-00
SEN01264-00
SEN01265-00
SEN01266-00
SEN01267-00
SEN01268-00
SEN01269-00
SEN01270-00
SEN01271-00
SEN01272-00
SEN01273-00
90 Diagrams and drawings

Hydraulic diagrams and drawings
Electrical diagrams and drawings
SEN00068-01
SEN00072-00
SEN00073-01
D85EX, PX-15E0
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
Q
SEN00069-02
Table of contents

Index
SEN00069-02
Composition of shop manual ...................................................................................................
2
Table of contents......................................................................................................................
4
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
SEN00071-00
Specification and technical data ..................................................................................................
2
Specification dimensions .........................................................................................................
2
Specifications...........................................................................................................................
3
Weight table ............................................................................................................................. 11
Table of fuel, coolant and lubricants ........................................................................................ 16
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
SEN00295-00
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
SEN00297-00
Power train, Part 2.......................................................................................................................
2
Bevel gear shaft, HSS and brake ............................................................................................
2
Brake valve .............................................................................................................................. 16
Final drive ................................................................................................................................ 22
SEN00298-00
Undercarriage and frame ............................................................................................................
2
Main frame...............................................................................................................................
2
D85EX, PX-15E0
SEN00069-02
Suspension..............................................................................................................................
4
Track frame..............................................................................................................................
8
Idler cushion ............................................................................................................................ 10
Idler.......................................................................................................................................... 12
Track roller............................................................................................................................... 14
Carrier roller............................................................................................................................. 16
Sprocket................................................................................................................................... 18
Track shoe ............................................................................................................................... 20
SEN00299-00
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
SEN00300-00
2
Control valve............................................................................................................................
2
Self pressure reducing valve ................................................................................................... 36
SEN00302-00
2
Oil cooler bypass valve............................................................................................................
2
PPC valve................................................................................................................................
4
Electric lever (steering)............................................................................................................ 20
Quick drop valve...................................................................................................................... 23
PPC lock valve ........................................................................................................................ 24
Accumulator............................................................................................................................. 25
Work equipment
SEN00305-00
Work equipment ..........................................................................................................................
3
Cylinder stay ............................................................................................................................
3
Blade .......................................................................................................................................
4
Cutting edge and end bit .........................................................................................................
6
Ripper ......................................................................................................................................
8
Hydraulic cylinder .................................................................................................................... 10
Piston valve ............................................................................................................................. 12
SEN00306-00
Cab and its attachments..............................................................................................................
2
Cab mount ...............................................................................................................................
2
Cab ..........................................................................................................................................
3
Air conditioner..........................................................................................................................
5
Electrical system
SEN00308-00
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
SEN00069-02

SEN00629-00
Standard service value table .......................................................................................................
2
Standard service value table for engine...................................................................................
2
Standard service value table for chassis .................................................................................
3
SEN00630-00
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
SEN00631-00
Testing and adjusting, Part 2 .......................................................................................................
2
Special functions of monitor panel (EMMS).............................................................................
2
D85EX, PX-15E0
SEN00069-02

SEN00632-00
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
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
SEN00634-00
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
SEN00069-02
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
SEN00635-00
3
Failure code [CA322] Injector No. 1 system disconnection or short circuit:
Disconnection, short circuit......................................................................................................
3
4
5
6
7
8
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
D85EX, PX-15E0
SEN00069-02

SEN00636-00
4
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
SEN00069-02
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
SEN00637-00
3
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
SEN00069-02

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
SEN00069-02

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
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
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
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
SEN01266-00
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
SEN01267-00
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
SEN00069-02

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
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
SEN01271-00
Work equipment ..........................................................................................................................
2
Removal and installation of blade assembly ...........................................................................
2
Disassembly and assembly of ripper assembly.......................................................................
4
SEN01272-00
Cab and its attachments..............................................................................................................
2
Removal and installation of ROPS guard assembly ................................................................
2
Removal and installation of operators cab assembly .............................................................
3
Removal and installation of operators cab glass (Stuck glass)...............................................
9
Removal and installation of floor frame assembly ................................................................... 18
Electrical system
SEN01273-00
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
SEN00072-00
Hydraulic diagrams and drawings ...............................................................................................
2
Power train hydraulic circuit diagram.......................................................................................
2
Hydraulic circuit diagram .........................................................................................................
3
SEN00073-01
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
14
SEN00070-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

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
SEN00070-00

Safety notice
(Rev. 2005/09)
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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine.
1) Before carrying out any greasing or
repairs, read all the safety plates stuck to
the machine. For the locations of the
safety plates and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR signs in the
operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
w eld in g wo rk , alw ay s wear wel din g
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
Prohibition of operation and handling by
5
unlicensed workers
6 Safety check before starting work
Wearing protective goggles
7
(for cleaning or grinding work)
Wearing shielding goggles and protectors
8
(for welding work)
9 Good physical condition and preparation
Precautions against work which you are
10
not used to or you are used to too much
2.
Preparations for work

1) Before adding oil or making any repairs,
park the machine on hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
D85EX, PX-15E0
3)
4)
3.
When disassembling or assembling, support the machine with blocks, jacks, or

stands before starting work.
Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
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
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
Precautions during work

1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
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 wiring. Damaged wiring may cause electrical
fires.
D85EX, PX-15E0
SEN00070-00
8)
9)
10)
11)
12)
13)
14)
15)
16)
When removing piping, stop the fuel or oil

from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
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
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particul 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
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
SEN00070-00
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.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with one rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding 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 forming 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 allowable 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
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular

load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.
D85EX, PX-15E0
If the load is unstable or the wire rope

or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
SEN00070-00
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
Precautions for using mobile crane

a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
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 immediately in an emergency.
D85EX, PX-15E0
7.
Selecting wire ropes

1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
SEN00070-00
How to read the shop manual

q
q
q
1.
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.
Materials and specifications are subject to change without notice.
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.
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 disassembly 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.
D85EX, PX-15E0
3.
4.
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 )
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Weight
Tightening
torque
5.
SEN00070-00
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight of parts of component or parts. Caution necessary when
selecting hoisting wire, or when working posture is important, etc.
Places that require special attention for tightening torque during
assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
D85EX, PX-15E0
SEN00070-00
Explanation of terms for maintenance standard
The maintenance standard values necessary for judgment of products and parts are described by the following terms.
1.
Standard size and tolerance

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 temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference 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.
q
Example:
Standard size
120
Tolerance
0.022
0.126
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)
Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
D85EX, PX-15E0
2.
Standard clearance and standard value

The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
SEN00070-00
5.
3.
Standard interference
When the size of a hole is smaller than the
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.
q
4.
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
Repair limit and allowable value

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 product 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 various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
q
D85EX, PX-15E0
SEN00070-00
Handling electric equipment and hydraulic component
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, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted 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 (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
2)
10
Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
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 soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

The connector is designed to make it difficult for water to enter (drip-proof structure), 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 connector 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 connector, the pins will be short-circuited by
the water, so if any water gets in, immediately dry the connector or take other
appropriate action before passing electricity 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 surface 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 compressed 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 compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
D85EX, PX-15E0
SEN00070-00
11
SEN00070-00
3.
Removing, installing, and drying connectors and wiring harnesses

1) Disconnecting connectors
1] Hold the connectors when disconnecting.
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 connectors apart.
a Never pull with one hand.
2]
q
12
When removing from clips

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

clip, pull the connector in a parallel
direction to the clip for removing stoppers.
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 connectors

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 disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
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 damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
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 breakage, 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 stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected 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 respectively, push them in until they click 2 times.
1.
2.
q
q
SEN00070-00
Male connector
Female connector
Normal locking state (Horizontal): a,
b, d
Incomplete locking state (Diagonal): c
D85EX, PX-15E0
13
SEN00070-00
4)
14
Drying wiring harness

If there is any oil or dirt on the wiring harness, 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 follows.
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 connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
D85EX, PX-15E0
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control 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 controller.
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 connectors 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 disconnecting 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 connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
D85EX, PX-15E0
SEN00070-00
15
SEN00070-00
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 performance 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 cleaning 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 equipment, 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 circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
D85EX, PX-15E0
SEN00070-00
17
SEN00070-00
How to read electric wire code

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 symbols. 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 nominal 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 indicated.)
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)
Type
Symbol
Low-voltage
wire for
automobile
AV
Thin-cover
low-voltage
wire for
automobile
AVS
Heat-resistant low-voltAEX
age wire for
automobile
18
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
D85EX, PX-15E0
2.
SEN00070-00
Dimensions
(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
3f
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)
AVS
CovAV
er D
AEX
d (approx.)
Standard
Standard
Standard
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
1.0
2.0
2.0
1.2
2.2
2.2
1.5
2.5
2.7
1.9
2.9
3.0
50
1.9
2.9
3.1
2.3
3.5
60
2.4
3.6
3.8
85
3.0
4.6
4.6
15
20
30
40
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
D85EX, PX-15E0
19
SEN00070-00
3.
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
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
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
20
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
R
B
R
D
Y
G
L
YW
GL
Gr
Br
D85EX, PX-15E0
SEN00070-00
Method of disassembling and connecting push-pull type coupler

k
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.
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
SEN00070-00
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 hexagonal 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 disconnect it. (Fig. 8)
2.
Connection
q
Hold the tightening portion and push body
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
22
D85EX, PX-15E0
SEN00070-00
Type 3
1.
Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect 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 hexagonal portion at the male end. (Fig. 13)
D85EX, PX-15E0
23
SEN00070-00
Standard tightening torque table

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

mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a
a Fig. A
Width across flats

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

mm
6
8
10
12
24
Width across flats

mm
10
13
14
27
Tightening torque
Nm
5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2
kgm
0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2
a Fig. B
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
10
12
16
3.
Width across flats

mm
14
17
22
Tightening torque
Nm
kgm
59 74
6.0 7.5
98 123
10.0 12.5
235 285
23.5 29.5
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.
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN00070-00
Thread diameter
mm
14
20
24
33
42
Width across flats

mm
Tightening torque Nm {kgm}

Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84 132 { 8.5 13.5}
103 {10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
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
No.
08
10
12
14
16
18
20
24
30
33
36
42
52
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
D85EX, PX-15E0
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
25
SEN00070-00
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.
Nominal
No. of
hose
Width
across
flats
02
19
22
24
27
32
36
41
46
55
03
04
05
06
(10)
(12)
(14)
6.
Range
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No. Thread diameNumber of
ter (mm) (Refthreads, type of
erence)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
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.
mm
6
8
10
12
14
Tightening torque
Bolt
Nm
10 2
24 4
43 6
77 12
BANJO bolt
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
Nm
8 2
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
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
mm
6
8
10
12
14
26
Target
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Thread size
7.
Taper seal
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
D85EX, PX-15E0
8.
SEN00070-00
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.
Thread size
inch
1/16
1/8
1/4
3/8
1/2
3/4
1
D85EX, PX-15E0
Tightening torque
Nm
31
82
12 2
15 2
24 4
36 5
60 9
kgm
0.31 0.10
0.81 0.20
1.22 0.20
1.53 0.20
2.45 0.41
3.67 0.51
6.12 0.92
27
SEN00070-00
Conversion table
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 horizontal 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
(A)
28
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
D85EX, PX-15E0
SEN00070-00
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43
17.64
19.84
35.27
37.48
39.68
41.89
57.32
59.53
61.73
63.93
79.37
81.57
83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
0
10
20
30
40
0
1
2
0
0.264
0.528
2.642
2.906
3.170
5.283
5.548
5.812
7.925
8.189
8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321 1.585
1.849
2.113
2.378
3.963 4.227
4.491
4.755
5.019
6.604 6.869
7.133
7.397
7.661
9.246 9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
D85EX, PX-15E0
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
29
SEN00070-00
Liters to U.K. Gallons
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540
1.760
1.980
3.520
3.740
3.950
4.179
5.719
5.939
6.159
6.379
7.919
8.139
8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
1 kgm = 7.233 ft.lb

7
8
9
50.6
57.9
65.1
123.0
130.2
137.4
195.3
202.5
209.8
267.6
274.9
282.1
340.0
347.2
354.4
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5
737.8 745.0
752.2
759.5 766.7
773.9
781.2
788.4
795.6
802.9
810.1 817.3
824.6
831.8 839.0
846.3
853.5
860.7
868.0
875.2
882.4 889.7
896.9
904.1
911.4
918.6
925.8
933.1
940.3
947.5
954.8 962.0
969.2
976.5 983.7
990.9
998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
30
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
D85EX, PX-15E0
SEN00070-00
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
D85EX, PX-15E0
31
SEN00070-00
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade 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.
C
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
F
40.0
31.0
22.0
13.0
4.0
C
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
F
51.8
53.6
55.4
57.2
59.0
C
7.8
8.3
8.9
9.4
10.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
32
1C = 33.8F
F
81
177.8
82
179.6
83
181.4
84
183.2
85
185.0
46
47
48
49
50
F
114.8
116.6
118.4
120.2
122.0
C
27.2
27.8
28.3
28.9
29.4
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
D85EX, PX-15E0
SEN00070-00

34
SEN00071-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
01 Specification

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

Specification dimensions
D85EX-15E0
Item
Unit
Power tilt dozer

+ fixed multi-shank ripper
Semi-U dozer
Overall length
mm
7,100
7,255
Overall height
(with ROPS)
mm
3,330
(3,324)
3,330
(3,324)
Overall width
mm
3,715
3,635
Item
Unit
Overall length
mm
7,155
7,310
Overall height
(with ROPS)
mm
3,330
(3,324)
3,330
(3,324)
Overall width
mm
3,715
3,635
Item
Unit
Power tilt dozer + drawbar
Overall length
mm
6,065
Overall height
(with ROPS)
mm
3,367
(3,361)
Overall width
mm
4,365
Power tilt dozer

Semi-U dozer
+ variable multi-shank ripper + variable multi-shank ripper
D85PX-15E0
D85EX, PX-15E0
01 Specification
SEN00071-00
Specifications
D85EX-15E0
Machine name and type
D85EX-15E0
Serial number
11001 and up
Bare tractor
kg
21,140
With semi-U dozer

+ ROPS + cab + air conditioner
+ side cover
kg
28,100
With semi-U dozer

+ variable multi-shank ripper
+ side cover
kg
28,220
Min. turning radius (F1)
2.0
Gradeability
deg.
30
Stability (front, rear, left, right)
deg.
35
Ground pressure
Performance
Travel speed
Weight
Machine weight
Forward
1st speed
2nd speed
3rd speed
km/h
3.3
6.1
10.1
Reverse
1st speed
2nd speed
3rd speed
km/h
4.4
8.0
13.0
Bare tractor
kPa {kg/cm2}
60.7 {0.62}
With power tilt dozer

+ side cover
kPa {kg/cm2}
79.9 {0.81}
With semi-U dozer

+ side cover
kPa {kg/cm2}
80.7 {0.82}

+ side cover
kPa {kg/cm2}
80.2 {0.82}
With semi-U dozer

+ side cover
kPa {kg/cm2}
81.0 {0.83}
D85EX, PX-15E0
SEN00071-00
D85EX-15E0
Serial number
11001 and up
mm
5,012

mm
7,100

mm
7,155
With semi-U dozer

mm
7,255
With semi-U dozer

mm
7,310
Bare tractor
mm
2,560

+ fixed/variable
multi-shank ripper
mm
3,715
With semi-U dozer

+ fixed/variable
multi-shank ripper
mm
3,635
To top of exhaust pipe (incl. grouser)
mm
3,330
To top of air intake duct

(incl. grouser, to top of control lever)
mm
2,592
When cab is installed

(incl. grouser, excluding exhaust pipe)
mm
3,163
When ROPS canopy is installed

(incl. grouser, excluding exhaust pipe)
mm
3,324
Track gauge
mm
2,000
Length of track on ground
mm
3,050
Shoe width (standard)
mm
560
Min. ground clearance

(To bottom of undercover)
mm
450
Name
SAA6D125E-5
Type
4-cycle, water-cooled, in-line 6-cylinder, direct-injection,

with turbocharger and air-cooled aftercooler
mm
6 125 150
l {cc}
11.04 {11,039}
Flywheel horsepower
kW {HP}/rpm
197 {264}/1,900 (Net)
Max. torque
Overall width
Overall length
Bare tractor
(to top of lift cylinder)
Overall height
Dimensions
01 Specification
No. of cylinders bore x stroke
Performance
Engine
Total piston displacement
Nm {kgm}/rpm
1,272 {130}/1,400 (Gross)
High idle speed under no load
rpm
2,100
Low idle speed under no load
rpm
750
g/kWh {g/HPh}
215 {160}
Min. fuel consumption ratio
Starting motor
Alternator
Battery
Type of radiator core
24 V, 7.5 kW
24 V, 50 A
12 V, 150 Ah x 2
Corrugated aluminum, 8.0/2
D85EX, PX-15E0
01 Specification
SEN00071-00
D85EX-15E0
Serial number
11001 and up
Torque converter
3-element, 1-stage, 1-phase type

Planetary gear, multiple disc,
hydraulic (electric),
gear pump pressure fed oil lubrication,
3 forward/reverse gear speeds,
electrically operated type
Transmission
Power train
HSS pump
HSS motor
MPa {kg/cm2}
Variable swash plate type (HPV160)

Max. discharge pressure: 40.2 {410}
l/min /rpm
Theoretical discharge amount: 341/2,133
MPa {kg/cm2}
Fixed swash plate type (HMF112)

Max. allowable working pressure: 40.2 {410}
Spiral bevel gear, gear pump pressure fed oil
lubrication type
HSS
Bevel gear shaft
Differential planetary gear, hydraulic motor drive,

electric motorized, hydraulically actuated type
HSS steering system
Wet multiple disc, spring-boosted,

hydraulically actuated, pedal operated type
Master brake
1-stage spur gear, 1-stage planetary gear,

splash lubrication type
Undercarriage
Final drive
Type of suspension
Rigid, balancing beam type
Carrier roller
2 pieces on each side
Track roller

Assembly type, single grouser,
41 pieces on each side, pitch: 216.3 mm
Track shoe (560 mm)
Power train + lubrication pump (tandem)
Gear type (SAL(3)63 + (2)50)
Scavenging pump
Gear type (SAR(3)80)
Work equipment
hydraulic system

(common use with HSS)
Work equipment relief pressure: 22.5 {230}
Fan driving
system
Work equipment pump
Fan pump
Fan motor
D85EX, PX-15E0
MPa {kg/cm2}
l/min /rpm
MPa {kg/cm2}
Variable swash plate type (LPV30)

l/min /rpm
MPa {kg/cm2}
Fixed swash plate type (LMF28)

Main control valve
SEN00071-00
01 Specification
D85EX-15E0
Serial number
11001 and up
Machine with fixed multi-shank ripper

Type
For blade lift
For blade tilt
For steering
For ripper lift
3 + 1 spool type, hydraulic assist type

+ blade lift
+ blade tilt
+ steering
+ ripper lift
Machine with variable multi-shank ripper

Type
For blade lift
For blade tilt
For steering
For ripper lift
For ripper tilt
3 + 1 spool type, hydraulic assist type

+ blade lift
+ blade tilt
+ steering
+ ripper lift
+ ripper tilt
Double acting piston
Cylinder bore
mm
100
Piston rod outer diameter
mm
65
Piston stroke (Max.)
mm
1,350
Max. distance between pins
mm
2,040
Min. distance between pins
mm
690
Cylinder bore
mm
150
mm
75
mm
130
mm
1,351
mm
1,221
Cylinder bore
mm
130
mm
70
mm
410
mm
1,320
mm
910
Cylinder bore
mm
130
mm
70
mm
410
mm
1,350
mm
940
Cylinder bore
mm
130
mm
70
mm
285
mm
1,225
mm
Lift cylinder
Lift cylinder
Tilt cylinder
Lift cylinder
Tilt cylinder
Fixed multi-shank ripper
Variable multi-shank ripper
Work equipment hydraulic system
Type
Hydraulic tank
940
Box type (external control valve type)
D85EX, PX-15E0
01 Specification
SEN00071-00
D85EX-15E0
Serial number
11001 and up
Hydraulic power tilt dozer
Hydraulic semi-U dozer
Type
Dimensions Performance Dimensions Performance
Semi-U dozer
Left: brace, Right: tilt cylinder
Max. lift (above ground)
mm
1,207
Max. drop (below ground)
mm
540
Max. tilt
mm
740
Blade capacity (SAE)
5.2
Blade width
mm
3,725
Blade height
mm
1,450
Tip angle of blade cutting edge
deg.
52
mm
1,207
mm
540
Max. tilt
mm
735
7.0
Blade width
mm
3,640
Blade height
mm
1,580
Tip angle of blade cutting edge
deg.
52
Weight
Parallelogram
kg
2,500
mm
2,246
Number of shanks
piece
Digging angle
deg.
Performance
Beam length
Digging depth
54
2 levels switchable
Max. digging depth
mm
653
Max. lift
mm
564
Type
Weight
Beam length
Number of shanks
Performance
Type
Work equipment
Power tilt dozer
Blade supporting method
Digging angle (standard)
Parallelogram
kg
2,570
mm
2,246
piece
deg.
Digging depth
42.4 63.6 (54)

2 levels switchable
Max. digging depth
mm
736
Max. lift
mm
720
D85EX, PX-15E0
SEN00071-00
01 Specification
D85PX-15
D85PX-15E0
Serial number
1201 and up
Bare tractor
kg
23,420

+ drawbar + ROPS + cab
+ air conditioner + side cover
kg
27,650
Min. turning radius (F1)
2.7
Gradeability
deg.
30
Stability (front, rear, left, right)
deg.
35
1st speed
2nd speed
3rd speed
km/h
3.3
6.0
10.0
Reverse
1st speed
2nd speed
3rd speed
km/h
4.4
7.9
12.7
Bare tractor
kPa {kg/cm2}
36.3 {0.37}

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

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

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

(incl. grouser, to top of control lever)
mm
2,629
When cab is installed

(incl. grouser, not incl. exhaust pipe)
mm
3,200
When ROPS canopy is installed

(incl. grouser, not incl. exhaust pipe)
mm
3,361
Track gauge
mm
2,250
Length of track on ground
mm
3,480
Shoe width (standard)
mm
910
Min. ground clearance

(To bottom of undercover)
mm
560
Travel speed
Forward
Overall height
Dimensions
Overall width Overall length Ground pressure
Performance
Weight
Machine weight
D85EX, PX-15E0
01 Specification
SEN00071-00
D85PX-15E0
Serial number
SAA6D125E-5
Type
4-cycle, water-cooled, in-line 6-cylinder, direct-injection, with turbocharger and air-cooled aftercooler
mm
6 125 150
Total piston displacement
l {cc}
11.04 {11,039}
Rated horsepower
kW {HP}/rpm
197 {264}/1,900 (Net)
Nm {kgm}/rpm
1,272 {130}/1,400 (Gross)
High idle speed under no load
rpm
2,100
Low idle speed under no load
rpm
750
g/kWh {g/HPh}
215 {160}
Performance
No. of cylinders bore x stroke
Engine
1201 and up
Name
Max. torque
Min. fuel consumption ratio
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),
gear pump pressure fed oil lubrication, 3 forward/
reverse gear speeds, electrically operated type
Transmission
HSS motor
MPa {kg/cm2}

l/min /rpm
MPa {kg/cm2}
Fixed swash plate type (HMF112)

Spiral bevel gear, gear pump pressure fed oil
lubrication type
Bevel gear shaft
HSS
Power train
HSS pump
Differential planetary gear, hydraulic motor drive,

electric motorized, hydraulically actuated type
HSS steering system
Wet multiple disc, spring-boosted,

hydraulically actuated, pedal operated type
Master brake
1-stage spur gear, 1-stage planetary gear,

splash lubrication type
Undercarriage
Final drive
Type of suspension
Rigid, balancing beam type
Carrier roller
Track roller

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

MPa {kg/cm }

(common use with HSS)
Work equipment relief pressure: 22.5 {230}
l/min /rpm
Work equipment pump
D85EX, PX-15E0
SEN00071-00
01 Specification
D85PX-15E0
Main control valve
Fan pump
Fan motor
1201 and up
MPa {kg/cm2}
Variable swash plate type (LPV30)

l/min /rpm
MPa {kg/cm2}
Fixed swash plate type (LMF28)

Type
For blade lift
For blade tilt
For steering
3 spool type, hydraulic assist type

+ blade lift
+ blade tilt
+ steering
Lift cylinder
Type
Tilt cylinder
Work equipment hydraulic system
Fan driving
system
Serial number
Double acting piston
Cylinder bore
mm
100
mm
65
mm
1,225
mm
2,153
mm
928
Cylinder bore
mm
150
mm
75
mm
130
mm
1,351
mm
1,221
Hydraulic tank
Box type (external control valve type)
Type
Hydraulic power tilt dozer
10
Power tilt dozer
Work equipment
Blade supporting method
Performance
Dimensions
Left: brace, Right: tilt cylinder
mm
1,222
mm
568
Max. tilt
mm
500
5.9
Blade width
mm
4,365
Blade height
mm
1,370
Tip angle of blade cutting

edge
deg.
55
D85EX, PX-15E0
01 Specification
SEN00071-00
Weight table
k
This weight table is prepared for your reference when handling or transporting the components.
D85EX-15E0
Unit: kg
D85EX-15E0
Serial number
11001 and up
Engine assembly (excluding coolant and oil)
1,483
Engine assembly
1,330
Damper assembly
131
Universal joint
17
Engine mounting parts (wiring)
Cooling assembly (excluding coolant and oil)
242
Radiator
15
Aftercooler
17
Hydraulic oil cooler
Power train oil cooler assembly
47
Fuel tank assembly
215
618
(when empty)
(when full)
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
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)
(double flange x 1)
Carrier roller assembly

Roller guard etc.
Track shoe assembly (560 mm, wet type)
D85EX, PX-15E0
72 5
80 2
39 2
130
1,945 2
11
SEN00071-00
01 Specification
Unit: kg
D85EX-15E0
Serial number
11001 and up
Pivot shaft assembly
82 2
Equalizer bar
158
Hydraulic tank assembly
95
Main control valve

(blade lift + blade tilt + ripper lift + steering)
95
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)

Tilt brace
Center brace
Tilt cylinder assembly
371/389
66
81 2
130
Semi-U dozer assembly
3,575
Semi-U blade assembly (incl. edge etc.)
1,860

Center brace
371/389
66 2
130
Radiator mask assembly
117
Blade lift cylinder assembly

Fixed multi-shank ripper assembly
Mount bracket
Ripper arm
115 2
2,500
124 2
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
74 2
ROPS assembly
371
Cab assembly
410
ROPS canopy
437
Dashboard (for machine with cab and air conditioner)

Floor frame assembly
76
350
Air conditioner assembly (incl. air conditioner unit assembly)
76
Operator seat assembly
68
12
D85EX, PX-15E0
01 Specification
SEN00071-00
D85PX-15E0
Unit: kg
D85PX-15E0
Serial number
1201 and up
Engine assembly (excluding coolant and oil)
1,483
Engine assembly
1,330
Damper assembly
131
Universal joint
17
Engine mounting parts (wiring)
Cooling assembly (excluding coolant and oil)
242
Radiator
15
Aftercooler
17
Power train oil cooler assembly
47
Fuel tank assembly
215
618
(when empty)
(when full)
Power train unit assembly (incl. HSS pump motor)
1,800
Torque converter and PTO assembly
322
Transmission assembly
443
HSS assembly
748
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
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)
(double flange x 1)
Carrier roller assembly

Roller guard etc.
Track shoe assembly (910 mm, wet type)
Equalizer bar
D85EX, PX-15E0
72 6
80 2
39 2
108
2,795 2
106 2
204
13
SEN00071-00
01 Specification
Unit: kg
D85PX-15E0
Serial number
1201 and up
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

Blade assembly (incl. edge etc.)
Tilt brace
Center brace
3,343
1,779
371/389
66
81 2
130
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
SEN00071-00
01 Specification
Table of fuel, coolant and lubricants
For details of notes (Notes 1 and 2...) in the table, see Operation and Maintenance Manual.
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
01 Specification
SEN00071-00
Unit: l
Supply point
D85EX-15E0
D85PX-15E0
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

18
SEN00293-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
10 Structure, function and

maintenance standard

Engine and cooling system ............................................................................................................................. 2
Engine mount ....................................................................................................................................... 2
Cooling system..................................................................................................................................... 4
Cooling fan pump ................................................................................................................................. 6
Cooling fan motor............................................................................................................................... 14
D85EX, PX-15E0
SEN00293-00

Engine mount
1
1
Unit: mm
No.
Check item
Clearance between bracket and
cushion
Free height of mount rubber
Criteria
Standard
size
60
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
0.100
0.300
+0.046
+0.046
0.100
0.346
0.4
Standard size
Repair limit
90
88
Replace
D85EX, PX-15E0
SEN00293-00
Cooling system
D85EX, PX-15E0
A:
B:
C:
D:
Power train oil cooler inlet

Power train oil cooler outlet
Hydraulic oil cooler inlet
Hydraulic oil cooler outlet
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Cooling fan motor

Aftercooler inlet hose
Radiator inlet hose
Reservoir tank
Aftercooler outlet hose
Radiator outlet hose
Power train oil cooler
Aftercooler
Radiator cap
Radiator
Drain plug
Cooling fan
SEN00293-00
Specifications
Core type
Fin pitch (mm)
Radiator
Power train
oil cooler
Aftercooler
Corrugated
aluminum
PTO-OL
3A-CS
Corrugated
aluminum
8.0/2
3.5
8.0/2
Total heat dissipation surface (m2)
34.81 2
2.259
1.86
33.0
Cracking pressure of pressure valve (kPa{kg/cm2})
88.3 14.7
{0.9 0.15}
Cracking pressure of vacuum valve (kPa {kg/cm2})
0 4.9
{0 0.05}
D85EX, PX-15E0
SEN00293-00
Cooling fan pump
Type: LPV30
P1:
PS:
T0:
T1:
PEPC:
PCEPC:
Pump discharge
Pump suction
Drain
Drain plug
EPC valve basic pressure input
EPC output pressure detection plug
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SEN00293-00
Shaft
Oil seal
Case
Rocker cam
Shoe
Piston
Cylinder block
Valve plate
Spring
Servo piston
D85EX, PX-15E0
SEN00293-00
Function
q
The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers
pressurized oil corresponding to the load.
q
It is possible to change the discharge amount
by changing the swash plate angle.
Structure
q
Cylinder block (7) is supported to shaft (1) by
spline (a), and shaft (1) is supported by the
front and rear bearings.
q
The tip of piston (6) is a concave ball, and shoe
(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 cylinder block (7) is sucked in and discharged
through valve plate (8).
D85EX, PX-15E0
SEN00293-00
Operation
Operation of pump
q
Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface (A). At
this point, since rocker cam (4) inclines with
ball (11) as fulcrum, inclination (a) between the
center line of rocker cam (4) and the shaft
direction of cylinder block (7) changes. (a) is
called swash plate angle.
q
With the condition of center line (X) of rocker
cam (4) has swash plate angle (a) to axial
direction of cylinder block (7), flat surface (A)
functions as cam against shoe (5).
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
When center line (X) of rocker cam (4) is the

same as the axial direction of cylinder block (7)
[s was h pl ate an gl e = 0], the d iffer e nc e
between volumes (E) and (F) inside cylinder
block (7) is 0, so pump does not suck and discharge, and no pumping is carried out. [The
swash plate angle is not set to 0 actually, however.]
In other word, swash plate angle (a) and the
pump discharge amount is in relation of proportion.
SEN00293-00
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 according to the signal pressure of the servo valve.
This straight line motion is transmitted to
rocker cam (4). Then, rocker cam (4) supported on ball (11) sways around ball (11).
10
D85EX, PX-15E0
SEN00293-00
Servo valve
P:
T:
PE:
PH:
EPC valve basic pressure

Drain
Control piston pressure
Pump discharge pressure
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
Plug
Lever
Retainer
Seat
Spool
Piston
Sleeve
11
SEN00293-00
A:
B:
C:
D:
12
Drain side
Pump discharge pressure input side
EPC output pressure received
EPC output pressure
D85EX, PX-15E0
Function
q
The servo valve controls the current input to
the EPC valve and the swash plate angle of
the pump so that they will be related as shown
in the diagram.
The relationship between input current (i) to

the EPC valve and output pressure (F) of EPC
valve is as follows.
D85EX, PX-15E0
SEN00293-00
Operation
q
The output pressure of EPC valve is applied to
piston chamber (C) to push piston (6). Piston
(6) pushes spool (5) until it is balanced with the
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 discharge 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 discharge 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 output is balanced with the spring force.
q
Accordingly, as the EPC output pressure is
heightened, the swash plate angle is
decreased. As the EPC output pressure is lowered, the swash plate angle is increased.
13
SEN00293-00
Cooling fan motor
Type: LMF28
P: From fan pump

T: From cooler to tank
TC: To tank
14
Specifications
Type
Capacity
Rated speed
Rated flow
Check valve
cracking pressure
: LMF28
: 28.0 cc/rev
: 1,650 rpm
: 46 l/min
: 0.044 MPa {0.45 kg/cm2}
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
Output shaft
Case
Thrust plate
Piston assembly
Cylinder block
Valve plate
End cover
SEN00293-00
8.
9.
10.
11.
12.
13.
14.
Center spring
Check valve spring
Check valve
Pilot valve
Spool for reversible valve
Spring for reversible valve
Safety valve
Unit: mm
No.
Check item
Criteria
Standard size
Check valve spring
D85EX, PX-15E0
Remedy
Repair limit
Free length
Installation Installation
Installation Replace spring if
outer
Free length
damaged or
length
load
load
diameter
deformed.
3.43 N
2.55 N
13.0 6.5
7.0
{0.35 kg}
{0.26 kg}
15
SEN00293-00
Hydraulic motor unit

Function
q
This hydraulic motor is called a swash platetype 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 generates 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 components (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 = (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 transmit the torque.
16
D85EX, PX-15E0
SEN00293-00
Suction valve
Function
q
If the fan pump stops, the pressurized oil does
not flow into the motor. Since the motor continues 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.
When stopping
Operation
When starting
If the engine is stopped and the input revolution of the fan pump lowers to 0 rpm, the pressurized 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.
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 cavitation.
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
SEN00293-00
Reversible valve
When the ON-OFF solenoid for the reversible
valve is demagnetized
18
If ON-OFF solenoid (1) for the reversible valve

is demagnetized, the pressurized oil from the
pump is blocked by ON-OFF selector valve (2),
and port (C) opens for the tank circuit.
Accordingly, reversible valve spool spring (3) is
pushed by reversible valve spool spring (4) to
the right to open motor port (MA) and then the
pressurized oil flows in to revolve the motor
forward (clockwise).
When the ON-OFF solenoid for the reversible

valve is energized
If ON-OFF solenoid (1) for reversible valve is

energized, ON-OFF selector valve (2) changes
to let the pressurized oil from the pump flow
through port (C) into spool chamber (D).
The pressurized oil in chamber (D) pushes
reversible valve spool (3) to the left against
reversible valve spring (4). As a result, motor
port (MB) opens and pressurized oil flows in to
revolve the motor in reverse (counterclockwise).
D85EX, PX-15E0
Safety valve
SEN00293-00
Function
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.
q
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 pressurized oil into port (T).
q
By this operation, generation of abnormal pressure in port (P) is prevented.
D85EX, PX-15E0
19
SEN00293-00

20
SEN00295-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN00295-00
Power train, Part 1

Power train
1
1
Outline
q
The power generated by engine (1) has its torsional vibration dampened by damper (2), and
then passes through universal joint (3) and is
transmitted to torque converter (8).
q
The power generated by engine (1) has its torsional vibration dampened by damper (2), and
then passes through universal joint (3) and is
transmitted to torque converter (8).
q
The power from the engine is transmitted to
the transmission input shaft (turbine shaft) via
the oil by torque converter (8) corresponding to
load change.
q
Transmission (9) uses a combination of a planetary gear system and hydraulic clutches to
reduce the speed and shift the gears (3 forward
speeds and 3 reverse speeds). It connects 2 sets
of clutches selected corresponding to the change
of the load, and transmits the power to bevel
gear (10) from the bevel pinion at the rear end of
the transmission.
The power transmitted to bevel gear shaft is

transferred to HSS (Hydrostatic Steering System) (11).
HSS pump (5) is driven by PTO (6), and discharged oil from the HSS pump drives HSS
motor (12).
The rotation of the pair of the HSS gears on
the right and left is controlled by HSS motor
(12). The turning direction is controlled by generating a difference in speed on the right and
left.
It is also possible to use the HSS mechanism
to rotate the right and left sides in opposite
directions to carry out counter-rotation.
Brake (13) of HSS is used for braking the
machine. Brake (13) is a wet, multiple disc
clutch and spring boosted type.
The power from brake (13) is transmitted to
final drive (14).
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).
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Engine
Damper
Universal joint
Scavenging pump
HSS pump
PTO
Cooling fan pump
Torque converter
Transmission
Bevel gear
D85EX, PX-15E0
SEN00295-00
11.
12.
13.
14.
15.
16.
17.
18.
19.
HSS unit
HSS motor
Brake
Final drive
Sprocket
Track shoe
Power train pump
Lubrication pump
Cooling fan motor
SEN00295-00
HSS system
a
HSS: Abbreviation for Hydrostatic Steering System
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Steering/directional/gear shift lever (PCCS lever)

Transmission and steering controller
Control valve
HSS pump
Engine
EPC valve
Hydraulic tank
Sprocket
Final drive
HSS motor
HSS circuit
Servo valve
Engine controller
Input and output signals

A. Forward and reverse signals
B. Steering signal
C. Engine control information
D. Work equipment oil pressure signal
E. CAN communication network
D85EX, PX-15E0
SEN00295-00
Outline
q
HSS system stands for Hydrostatic Steering
System.
The hydrostatic is equal to fluid statics.
q
The HSS system consists of control valve,
HSS pump and HSS motor as shown in the figure. It turns the machine continuously without
lowering the traveling speed by making a difference in speed between both track shoes.
q
Transmission and steering controller uses the
EPC valve of the control valve to control the
rotating direction and speed of the HSS motor
according to the tilting direction and angle of
the PCCS lever.
The HSS motor acts on the planetary gear
mechanism of the bevel gear shaft making a
difference in speed between right and left
sprockets to turn the machine.
q
Transmission and steering controller detects
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 controller and transmission and steering controller.
SEN00295-00
General view of power train unit
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Transmission
Torque converter and PTO
HSS pump
Power train pump
Lubrication pump
Fan pump
HSS motor
Brake valve
HSS unit
Main relief valve
Scavenging pump
Power train oil strainer
D85EX, PX-15E0
SEN00295-00
Outline
q
The power train unit broadly consists of torque
converter and PTO (2), transmission (1), and
HSS unit (9). Therefore, after the power train
unit is removed, it can be divided into torque
converter and PTO (2), transmission (1), and
HSS unit (9).
q
HSS unit consists of the bevel pinion unit,
bevel gear shaft, HSS motor, planetary gear
mechanism and brake.
SEN00295-00
Power train hydraulic piping drawing
A:
B:
Brake oil pressure detection port

Transmission 3rd clutch oil pressure detection
port (3RD)
C: Transmission 2nd clutch oil pressure detection
port (2ND)
D: Transmission 1st clutch oil detection port (1ST)
E: Transmission R clutch oil pressure detection
port (R)
F: Transmission F clutch oil pressure detection
port (FWD)
G: Torque converter inlet pressure detection port
(IN)
H: Transmission main relief pressure detection
port (TM)
J: Torque converter outlet pressure detection port
(OUT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
HSS pump
Lubrication pump
Power train pump
Brake control valve
HSS motor
Main relief valve
Centralized pressure pick-up port
Scavenging pump
Power train oil filter
Power train oil cooler
Transmission clutch ECMV
D85EX, PX-15E0
Transmission control
SEN00295-00
a
a
For the operation of PCCS lever relating to the operation of the steering, see Steering and brake control.
PCCS: Abbreviation for Palm Command Control System
1.
2.
3.
Brake pedal
Parking brake lever
Steering/directional/gear shift lever (PCCS lever)
3A. Up switch
(Gear is shifted up each time this switch is
pressed.)
3B. Down switch
(Gear is shifted down each time this
switch is pressed.)
Transmission neutral safety switch
Cable
4.
5.
6.
D85EX, PX-15E0
Lever positions
A: Neutral
B: Forward
C: Reverse
D: OFF
E: Shift up
F: Shift down
G: Free
H: Lock
Outline
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.
SEN00295-00
Steering and brake control

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

A: Neutral
B: Forward straight
C: Reverse straight
D: Left turn
E: Right turn
F: Brake released
G: Brake operated
H: Free
J: Lock
1.
2.
3.
4.
5.
6.
7.
8.
9.
Brake pedal
Parking brake lever
Brake valve
Steering/directional/gear shift lever
(PCCS lever)
Limit switch
Cable
Rod (from brake pedal)
Potentiometer
D85EX, PX-15E0
SEN00295-00
Outline
q
PCCS lever (4) sends electric signals to transmission and steering controller (6). Upon
receiving these electric signals, the transmission and steering controller (6) sends signals
to the EPC valve of the control valve to change
the discharge of the pump and operate the
steering motor.
q
Brake pedal (1) operates brake valve (3)
through rod (8) to control the brake.
q
Parking brake lever (2) is connected to brake
valve (3) and is also used as the parking
brake.
11
SEN00295-00
Damper and universal joint
12
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
SEN00295-00
Breather
Oil level gauge
Drain plug
Output shaft
Flywheel
Outer body
Coupling
Universal joint
Cover
Rubber coupling
Inner body
Unit: mm
No.
Check item
Clearance between flywheel

12
housing and cover
13
Clearance between flywheel

and damper
14
Outer diameter of oil seal

contact surface of coupling
Criteria
Tolerance
Standard
size
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
511.18
0.022
0.092
+0.070
+0.070
0.022
0.162
0.2
466.72
0.020
0.083
+0.063
+0.063
0.020
0.146
0.2
Standard size
Tolerance
Repair limit
90
0.087
0.087
89.8
Replace
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
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
SEN00295-00
Torque converter and PTO

a
14
PTO: Abbreviation for Power Take Off
D85EX, PX-15E0
D85EX, PX-15E0
SEN00295-00
15
SEN00295-00
A:
B:
C:
D:
E:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
16
Torque converter oil inlet port

To oil cooler
From transmission case
(to scavenging pump)
From transmission case
(to power train and lubrication pump)
To transmission case (passage)
HSS and work equipment pump mounting port
Scavenging pump mounting port
Power train and lubrication pump mounting port
Power train oil strainer
PTO lubrication tube
Cooling fan pump mounting port
Input coupling
PTO idler gear (number of teeth: 55)
PTO idler gear shaft
PTO idler gear (number of teeth: 74)
PTO case
Drive case
Turbine
Pump
Stator
Stator shaft
Transmission input shaft
Power train and lubrication pump drive gear
(number of teeth: 47)
HSS, work equipment pump and fan pump drive
gear (number of teeth: 49)
Scavenging pump drive gear
(number of teeth: 48)
Scavenging pump strainer
Sleeve
Outline
q
The torque converter is a 3-element, 1-stage,
and 1-phase type, which is integral with the
transmission.
q
Pump (14) is integrated with input coupling (7),
PTO drive gear (8) and drive case (12), and
rotates by the power from the engine.
q
Turbine (13) is integrated with transmission
input shaft (17), and rotates by the oil from
pump (14) as medium.
q
Stator (15) is integrated with stator shaft (16),
and fixed to PTO case (11).
q
Each pump installed to PTO case is driven with
the power transmitted through PTO drive gear
(8) to PTO idler gear (10), and pump drive
gears (18), (19) and (20).
D85EX, PX-15E0
D85EX, PX-15E0
SEN00295-00
17
SEN00295-00
18
D85EX, PX-15E0
SEN00295-00
Unit: mm
No.
Check item
Criteria
Tolerance
Repair limit
100
0.054
0.054
99.8
120
+0.040
+0.040
120.3
3.95
0.1
0.1
3.5
4.6
0.1
4.1
Outer diameter of oil seal contact surface of input coupling
Inner diameter of seal ring

contact surface of retainer
Wear of stator shaft Width

seal ring
Thickness
Backlash between PTO drive

gear and PTO idler gear
0.192 0.485
Backlash between PTO idler

gear and power train and lubrication pump drive gear
0.192 0.485
Backlash between PTO idler

gear and HSS pump and fan
pump drive gear
0.192 0.485
Backlash between PTO drive

gear and scavenging pump
drive gear
0.192 0.485
D85EX, PX-15E0
Remedy
Standard size
Repair by hard
chrome plating
or replace
Replace
19
SEN00295-00
Transmission
20
D85EX, PX-15E0
A:
B:
C:
D:
E:
F:
To forward clutch
To reverse clutch
To 3rd clutch
To 2nd clutch
To 1st clutch
To torque converter case
(to power train and lubrication pump)
G: From torque converter case
H: To scavenging pump
J: To torque converter case
K: From power train and lubrication pump
D85EX, PX-15E0
SEN00295-00
L:
M:
N:
P:
To steering valve
From steering case
Transmission lubrication oil inlet port
Transmission 1st clutch oil pressure pick-up
port
Q: Transmission 3rd clutch oil pressure pick-up
port
R: Transmission R clutch oil pressure pick-up port
S: Transmission 2nd clutch oil pressure pick-up
port
T: Transmission F clutch oil pressure pick-up port
21
SEN00295-00
22
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Main relief valve

Transmission case
Transmission control valve and valve cover
Lubrication relief valve
Input shaft
Reverse sun gear (number of teeth: 30)
Pinion shaft
Reverse ring gear (number of teeth: 70)
Reverse planetary pinion (number of teeth: 20)
Disc
Plate
Piston
Forward planetary pinion (number of teeth: 20)
3rd planetary pinion (number of teeth: 30)
3rd ring gear (number of internal teeth: 76,
number of external teeth: 90)
2nd sun gear (number of teeth: 35)
1st planetary pinion (number of teeth: 18)
1st sun gear (number of teeth: 39)
Output shaft (number of 3rd sun gear teeth: 17)
1st ring gear (number of internal teeth: 75,
1st carrier (number of teeth: 76)
1st clutch housing
2nd clutch housing
2nd planetary pinion (number of teeth: 21)
2nd ring gear (number of internal teeth: 76,
3rd clutch housing
2nd, 3rd carrier
Forward 3rd clutch housing
Forward sun gear (number of teeth: 35)
Forward ring gear (number of internal teeth:
75, number of external teeth: 90)
Forward carrier (number of teeth: 70)
Reverse and forward clutch housing
Return spring
Reverse ring gear (hub)
(number of internal teeth: 75,
Pin
Reverse carrier (number of teeth: 75)
D85EX, PX-15E0
SEN00295-00
Outline
q
The transmission adopted is a forward 3-gear
speed and reverse 3-gear speed transmission
which consists of the planetary gear mechanisms and the disc clutches.
q
Among the 5 sets of planetary gear system
and disc clutches of the transmission, 2
clutches are fixed hydraulically with the control
valve to select 1 rotating direction and rotating
speed.
q
Clutches No.1, No.2, No.3, No.4, and No.5 are
fixed respectively when the reverse, forward,
3rd, 2nd, and 1st gears are selected.
Number of plates and discs used
Clutch No.
Number of plates Number of discs
No.1 clutch
No.2 clutch
No.3 clutch
No.4 clutch
No.5 clutch
Gear speeds and operated clutches

Gear speed
Operated clutches
Forward 1st
No.2 No.5
Forward 2nd
No.2 No.4
Forward 3rd
No.2 No.3
Neutral
*1
Reverse 1st
No.1 No.5
Reverse 2nd
No.1 No.4
Reverse 3rd
No.1 No.3
*1: Speed clutch No. 5, No. 4, or No. 3 is simply

filled with low-pressure oil.
23
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24
D85EX, PX-15E0
SEN00295-00
Unit: mm
No.
Check item
Criteria
Standard size
1 No.1 clutch spring (10 pcs.)
Free length
Remedy
Repair limit
Installation
Free length
length
load
load
77
60
120.6 N
{12.3 kg}
74.7
114.5 N
{11.6 kg}
77
63
99.5 N
{10.2 kg}
74.7
94.5 N
{9.6 kg}
55.7
37.5
206.8 N
{21.1 kg}
57.2
196.4 N
{20.0 kg}
55.7
37.5
206.8 N
{21.1 kg}
57.2
196.4 N
{20.0 kg}
59
45
137.3 N
{14.0 kg}
57.2
130.4 N
{13.3 kg}
Standard size
Tolerance
Repair limit
5.0
0.1
4.4
Thickness of clutch disc

(No.3, 4, 5 clutches)
5.0
0.1
4.3
Thickness of clutch plate

(No.1, 2, 3, 4, 5 clutches)
3.2
0.1
2.9
Total thickness of No.1 clutch assembly consisting of 5 discs and 5 plates
41.0
0.3
38.9
10
46.0
0.4
43.7
11
29.6
0.3
20.2
12
29.6
0.3
20.2
13
29.6
0.3
20.2
Thickness of clutch disc

(No.1, 2 clutches)
Backlash between each sun gear and

14 planetary pinion (forward, reverse,
2nd and 3rd)
Replace
0.13 0.32
Backlash between reverse planetary

pinion and internal teeth of ring gear
0.13 0.37
Backlash between each planetary

16 pinion and internal teeth of ring gear
(forward, 1st and 3rd)
0.14 0.37
15
17
Backlash between reverse carrier

and internal teeth of ring gear
0.17 0.47
18
Backlash between forward carrier

and internal teeth of ring gear
0.17 0.53
19
Backlash between 1st carrier and

internal teeth of ring gear
0.30 0.64
20
Backlash between1st sun gear and

planetary pinion
0.14 0.35
21
Backlash between 2nd planetary pinion and internal teeth of ring gear
0.14 0.43
D85EX, PX-15E0
25
SEN00295-00
Operation
Operation of disc clutch
q
The disc clutch consists of piston (12), plate
(11), disc (10), pin (35), return spring (33), etc.
to secure ring gear (hub) (34).
q
The internal teeth of discs (10) are meshed
with the external teeth of ring gear (hub) (34).
q
The teeth on the outer diameter of plate (11)
engage with pin (35) fixed to clutch housing
(32).
Clutch disengaged (released)

q
When the supply of pressure oil from the control valve is shut off, piston (12) is returned to
the right direction by the force of piston return
spring (33). This releases the frictional force
between plates (11) and discs (10), making the
ring gear (hub) (34) release.
Clutch engaged (fixed)

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 rotation of discs so ring gear (hub) (34) meshing
with the internal teeth of the disc is locked.
q
26
D85EX, PX-15E0
SEN00295-00
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 electronically 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 forward 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
SEN00295-00
Power transmitting route

Forward 1st speed
28
When the transmission is set to forward 1st,

the No. 2 clutch and No. 5 clutch are engaged.
The motive force from the torque converter
transmitted to input shaft (5) is then transmitted to output shaft (19).
No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds ring
gear (30) in position. No. 5 clutch is actuated
by the hydraulic pressure applied to the clutch
piston, and holds ring gear (20) in position.
The motive force from the torque converter is
transmitted to input shaft (5), and the rotation
of the input shaft passes through sun gear (29)
and is transmitted to planetary pinion (13).
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).
Carrier (31) and carrier (27) are joined by a

spline, and rotate as one unit, so the rotation of
carrier (31) passes through planetary pinion
(24) and is transmitted to ring gear (25).
Carrier (21) is meshed with ring gear (25), and
rotates as one unit, so the rotation is transmitted to planetary pinion (17).
Ring gear (20) is being held in position by No.
5 clutch, so the rotation of planetary pinion (17)
rotates sun gear (18), and this rotates output
shaft (19).
D85EX, PX-15E0
SEN00295-00
Forward 2nd speed
When the transmission is set to forward 2nd,

ring gear (30).
D85EX, PX-15E0

shaft (19).
29
SEN00295-00
Forward 3rd speed
30
When the transmission is set to forward 3rd,

ring gear (30).

rotates output shaft (19).
D85EX, PX-15E0
SEN00295-00
Reverse 1st speed
When the transmission is set to reverse 1st,

No. 1 clutch is actuated by the hydraulic pressure applied to the clutch piston, and holds
carrier (36) in position. No. 5 clutch is actuated
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
Carrier (31) and carrier (27) are joined by a

spline, and rotate as one unit, so the rotation of
carrier (31) passes through planetary pinion
(24) and is transmitted to ring gear (25).
shaft (19).
31
SEN00295-00

a
32
ECMV: Abbreviation for Electronic Control Modulation Valve
D85EX, PX-15E0
A:
B:
C:
D:
E:
F:
P:
T:
1st clutch oil pressure pick-up port

3rd clutch oil pressure pick-up port
R clutch oil pressure pick-up port
2nd clutch oil pressure pick-up port
F clutch oil pressure pick-up port
To clutch
From pump
Drain
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Proportional solenoid valve (for 3rd clutch)

Proportional solenoid valve (for 1st clutch)
Proportional solenoid valve (for R clutch)
Proportional solenoid valve (for 2nd clutch)
Proportional solenoid valve (for F clutch)
Fill switch (for 3rd clutch)
Fill switch (for 2nd clutch)
Fill switch (for 1st clutch)
Fill switch (for R clutch)
Fill switch (for F clutch)
Connector for proportional solenoid valve (for 1st clutch)
Connector for proportional solenoid valve (for 3rd clutch)
Connector for proportional solenoid valve (for R clutch)
Connector for proportional solenoid valve (for 2nd clutch)
Connector for proportional solenoid valve (for F clutch)
Connector for fill switch (for 3rd clutch)
Connector for fill switch (for 2nd clutch)
Connector for fill switch (for 1st clutch)
Connector for fill switch (for R clutch)
Connector for fill switch (for F clutch)
Filter
Pressure control valve
Pressure detection valve
Pressure control valve spring
D85EX, PX-15E0
SEN00295-00
33
SEN00295-00
Outline of ECMV
q
The ECMV consists of 1 pressure control valve
and 1 fill switch.
q
Pressure control valve
This valve receives the current from the transmission controller with the proportional solenoid, and then converts it into oil pressure.
q
Fill switch
This switch detects that the clutch is filled with
oil and has the following functions.
1. Outputs a signal (a fill signal) to the controller
to notify that filling is completed when the
clutch is filled with oil.
2. Keeps outputting signals (fill signals) to the
controller to notify presence or absence of oil
pressure while oil pressure is applied to the
clutch.
ECMV and proportional solenoid

q
For each ECMV, 1 proportional solenoid is
installed.
The proportional solenoid generates thrust
shown below according to the command current from the controller.
The thrust generated by the proportional solenoid is applied to the pressure control valve
spool to generate oil pressure as shown in the
figure below. Accordingly, the thrust is changed
by controlling the command current to operate
the pressure control valve to control the flow
and pressure of the oil.
Current of propulsion solenoid thrust characteristics
Thrust of proportional solenoid oil pressure

characteristics
Region A:
Area B:
Range C:
Range D:
Point E:
Point F:
a
34
Before shifting gear (when draining)

During filling
Pressure regulation
During filling (During triggering)
Start of filling
End of filling
ECMV and fill switch

q
For each ECMV, 1 fill switch is installed.
As the clutch complete filling, the fill switch is
turned ON by the pressure of the clutch. This
signal starts increasing the oil pressure.
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
Operation of ECMV
q
ECMV is controlled with the command current
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.
SEN00295-00
Before shifting gear (when draining) (Range A

in chart)
Region A:
Area B:
Range C:
Range D:
Point E:
Point F:
a
Before shifting gear (when draining)

During filling
Pressure regulation
During filling (During triggering)
Start of filling
End of filling
Under the condition where any current is not

sent to proportional solenoid (1), pressure control 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
turnedoff.
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
SEN00295-00
During filling (Range B in chart)
36
If current is supplied to proportional solenoid

(1) with no oil in the clutch, the oil pressure
force balanced with the solenoid force is
applied to chamber (B) and pushes pressure
control valve (2) to the right. As a result, pump
port (P) and clutch port (A) open and oil starts
filling the clutch. If the clutch is filled with oil,
pressure detection valve (3) is actuated and fill
switch (4) is turnedon.
Pressure regulation (Range C in chart)
If current is applied to proportional solenoid

(1), the solenoid generates propulsion force
that is proportionate to the current. The pressure is adjusted by balancing the propulsion
force of the solenoid, the propulsion force of
clutch port (A), and reaction force of pressure
control spring (5).
D85EX, PX-15E0
SEN00295-00
Main relief valve and torque converter relief valve
A:
B:
C:
D:
E:
P1:
P2:
1.
2.
3.
4.
5.
Drain (Torque converter relief)

Drain
From pump
Drain
To torque converter
Main relief oil pressure pick-up port
Torque converter relief oil pressure pick-up port
Body
Piston
Torque converter relief valve
Piston
Main relief valve
Unit: mm
No.
Check item
Clearance between main relief
valve and valve body
Clearance between torque converter relief valve and valve
body
Criteria
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
28
0.035
0.045
+0.013
+0.013
0.035
0.058
0.078
22
0.035
0.045
+0.013
+0.013
0.035
0.058
0.078
Standard size
8
Main relief valve spring

(outside)
Remedy
Free length
Repair limit
Installation
Free length
length
load
load
128
75.3
508.6 N
{51.9 kg}
124.2
483.2 N
{49.3 kg}
Main relief valve spring

(inside)
108
75.3
401.8 N
{41.0 kg}
104.8
381.7 N
{39.0 kg}
10

spring
50
40.5
182.1 N
{18.6 kg}
48.5
173 N
{17.7 kg}
D85EX, PX-15E0
Replace
37
SEN00295-00
Outline
Main relief valve
q
The main relief valve is keeping each oil pressure circuit of the transmission and the brake
below the set pressure.
Set pressure: 3.40 MPa {34.7 kg/cm2}
(Engine at rated speed)
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}
(Cracking pressure)
Operation
Operation of main relief valve
q
The oil from the hydraulic pump passes
through the filter and enters port (A) of the
relief valve. It then passes through orifice (a) of
spool (6) and enters chamber (B).
When the oil from the pump fills the circuit, the
oil pressure starts to rise.
38
Operation of torque converter relief valve

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
(2) and enters chamber (D).
When the circuit leading to the torque converter becomes filled with oil, the oil pressure
starts to rise.
q
As the oil pressure going to the torque converter rises, the oil entering chamber (D)
pushes piston (9). The reaction force moves
spool (2) to the right to open the circuit
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).
D85EX, PX-15E0
Lubrication relief valve
SEN00295-00
Unit: mm
No.
Check item
Criteria
Standard size
Lubrication relief valve spring
Free length
26
2.
3.
4.
Piston
Spring
Forward clutch housing
A:
B:
C:
From oil cooler

Drain
Drain
D85EX, PX-15E0
Remedy
Repair limit
Installation
Free length
length
load
load
23.7
12.0 N
{1.22 kg}
25.2
Replace
11.4 N
{1.16 kg}
Outline
q
The oil leaving the torque converter passes
through the oil cooler built in the radiator lower
tank. It then goes through the lubrication relief
valve and lubricates the transmission and
PTO.
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 pressure) is 0.34 MPa {3.5 kg/cm2}.
The normal oil pressure is 0.08 0.20 MPa
{0.8 2.0 kg/cm2}.
39
SEN00295-00

40
SEN00297-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN00297-00
Power train, Part 2
Bevel gear shaft, HSS and brake 1

a
D85EX, PX-15E0
D85EX, PX-15E0
SEN00297-00
SEN00297-00
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
SEN00297-00
Output shaft
Brake spring (large)
Brake spring (small)
Stopper
Hub
Cage
Piston (number of teeth: 109)
Cover
Plate (one side: 5 pcs.)
Disc (one side: 6 pcs.)
Brake drum (number of teeth: 109)
Brake hub (number of teeth: 72)
Gear A (number of teeth: 55)
Cage
Gear B (number of teeth: 32)
Bevel gear shaft
Bevel gear (number of teeth: 35)
Bearing
Shaft
Gear C (number of teeth: 32)
Planetary pinion (number of teeth: 26)
Ring gear (number of teeth: 91)
Planetary shaft
Hub (number of teeth: 91)
Carrier
Gear D (number of teeth: 48)
HSS motor drive gear (number of teeth: 25)
HSS motor
D85EX, PX-15E0
SEN00297-00
D85EX, PX-15E0
SEN00297-00
Unit: mm
No.
Check item
Thickness of bake plate
1
Brake plate distortion
Thickness of bake disc
2
Brake disc distortion
Criteria
Remedy
Standard size
Repair limit
3.0
2.7
Tolerance
Repair limit
Max 0.15
0.3
Standard size
Repair limit
5.2
4.9
Tolerance
Repair limit
Max 0.25
0.4
Standard size
Repair limit
46.2
43.3
Standard clearance
Clearance limit
0.06 0.65
Total assembled thickness of brake

plates and discs
Backlash between gear A and

gear B
Backlash between sun gear and

planetary pinion
0.14 0.35
Backlash between planetary pinion

and ring gear
0.15 0.38
Backlash between bevel gear and

pinion
0.20 0.28
0.45
Preload of taper roller bearing for

bevel gear shaft
D85EX, PX-15E0
Replace
Repair or replace
Replace
Repair or replace
Replace
Adjust
Starting torque 10.3 14.7 Nm {1.05 1.50 kgm}
SEN00297-00
Unit: mm
No.
Check item
Remedy
Standard clearance
Clearance limit
0.09 0.64
Backlash between gear C and

gear D
0.15 0.49
Backlash between gear D and

HSS motor drive gear
0.10 0.40
Backlash between gear A and

gear D
2
3
Criteria
Replace
D85EX, PX-15E0
SEN00297-00
Outline
Bevel gear shaft
q
The engine power is transmitted through the
torque converter to the transmission. Then,
the bevel gear shaft system engages the bevel
pinion with bevel gear (17) to turn the engine
power at a right angles into the lateral direction
and reduce the rotation speed.
q
The bevel gear shaft system adopts the spiral
bevel gear at the bevel pinion and bevel gear
(17), and it adopts the splash lubrication with
the oil from the lubrication pump and the scavenging pump for lubrication.
q
The bevel gear shaft system consists of bevel
gear (17) which meshes with the bevel pinion,
bevel gear shaft (16), bevel gear shaft bearing
(18) which supports the bevel gear shaft and
cage (14).
HSS
q
The HSS (Hydrostatic Steering System) is constructed from the transfer area which transmits
the rotation of HSS motor (28) by turning it in
the reverse direction, and the planetary area
which adjusts the inputs to ring gear (22) and
gear A (13) and then outputs to carrier (25).
The tur nin g dir ec tion o f the m achi ne is
changed by stopping or reversing the revolution of the HSS motor (28).
q
The transfer unit employs a spur gear speed
reduction mechanism and is lubricated with oil
splashed by the scavenging pump and lubrication pump.
q
Planetary area adopts forced lubrication with
oil from scavenging pump and lubrication
pump for lubrication.
q
The transfer unit consists of HSS motor drive
gear (27) connected to HSS motor (28) by the
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) connected to brake inner drum (12).
D85EX, PX-15E0
Brake
q
The brake is established only to control the
movement of the machine, and is attached to
brake inner drum (12).
q
The brake adopts the wet multiple disc clutch
type and the spring-boosted type, and it is the
hydraulic actuated type by the brake valve
which is activated with the operation of the
brake pedal.
In addition, lubrication adopts the forced lubrication type which sends the oil from the power
train lubrication pump and the scavenging
pump to the housing and the cage through the
passage inside the steering case, and eventually to the disc plate.
When the engine is stopped, the back pressure of the brake piston descends even if the
brake pedal is not depressed, which initiates
the brake to operate. However, the parking
brake must be in the lock position, because
the brake is released as the oil pressure
within the circuit rises when the engine is
restarted.
The brake is constructed from; carrier (25),
inner drum (12) attached to brake hub (5), disc
(10) meshed with the inner drum, plate (9)
whose outside perimeter is connected to brake
drum (11) by the gear, brake drum (11), piston
(7) and springs (2) and (3) which compress the
disc and the plate, and cage (6), brake cover
(8) and output shaft (1) which support all of
them.
Brake drum (11) and brake cover (8) are fixed
to the steering case.
Output shaft (1) is connected to brake hub (5)
by the spline and fixed in the axial direction
with stopper (4).
SEN00297-00
HSS operation
When steering operation is at neutral (straight travel)
When the steering lever is at the neutral position,

the rotation of the gear in the transfer section and
the left and right gears A (13) in the planet section
is also stopped.
Under this condition, the power from bevel gear
shaft (16) is input to ring gear (22), is transmitted to
carrier (25) through planetary pinion (21) and planetary pinion shaft (23), and then to output shaft (1)
through brake inner drum (12) and brake hub (5).
Therefore, the number of the output rotation of left
and right is the same and the machine travels
straight.
10
Rotation direction of HSS motor

PCCS lever
steering operation
Neutral
PCCS lever
forward/reverse
switching operation
Free,
*
not
Neuspectral
ified
*
For- Reve
Neuward rse
tral
Rotation direction
of HSS motor
viewed from left side
of machine
Does
not
rotate
Left
Right turn
Left
Left turn
For- Reve
ward rse
Right Right Right
Left
*: Counter-rotation
D85EX, PX-15E0
SEN00297-00
When steering operation is at right turn (forward travel)
*A: Transmission power

*B: HSS motor power
*C: Combined power
*1.
*2.
*3.
*4.
*5.
*6.
Transmission output speed

Increase in speed from HSS motor
Left bevel gear shaft output speed (*1. + *2.)
Decrease in speed from HSS motor
Right bevel gear shaft output speed (*4. *5.)
D85EX, PX-15E0
If the steering lever is operated to theright when

traveling forward; HSS motor (28) rotates counterclockwise, gear A (13) on the left side of the
machine rotates clockwise, and gear A (13) on the
right side of the machine rotates counterclockwise,
viewing from the left side of the machine.
When traveling forward, bevel gear shaft (16) and
ring gear (22) linked to the shaft, rotate clockwise,
viewing from the left side of the machine.
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. Therefore, the machine travels forward turning to the right
whose output rotation speed is lower.
11
SEN00297-00
When steering operation is at right turn (reverse travel)

*B: HSS motor power
*C: Combined power
*1.
*2.
*3.
*4.
*5.
*6.

Left bevel gear shaft output speed (*1. + *2.)
Right bevel gear shaft output speed (*4. *5.)
If the steering lever is operated to the right when

the machine is traveling in reverse, the action of the
selector valve makes HSS motor (28) rotate in the
opposite direction when traveling forward. That is,
the HSS motor rotates clockwise and gear A (13)
on the left side of the machine rotates counterclockwise while gear A (13) on the right side of the
12
machine rotates clockwise viewing from the left

side of the machine.
When the machine is traveling in reverse, bevel
gear shaft (16) and ring gear (22) which are interconnected, rotate counterclockwise viewing from
the left side of the machine.
element in pair of planetary gears, that of left side carrier (25) increases its speed (in the reverse direction)
with the power of HSS motor, and that of right side
carrier (25) slows down, compared to that of straight
forward. Therefore, the machine travels backward
turning to the right side whose output rotation speed is
lower.
D85EX, PX-15E0
SEN00297-00
When steering operation is at left turn (forward travel)

*B: HSS motor power
*C: Combined power
*1.
*2.
*3.
*4.
*5.
*6.

Left bevel gear shaft output speed (*1 *2)
Right bevel gear shaft output speed (*4. + *5.)
If the steering lever is operated to the left, when

traveling forward; HSS motor (28) rotates clockwise, gear A (13) on the left side of the machine
rotates counterclockwise, and gear A (13) on the
right side of the machine rotates clockwise, viewing
from the left side of the machine.
On the other hand, when traveling forward, bevel
gear shaft (16) and ring gear (22) linked to the
shaft, rotate clockwise, viewing from the left side of
the machine.
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. Therefore, the machine travels forward turning to the left
whose output rotation speed is lower.
D85EX, PX-15E0
13
SEN00297-00
When steering operation is at left turn (reverse travel)

*B: HSS motor power
*C: Combined power
*1.
*2.
*3.
*4.
*5.
*6.

Left bevel gear shaft output speed (*1 *2)
Right bevel gear shaft output speed (*4. + *5.)
If the steering lever is operated to the left when

the machine is traveling in reverse, the action of the
selector valve makes HSS motor (28) rotate in the
opposite direction when traveling forward. That is,
the HSS motor rotates counterclockwise and gear
A (13) on the left side of the machine rotates clockwise while gear A (13) on the right side of the
14
machine rotates counterclockwise viewing from the

left side of the machine.
When the machine is traveling in reverse, bevel
gear shaft (16) and ring gear (22) which is interconnected, rotate counterclockwise viewing from the
left side of the machine.
element in pair of planetary gears, that of right side
carrier (25) increases its speed (in the reverse
direction) with the power of HSS motor, and that of
left side carrier (25) slows down, compared to that
of straight forward. Therefore, the machine travels
backward turning to the left side whose output rotation speed is lower.
D85EX, PX-15E0
SEN00297-00
Brake operation
When brake is released
When the brake pedal is at the released position,
the brake valve is at the neutral position and the
back pressure port of brake piston (7) is filled with
the oil.
Rising of the oil pressure makes the piston move
towards the left direction and compress springs (2)
and (3), and release disc (10) and plate (9). Then,
the power transmitted from bevel gear shaft (16) via
HSS steering to brake inner drum (12), is transmitted from hub (5) to output shaft (1) and then to the
final drive.
D85EX, PX-15E0
When brake is operated (when brake pedal

depressed)
When the brake pedal is depressed, the brake
valve is switched and the oil which applies the back
pressure to piston (7) is connected to the drain circuit.
In this condition, piston (7) moves to the right direction using tension of springs (2) and (3), and compresses disc (10) and plate (9) against the stopper
portion of brake outer drum (11). The brake outer
drum is connected and fixed to the steering case.
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 piston (7), the brake pedal can adjust the braking
power.
15
SEN00297-00
Brake valve
P:
T1:
T2:
Br (R):
Br (L):
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
16
From power train pump

To steering case
To steering case
To right brake
To left brake
Parking brake valve

Main brake valve
Body
Return spring
Plug
Return spring
Brake valve
Piston
Shaft
Modulating spring
Guide
Outline
The brake valve is located in the circuit
between the power train pump through the
main relief valve and the piston of the brake
inside HSS unit. It consists of the main brake
valve and the parking brake valve.
q
When the brake pedal is depressed, the oil
flow to the brake piston is interrupted, the
brake piston compresses the disc and the
plate by the force of the spring and the brake is
operated.
In case of HSS, since the brake is for braking
power control [not involved in steering operation], both left and right brake operates concurrently.
q
D85EX, PX-15E0
SEN00297-00
Unit: mm
No.
Check item
Clearance between brake valve
and body
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
19
0.020
0.030
+0.013
+0.013
0.020
0.043
0.07
Clearance between brake valve

and piston
0.030
0.040
+0.015
+0.015
0.030
0.055
0.08
Clearance between parking brake

valve and body
19
0.034
0.043
+0.013
+0.013
0.034
0.056
0.08
Standard size
Brake modulating spring
Brake valve return spring
Parking brake valve return spring
D85EX, PX-15E0
Repair limit
Free length
Installation
length
Installation
load
Free length
Installation
load
48
36
75.3 N
{7.68 kg}
46.6
71.6 N
{7.3 kg}
52
37
169 N
{17.3 kg}
50.4
162 N
{16.5 kg}
36.5
28.5
16.7 N
{1.7 kg}
35.4
15.7 N
{1.6 kg}
Replace
17
SEN00297-00
Operation
When the brake is released (brake pedal released, parking brake lever free)
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 measured at pressure pick-up port (Q).
18
D85EX, PX-15E0
SEN00297-00
When the brake is engaged (when brake pedal depressed, parking brake lever free)
When starting to depress the brake pedal,

guide (11) and shaft (9) are pushed to the right
direction and compress modulating spring
(10), and its reaction force moves brake valve
(7) to the right direction. When this happens,
chamber (C) and port (D) close and port (D)
and port (E) open. The oil from the power train
pump enters chamber (B) through port (A) and
blocked by chamber (C).
A portion of oil which had flown into the brake
piston back pressure port is drained from port
(D) to port (E). The other portion of oil flows
through port (D) and orifice (a) to chamber (H).
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 maintained not to be reduced.
D85EX, PX-15E0
As the brake pedal is depressed further, the

operation as described above is repeated until
brake valve (7) reaches to the stroke end, at
which the brake is fully engaged.
The oil pressure behind port (D) is determined
by the tension of return spring (6) of which load
varies in accordance with the brake pedal
travel.
When the brake pedal travel is short, the oil
pressure behind port (D) is high, meaning that
the brake is half way engaged, and when the
travel is long, the oil pressure is low, meaning
that the brake is engaged.
19
SEN00297-00
When the brake is parked (brake pedal released, parking brake lever locked)
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).
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
SEN00297-00
21
SEN00297-00
Final drive
Outline
q
The final drive is a single-stage spur gear, single-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 lubrication oil leakage.
22
D85EX, PX-15E0
SEN00297-00
D85EX-15E0
D85EX, PX-15E0
23
SEN00297-00
D85PX-15E0
24
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEN00297-00
10.
11.
12.
13.
14.
15.
16.
17.
Floating seal
Sun gear
Carrier
Sprocket boss
Sprocket teeth
Cover
Planetary gear
Ring gear
Cover
No.1 pinion
Final drive case
Bearing cage
No.1 gear
No.1 gear hub
Shaft
Wear guard
Pivot shaft
Unit: mm
No.
Check item
18
Backlash between No.1 pinion and

No.1 gear
19
Criteria
Remedy
Standard clearance
Clearance limit
0.23 0.79
0.79
Backlash between sun gear and

planetary gear
0.20 0.74
0.74
20
Backlash between planetary gear

and ring gear
0.24 0.83
0.83
21
Outer diameter of oil seal contact

surface of No.1 pinion
22
Thickness of thrust collar of inner

body roller bearing
Interference between outer diameter of planetary gear shaft and inner

23
diameter of carrier hole (small
diameter)
Interference between outer diameter of planetary gear shaft and inner
24
diameter of carrier hole (large
diameter)
25
Standard size
Tolerance
Repair limit
70
0.074
0.074
69.9
23
D85EX, PX-15E0
Replace or
repair
22.95
Tolerance
Shaft
Hole
Standard
interference
Interference
limit
70
+0.021
+0.002
0.03
0.03
0.002
0.051
0.002
84
+0.059
+0.037
+0.035
+0.035
0.002
0.059
0.002
Standard
size
Standard shim thickness for No.1

pinion bearing cage
26 Wear of wear guard
Replace
Replace
Adjust
Standard size
Repair limit
52
21
Replace or repair
25
SEN00297-00
Power transmitting route
26
D85EX, PX-15E0
SEN00297-00
The power from the bevel gear and the steering clutch is transmitted to No.1 pinion (10) and
to No.1 gear (13) which meshes with No.1 pinion (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

28
SEN00298-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up


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
SEN00298-00
Main frame
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
SEN00298-00
Main frame
Cage
Clamp
Cover
Seal
Clamp
Cap
Plate
Unit: mm
No.
Check item
Clearance between equalizer bar
shaft and bushing
Criteria
Standard
size
80
10
Press fit force of equalizer bar shaft

mounting bushing
D85EX, PX-15E0
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
0.030
0.076
+0.179
+0.100
0.130
0.255
1.5
21.6 71.6 kN {2.2 7.3 ton}
Replace
Adjust
SEN00298-00
Suspension
1.
2.
3.
4.
5.
6.
7.
Equalizer bar
Cover
Thrust plate
Thrust plate
Pivot shaft
Seal cage
Outline
The front of the track frame rocks up and down
using rear pivot shaft (6) as a fulcrum. Equalizer bar (1) is connected to the right and left
track frames by side pin (10) and sways using
center pin (11) as a fulcrum.
D85EX, PX-15E0
8.
9.
10.
11.
12.
SEN00298-00
Seal
Bushing
Side pin
Center pin
Bushing
Unit: mm
No.
Check item
Criteria
Press-fitting force of side pin bushing
15.7 35.3 kN {1.6 3.6 ton}
12
14
Press-fitting force of center pin

bushing
Clearance between center pin and

13
bushing
Clearance between side pin and
bushing
Interference between side pin boss

15
and bushing
57.9 161.8 kN {5.9 16.5 ton}

Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
80
0.030
0.076
+0.234
0.169
0.199
0.310
1.0
60
0.030
0.060
+0.046
+0.046
0.030
0.106
1.0
Standard
size
110
D85EX, PX-15E0
Remedy
Tolerance
Shaft
Hole
Standard
interference
Interference
limit
+0.035
+0.017
0.024
0.059
0.041
0.094
Replace bushing
SEN00298-00
Unit: mm
No.
Check item
Interference between pivot shaft

16
and seal stopper ring
Criteria
Standard
size
157
Clearance between pivot shaft and

17
bushing
18
Clearance between pivot shaft and

bushing
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
interference
Interference
limit
+0.083
+0.043
0.050
0.090
0.093
0.173
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
148
0.145
0.208
+0.099
+0.035
0.180
0.307
1.0
155
0.145
0.208
+0.132
+0.059
0.204
0.340
1.0
Replace
Replace bushing
D85EX, PX-15E0
SEN00298-00
Track frame
a
The figure shows D85EX-15E0.
1.
2.
3.
4.
5.
6.
7.
8.
Equalizer bar
Idler
Carrier roller
Track frame
Sprocket
Track roller guard
Track roller
Pivot shaft
Track roller
D85EX-15E0
Quantity for
one side
Flange type and arrangement
7 pieces
S, D, S, S, S, D, S
Quantity for
one side
Flange type and arrangement
8 pieces
S, S, D, S, S, S, D, S
S: Single flange
D: Double flange
D85PX-15E0
S: Single flange
D: Double flange
D85EX, PX-15E0
SEN00298-00
Unit: mm
No.
Check item
Deformation of track frame
D85EX, PX-15E0
Criteria
Remedy
Item
Repair limit
Bending
7 (for level length of 3,000)
Twisting
3 (for level length of 300)
Dent (pipe portion)
12
Repair or replace
SEN00298-00
Idler cushion
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
10
Yoke
Dust seal
Rod
Recoil spring
Wear ring
Lubricator
Nut
Housing
Cylinder
Holder
Outline
The idler cushion moves rod (3) back and forth
by filling or draining grease from lubricator (6)
and adjusts the track shoe tension. The idler
cushion also dampenes any sudden shock to
the idler.
D85EX, PX-15E0
SEN00298-00
Unit: mm
No.
Check item
Criteria
Remedy
Press-fitting force of idler yoke
392 kN {40 ton}
Adjust
Clearance between rod and

bushing
Standard
size
90
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.120
0.207
+0.270
+0.061
0.181
0.477
1.0
Standard size
Recoil spring
D85EX, PX-15E0
Repair limit
Free length
Installation
length
Installation
load
Free length
Installation
load
787.4
651
227.5 kN
{23,200 kg}
855
208.9 kN
{21,300 kg}
Replace
11
SEN00298-00
Idler
12
D85EX, PX-15E0
SEN00298-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
686
Outer diameter of tread
650
625
Depth of tread
18
30.5
Thickness of tread
23
10.5
Width of tread
49.5
53.5
Overall width
204.0
Clearance between shaft and

bushing
Outer diameter of projection

support
Axial play of shaft
Clearance between guide plate and

10
support
Standard
size
Tolerance
Standard clearance
Shaft
Hole
68
0.250
0.350
+0.188
0.024
0.226 0.538
68
0.250
0.290
-0.110
0.220
0.030 0.180
Replace
0.26 0.66
2.0
Build-up welding or
replace
Adjust shim or
replace plate
11
Clearance between guide plate and

side plate
0.5 1.0
12
Standard shim thickness for guide

plate
13

plate
14

plate
D85EX, PX-15E0
Build-up welding or
replace
Adjust
13
SEN00298-00
Track roller
14
D85EX, PX-15E0
SEN00298-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
254
246
222.0
182
Thickness of tread
53.5
33.5
Width of flange (outside)
21.0
Width of flange (inside)
21.0
Width of tread (single flange)
55.6
Width of tread (double flange)
51.6
Overall width
251.2
Outer diameter of flange (outside)
Outer diameter of flange (inside)
Outer diameter of track roller tread
4
5

10
bushing
Standard
size
70
Interference between outside

11
bushing and roller
Standard
size
115
Tolerance
Shaft
Hole
0.210
0.260
+0.134
+0.060
Tolerance
Shaft
Hole
+0.094
+0.040
+0.027
0.047
D85EX, PX-15E0
Standard clearance
0.270 0.394
Replace
0.013 0.141
Standard clearance
12 Axial play of shaft

13 Width of collar on shaft
Build-up welding or
replace
0.50 0.75
Standard size
Allowable size
20.0
15
SEN00298-00
Carrier roller
16
D85EX, PX-15E0
SEN00298-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
217
Outer diameter of carrier roller

tread
185
162
Thickness of tread
37.5
26
Width of carrier roller tread
57
Width of flange
19
Outer diameter of flange

support
Standard
size
58
Interference between shaft and

seal guard
Standard
size
59
Axial play of roller
D85EX, PX-15E0
Build-up welding or
replace
Tolerance
Shaft
Hole
0.2
0.2
+0.300
+0.300
Tolerance
Shaft
Hole
+0.046
+0.046
0.12
0.17
Standard clearance
Replace bushing
0 0.5
0.120 0.216
Replace
Standard clearance
0 0.22
17
SEN00298-00
Sprocket
Unit: mm
No.
Check item
Wear of tooth tip
Thickness of tooth root
18
Criteria
Remedy
Standard size
Repair limit
229
217
22
17
Replace or repair
D85EX, PX-15E0
SEN00298-00
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
SEN00298-00
Track shoe
*1. Single shoe

*2. Swamp shoe
a P portion shows the link of bushing press fitting end.
20
D85EX, PX-15E0
SEN00298-00
Unit: mm
No.
Check item
Criteria
Link pitch
Outer diameter of bushing
Height of link
Thickness of link (Press-fitting

portion of bushing)
Shoe bolt
(single shoe)
(heavy duty shoe)
Shoe bolt
(swamp shoe)
Standard size
Repair limit
216.3
219.3
a. Regular link
Reverse
Standard size
Thickness of bushing
Remedy
Light load
Heavy load
79.5
69.3
71.9
15.9
5.7
8.3
Standard size
Repair limit
140
127.5
43.5
31
Tightening torque
(Nm {kgm})
Repair or replace
Retightening angle (angle)

Standard tightening
angle
Allowable
tightening angle
343 39 {35 4}
120
10
b. Master
link
343 39 {35 4}
180
00
20
a. Regular link
539 49 {55 5}
120
10
b. Master
link
343 39 {35 4}
180
00
20
Interference between bushing and

link
Interference between regular pin
and link
Standard
size
Reverse or replace
Allowable size
Retighten
Shaft
Hole
74
+0.344
+0.304
+0.074
+0.074
0.230 0.344
47
+0.190
+0.130
0.138
0.200
0.268 0.390
Adjust or replace
Standard clearance
Clearance between link and link
D85EX, PX-15E0
Each side
Both sides
1.4
2.8
21
SEN00298-00
Single shoe, Heavy duty shoe
Unit: mm
No.
Check item
Height of grouser
Thickness of grouser
Criteria
Remedy
Standard size
Repair limit
Single
shoe
71.4
25
Heavy
duty shoe
71.4
25
Single
shoe
86.4
40
88
41.6
Heavy
duty shoe
Build-up welding or
replace
Swamp shoe
Unit: mm
No.
Check item
Height of grouser
Thickness of grouser
22
Criteria
Remedy
Standard size
Repair limit
120
98
27
Build-up welding or
replace
D85EX, PX-15E0
SEN00298-00

24
SEN00299-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up


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
SEN00299-00
Work equipment hydraulic piping diagram
Semi-U dozer
1.
2.
3.
4.
1. Blade tilt cylinder

R.H. blade lift cylinder
Control valve
Accumulator
5.
6.
7.
8.
Hydraulic tank
HSS pump
L.H. blade lift cylinder
Oil cooler
D85EX, PX-15E0
SEN00299-00
1.
2.
3.
Control valve
Divider block
Ripper lift cylinder
D85EX, PX-15E0
SEN00299-00
1.
2.
3.
4.
Control valve
Divider block
Ripper tilt cylinder
D85EX, PX-15E0
PPC control piping diagram

a
SEN00299-00
PPC: Abbreviation for Proportional Pressure Control
Blade, ripper control
1.
2.
3.
4.
Accumulator
Control valve
Work equipment lock lever
Blade PPC valve
D85EX, PX-15E0
5.
6.
7.
8.
Ripper PPC valve

PPC lock valve
HSS pump
Self pressure reducing valve
SEN00299-00
Work equipment control
D85EX, PX-15E0
1.
2.
3.
4.
SEN00299-00
Work equipment lock lever

Blade control lever
Ripper control lever
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
SEN00299-00
Hydraulic tank and filter
1.
2.
3.
4.
5.
6.
Pressure valve
Drain valve
Drain plug
Cover
Cover
Hydraulic tank
7.
8.
9.
10.
11.
12.
Strainer
Suction valve
Spring
Hydraulic oil filter element
Oil filler cap
Sight gauge
D85EX, PX-15E0
SEN00299-00
Specified value
Tank total capacity (l)
Hi
Hydraulic
tank
Tank capacity (l) Middle
Lo
Oil filler
cap
Cracking pressure
(kPa {kg/cm2})
Actuating pressure of
vacuum valve
(kPa {kg/cm2})
95
74
67
64
38.2 14.7
{0.39 0.15}
0 4.5
{0 0.046}
Specified value
Cracking pressure
(kPa {kg/cm2})
Filter mesh size
Hydraulic oil (mm)
filter
Filtering area (cm2)
Strainer
147 29.4
{1.5 0.3}
20/10/5
13,600
Filtering oil flow

(l/min)
195
Filter mesh size

(mm)
105
Filtering area (cm2)
D85EX, PX-15E0
1,850
SEN00299-00
Scavenging pump
SAR(3)80
A: Suction port
B: Discharge port
Unit: mm
No.
1
Check item
Criteria
Spline shaft rotating torque
Delivery
Oil: SAE10W
Oil temperature: 45 55C
7.85 11.8 Nm {0.8 1.2 kgm}
Type
Speed
(rpm)
Discharge
pressure
(MPa {kg/cm2})
Standard
discharge
amount
(l)
Discharge
amount limit
(l)
SAR(3)80
2,500
0.29 {3.0}
Specifications
Type: SAR(3)80
Theoretical discharge capacity: 80.0 cc/rev
Max. discharge pressure: 20.6 MPa {210 kg/cm2}
Max. revolving speed: 2,500 rpm
10
Remedy
Outline
q
The scavenging pump is installed to the lower
part of the torque converter and the PTO case
and driven with the power from the engine.
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.
D85EX, PX-15E0
SEN00299-00
Power train and steering lubrication pump
SAL(3)63+(2)50
Unit: mm
No.
Check item
Side clearance
Clearance between plain bearing

inner diameter and gear shaft outer
diameter
Pin driving depth
Criteria
Remedy
Type
Standard clearance
Clearance limit
SAL(3)63
0.10 0.15
SAL(2)50
0.10 0.15
SAL(3)63
SAL(2)50
0.060 0.149
Standard size
Tolerance
14
0.5
0.5
Pin driving depth
13
0.5
0.5
Pin driving depth
12
0.5
0.5
Spline shaft rotating torque
9.8 18.6 Nm {1.0 1.9 kgm}
Type
Delivery
Oil: SAE10W
Speed
(rpm)
SAL(3)63
2,500
SAL(2)50
D85EX, PX-15E0
Build-up welding
Discharge
pressure
(MPa {kg/
cm2})
Standard
delivery
(l/min)
Discharge
amount limit
(l/min)
3.3
{34}
63.1
0.29
{3.0}
50.1
11
SEN00299-00
HSS pump
a
Type: HPV160
PA: Pump discharge

PS: Pump suction
PD1: Pump drain
PD2: Pump drain plug
PEN: Control pressure pick-up plug
PLS1: Load pressure input
1.
2.
12
Piston pump
Servo valve
Outline
This pump consists of a variable displacement
swash plate type piston pump and a servo
valve.
Specifications
Type
HPV160
Theoretical delivery (cm3/rev)
160 1
Rated speed (rpm)
2,133
Max. cut off pressure

(MPa {kg/cm2})
38.2 {390}
D85EX, PX-15E0
SEN00299-00
Piston pump
PA:
PS:
PA1:
PEN:
Pump discharge
Pump suction
Pump pressure signal
Control pressure
D85EX, PX-15E0
13
SEN00299-00
1.
2.
3.
4.
5.
6.
7.
14
Shaft
Case
Cradle
Rocker cam
Shoe
Servo piston
Rod
8.
9.
10.
11.
12.
13.
Piston
Cylinder block
Valve plate
End cap
Impeller
Spline
D85EX, PX-15E0
Function
q
The pump converts the engine rotation transmitted to its shaft to oil pressure and delivers
pressurized oil corresponding to the load.
q
It is possible to change the discharge amount
by changing the swash plate angle.
D85EX, PX-15E0
SEN00299-00
Structure
q
Cylinder block (9) is supported to shaft (1) by
spline (13), and shaft (1) is supported by the
front and rear bearings.
q
The end of piston (8) has a concave ball
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 cradle (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).
q
to valve plate (10) while sealing the pressurized 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 cylinder chamber by centrifugal force.
15
SEN00299-00
Operation
Operation of pump
q
Cylinder block (9) rotates together with shaft
(1), and shoe (5) slides on flat surface (A).
When this happens, angle (a) of center line (X)
of rocker cam (4) to the axial direction of cylinder block (9) changes. (a) is called swash plate
angle.
16
When center line (X) of rocker cam (4) is the

same as the axial direction of cylinder block (9)
[s was h pl ate an gl e = 0], the d iffer e nc e
between volumes (E') and (F') inside cylinder
block (9) is 0, so pump does not suck and discharge, and no pumping is carried out. [The
swash plate angle is not set to 0 actually, however.]
In other word, swash plate angle (a) and the
pump discharge amount is in relation of proportion.
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).
In this way, piston (8) slides inside cylinder
block (9), and as a result, a difference is generated between volumes (E) and (F) inside cylinder block (9). The amount of suction and
discharge is equal to difference (F) (E).
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 pressurized oil is sucked in this process.
D85EX, PX-15E0
SEN00299-00
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 according 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 surface 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 pressure (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
SEN00299-00
Servo valve
PA1:
PEN11:
PEN12:
PLS1:
PT:
18
Pump self pressure

Control pressure
Control pressure pick-up plug
Load pressure input
Drain
D85EX, PX-15E0
LS valve
1. Locknut
2. Plug
3. Spring
4. Spool
5. Sleeve
6. Piston
7. Plug
D85EX, PX-15E0
TVC valve
8. Solenoid
9. Piston
10. Sleeve
11. Spring
12. Spring
13. Piston
14. Lever
15. Valve body
SEN00299-00
Variable throttle valve

16. Screw
17. Locknut
18. Spring
19. Seat
20. Spool
21. Block
22. Plug
19
SEN00299-00
Function
LS valve
q
LS valve detects the load and controls the discharge 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 pressure (dPLS) [ = PP PLS], the difference
between main pump pressure (PP) and LS
pressure (PLS), and discharge amount (Q)
changes as shown in the diagram.
During the high load operation, or when the engine

speed slowed down etc., the current is supplied to
TVC valve solenoid by the controller command.
It reduces the pump discharge amount [pump
absorption torque], and reduces the load of engine.

Because the main pump controls its own pressure, 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 excessive response.
2) To prevent cavitation at the suction port
caused by the sudden increase in the suction
volume when changing from minimum to maximum.
q
The characteristics of the variable throttle
valve are as shown in the diagram. It has the
function and property of maintaining the
response during operations at low pressure by
making the area of the opening smaller at high
pressure and the area of the opening larger at
low pressure, and by preventing the above
problems 1) and 2) at high pressure.
q
TVC valve
q
When the pump discharge pressure (PP) is
high, the TVC valve controls the pump so that
no more oil than the constant flow (in accordance with the discharge pressure) flows even
if the stroke of the control valve becomes
larger. It carries out equal horsepower control
so that the horsepower absorbed by the pump
does not exceed the engine horsepower.
q
If the load during the operation becomes larger
and the pump discharge pressure rises, it
reduces the discharge amount from the pump;
and if the pump discharge pressure drops, it
increases the discharge amount from the pump.
q
The relationship between pump discharge pressure (PP) and pump discharge amount (Q) with
the electric current value given to TVC valve
solenoid as the parameter is shown in the diagram.
20
D85EX, PX-15E0
SEN00299-00
Operation
LS valve
(1) When control valve is at neutral position
LS valve is a 3-way selector valve, with pressure [LS pressure] (PLS) from the outlet port of
the control valve brought to spring chamber (i),
and main pump discharge pressure (PP)
brought to chamber (j) of plug (6).
The size of LS pressure (PLS) + force (F) of
spring (3) and the main pump pressure [self
pressure] (PP) determines the position of spool
(4).
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)]
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 interconnected to the drain circuit via the control valve
spool)
Spool (4) is pushed to the left, and port (d) and
port (c) are connected.
D85EX, PX-15E0
Pump pressure (PP) enters the large diameter

end of the piston from port (h). The same
pump pressure (PP) also enters the small
diameter end of the piston, so the swash plate
is moved to the minimum angle by the difference in area of piston (1).
21
SEN00299-00
(2) Operation in direction for maximum pump discharge amount
q
q
22
When the difference between main pump pressure (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).
When spool (4) moves, port (b) and port (c) are
joined and connected to the TVC valve.
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.]
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.
Rod (2) moves to the right and moves the
swash plate in the direction to make the discharge amount larger.
D85EX, PX-15E0
SEN00299-00
(3) Operation in the direction for minimum pump discharge amount
The following explains the situation if servo

piston (1) moves to the left [the discharge
amount becomes smaller].
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.
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.
Main pump pressure (PP) also enters the small
piston diameter end, but because of the difference in area between the large and the small
piston diameter ends of servo piston (1), servo
piston (1) is pushed to the left.
Rod (2) moves in the direction to make the
swash plate angle smaller.
D85EX, PX-15E0
23
SEN00299-00
(4) When servo piston is balanced
24
Let us take the area receiving the pressure at

the large diameter end of the piston as (A1),
the area receiving the pressure at the small
diameter end as (A0), and the pressure flowing
into the large diameter end of the piston as
(PEN).
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).
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.]
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.
The position where spool (4) is balanced and

stopped is the standard center, and the force of
spring (3) is adjusted so that it is determined
when (PP) (PLS) = 1.96 MPa {20 kg/cm2}.
D85EX, PX-15E0
SEN00299-00
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.
q
q
q
Operation of solenoid (1)

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).
On the opposite side to the force pushing this
solenoid push pin (11) is the spring set pressure of springs (3) and (4) and pump pressure
(PP). Piston (2) stops at a position where the
combined force pushing piston (2) is balanced.
The pressure output from TVC valve [pressure
of port (c)] changes according to this position.
The size of command current (X) is determined
by the nature of the operation (lever operation), the selected working mode, and the set
value and actual value of the engine speed.
D85EX, PX-15E0
25
SEN00299-00
b.
q
q
q
q
q
q
q
26
Operation of springs (3) and (4)

The spring load of springs (3) and (4) in the
TVC valve is determined by the swash plate
position.
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.
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.
The spring load is changed by piston (5)
expanding or contracting springs (3) and (4).
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.
Port (c) of the TVC valve is connected to port
(e) of the LS valve [see LS valve]. Self pressure (PP) enters port (b), the small piston
diameter end of servo piston (9), and port (g).
When pump pressure (PP) is small, piston (2)
is on the right.
Port (c) and port (d) are connected, and the
pressure entering the LS valve becomes drain
pressure (PT).
If port (h) and port (e) of LS valve are connected [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.
The pump delivery will be set to the increasing
trend.
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.
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.
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.
The stop position for piston (9) [ = pump discharge 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 piston (2) are in balance.
D85EX, PX-15E0
SEN00299-00
2) When the load on the actuator is small and pump discharge pressure (PP) is high
When the load is large and pump discharge

pressure (PP) is high, the force pushing piston
(2) to the left becomes larger and piston (2)
moves to the position shown in the diagram
above.
As shown in the diagram above, part of the
pressurized oil from port (b) flows out to port
(d) and the pressure oil flowing from port (c) to
the LS valve becomes approximately half of
main pump pressure (PP).
When port (h) and port (e) of LS valve are connected [see LS valve], the pressure from port
(f) enters the large piston diameter end of
servo piston (9), and servo piston (9) stops.
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.
When piston (9) moves to the left, piston (5) is
moved to the right by cam (7) and lever (6).
D85EX, PX-15E0
q
q
Springs (3) and (4) are compressed and push

back piston (2). Because of this force, piston
(2) cuts of the connection from port (b) to port
(c), and port (c) and port (d) are connected.
As a result, the pressure at port (c) [= (f)]
drops, and piston (9) stops moving to the left.
The position in which piston (9) stops when
this happens is further to the left than the position when pump pressure (PP) is low.
27
SEN00299-00
28
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.
D85EX, PX-15E0
SEN00299-00
(1) Operation in direction for maximum pump

delivery
q
Pump discharge pressure (PP) enters the variable throttle valve through port (a).
1)
q
2)
q
When main pump pressure (PP) is high

If the pressure becomes higher than the force
of spring (3) because of the difference in sectional area of spool (4) in chamber (e), spool
(4) moves to the right.
If spool (4) moves to the right, the opening
area between ports (c) and (b) is reduced by
the notch at part (A). Accordingly, less oil flows
from the large diameter end of servo piston (1)
and the moving speed of servo piston (1) is
lowered.
The opening area of part (A) increases and the

oil flowing from the large diameter end of servo
piston (1) through port (c) to port (b) is not limited and the moving speed of servo piston (1)
is heightened.
(2) Operation in the direction for smaller pump

delivery
q
The hydraulic oil flows from port (b) through
port (c) to the large diameter side of servo piston (1).
q
Spool (4) operates according to main pump
pressure (PP) as explained in the above section.
When main pump pressure (PP) is low

Even if main pump pressure (PP) enters chamber (e) through port (a), spool (4) pushes
spring (3) less strongly and moves to the right
for shorter distance.
D85EX, PX-15E0
29
SEN00299-00
HSS motor
a
Type: HMF112
PA: From control valve

PB: From control valve
T2: To hydraulic tank
1.
2.
3.
4.
30
HSS motor
Counterbalance valve
Safety valve
Check valve
Outline
q
This motor is composed of the fixed capacity
swash plate type piston motor, flashing shuttle
valve, bypass valve and charge relief valve.
Specifications
Type
HMF112
Theoretical displacement
(cc/rev)
112.7
Rated output pressure

(MPa {kg/cm2})
38.2 {390}
Rated speed (rpm)
2,241
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
SEN00299-00
10.
11.
12.
13.
14.
15.
16.
17.
Output shaft
Motor case
Thrust plate
Piston
Cylinder block
Valve plate
End cover
Spool return spring
Counterbalance valve
Safety valve
Check valve
Check valve spring
Sub bearing
Spline
Shoe
Main bearing
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
18 Spool return spring
19 Check valve spring
D85EX, PX-15E0
Repair limit
Free length
outer
diameter
Installation
length
Installation
load
Free length
Installation
load
42.7 30.0
40.5
192 N
{19.6 kg}
154 N
{15.7 kg}
43 13.8
32.9
1.27 N
{0.13 kg}
0.98 N
{0.10 kg}
Replace spring if
damaged or
deformed.
31
SEN00299-00
Outline
q
Pressurized oil sent from pump is converted to
rotating torque and is transmitted to output
shaft.
Structure
Cylinder block (5) is supported to output shaft
(1) by spline (15), and output shaft (1) is supported 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).
q
to valve plate (6) while sealing the pressurized
oil.
q
This surface ensures that the hydraulic balance 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 stationary section [valve plate].
q
32
D85EX, PX-15E0
SEN00299-00
Operation
Operation of motor
q
The pressurized oil sent from the pump enters
cylinder block (5) and pushes piston (4) from
the back face.
q
In the case of the motor, the center line of plate
(3) is always at an angle [swash plate angle
(a)] to the axial direction of cylinder block (5).
q
As a result, if we take the example of one of
pistons (4), the oil pressure is applied to the
back face of the piston, and the piston axial
force (FO) is generated.
q
With shoe (16), which is joined to piston (4) by
the spherical surface, reaction force (FR) in a
direction at right angles to flat surface (A) is
generated. The combined force of (FO) and
(FR) is (FP) and this becomes the force to
rotate cylinder block (5).
Rotation speed and torque control

q
As flow (Q) from the HSS pump is increased,
motor speed (N) is heightened.
q
Since the swash plate angle of the HSS motor
is fixed [(a) is constant], rotating torque (T) is
proportional to pressure (P).
q
Swash plate angle (a) is approx. 19.
Q = qN
(q = E F)
T = Pq/2x
Q:
q:
N:
P:
T:
Total flow
Flow per 1 turn
Rotation speed
Pressure
Rotating torque
Shaft (1), which is meshed to cylinder block (5)

by spline (15) transfers this rotating torque to
the output side.
Cylinder block (5) rotates, and while the condition changes from volume (E) to volume (F),
pressurized oil from the pump flows into the
cylinder chamber, and pressure (P) is generated according to the load.
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
SEN00299-00
Brake valve operation

q
The brake valve consists of check valve (12),
counterbalance valve (10), and safety valve
(11), and forms the circuit as shown below.
q
The function and the operation of each component is as given below.
Operation when oil is supplied

q
When the steering lever is operated, the pressurized oil from the control valve is supplied to
port (PA). It pushes open check valve (12a),
and flows from HSS motor inlet port (MA) to
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
The pressurized oil at the side where the oil is

being supplied flows from orifice (E1) of spool
(10) into chamber (S1). And when the pressure in chamber (S1) becomes greater than
the spool switching pressure, spool (10) is
pushed to the right.
In this way, port (MB) and port (PB) are connected, so the outlet port side of the HSS
motor is opened and the HSS motor starts to
turn.
D85EX, PX-15E0
SEN00299-00
Action of brakes when operating steering on

downhill slopes
q
When the steering is operated on a downhill
slopes, if the machine attempts to run away,
the HSS motor will rotate under no load, and
the oil pressure at the inlet port of the HSS
motor will drop. This drop in the pressure will
pass through orifice (E1), so the pressure in
chamber (S1) will also drop.
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 rotation 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.
35
SEN00299-00
Safety valve
Function
q
When the operation of the steering stops,
counterbalance valve (10) closes the circuit at
the inlet and outlet ports of the HSS motor.
q
But the HSS motor continues to turn because
of inertia. As a result, the pressure at the outlet port of the HSS motor becomes extremely
high, and this will damage the HSS motor and
the piping.
q
The safety valve acts to release this abnormal
pressure to the inlet port of the HSS motor to
protect the equipment from damage.
If the pressure in chamber (E) [or chamber (F)]

goes above the set pressure, the force of x/4
(D12 D22) pressure resulting from the difference in area of (D1) and (D2) [or the force
of x/4 (D3 2 D12 ) pressure resulting from
the difference in area of (D3) and (D1)]
becomes greater than the force of the spring
and moves the poppet to the right. The oil then
flows to chamber (F) [or chamber (E)] in the
circuit on the opposite side.
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 outlet port circuit, but the pressure at the outlet
port side continues to rise because of inertia.
36
D85EX, PX-15E0
SEN00299-00

38
SEN00300-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up


Control valve ........................................................................................................................................ 2
Self pressure reducing valve.............................................................................................................. 36
D85EX, PX-15E0
SEN00300-00

Control valve
1
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
D85EX, PX-15E0
D85EX, PX-15E0
SEN00300-00
SEN00300-00
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Cover
Lift spool
Tilt spool
Steering spool
Valve body
Steering priority valve
Load check valve
Pressure compensation valve
Main relief valve
LS relief valve (for steering valve)
Unload valve
LS relief valve (for work equipment valve)
LS check valve (for work equipment valve)
LS check valve (for steering valve)
D85EX, PX-15E0
SEN00300-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
15 Spool return spring (for lift)
Repair limit
Free length
outer
diameter
Installation
length
Installation
load
Free length
Installation
load
73.4 31
68.5
224 N
{22.8 kg}
178 N
{18.2 kg}
16
Spool return spring

(for tilt, steering)
51.7 31.3
50
140 N
{14.3 kg}
112 N
{11.4 kg}
17
Spool return spring

(for lift float)
65.3 36.5
33.5
335 N
{34.2 kg}
269 N
{27.4 kg}
18 Load check valve spring
20.8 10.2
13.5
12.7 N
{1.3 kg}
9.81 N
{1.0 kg}
19

spring (steering valve)
109.4 29.5
81
563 N
{57.4 kg}
450 N
{45.9 kg}
20

spring (tilt valve)
70 6.5
62.5
197 N
{20.1 kg}
158 N
{16.1 kg}
21

spring (lift valve)
97.7 29.5
81
453 N
{46.2 kg}
363 N
{37.0 kg}
86.7 30
66
192 N
{19.6 kg}
154 N
{15.7 kg}
22 Unload valve spring
D85EX, PX-15E0
Replace spring if
damaged or
deformed.
SEN00300-00
1.
2.
3.
Suction valve
Preset check valve
LS bypass valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Suction valve spring
Repair limit
Free length
outer
diameter
Installation
length
Installation
load
Free length
Installation
load
64.9 12.5
56
6.4 N
{0.65 kg}
5.1 N
{0.52 kg}
Replace spring if
damaged or
deformed.
D85EX, PX-15E0
SEN00300-00
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:
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
D85EX, PX-15E0
D85EX, PX-15E0
SEN00300-00
SEN00300-00
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
10
Valve block
Ripper spool
Lift spool
Tilt spool
Steering spool
Valve body
Steering priority valve
Load check valve
Main relief valve
LS relief valve (for steering valve)
Unload valve
LS relief valve (for work equipment valve)
LS check valve (for work equipment valve)
LS check valve (for steering valve)
D85EX, PX-15E0
SEN00300-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
16
Spool return spring

(for lift)
Repair limit
Free length
outer
diameter
Installation
length
Installation
load
Free length
Installation
load
73.4 31
68.5
224 N
{22.8 kg}
178 N
{18.2 kg}
17
Spool return spring

(for tilt, steering)
51.7 31.3
50
140 N
{14.3 kg}
112 N
{11.4 kg}
18
Spool return spring

(for lift float)
65.3 36.5
33.5
335 N
{34.2 kg}
269 N
{27.4 kg}
19 Load check valve spring
20.8 10.2
13.5
12.7 N
{1.3 kg}
9.81 N
{1.0 kg}
20

spring (steering valve)
109.4 29.5
81
563 N
{57.4 kg}
450 N
{45.9 kg}
21

spring (tilt valve)
70 26.5
62.5
197 N
{20.1 kg}
158 N
{16.1 kg}
22

spring (lift valve)
97.7 29.5
81
453 N
{46.2 kg}
363 N
{37.0 kg}
64.5 26.5
62.5
51.3 N
{5.23 kg}
41 N
{4.18 kg}
86.7 30
66
192 N
{19.6 kg}
154 N
{15.7 kg}
23 spring
(ripper valve)
24 Unload valve spring
D85EX, PX-15E0
Replace spring if
damaged or
deformed.
11
SEN00300-00
1.
2.
Suction valve
Preset check valve
3.
4.
LS bypass valve
Suction valve
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
12
Repair limit
Free length
outer
diameter
Installation
length
Installation
load
Free length
Installation
load
64.9 12.5
56
6.4 N
{0.65 kg}
5.1 N
{0.52 kg}
46.8 7.5
40.6
5.49 N
{0.56 kg}
4.41 N
{0.45 kg}
Replace spring if
damaged or
deformed.
D85EX, PX-15E0
SEN00300-00
Operation of control valve

At hold (operation of unload valve)
Function
q
When the main spool is at the hold position, it
drains the excess oil discharged by the pump,
and prevents the pressure from being formed
in the circuit from rising.
14
Operation
q
When the main spool is at the hold position,
the pump pressure passes from chamber (A)
through throttle (4) to chamber (D). Chambers
(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 determined 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).
D85EX, PX-15E0
SEN00300-00
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
When the spool is at the hold position, the
pump pressure is sent from chamber (A)
through the notch in spool (3) of the steering
priority valve, and passes through chamber (B)
to chamber (C).
D85EX, PX-15E0
Chamber (G) is drained through chamber (H)

to chamber (F). When this happens, the pump
pressure is acting on the left end of spool (3) of
the steering priority valve, so it pushes against
the load of spring (4) and moves to the right to
the maximum stroke position.
In this condition, the area of the opening to
spool (1) of the steering valve is at its minimum.
15
SEN00300-00
2)
q
q
q
When turning to the left
dPLS = Differential pressure between ports (K)

and (J) = 2.0 MPa {20 kg/cm2}
dPLS' = Differential pressure between ports (I)
and (D)
dPLS C dPLS'
Operation
When the steering lever is operated to turn the
machine to the left, pilot pressure (PI) acts on
the right end of spool (1) through the EPC
valve.
q
When the pressure becomes greater than the
set load of spring (2), spool (1) moves to the
left. It becomes balanced at a position that
matches pilot pressure (PI).
16
Chamber (C) and chamber (D) are connected,

and the oil from the pump flows through ports
(A), (B), (C) and (D) to HSS motor (6).
At the same time, the load pressure in chamber (D) passes through LS orifice (5) and
chamber (H), and is sent to chamber (G). It is
also sent from LS circuit (O) to pump servo
valve (7).
The condition of the pressure of spool (3) is
chamber (B) pressure C chamber (C) pressure,
and chamber (G) pressure C chamber (D)
pressure, so spool (3) is controlled by the differential pressure of spool (1) (chamber (C)
pressure chamber (D) pressure), and balances with spring (4).
D85EX, PX-15E0
SEN00300-00
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.
On the other hand, if the oil flow is too small,
spool (3) moves in the direction to increase the
oil flow.
In addition, pump servo valve (7) is controlled
so that the differential pressure between pump
pressure (P) and LS pressure (LS) (LS differential 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).
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 opening of the spool.
The return oil flow from HSS motor (6) passes
through chamber (E) and chamber (F), and is
drained.
D85EX, PX-15E0
17
SEN00300-00
2.
18
Work equipment valve (tilt valve, lift valve, ripper valve)

a The diagram shows the blade lift valve.
D85EX, PX-15E0
SEN00300-00
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. Steering valve, the position of pressure compensation
valve spool (3) is determined to match the opening 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
SEN00300-00
3.
20
Meter-out control when blade moves down under its own weight
D85EX, PX-15E0
SEN00300-00
Function
q
If the blade moves down under its own weight,
the oil flow of return oil from cylinder is controlled by the area of the opening of main spool
(1).
Operation
When the spool port is opened by pilot pressure (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 opening between ports (A) and (B), so the downward 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.
q
D85EX, PX-15E0
21
SEN00300-00
4.
22
Meter-out control when blade moves down under its own weight (work equipment lever at float)
D85EX, PX-15E0
SEN00300-00
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
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 circuit, 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 controlled.
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 compound operations with other control valves.
q
D85EX, PX-15E0
23
SEN00300-00
At relief
1. Steering valve
a The diagram shows the condition at relief for steering LS relief valve (5).
24
D85EX, PX-15E0
q
q
q
q
q
SEN00300-00
dP1 = dP3 + dP4 = Differential pressure between ports (M) and (E)
dP2 = Differential pressure between ports (E) and (N)
dP3 = Differential pressure between ports (M) and (B)
dP4 = Differential pressure between ports (B) and (E)
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
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 chambers (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 + leakage 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.
q
D85EX, PX-15E0
25
SEN00300-00
2.
26
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.
D85EX, PX-15E0
q
q
q
q
q
SEN00300-00
dP1 = dP3 + dP4 = Differential pressure between ports (M) and (P)
dP2 = Differential pressure between ports (P) and (N)
dP3 = Differential pressure between ports (M) and (B)
dP4 = Differential pressure between ports (B) and (P)
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 chambers (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 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 + leakage 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
SEN00300-00
3.
28
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.
D85EX, PX-15E0
q
q
q
SEN00300-00
d = P P2
dPO = Differential pressure between ports (H) and (K)
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 compensation valve (3) in the work equipment
valve, and the port pressure is maintained at a
constant value.
Operation
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 compensation 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 minimum 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 equipment LS relief valve (5).
q
D85EX, PX-15E0
29
SEN00300-00
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
q
The steering valve is equipped with steering
priority valve (3), so if the steering valve and
the downstream work equipment valve are
operated at the same time, priority is given to
the flow of oil to the steering valve, and the rest
of the oil discharged from the pump goes to the
work equipment valve.
Operation
When steering spool (1) is operated by pilot
pressure (P1) and the oil flows, a differential
pressure is created between chambers (C) and
(D).
q
Steering priority valve (3) is controlled by this
differential pressure, and at the same time, the
pump swash plate angle is controlled at
(dPLS) = 2.0 MPa {20 kg/cm2}, and the flow of
oil to the steering valve is fixed.
q
For details, see topic 1. Steering valve of
Control of oil flow.
q
In this condition, if downstream work equipment lift spool (2) is operated, the pump pressure momentarily drops.
q
At this point, the differential pressure between
chambers (C) and (D) becomes smaller, and
steering priority valve (3) is moved to the left by
the pressure in chamber (E) in the direction to
throttle the opening to the work equipment
valve.
q
At the same time, (dPLS) becomes smaller, so
the pump swash plate angle moves in the maximum direction to supply an oil flow to make up
the amount that the pressures drops.
q
SEN00300-00
When pump swash plate does not reach maximum angle

q
When the maximum oil flow from the pump is
greater than the sum of the flow demanded by
the steering valve and work equipment valve,
an amount of oil that matches the opening of
steering spool (1) flows to the steering valve.
q
An amount of oil decided by the pump pressure, the load pressure and the area of the
spool opening flows to the work equipment
valve.
When pump swash plate is at maximum angle
q
When the maximum flow of oil from the pump
is smaller than the sum of the oil flow
demanded by the steering valve and work
equipment valve.
1)
q
2)
q
D85EX, PX-15E0
When steering valve load Z work equipment

valve load.
An amount of oil that matches the opening of
steering spool (1) flows to the steering valve,
and the remaining oil flows to work equipment
valve.
When steering valve load > work equipment
valve load.
Pump pressure (P) is determined by the steering valve load, but in this condition, if the
downstream work equipment valve where the
load is smaller is operated, the difference in
pressure will cause the oil to try to flow to the
work equipment valve, so the pump pressure
will drop.
When this happens, steering priority valve (3)
increases the size of the opening to the steering 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.
In this condition, the flow of oil is divided in proportion to the difference in pressure between
differential pressure (P) (P1) and differential
pressure (P) (P2).
The bigger (P1) (P2) is, the smaller the flow
of oil to the steering system becomes.
31
SEN00300-00
2.
32
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.
D85EX, PX-15E0
SEN00300-00
Function
q
It consists of a parallel circuit, so when compound operations are carried out, the oil flow is
divided according to the size of each spool
opening.
Operation
When tilt spool (1) and lift spool (2) are at the
hold position or are operated, steering priority 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.
q
When pressure (P2) Z (P3)

q
Lift valve load pressure (P3) is sent to pump
LS valve (4) through LS passage (O).
1)
q
2)
q
When pump swash plate does not reach maximum angle

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.
When pump swash plate is at maximum angle
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).
In other words, more oil flows to (P2) where
the load is small.
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)

(P) (P2) C (P) (P3), so an oil flow proportional to the size of the spool opening is distributed to each spool.
D85EX, PX-15E0
33
SEN00300-00
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
SEN00300-00
Function
q
This improves the response of the system
including the pump swash plate and pressure
compensation valve by sending the pilot pressure (basic pressure of PPC valve) to the LS
circuit, and compensating the rise of the LS circuit pressure.
Operation
When lift valve spool (1) is at the hold position, pilot pressure (P1) (basic pressure of
PPC valve) is sent through preset check valve
(3) to chamber (F) of the pressure compensation valve. This pressure is called preset pressure (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 supplied 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.
q
D85EX, PX-15E0
35
SEN00300-00
T:
P1:
P2:
PR:
36
To tank
From pump
To fan motor
Supply to PPC valve and EPC valve
D85EX, PX-15E0
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SEN00300-00
Valve (sequence valve)

Spring
Screw
Poppet
Spring (pressure reducing valve pilot)
Spring (pressure reducing valve main)
Valve (pressure reducing valve)
Spring (safety valve)
Ball
Filter
D85EX, PX-15E0
37
SEN00300-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
Free length
outer
diameter
Installation
length
Installation
load
Free length
Installation
load
19.2 7.20
16.1
19.6 N
{2.0 kg}
17.7 N
{1.80 kg}
17.8 7.20
12.7
28 N
{2.90 kg}
25.6 N
{2.60 kg}
13 Spring
71.0 18.0
59.0
200 N
{20.4 kg}
186 N
{19.0 kg}
14 Spring (safety valve)
16.1 7.80
13.4
61.7 N
{6.30 kg}
58.8 N
{6.0 kg}
11
12
Spring
(pressure reducing valve main)
Spring
(pressure reducing valve pilot)
Replace spring if
damaged or
deformed.
Function
q
The self pressure reducing valve reduces the
discharge pressure of the fan pump and supplies it to the PPC valve, EPC valve, etc. as the
control pressure.
38
D85EX, PX-15E0
SEN00300-00
Operation
At engine stop (total low pressure)
Spring (6) pushes poppet (5) to the seat, and

the circuit between ports (PR) and (T) is
closed.
Spring (7) pushes valve (8) to the left side, and
the circuit between ports (P1) and (PR) is
open.
Spring (3) pushes valve (2) to the upper side,
and the circuit between ports (P1) and (P2) is
closed.
D85EX, PX-15E0
39
SEN00300-00
When load pressure (P2) is lower than output pressure (PR) of the self pressure reducing valve
40
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).
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).
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
SEN00300-00
At raise of load pressure (P2)
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.
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).
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
SEN00300-00
In the case of abnormal high pressure
42
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 supplied, is protected from the abnormal high
pressure.
D85EX, PX-15E0
SEN00300-00

44
SEN00302-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN00302-00

Oil cooler bypass valve
C : From hydraulic oil cooler

M: From fan motor
T : To hydraulic tank
1.
2.
3.
4.
Plug
Poppet
Spring
Body
1
1
Outline
This valve is installed in the circuit between the
fan motor oil return circuit and the oil cooler. If
any abnormal pressure is generated in the oil
flowing to the oil cooler, this valve acts to
return the oil directly to the hydraulic tank.
Specified pressure
Cracking pressure
(MPa {kg/cm2})
0.78 {8.0}
D85EX, PX-15E0
SEN00302-00
Unit: mm
No.
Check item
Criteria
Standard size
Spring
Clearance between oil cooler

bypass valve and valve body.
Repair limit
Free length
Installation
length
Installation
load
Free length
Installation
load
30.4
24.5
61.5 N
{6.28 kg}
29.5
58.4 N
{5.96 kg}
Standard
size
14
D85EX, PX-15E0
Remedy
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.032
0.059
+0.027
+0.027
0.032
0.086
0.11
Replace
SEN00302-00
PPC valve
a
For blade lift and blade tilt
D85EX, PX-15E0
P:
T:
P1:
P2:
P3:
P4:

To hydraulic tank
To blade lift valve (port PA3)
To blade lift valve (port PB3)
To blade tilt valve (port PA2)
To blade tilt valve (port PB2)
D85EX, PX-15E0
SEN00302-00
1.
2.
3.
Disc
Plate
Body
SEN00302-00
Operation
At neutral
For blade lift
q
Ports (PA3) and (PB3) of the blade lift control
valve and ports (P1) and (P2) of the PPC valve
are connected to drain chamber (D) through
fine control hole (f) of spool (1).
For blade tilt

q
Ports (PA2) and (PB2) of the blade tilt control
valve and ports (P3) and (P4) of the PPC valve
are connected to drain chamber (D) through
fine control hole (f) of spool (1).
D85EX, PX-15E0
SEN00302-00
During fine control

1.
Control lever neutral o fine control

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 pressure 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 pressure 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 balanced 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 compressed 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 position where the pressure in chamber (PA3)
[same as pressure at port (P1)] is balanced with the force of the return spring.
q
D85EX, PX-15E0
SEN00302-00
2.
When control lever is returned

When disc (5) starts to be returned, spool
(1) is pushed up by the force of centering
spring (3) and the pressure at port (P1).
q
Because of this, fine control hole (f) is connected to drain chamber (D), and the
pressurized oil at port (P1) is released.
q
If the pressure at port (P1) goes down too
far, spool (1) is pushed down by metering
spring (2). Fine control hole (f) is shut off
from drain chamber (D), and almost simultaneously, it is connected to pump pressure 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.
q
During full stroke

q
When disc (5) pushes down piston (4) and
retainer (9) pushes down spool (1), fine control
hole (f) is shut off from drain chamber (D) and
is connected to pump pressure chamber (PP).
q
Therefore, the pilot pressure oil passes
through fine control hole (f), is taken from port
(P1) to chamber (PA3), and pushes the control
valve spool.
q
The return oil from chamber (PB3) passes from
port (P2) through fine control hole (f'), and then
flows to drain chamber (D).
D85EX, PX-15E0
When blade is operated to float

q
When piston (4) at port (P1) lower side is
pushed by disc (5) and moves down, ball (11)
contacts protrusion (a) of the piston during the
stroke. [Detent starts to act]
q
When piston (4) is pushed in further, ball (11)
pushes up collar (12), which is being held by
detent spring (13). While pushing up collar
(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 protrusion (a) of the piston, passage (d) and
chamber (E) which were shut off, are connected 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 pressure inside chamber (E), so even if the lever is
released, it is held at the float position.
D85EX, PX-15E0
SEN00302-00
When blade is released from float

q
When disc (5) is returned from the float position, it is pushed down by a force greater than
the hydraulic force in chamber (E).
q
As a result, chamber (E) is shut off from passage (d) and is connected to the drain chamber. Therefore, the oil pressure inside chamber
(E) is lost, and the float position is canceled.
SEN00302-00
For fixed multi-shank ripper
T:
P:
P1:
P2:
10
To tank
To ripper valve (port PB4)
To ripper valve (port PA4)
1.
2.
3.
4.
5.
6.
7.
8.
Spool
Metering spring
Centering spring
Piston
Lever
Plate
Retainer
Body
D85EX, PX-15E0
SEN00302-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Centering spring
10 Metering spring
D85EX, PX-15E0
Repair limit
Free length
outer
diameter
Installation
length
Installation
load
Free length
Installation
load
33.9 15.3
28.4
125 N
{12.7 kg}
100 N
{10.2 kg}
22.7 8.10
22.0
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
Replace spring if
damaged or
deformed.
11
SEN00302-00
Operation
At neutral
q
Ports (A) and (B) of the control valve and ports
(P1) and (P2) of the PPC valve are connected
to drain chamber (D) via fine control hole (f) in
spool (1).
As a result, spool (1) moves up and down

until the force of metering spool (2) is balanced with the pressure at port (P1).
The relation between the positions of
spool (1) and body (8) [fine control hole (f)
is at the midpoint between drain chamber
(D) and pump pressure chamber (PP)]
does not change until retainer (7) contacts
spool (1).
In this way, the control valve spool moves
to a position where the pressure of chamber (A) [same as pressure at port (P1)]
and the force of the return spring of the
control valve spool are balanced.
During fine control

1. Control lever neutral o 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).
q
simultaneously, it is connected to pump
(A).
q
12
D85EX, PX-15E0
2.

When lever (5) starts to be returned, spool
q
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.
q
D85EX, PX-15E0
SEN00302-00
During full stroke

q
When lever (5) pushes down piston (4) and
q
(P1) to chamber (A), and pushes the control
valve spool.
q
The oil returning from chamber (B) passes
from port (P2) through fine control hole (f') and
13
SEN00302-00
For scraper and variable multi-shank ripper
P:
T:
P1:
P2:
P3:
P4:
From PPC lock valve

To tank
To scraper ball or ripper tilt spool (port PA5)
To scraper ball or ripper tilt spool (port PB5)
To scraper apron or ripper lift spool (port PA4)
To scraper apron or ripper lift spool (port PB4)
D85EX, PX-15E0
15
SEN00302-00
1.
2.
3.
4.
5.
6.
16
Spool
Metering spring
Centering spring
Piston
Disc
Nut (for lever connection)
7.
8.
9.
10.
11.
Joint
Plate
Retainer
Body
Filter
D85EX, PX-15E0
SEN00302-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
12
13
Centering spring
(For ports P3 and P4)
Centering spring
(For ports P1 and P2)
14 Metering spring
D85EX, PX-15E0
Repair limit
Free length
outer
diameter
Installation
length
Installation
load
Free length
Installation
load
50.4 15.5
34.0
55.9 N
{5.7 kg}
44.7 N
{4.56 kg}
50.1 15.5
34.0
71.4 N
{7.28 kg}
56.9 N
{5.8 kg}
26.5 8.20
24.9
16.7 N
{1.70 kg}
13.3 N
{1.36 kg}
Replace spring if
damaged or
deformed.
17
SEN00302-00
Operation
At neutral
q
Ports (A) and (B) of the control valve and ports
(P1), (P2), (P3) and (P4) of the PPC valve are
connected to drain chamber (D) through fine
control hole (f) of spool (1).
q
As a result, spool (1) moves up and down

so that the force of metering spring (2) is
balanced 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).
In this way, the control valve spool moves
to a position where the pressure of chamber (A) [same as pressure at port (P1)]
and the force of the return spring of the
control valve spool are balanced.
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
simultaneously, it is connected to pump
(A).
q
18
D85EX, PX-15E0
2.

When disc (5) starts to be returned, spool
q
q
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.
q
D85EX, PX-15E0
SEN00302-00
During full stroke

q
When disc (5) pushes down piston (4) and
q
(P1) to chamber (A), and pushes the control
valve spool.
q
The oil returning from chamber (B) passes
from port (P2) through fine control hole (f') and
19
SEN00302-00
Electric lever (steering)
Do not disassemble.
Otherwise, adjustments will be required for the characteristics of voltage output and operating efforts.
1.
2.
3.
4.
Boot
Bracket
Plate
Bolt
20
5.
6.
7.
Screw
Lever
Connector
D85EX, PX-15E0
SEN00302-00
Function
Operating effort characteristics
1. Operation for forward and reverse travel
q
The control lever is held at 3 positions:
forward, neutral and reverse.
D85EX, PX-15E0
2.
Operation for left and right steering

Free return
21
SEN00302-00
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, steering controller.
q
A potentiometer is installed in each of longitudinal direction and lateral direction. Each
potentiometer outputs 2 signal voltages which
are opposite to each other as shown in the figure at right.
22
D85EX, PX-15E0
Quick drop valve
SEN00302-00
(lift cylinder)
Unit: mm
No.
Check item
Clearance between spool and
valve body
Criteria
Standard
size
38.0
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.011
0.016
+0.010
+0.010
0.011
0.026
0.03
Standard size
Valve spring
D85EX, PX-15E0
Remedy
Repair limit
Free length
Installation
length
Installation
load
Free length
Installation
load
75.2
55.9
136.3 N
{13.9 kg}
67.7
122.6 N
{12.5 kg}
Replace
23
SEN00302-00
PPC lock valve

a

1.
2.
3.
4.
5.
Lever
End cap
Ball
Seat
Body
Outline
q
The PPC lock valve is installed in the PPC circuit 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 equipment lock lever. This stops the oil in the PPC
circuit and makes it impossible to operate the
work equipment.
24
D85EX, PX-15E0
SEN00302-00
Accumulator
For PPC circuit
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
Outline
The accumulator is installed between the cooling 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 equipment lower with its own weight by using nitrogen gas pressure in the accumulator.
Specifications
Gas used:
Quantity of gas:
Charged gas pressure:
Max. allowable working
pressure:
D85EX, PX-15E0
Nitrogen gas
300 cc
1.18 MPa {12 kg/cm2}
(at 80 C)
6.86 MPa {70 kg/cm2}
25
SEN00302-00

26
SEN00305-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN00305-00
Work equipment
Cylinder stay
1.
2.
3.
4.
5.
Yoke
Oil seal
Bushing
Bushing
Air breather plug
Unit: mm
No.
Check item
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
115
0.144
0.198
+0.054
+0.054
0.144
0.252
Clearance between cylinder yoke

and bushing
76
0.147
0.193
+0.046
+0.046
0.147
0.239
Clearance between lift cylinder

support shaft and bushing
75
0.100
0.174
+0.075
+0.075
0.100
0.249
0.5
Clearance between cylinder yoke

and bushing
D85EX, PX-15E0
Standard
size
Replace
SEN00305-00
Blade
Semi-U dozer
D85EX, PX-15E0
SEN00305-00
Unit: mm
No.
Check item
Clearance between brace and pin
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
+0.5
+0.3
0.6 1.0
Shaft
Hole
60
0.3
0.5
Clearance between brace pin and

bracket
60
0.3
0.5
+0.5
+0.2
0.5 1.0
Clearance between brace spherical

surface and cap
100
0.1
0.1
+0.5
+0.2
0.2 0.6
Clearance between center brace

spherical surface and cap
100
0.1
0.1
+0.5
+0.2
0.2 0.6
Clearance between joint and blade

bracket
120
0.2
0.7
+0.5
+0.3
0.5 1.2
Clearance between frame pin and

joint
60
0.3
0.5
+0.3
+0.3
0.3 0.8
Clearance between blade bracket

pin and blade bracket
60
0.3
0.5
+0.3
+0.3
0.3 0.8
Clearance between blade bracket

pin and joint
60
0.3
0.5
+0.3
+0.3
0.3 0.8
Clearance between center brace

spherical surface and cap
100
0.1
0.1
+0.5
+0.2
0.2 0.6
10
Clearance between center link pin

and center link
85
0.3
0.5
+0.1
0.1
0.2 0.6
11
Clearance between center link pin

and blade bracket
85
0.3
0.5
+0.3
+0.3
0.3 0.8
12
Clearance between center link and

blade bracket
196
0.1
0.1
+0.5
+0.3
0.3 0.6
13
Clearance between trunnion spherical surface and cap
160
0.5
1.0
+0.5
+0.5
0.5 1.5
D85EX, PX-15E0
Replace
Adjust shim
or replace
Replace
Adjust shim
or replace
Replace
SEN00305-00
Cutting edge and end bit
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
254
213
302
211
Height of cutting edge
Height of end bit (outside)
Height of end bit (inside)
254
211
Width of end bit
447
360
Replace or reverse
(after reversing
max. 172 mm)
Replace
D85EX, PX-15E0
SEN00305-00
Ripper
Unit: mm
No.
Check item
Clearance between link pin and
bushing
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
75
0.030
0.076
+0.396
+0.199
0.229
0.472
1.5
75
0.030
0.076
+0.165
+0.115
0.145
0.241
1.5
Standard
size

bushing
Clearance between shank holder

and shank pin
Shaft: 60
Hole: 62
+0.300
0.300
+0.300
0.300
1.400
2.600
10.0
Clearance between shank pin and

shank hole
Shaft: 60
Hole: 65
+0.300
0.300
+1.000
1.000
3.700
6.300
15.0
Wear of point
Wear of protector
Standard size
Repair limit
335
225
113
93
Replace
D85EX, PX-15E0
SEN00305-00
Unit: mm
No.
Check item
bushing
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
85
0.036
0.090
+0.207
+0.120
0.156
0.297
1.5
Clearance between shank holder

and shank pin
Shaft: 60
Hole: 62
+0.300
0.300
+0.300
0.300
1.400
2.600
10.0
Clearance between shank pin and

shank hole
Shaft: 60
Hole: 65
+0.300
0.300
+1.000
1.000
3.700
6.300
15.0
Wear of point
Wear of protector
D85EX, PX-15E0
Standard size
Repair limit
335
225
113
93
Replace
SEN00305-00
Hydraulic cylinder
For power tilt dozer

Lift cylinder
Tilt cylinder

Ripper tilt cylinder (for variable multi-shank ripper)
10
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.
D85EX, PX-15E0
SEN00305-00
Unit: mm
No.
Check item
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
Lift
65
0.030
0.076
+0.250
+0.055
0.085
0.326
0.626
Tilt
75
0.030
0.076
+0.279
+0.065
0.095
0.355
0.655
Ripper
lift/tilt
70
0.030
0.104
+0.271
+0.075
0.105
0.375
0.675
Clearance between piston rod spherical surface and blade ball

portion
Lift
S85
+0.3
+0.3
1.0
Clearance between cylinder support shaft

bushing and yoke
Lift
75
0.100
0.174
0.5
Clearance between piston rod spherical surface and cap
Tilt
S100
0.200
0.300
Tilt
60
+0.174
+0.100
1.0
Clearance between
cylinder bottom support
shaft and bushing
Ripper
lift/tilt
75
+0.286
+0.184
1.0
Ripper
lift/tilt
75
+0.286
+0.184
1.0
Clearance between
piston rod and bushing
Clearance between
piston rod support shaft
and bushing
D85EX, PX-15E0
Replace
11
SEN00305-00
Piston valve
(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 contact with the cylinder head or the bottom, and
serves to reduce the subsequent surge pressure in the cylinder by letting the oil escape
from the cylinder before the piston reaches its
stroke end.
Operation
Piston valve closed
The oil from the work equipment pump acts on piston (2) and piston valve (3).
Piton valve (3) is pushed to the right and it seals the
tapered section of piston valve seat (4). This
causes the pressure in the cylinder to rise and the
piston (2) moves to the right.
12
Piston valve open
Just before piston rod (1) reaches its stroke end,

the tip of valve (6) contacts the cylinder bottom, so
valve (6) and piston valve (3) stop at the position
and do not move further. Only piston (2) moves further.
At this moment, the oil at the cylinder head, which
was sealed by piston valve (3), escapes from piston
valve seats (4) and (5), and the pressure inside the
cylinder stops rising.
D85EX, PX-15E0
SEN00305-00

14
SEN00306-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up


Cab and its attachments ................................................................................................................................. 2
Cab mount............................................................................................................................................ 2
Cab....................................................................................................................................................... 3
Air conditioner ...................................................................................................................................... 5
D85EX, PX-15E0
SEN00306-00

Cab mount
1.
2.
3.
Support
Damper mount (front)
Damper mount (rear)
1
1
Outline
Mounts are installed at two places in the front
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.
q
D85EX, PX-15E0
Cab
1.
2.
3.
4.
SEN00306-00
Front wiper
Front window
Rear wiper
Door
D85EX, PX-15E0
SEN00306-00
ROPS: Abbreviation for RollOver Protective Structure
1.
ROPS guard
D85EX, PX-15E0
Air conditioner
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Condenser
Hot water outlet
Hot water pickup piping
Refrigerant piping
Receiver tank
Hot water return piping
Compressor
Hot water inlet
Front window defroster
Air conditioner unit
Vent
Blower motor
Side window defroster
D85EX, PX-15E0
SEN00306-00
A: Fresh air inlet

B: Recirculated air
C: Hot air/cold air
SEN00306-00

SEN00308-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN00308-00
Electrical system
Monitor system
The monitor system notifies the operator of the

machine condition. It monitors the machine
condition with the sensors installed to various
parts of the machine and processes and displays the obtained information on the panel
immediately.
The contents displayed on the panel are
roughly classified as shown bellow.
1.
2.
3.
4.
The CPU (Central Processing Unit) in the monitor panel displays and outputs various information items processed by the transmission
steering controller. The display unit is LCD
(Liquid Crystal Display).
Machine trouble alarm (Monitor section)

Coolant temperature, torque converter oil
temperature, and fuel level (gauge section)
Error code
Current and voltage of each sensor and
solenoid
D85EX, PX-15E0
SEN00308-00
Processing in monitor panel (Common to all specifications)

Display of monitor panel
Contents and conditions of processing
1.
2.
3.
Method
Display of travel direction and gear speed

F1, R3, etc. are notified by CAN signal according to information of
transmission and steering controller.
CAN signal
Display of gauges of engine speed, engine coolant temperature, etc.

Controller converts the sensor signals into gauge numbers and sends
them to the monitor panel by CAN signal.
CAN signal
Display of trouble
When the machine has a trouble, the corresponding failure code is
notified to the monitor panel by CAN signal.
Which one should be turned on, the buzzer or the caution lamp, is
notified, too.
1) In normal state
User code
2) In trouble history display mode
The service code (6-digit code) and the following items are displayed
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.
Flow of signals
Each sensor/solenoid
O
Controller
O
Monitor panel
CAN signal
Display of monitoring condition

1.
Method
Flow of signals
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
by CAN signal.
The monitor panel displays the items and each value on its multi-information section.
CAN signal
2.
Each items is selected by using the cursor switches, selector switches,

buzzer cancel switch, and shift UP/DOWN switches.
CAN signal
For details of the operating method, see Testing and adjusting, Special functions of monitor panel
(EMMS).
Each sensor
O
Controller
O
Monitor panel
Other items
Method
Flow of signals
CAN signal
Each sensor
O
Controller
O
Monitor panel
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Maintenance mode
Pm clinic auxiliary mode
Adjustment mode
Failure code display mode
Maintenance interval change mode
Electric system failure code display mode
Mechanical system failure code display mode
Adjustment mode
Load saving display mode
Real-time monitoring mode
Dual display monitoring mode
For details of the operating method, see Testing and adjusting, Special functions of monitor panel
(EMMS).
D85EX, PX-15E0
SEN00308-00
Monitor panel
1.
2.
3.
4.
5.
6.
7.
Display panel A (gear speed display and

engine speed)
Charge level caution lamp
Power train oil temperature gauge
Coolant temperature gauge
Fuel gauge
Hydraulic oil temperature gauge
Hydraulic oil temperature caution lamp
Outline
q
The monitor panel consists of the monitor section which issues an alarm when the machine
has any trouble, the gauge section which displays the machine condition constantly, and
the service meter display section.
A microcomputer is installed in the monitor
panel and the signals from each sensor and
controller are processed and displayed.
The items displayed on the monitor section
and the gauge section are listed in the table on
the next page.
Operation
When power is turned ON (When starting switch
is turned to on position)
1) All items of the gauge section and the monitor
section light up for 3 seconds.
2) The warning lamp lights up for 2 seconds.
8.
9.
10.
11.
12.
13.
14.
Power train oil temperature caution lamp

Coolant temperature caution lamp
Engine oil pressure caution lamp
Maintenance caution lamp
Preheating pilot lamp
Coolant level caution lamp
Display panel B (Multi-information)
Check before starting

1) After all the lighting described above is terminated, if there is any error in the check-beforestarting items, the corresponding item flashes
and the contents of the error are displayed on
the display panel B (14).
2) If the engine is started, the light of the checkbefore-starting items turns off. (Whether the
engine is running is judged by the signal (CAN)
from the engine controller.)
Caution items
The caution items are checked constantly
while the engine is running.
If an error occurs, the error is displayed by
flashing and the warning lamp synchronously
flashes.
Further, if an emergency item flashes, the
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 10C), however, this does
not indicate any abnormality.
D85EX, PX-15E0
SEN00308-00
Display of monitor panel
D85EX, PX-15E0
SEN00308-00
D85EX, PX-15E0
SEN00308-00
Engine control
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Decelerator pedal
Decelerator potentiometer
Starting switch
Fuel dial
Battery
Battery relay
Engine controller
Starting motor
Fuel supply pump
Outline
The throttle signals of fuel dial (4) and decelerator pedal (1) enter transmission and steering
controller (7) and are processed together with
the 3rd throttle signal, then are sent to engine
controller (8) as throttle commands. Engine
controller (8) controls the engine according to
the commands.
D85EX, PX-15E0
Engine control system
Outline
q
The engine controller receives the fuel control
dial signal of the 1st throttle, the decelerator
pedal signal of the 2nd throttle, and the 3rd
throttle signal which is a control signal from the
transmission and steering controller, and then
selects the command signal indicating the lowest engine speed and controls the fuel supply
pump.
The control signals of the 3rd throttle are as
follows.
1) Automatic-deceleration (F3, R3, F2, R2)
2) Neutral deceleration
q
The transmission and steering controller calculates a proper engine speed from the information such as 1) and 2) and sends it as the 3rd
throttle signal to the engine controller.
D85EX, PX-15E0
SEN00308-00
The information from the engine controller is

possessed jointly by the other controllers
through the network and used for the optimum
control of the relationship between the engine
and the machine body.
The automatic deceleration is a function of lowering the engine speed temporarily when the travel
direction is changed from F3, R3, F2 or R2 (for
protection of the transmission clutch).
The neutral deceleration is a function of limiting the high idle speed when the transmission
is set in neutral.
SEN00308-00
System components
Fuel control dial
1.
2.
3.
4.
5.
6.
10
Knob
Dial
Spring
Ball
Potentiometer
Connector
Function
The fuel control dial is installed to the left side
of the operator's seat.
q
If knob (1) is turned, the shaft of potentiometer
(5) is turned to change the resistance of the
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.
q
D85EX, PX-15E0
SEN00308-00
Deceleration potentiometer
1.
2.
3.
4.
5.
6.
7.
Connector
Lever
Body
Potentiometer
Coupling
Shaft
Stopper
D85EX, PX-15E0
Outline
q
The deceleration potentiometer is installed to
the front lower part of the operator's cab and
connected to the decelerator pedal by linkage.
q
If the decelerator pedal is pressed, the throttle
potentiometer shaft rotates by the linkage and
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.
11
SEN00308-00
Engine controller
The signal classification used in the following

terminal table is as follows:
A: Power source
B: Input
C: Ground/shield/return
D: Output
E: Communication
CN-CE01
Pin No.
Signal name
Pin No.
Signal name
Input/
Output
11
EGR valve ()
12
NC (*)
13
Engine oil pressure sensor
14
NC (*)
15
Water temperature sensor
Input/
Output
16
Sensor power source (5V)
17
NC (*)
NC (*)
18
NC (*)
NC (*)
19
EGR valve position sensor
Atmospheric pressure sensor
20
NC (*)
Supply pump #1 (+)
21
NC (*)
Supply pump #1 ()
22
EGR valve (+)
CAN ()
23
Boost temperature sensor
NC (*)
24
NC (*)
CAN (+)
25
Common rail pressure sensor
Supply pump #2 (+)
26
Bkup sensor (+)
10
Supply pump #2 ()
27
NE sensor (+)
*: Do not connect to NC since it will cause malfunction and trouble.
12
CN-CE01
D85EX, PX-15E0
CN-CE01
SEN00308-00
CN-CE02
Pin No.
Signal name
Input/
Output
Pin No.
Signal name
Input/
Output
28
NC (*)
13
NC (*)
29
NC (*)
14
NC (*)
30
Fuel temperature sensor
15
NC (*)
31
NC (*)
16
NC (*)
32
NC (*)
17
NC (*)
33
18
NC (*)
34
NC (*)
19
NC (*)
35
NC (*)
20
NC (*)
36
NC (*)
21
NC (*)
37
22
Fuel dial (+5V)
38
GND
23
Fuel dial ()
39
NC (*)
24
NC (*)
40
NC (*)
25
NC (*)
41
NC (*)
26
NC (*)
42
NC (*)
27
NC (*)
43
NC (*)
28
NC (*)
44
Boost pressure sensor
29
NC (*)
45
Injector #1 (+)
30
NC (*)
46
Injector #5 (+)
31
NC (*)
47
Sensor GND
32
NC (*)
48
Ne sensor ()
33
NC (*)
49
NC (*)
34
NC (*)
50
NC (*)
35
NC (*)
51
Injector #2 ()
36
NC (*)
52
Injector #3 ()
37
CAN (shield)
53
Injector #1 ()
38
NC (*)
54
Injector #2 (+)
39
Key switch (ACC)
55
Injector #3 (+)
40
Intake air heater relay activate
56
Injector #4 (+)
41
NC (*)
57
Injector #6 (+)
42
GND
58
Injector #4 ()
43
NC (*)
59
Injector #6 ()
44
NC (*)
60
Injector #5 ()
45
NC (*)

CN-CE02
Pin No.
Signal name
Input/
output
46
CAN(+)
47
CAN()
48
NC (*)
49
NC (*)
50
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
GND
NC (*)
GND
NC (*)
Power source (+24V constant)
Power source (+24V constant)
Fuel control dial (+)
10
NC (*)
11
NC (*)
12
NC (*)

CN-CE03
Pin No.
Signal name
Input/
Output
*: Never connect to NC or malfunctions or failures will occur.
D85EX, PX-15E0
13
SEN00308-00
14
D85EX, PX-15E0
SEN00308-00

DEUTSCH-24P [CN-PTC1]
Pin No.
Signal name
Input/Output
signal
Pin No.
Signal name
Input/Output
signal
Work equipment oil pressure sensor
Input
13
Travel lever position 3
Steering lever potentiometer 1
Input
14
NC
3
4
Brake pedal potentiometer

GND (signal)
Input
15
16
Alternator (R)
Sensor power source (+24 V)
NC
17
Key C signal
Input
Service SW
Input
18
Shift down SW (NO)
Input
7
8

Pitch angle sensor
Input
Input
19
20

Fuel dial
Input
Input
Input
21
GND (analog)
22
Sensor power source (+5 V)
Input
23
24
NC
Shift down SW (NC)
Input/Output
signal
Pin No.
Hydraulic oil temperature sensor
10
NC
11
12
NC
Shift up SW (NC)
Input
Input
Output
Output
Input
DEUTSCH-40P(1) [CN-PTC2]
Pin No.
Signal name
Signal name
Input/Output
signal
NC
21
NC
NC
22
CAN0 (L)
3
4
NC
Flash ROM write (Rx)
Input
23
24
NC
Flash ROM write permission signal
Input
5
6
Parking SW (NC)
Cursor SW2
Input
Input
25
26
T/M reverse fill SW

Select SW
Input
Input
7
8
Fan reverse SW
Neutral safety relay
Input
Output
27
28
NC
NC
9
10
Engine controller activating command

Manual mode SW
Output
Input
29
30
GND (Pulse)
Bevel speed
11
12
NC
CAN shield
31
32
NC
CAN0 (H)
13
14
NC
Flash ROM write (Tx)
Output
33
34
NC
GND (Flash ROM write)
15
16
Parking SW (NO)
Cursor SW1
Input
Input
35
36
T/M forward fill SW

Alarm buzzer cancel SW
Input
Input
17
18
Fan forward SW
Backup alarm relay
Input
Output
37
38
Automatic shift-down SW
NC
Input
19
Engine controller shutoff relay
Output
39
NC
20
Relay input
Input
40
NC
Input/Output
Input
Input/Output
DEUTSCH-40P(2) [CN-PTC3]
Power source (Controller)
Input/Output
signal
Input
21
GND (Power source)
2
3
Power source (Solenoid)

GND (Solenoid, common)
Input
Input
22
23

4
5
For activating battery relay

NC
Output
24
25
Starting switch (ACC)

HSS spool (Left)
Input
Output
6
7
1st gear speed ECMV

NC
Output
26
27
3rd gear speed ECMV

Forward ECMV
Output
Output
8
9
NC
Shift up SW (NO)
Input
28
29
NC
T/M 2nd gear fill SW
Input
10
NC
30
HSS specification selection
Input
11
12
Power source (Controller)

Input
Input
31
32
GND (Power source)

GND (Power source)
Input
Input
13
14

Input
Input
33
34
GND (Power source)

Sensor power source (+5V)
Input
Output
15
16
NC
2nd gear speed ECMV
Output
35
36
HSS spool (Right)

Fan control SOL
Output
Output
17
18
HSS pump TVC SOL

Fan reverse SOL
Output
Output
37
38
Reverse ECMV
NC
Output
19
20
T/M 1st gear fill SW

NC
Input
39
40
T/M 3rd gear fill SW

C/B specification selection
Pin No.
Signal name
D85EX, PX-15E0
Pin No.
Signal name
Input/Output
signal
Input
Input
Input
Input
Input
15
SEN00308-00
Engine oil pressure switch
1.
2.
3.
Connector
Sensor
O-ring
Coolant temperature sensor

Fuel temperature sensor
1.
2.
3.
16
Connector
Sensor
O-ring
D85EX, PX-15E0
SEN00308-00
Engine speed sensor
1.
2.
3.
Connector
Sensor
O-ring
1.
2.
Connector
Pressure induction hole
D85EX, PX-15E0
17
SEN00308-00
Boost pressure sensor
1.
2.
3.
O-ring
Sensor
Connector
Boost temperature sensor
1.
2.
3.
18
Connector
Sensor
O-ring
D85EX, PX-15E0
SEN00308-00
EGR valve stroke sensor
1.
2.
3.
4.
Core
O-ring
Sensor
Connector
D85EX, PX-15E0
19
SEN00308-00
CRI engine control system
a CRI: Abbreviation for Common Rail Injection.

System diagram
1.
2.
3.
4.
20
Fuel tank
Fuel supply pump assembly
2A. PCV
2B. High pressure pump
2C. Priming pump
2D. Feed pump
2E. Bypass valve
2F. G speed sensor
Fuel filter
Overflow valve
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Common rail
Pressure limiter
Flow damper
Injector assembly
Fuel cooler
Engine controller
NE speed sensor
Large-capacity priming pump
Check valve
Additional fuel filter
D85EX, PX-15E0
SEN00308-00
Outline
q
The signals detected by various sensors are
input to the engine controller.
q
The input signals are processed by the controller 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
pump, common rail, injector, engine controller
to control them, and sensors.
q
The fuel supply pump generates fuel pressure
in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply
pump.
q
The discharge rate is controlled by turning on
and off the PCV (pressure control valve) of the
fuel supply pump according to the electric signals from the engine controller.
q
The common rail receives the pressurized fuel
from the fuel supply pump and distributes it to
the cylinders.
q
The fuel pressure is sensed by the common
rail fuel pressure sensor installed to the common rail.
q
A feedback control is applied so that the actual
fuel pressure will match to the command pressure set according to the engine speed and the
load on the engine.
D85EX, PX-15E0
The fuel pressure in the common rail is applied

to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).
If the TWV is turned on (energized), the fuel
circuit is so changed that the high-pressure
fuel in the control chamber will flow through the
orifice. As a result, the needle valve is raised
to start fuel injection by the nozzle cracking
pressure of the high-pressure fuel on the nozzle side.
If the TWV is turned off (de-energized), the fuel
circuit is so changed that the high-pressure
fuel will be applied to the control chamber
through the orifice. As a result, the needle
valve lowers and finishes fuel injection.
Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.
21
SEN00308-00
Palm command control system
1.
2.
3.
4.
5.
6.
7.
8.
9.
22
Monitor panel (Multi-information)

Preset mode switch
Auto shift-down switch
Engine controller
Engine speed sensor
Steering control valve
Transmission output shaft speed sensor
D85EX, PX-15E0
Shift mode function

1. Function
When you shift the PCCS lever to the forward
or reverse, the gear speed selected from the
shift mode is applied.
q
Shift mode 1: F1/R1
q
Shift mode 2: F1/R2
q
Shift mode 3: F2/R1
q
Shift mode 4: F2/R2
2.
3.
4.
SEN00308-00
Auto shift-down function

1. Function
This function automatically shifts the gear
speed down if load is increased while the
machine is traveling at 2nd or 3rd speed or
while the machine is in operation.
1)
Type of modes
1) F1-R1
2) F1-R2
3) F2-R1
4) F2-R2
2)
How to use
Turn the preset mode switch on.
Shift the PCCS lever to N.
Select a mode with the shift up switch and shift
down switch.
Display
The selected mode is displayed on the monitor
panel.
D85EX, PX-15E0
3)
2.
This function turns on the shift-down automatically by calculating the drawbar pull
(load to the machine body) based the
engine speed, transmission speed and
throttle information from the transmission
and steering controller.
Once the transmission gear is shifted
down automatically, it is not shifted up
again to the former gear speed automatically.
(It can be shifted up with the shift switch,
however)
This function is applicable to both forward
and reverse travels.
How to use
Turn auto shift-down switch (1) on.
23
SEN00308-00
KOMTRAX terminal system
(if equipped)
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
SEN00308-00
KOMTRAX terminal
1.
2.
3.
Communication antenna connector

GPS antenna connector
Machine harness connector (DEUTSCH-40P)

DEUTSCH-40P [CN-G01]
Pin No.
Signal name
Input/Output
signal
Pin No.
Signal name
Input/Output
signal
NC
21
Operation mode selection 1
Input
NC
22
Operation mode selection 2
Input
NC
23
NC
NC
24
NC
NC
25
NC
CAN shield GND
26
NC
CAN signal (L)
Input/Output
27
Starting switch (C)
Input
CAN signal (H)
Input/Output
28
Alternator (R)
Input
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
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
Input
Outline
q
The KOMTRAX controller can send information 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 troubleshooting.
q
The information of the LED lamp and the 7segment indicator lamp can be checked on the
monitor panel by EMMS.
D85EX, PX-15E0
25
SEN00308-00
Sensor
q
q
q
The signals from the sensors are input through the controller to the monitor panel.
The sensors are classified into 4 types of contact, resistance, electromagnetic, and capacitor.
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
Contact
ON
OFF
Radiator coolant level

Fuel level
Resistance
Bevel speed
Electromagnetic
Pitch angle
Capacitor
Resistance
Pump pressure
Power train oil temperature sensor

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

30
SEN00629-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

Standard service value table ........................................................................................................................... 2
Standard service value table for engine ............................................................................................... 2
Standard service value table for chassis .............................................................................................. 3
D85EX, PX-15E0
SEN00629-00
Standard service value table for engine
Machine model
D85EX,PX-15E0
Engine
Check item
SAA6D125E-5
Measurement conditions
Standard value for

new machine
Permissible value
2,100 50
2,100 50
750 (+50/0)
750 (+50/0)
1,900
kPa
{mmHg}
Min. 93
{Min. 700}
73
{550}
Bosch
index
Max. 2.5
Max. 1.0
Max. 650
700
Unit
High idle
Rotation speed
Low idle
rpm
Rated speed
Air boost pressure
(Boost pressure)
Exhaust gas color
Exhaust temperature
Valve clearance
(Normal temperature)
At rated horsepower
At sudden acceleration
At high idle
Whole speed range
(Ambient temperature 20C)
Intake valve
mm
Exhaust valve
0.33
0.71
Compression pressure

(Engine speed)
MPa
{kg/cm2}
(rpm)
Min. 2.9
{Min. 30}
(200 250)
2.0
{20}
Blow-by pressure
At rated horsepower
Coolant temperature: Min. 70C
kPa
{mmH2O}
Max. 0.98
{Max. 100}
1.96
{200}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
Oil pressure
At rated horsepower
Engine oil temperature: SAE0W30EOS
Min. 80C SAE5W40EOS
SAE10W30DH
At low idle
SAE15W40DH
Engine oil temperature: SAE30DH
Min. 80C
Min. 0.05
{Min. 0.5}
0.03
{0.3}
90 110
Min. 120
13 16
16 20
Oil temperature
Belt tension
Whole speed range (Inside oil pan)

Deflection when
Alternator
pressed with finger
Crankshaft
force of approx. 58.5 N
pulley
{approx. 6 kg}
Deflection when
pressed with finger
force of approx. 98 N
{approx. 10 kg}
Air conditioner
compressor
Crankshaft
pulley
MPa
{kg/cm2}
mm
D85EX, PX-15E0
SEN00629-00
Standard service value table for chassis
Classification
Machine model
Check item
D85EX,PX-15E0
Standard
value for new
machine
Permissible
value
1,025 25
1,025 25
1,875 25
1,875 25
1,760 50
1,760 50
1,710 50
1,710 50
Neutral o
Forward
30 10
30 10
Neutral o
Reverse
30 10
30 10
Measurement condition
Unit
Engine speed
Decelerator pedal
speed
Coolant temperature: Within operating range

Torque converter oil temperature:
Within operating range
Auto-deceleration
Hydraulic
oil
temperature:
speed
Torque converter stall Decelerator pedal speed: Press pedal.
speed
Auto-deceleration speed: Full neutral
Torque converter stall + Torque converter stall speed: F3
Work equipment relief Torque converter + Work equipment speed:
F3 + Ripper RAISE
speed
Stroke of control lever and pedal
PCCS
lever
Forward
and
reverse
Neutral o Left
40 10
40 10
(Play: Max. 3) (Play: Max. 3)
Neutral o Right
40 10
40 10
(Play: Max. 3) (Play: Max. 3)
Steering
Decelerator pedal
Engine stopped
Center of pedal
Brake pedal
Engine low idle

Center of pedal
Blade control lever
Engine low idle

Hydraulic oil temperature:
Center of lever knob

(for EX)
Operating effort of control

lever and pedal
Engine stopped
rpm
PCCS
lever
Forward
and
reverse
45 15
45 15
77 8
77 8
Stroke to 0 of oil
pressure
64 10
64 10
Neutral Raise
or Float
72 10
72 10
Neutral Left or
Right tilt
53 10
53 10
Engine low idle

Hydraulic oil temperature: Neutral Raise
Within operating range or Lower
55 10
55 10
Neutral o
Forward or
Reverse
56.9 6.9
{5.8 0.7}
56.9 6.9
{5.8 0.7}
Forward or
Reverse o
Neutral
51 6.9
{5.2 0.7}
51 6.9
{5.2 0.7}
24.5 4.9
{2.5 0.5}
24.5 4.9
{2.5 0.5}
27.4 4.9
{2.8 0.5}
27.4 4.9
{2.8 0.5}
Engine stopped
All stroke
Neutral o Left
Steering
Neutral o Right
mm
N
{kg}
Decelerator pedal
Engine stopped
Center of pedal
49.0 9.8
{5.0 1.0}
49.0 9.8
{5.0 1.0}
Brake pedal
Engine low idle

Center of pedal
460.6 49.0
{47 5.0}
460.6 49.0
{47 5.0}
D85EX, PX-15E0
SEN00629-00
Operating effort of control

lever and pedal
Classification
Machine model
Check item
Blade control lever

(for EX)
Torque converter outlet

pressure
Transmission main
relief pressure
Transmission F clutch
pressure
Power train oil pressure
Standard
value for new
machine
Permissible
value
39.2 9.8
{4.0 1.0}
39.2 9.8
{4.0 1.0}
82.3 9.8
{8.4 1.0}
82.3 9.8
{8.4 1.0}
28.4 9.8
{2.6 1.0}
28.4 9.8
{2.6 1.0}
Neutral o Raise
or Lower
25.5 9.8
{2.6 1.0}
25.5 9.8
{2.6 1.0}
Neutral Tilt in
or out
25.5 9.8
{2.6 1.0}
25.5 9.8
{2.6 1.0}
Engine low idle
0.1 0.5
{1 5}
0.1 0.5
{1 5}
Engine high idle
Max. 1.02
{Max. 10}
Max. 1.02
{Max. 10}
Engine low idle
0.1 0.31
{1 3}
0.1 0.31
{1 3}
Engine high idle
0.61 0.81
{6 8}
0.61 0.81
{6 8}
Engine low idle
2.82 3.02
{28.8 30.8}
Min. 2.65
{Min. 26.8}
Engine high idle
3.24 3.53
{33 36}
Min. 3.04
{Min. 31}
Engine low idle
2.16 2.45
{22 25}
Min. 1.96
{Min. 20}
Engine high idle
2.16 2.45
{22 25}
Min. 1.96
{Min. 20}
Engine low idle
2.75 3.02
{28 30.8}
Min. 2.55
{Min. 26}
2.75 3.04
{28 31}
Min. 2.55
{Min. 26}
2.35 2.65
{24 27}
Min. 2.16
{Min. 22}
Engine high idle
2.35 2.65
{24 27}
Min. 2.16
{Min. 22}
Engine low idle
2.55 2.84
{26 29}
Min. 2.35
{Min. 24}
Engine high idle
2.55 2.84
{26 29}
Min. 2.35
{Min. 24}
Engine low idle
2.75 3.02
{28 30.8}
Min. 2.55
{Min. 26}
Engine high idle
2.75 3.04
{28 31}
Min. 2.55
{Min. 26}
Engine high idle
0.1 0.25
{1.0 2.5}
0.1 0.25
{1.0 2.5}
Engine low idle
2.75 2.94
{28 30}
Min. 2.26
{Min. 23}
Engine high idle
2.75 2.94
{28 30}
Min. 2.45
{Min. 25}
Unit
Neutral o Raise
Torque converter inlet

pressure
Transmission R clutch
pressure
Transmission 1st clutch

pressure
Transmission 2nd
clutch pressure
Transmission 3rd
clutch pressure
Transmission
lubricating oil pressure
(For reference)
Steering brake
pressure
D85EX,PX-15E0
Engine low idle

Neutral o Float
Neutral Left or
Right tilt
Engine low idle
N
{kg}
Torque converter oil

Engine high idle MPa
temperature:
{kg/cm2}
Engine low idle
D85EX, PX-15E0
SEN00629-00
Performance of power train
HSS
pressure
Classification
Machine model
Check item
Relief pressure
LS pressure (Load
sensing pressure)
Travel speed
D85EX,PX-15E0
Standard
value for new
machine
Permissible
value
38.2 41.7
{390 425}
38.2 41.7
{390 425}
36.2 38.1
{369 389}
36.2 38.1
{369 389}
F1
3.3 0.2/
3.3 0.2
3.3 0.2/
3.3 0.2
F2
6.1 0.3/
6.0 0.3
6.1 0.3/
6.0 0.3
F3
10.1 0.5/
10.0 0.5
10.1 0.5/
10.0 0.5
R1
4.4 0.2/
4.4 0.2
4.4 0.2/
4.4 0.2
R2
8.0 0.4/
7.9 0.4
8.0 0.4/
7.9 0.4
R3
13.0 0.7/
12.7 0.7
13.0 0.7/
12.7 0.7
Unit
Hydraulic oil temperature: Within operating

range
Engine at high idle
Flat road
Coolant temperature:
Torque converter oil
temperature:
EX/
Within operating range PX
Engine at high idle
Before measuring, run machine
10 30 m.
Measuring distance: 20 m
km/h
Engine low idle

Unload pressure
Engine high idle
21.6 1.18
{220 12}
22.54 1.18
Engine high idle
{230 12}
21.6 1.18
Engine low idle
Unload pressure: Set all
{220 12}
equipment in neutral.
Blade tilt relief pressure
22.54 1.18
Relief pressure:
Engine high idle
{230 12}
Set cylinder to stroke end.
MPa
LS pressure:
21.6 1.18
Engine low idle {kg/cm2}
Set cylinder to stroke end.
{220 12}
Ripper lift relief
pressure (for EX)
22.54 1.18
Engine high idle
{230 12}
22.54 1.18
{230 12}
Engine low idle
20.2 0.98
{206 10}
20.2 0.98
{206 10}
Engine high idle
20.2 0.98
{206 10}
20.2 0.98
{206 10}
Blade lift relief pressure
LS pressure (Load
sensing pressure)
Work equipment
speed
PPC valve output

pressure
Blade lift
D85EX, PX-15E0
Hydraulic oil temperature: Within operating

range
Engine at high idle
a See figure A
Hydraulic oil temperature: 45 55C
Apply no load to blade.
Between ground level
and rising end of blade
Raise
Control circuit main

pressure
(HSS, PPC, fan)
Lower
Work equipment oil pressure
2.45(+1.37/0) 2.45(+1.37/0)
{25(+14/0)}
{25(+14/0)}
21.6 1.18
{220 12}
Engine low idle
Work equipment
MPa
{kg/cm2}
Low idle
High idle
Low idle
High idle
21.6 1.18
{220 12}
22.54 1.18
{230 12}
21.6 1.18
{220 12}
22.54 1.18
{230 12}
3.97(+0.49/0) 3.97(+0.49/0)
{40.5 (+5/0)} {40.5 (+5/0)}
3.82 4.12
{39 42}
3.82 4.12
{39 42}
8 15
20
EX: 2.5 4.5

Second PX: 2.2 4.2
1.0 1.7
1.0 1.7
5.5
5.2
2.2
2.2
SEN00629-00
Standard
value for new
machine
Permissible
value
Left tilt
Low idle
35
High idle
2.7 0.5
3.5
Right tilt
Low idle
35
High idle
2.2 0.5
3.5
Raise
Low idle
7 10
13
High idle
2.5 0.5
4.0
Low idle
23
4.0
High idle
1.5 0.5
4.0
Max. 8
11
Max. 1.8
2.5
Max. 6
Max. 1.5
2.5
Hydraulic drift
of lifted blade
a See figure D
Stop engine.
Measure reduction of blade bottom height h
(for 15 minutes).
Max. 200/
15 minutes
300/
15 minutes
Hydraulic drift
of machine
lifted by blade
a See figure E
Stop engine.
Measure reduction of idler center height h
(for 5 minutes).
Max. 50/
5 minutes
100/
15 minutes
Hydraulic drift
of machine
tilted by blade
a See figure F
Stop engine.
Measure reduction of idler center height h
(for 5 minutes).
Max. 50/
5 minutes
100/
15 minutes
Hydraulic drift
of lifted ripper
(for EX)
a See figure G
Stop engine.
Measure reduction of shank bottom height h
(for 15 minutes).
Max. 80/
15 minutes
160/
15 minutes
Hydraulic drift
of machine
lifted by ripper
(for EX)
a See figure H
Stop engine.
Measure reduction of sprocket center height
h (for 5 minutes).
Max. 50/
5 minutes
100/
5 minutes
Work equipment speed
Check item
Blade tilt
Time lag
Hydraulic drift
Work equipment
a See figure B
Apply no load to blade.
Between left tilt end
and right tilt end
a See figure C
Ripper lift (EX) Apply no load to ripper.
Between ground level
and rising end of ripper.
Blade
D85EX,PX-15E0
Lower
Classification
Machine model

45 55C
Low idle
Move lever to stroke end.
Lower blade from max. rising position and measure
time after blade comes in
High idle
contact with ground until
idler is lifted.
Unit
Second

45 55C
Low idle
Move lever to stroke end.
Lower ripper from max. risRipper (for EX)
ing position and measure
time after ripper comes in
High idle
contact with ground until
sprocket is lifted.
mm/
min.
D85EX, PX-15E0
SEN00629-00
Cooling fan
Check item
Leakage from cylinder
Work equipment
Classification
Machine model
D85EX,PX-15E0
Unit
Blade tilt
cylinder
Ripper lift
cylinder
(for EX)
Ripper tilt
cylinder
(for EX)
Fan speed
Fan pump pressure
D85EX, PX-15E0
Engine at high idle

Relieve cylinder and measure leakage for 1
minute.
Fan 100% speed mode

Engine: Low idle
Min. speed
Fan 100% speed mode

Engine at high idle
Max. speed
Fan 100% speed mode

Engine at high idle
cc/min
Standard
value for new
machine
Permissible
value
16
16
16
800 50
400
1,650 50
1,550
rpm
MPa
14.7 17.6
{kg/cm2} {150 180}
14.7 17.6
{150 180}
SEN00629-00
Illustrations related to standard value table

Figure A
Figure D
Figure B
Figure E
Figure C
Figure F
D85EX, PX-15E0
SEN00629-00
Figure G
Figure H
D85EX, PX-15E0
SEN00629-00

10
SEN00630-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

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
SEN00630-00
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
D85EX, PX-15E0
SEN00630-00
Tools for testing, adjusting, and troubleshooting
Testing or adjusting
item
Part No.
Part name
Quantity
Symbol
Remarks
Air boost pressure

(boost pressure)
799-201-2202 Boost gauge kit
1 101 200 kPa {760 1,500 mmHg}
Water temperature, oil

temperature and
exhaust temperature
799-101-1502 Digital temperature gauge
1 99.9 1,299C
799-201-9001 Handy smoke checker
1
Exhaust gas color
Valve clearance
Compression pressure
Blow-by pressure
Engine oil pressure
Testing fuel return and

leak amount
Power train oil pressure K
1
0 6.9 MPa {0 70 kg/cm2}
KIT Part No.: 795-502-1205
795-471-1420 Adapter
1 For 125E-5
6217-71-6112 Gasket
799-201-1504 Blow-by checker
1 0 5 kPa {0 500 mmH2O}
799-101-5002 Hydraulic tester
Pressure gauge:
2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
Pressure gauge:
58.8 MPa {600 kg/cm2}
1 Pressure gauge: 0.98 MPa {10 kg/cm2}
1 *As common as G2
6151-51-8490 Spacer
6206-71-1770 Joint
Commercial
item
Hose
Commercial
item
Hose
Commercial
item
Measuring cylinder
Commercial
item
Stopwatch
2
3
D85EX, PX-15E0
Clearance gauge
1
L
Commercial
item
Bosch index: 0 9
Emergency escape
method when power
train has trouble
795-502-1590 Compression gauge
2
Testing fuel pressure
Smoke meter
Commercial
item
*As common as G1
*As common as G1
1 *As common as G2
19M-06-32820 Switch assembly
17M-06-41530 Wiring harness
799-101-5220 Nipple (10 x 1.25 mm)
07002-11023
O-ring
790-190-1601 Pump assembly
1
1
Testing and adjusting

work equipment and
HSS oil pressure
Testing control circuit

basic pressure
Measuring PPC valve

output pressure
Part No.
1
M
2
1
Measuring internal
leakage of work
equipment cylinder
Measuring fan motor

speed
799-101-5220 Nipple (10 x 1.25 mm)
07002-11023
O-ring
799-401-3200 Adapter (size 03)
1
1
799-401-3100 Adapter (size 02)
799-401-3200 Adapter (size 03)
Commercial
item
1
Measuring fan pump
circuit pressure
1
P
Part name
Quantity
Testing or adjusting
item
Symbol
SEN00630-00
S 2
3
Measuring cylinder
Remarks
*As common as G1
*As common as L2
*As common as G1
*As common as G1
799-205-1100 Tachometer KIT
799-401-3400 Adapter (size 05)
799-101-5220 Nipple (10 x 1.25 mm)
07002-11023
O-ring
79A-264-0021 0 294 N {0 30 kg}
79A-264-0091 0 490 N {0 50 kg}
Operating effort
Stroke and hydraulic

drift
Commercial
item
Scale
Work equipment speed
Commercial
item
Stopwatch
Voltage and resistance
Commercial
item
Tester
*As common as G1
*As common as L2
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.
D85EX, PX-15E0
SEN00630-00
Measuring engine speed

a
Measure the engine speed under the following

condition.
q
q
q
Power train oil temperature:
1.
Preparatory work
Turn the starting switch ON and set the monitor
panel in the Monitoring mode to prepare for
measurement of the engine speed.
a For the operating method, see Special
functions of monitor panel (EMMS).
q
Monitoring code: 01000 (Engine speed)
2.
Measuring low idle speed

1) Start the engine and set the fuel control
dial in the low idle position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the
engine speed.
D85EX, PX-15E0
1
3.
Measuring high idle speed

dial in the high idle position.
control lever in neutral and measure the
engine speed.
a The high idle speed measured in the
Monitoring mode or in the Pm Clinic
auxiliary mode is the auto-deceleration
speed.
a When measuring the high idle speed of
the engine, use the Adjustment mode.
Adjustment code:
0007 (Engine decelerator cut mode)
4.
Measuring decelerator pedal speed

dial in the high idle position.
control lever in neutral, and measure the
engine speed with the decelerator pedal
depressed.
SEN00630-00
5.
Measuring torque converter stall speed

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 forward and 3rd gear speed position.
a Before going to the next step, check
that the upper display unit of the monitor 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)
6.
6)
7)
Repeat above steps 2) 5) 3 times.

Change the monitor panel to [Adjustment
mode] display and prepare to measure the
torque converter stall speed.
a Refer to Special functions of monitor
panel (EMMS) for the operating
method.
Adjustment code: 0530 (stall speed

check mode)
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.
Measuring torque converter stall + work

equipment relief speed (full stall speed)
dial in the low idle position. Operate the
ripper lever and raise up the ripper lift cylinder to the stroke end.
2) With the brake pedal depressed securely
and the parking brake lever in the free
position, set the PCCS lever in the forward and 3rd gear speed position.
a Before going to the next step, check
that the upper display unit of the monitor 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.
D85EX, PX-15E0

k
5)
6)
7)
Keep pressing the brake pedal

Just after the power train oil temperature
range, return the direction of the PCCS
lever into neutral.
Repeat above steps 2) 5) 3 times.

Change the monitor panel to [Adjustment
mode] display and prepare to measure the
torque converter stall speed.
method.
q
Adjustment code: 0530 (stall speed
check mode)
D85EX, PX-15E0
SEN00630-00
8)
Perform steps 2) 4) and also operate ripper RAISE relief using ripper lever and
measure the engine speed about 5 seconds after the power train oil temperature
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.
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, measure the high idle speed of the
engine in the Adjustment
mode).
SEN00630-00
Measuring intake air pressure

(boost pressure)
a
Part No.
799-201-2202
Measure the intake air pressure (boost pressure) while the engine is running at high idle
and the torque converter is stalling.
a For the procedure for stalling the torque
converter, see Measuring engine speed.
a Normally, the intake air pressure (boost
pressure) should be measured while the
engine is running at the rated output. In
the field, however, an approximate value
can be obtained by stalling the torque converter.
6.
After finishing measurement, remove the measuring instrument and reinstall the removed
parts.
Part name
Boost gauge kit
When installing and removing the measuring instrument, take care not to touch a hot
part of the engine.
Measure the intake air pressure (boost pressure) under the following condition.
q
q
q
Open the left side cover of the engine.
2.
Remove air intake connector boost pressure

pickup plug (1) (R1/8).
5.
1.
3.
Run the engine at medium or higher speed and

drain the oil from the hose.
a Insert the joint of the gauge and hose halfway and open the self-seal on the hose
side repeatedly, and the oil is drained.
a If Pm kit (A) is available, the air bleeding
coupling (790-261-1130) in it may be
used.
a If any oil is left in the hose, the gauge does
not move. Accordingly, be sure to drain
the oil.
Measuring instruments for intake air pressure

(boost pressure)
Symbol
4.
Install nipple [1] of boost gauge kit A and connect gauge [2].
D85EX, PX-15E0

a
SEN00630-00
The boost pressure can be measured in the

Pm Clinic auxiliary mode of the monitor
panel.
D85EX, PX-15E0
SEN00630-00
Measuring exhaust temperature 1

a
4.
Procedure for measuring the maximum value

for troubleshooting
Operate the machine actually and measure the
maximum exhaust temperature.
a Use the PEAK mode of the digital temperature gauge.
a The exhaust temperature largely depends
on the ambient temperature (intake air
temperature of the engine). Accordingly, if
any abnormal value is obtained, compensate it by the following calculation.
q
Corrected value [C] = Measured value
+ 2 x (20 Ambient temperature)
5.
Procedure for measuring periodically for preventive maintenance

a If the torque converter is stalled simply,
the torque converter oil temperature is
overheated before the exhaust temperature is stabilized. Accordingly, measure
according to the following procedure.
1) Stall the torque converter fully to raise the
exhaust temperature to about 650C
according to the following procedure (condition (a) in the figure).
1] Start the engine and set the fuel control dial to the low idle position, and
then operate the ripper lever to raise
the ripper lift cylinder to the stroke end.
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 finished.
Measuring instrument for exhaust temperature
Symbol
Part No.
799-101-1502
1.
Part name
Digital temperature gauge
Install and remove the measuring instrument after the exhaust manifold is cooled.
Measure the exhaust temperature under the
following condition.
q
Coolant temperature: Within operating
range
q
Hydraulic oil temperature: Within operating range
q
Power train oil temperature: Within operating range
Open the right inspection cover of the engine
and remove turbocharger heat insulation cover
(1).
2.
Remove exhaust temperature measurement

plug (2).
3.
Install sensor [1] and connect them to digital

temperature gauge B.
a Clamp the wiring harness of the digital
temperature gauge so that it will not touch
a hot part during measurement.
10
D85EX, PX-15E0
2)
3)
6.
SEN00630-00
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).
After the temperature lowers and is stabilized, measure it (condition (c) in the figure).
k Just after the power train oil temp 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
SEN00630-00
Measuring exhaust gas color

a
Measuring instrument for exhaust gas color
Symbol
C
k
1.
799-201-9001
Commercial
item
Part name
Handy smoke checker
Smoke meter
When installing and removing the measuring instrument, take care not to touch a hot
part.
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.
Measure the exhaust gas color under the following condition.
q
Measuring with handy smoke checker C1
1) Stock a sheet of filter paper to smoke
checker C1.
2) Insert the exhaust gas intake pipe in the
exhaust pipe.
3) Start the engine.
4) As increasing the engine speed rapidly or
running it at high idle, operate the handle
of smoke checker C1 so that the filter
paper will absorb the exhaust gas.
6)
12
Part No.
5)
2.
Remove the filter paper and compare it

with the attached scale to make a judgement.
After finishing measurement, remove the
measuring instrument and reinstall the
removed parts.
Measuring with smoke meter C2

1) Insert probe [1] of smoke meter C2 in the
outlet of the exhaust pipe and fix it to the
exhaust pipe with a clip.
2)
3)
4)
5)
6)
7)
8)
9)
Connect the probe hose, receptacle of the

accelerator switch, and air hose to smoke
meter C2.
a Restrict the supplied air pressure
below 1.5 MPa {15 kg/cm2}.
Connect the power cable to a receptacle
of AC100V power source.
a Before connecting the cable, check
that the power switch of the smoke
meter is turned off.
Loosen the cap nut of the suction pump
and fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
Turn on the power switch of smoke meter
C2.
Start the engine.

As increasing the engine speed rapidly or
running it at high idle, press the accelerator pedal of smoke meter C2 and collect
the exhaust gas with the filter paper.
Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
removed parts.
D85EX, PX-15E0
SEN00630-00
Adjusting valve clearance

a
4.
Rotate the crankshaft forward, align of damper

1.6TOP stamp line (a) to pointer (8), and then
set the No.1 cylinder to the compression top
dead center.
a Always crank forward using damper
mounting bolt (width across flats: 24 mm)
to prevent loosening the bolt.
a When No. 1 cylinder is at the compression
top dead center, the rocker arms on both
intake side and exhaust side can be
moved by the valve clearance with the
hand. If the rocker arms cannot be moved,
rotate the crankshaft one more turn.
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.
Adjusting instrument for valve clearance
Symbol
Part No.
Commercial
item
Part name
Clearance gauge
1.
Open the left upper side cover of the engine.
2.
Remove air cleaner (1) and bracket (2).
3.
Remove all cylinder head cover (3).
D85EX, PX-15E0
13
SEN00630-00
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.
After finishing the adjustment of all the

valves marked with q, rotate the crankshaft 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 arrangement 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
SEN00630-00
Measuring compression
pressure
a
Set cylinder to be tested at compression top

dead center and remove rocker arm assembly
(4).
a Refer to Adjusting valve clearance.
5.
Disconnect the fuel high-pressure tube (5) and

injector harness (6), and remove injector (7).
a Before disconnecting the fuel high-pressure tube, loosen all the intermediate
clamps on the tube.
a To remove injector harness from injector,
disconnect the terminal in the injector side
and the bracket in the rocker housing side
and pull them out of the rocker arm housing. (Loosen 2 terminal nuts alternately.)
a Lead a wire under the fuel pipe which
comes out sideways from the injector and
pull up the wire to remove injector (do not
ply the upper part of the injector to remove
it).
Measuring instruments for compression pressure
Symbol
E
4.
Part No.
Part name
795-502-1590
Compression gauge
795-471-1420
Adapter
6217-71-6112
Gasket
When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 60C)
1.
2.
Remove air cleaner (1) and bracket (2).
3.
Remove all 6 cylinder head covers (3).
D85EX, PX-15E0
15
SEN00630-00
6.
Install gasket E3 and install adapter E2 to the

mounting hole of the injector and connect compression gauge E1.
a Fix the adapter with the holder for injector.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Leakage can be prevented by applying a
little amount of engine oil to the fitting
faces of the adapter and gauge.
7.
Install rocker arm assembly (4) and adjust

valve clearance.
3 Rocker arm assembly mounting bolts:
58.8 73.5 Nm {6.0 7.5 kgm}
a Refer to Adjusting valve clearance.
8.
Disconnect connector EGC3 of engine controller.
16
Be sure to disconnect the connector.

Otherwise, engine may start during the
measurement and this may create a
dangerous condition.
Since connector (EGC3) includes the
power source circuit of engine controller, cover the connector on the harness
side with a vinyl sheet, etc. to prevent
electric leakage and ground fault.
Adjust mode of the monitor panel no
injection cranking mode can be set.
9.
Crank the engine with the starting motor and

check the compression pressure.
a Measure the pressure when the pointer of
the gauge is stabilized.
10. When the checking is completed, remove the

instruments and reinstall the removed parts.
a Install the injector, injector harness and
fuel high-pressure tube according to following procedure.
1) Install O-ring and gasket to injector (7).
2) Set holder (8) to injector (7) and install it
temporarily to the cylinder head integrally.
3) Tighten mounting bolt (9) with spherical
washer (10) to install injector to cylinder
head.
2 Spherical surface section of spherical 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 piping.
3 Clamping bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
Rocker arm assembly mounting

bolts:
58.8 73.5 Nm {6.0 7.5 kgm}
a Adjust valve clearance referring to
Adjusting valve clearance.
3 Cylinder head cover mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
D85EX, PX-15E0
SEN00630-00
Measuring blow-by pressure

a
Measure the blow-by pressure while the

engine is running at high idle and the torque
converter is stalling.
a For the procedure for stalling the torque
converter, see Measuring engine speed.
a Normally, the blow-by pressure should be
measured while the engine is operated at
the rated output. In the field, however, an
approximate value can be obtained by
stalling the torque converter.
a If it is impossible to run the engine at the
rated output or stall the torque converter,
measure while the engine is running at
high idle.
The value obtained in this case is about
80% of the blow-by pressure at the rated
output.
a The blow-by pressure may vary largely
with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, premature deterioration or contamination of oil, etc. which are related to
the abnormal blow-by pressure.
5.
After completing the measurement, remove

the measuring instrument and set to the original condition.
Measuring instrument for blow-by pressure
Symbol
Part No.
799-201-1504
Part name
Blow-by checker
Measure the blow-by pressure under the following condition.

q
range
q
q
Power train oil temperature: Within operating range
1.
2.
Remove the mounting clamp of blow-by hose

(1) on the engine side which is mounted on No.
6 cylinder head cover and pull out the hose to
the left outer side of the engine.
3.
4.
It also can be done by loosening clamp (2)

and di sconnect hose (1) and install
another hose (KES07287-01914 or equivalent).
Install nozzle [1] of blow-by checker F to blowby hose (1) and connect to gauge [2].
D85EX, PX-15E0
17
SEN00630-00
Measuring engine oil pressure

a
1
2
Part No.
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
Measure the engine oil pressure under the following condition.

q
range
1.
2.
Remove oil pressure inspection plug (1).
18
Start the engine and measure the engine oil

pressure when the engine is running at low idle
and at high idle.
5.
parts.
Part name
3.
4.
Measuring instruments for engine oil pressure
Symbol
G
Install nipple [1] of hydraulic tester G1 to the

plug installation portion and connect to hydraulic tester G2.
D85EX, PX-15E0
Handling of fuel system devices 1

a
Precautions for testing and maintaining fuel

system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly
with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use Komatsu genuine fuel filter cartridge.
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent foreign matter from entering it.
If a filter other than the genuine one is used,
the fuel system may have a trouble. Accordingly, never use such a filter.
D85EX, PX-15E0
SEN00630-00
Releasing residual pressure from

fuel system
1
a
Pressure is generated in the low pressure circuit and high pressure circuit of the fuel system
while the engine is running.
Low pressure circuit: Feed pump Fuel main
filter Fuel supply pump
High-pressure circuit: Fuel supply pump
Common rail Fuel injector
The pressure in both low pressure circuit and
high pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping the engine until the residual pressure
in the fuel circuit is released. (Do not start
the work just after stopping the engine
since there is residual pressure.)
19
SEN00630-00
Testing fuel pressure

a
1
2
a
k
1.
3.
Measuring tools for fuel pressure
Symbol
H
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester
Measure the fuel pressure only for the low

pressure circuit between the feed pump fuel
filter fuel supply pump.
Since the pressure in the high pressure circuit from the fuel supply pump through the
common rail to the injector is very high, it
cannot be measured.
20
Engine speed
Fuel pressure
At high idle or
at the equivalent of rated
output speed
0.15 0.3 MPa

{1.5 3 kg/cm2}
Open the left upper side cover of the engine

and remove fuel pressure inspection plug (1)
(R1/8) of fuel filter head.
4.
2.
Start the engine and inspect the fuel pressure

with the engine running at high idle or at the
equivalent of rated output speed (stall load).
a If the fuel pressure is in the following
range, it is normal.
After finishing testing, remove the testing tools

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

tester H1, and connect to hydraulic tester H2.
D85EX, PX-15E0
Handling of reduced cylinder

mode operation
a
1.
2.
3.
SEN00630-00
Reduced cylinder mode operation means to

run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When engine speed and output do not change
from the normal operation (all cylinder operating 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 system)
q
Defective electrical system
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 easily.
a To implement reduced cylinder mode
operation, see Special functions of monitor panel.
D85EX, PX-15E0
Handling of no injection cranking

operation
1
a
No injection cranking means to crank the

engine with the starting motor while all the
injections are stopped electrically. The purpose and effect of this operation are as follows.
Before the engine is started after it or the
engine unit has been stored for a long period,
the no injection cranking is performed to lubricate the engine parts and protect them from
seizure.
To implement no injection cranking operation,
see Special functions of monitor panel.
21
SEN00630-00
Testing fuel return and leak amount
Testing tools for fuel return and leak amount
Symbol
Part No.
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
Commercially
available
Hose
Commercially
available
Hose
Commercially
available
Measuring cylinder
Commercially
available
Stopwatch
1.
Preparation work
1) Remove tube (3) between common rail (1)
and return block (2).
Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
2)
22
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.
D85EX, PX-15E0
3)
4)
SEN00630-00
a
Insert joint J2 to common rail (1) side and

retighten it with the currently removed joint
bolt.
a Be sure to fit the gaskets to both ends
of the joint.
Connect inspection hose J3 to the tip of
joint J2.
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)
3.
2.
Testing leakage from pressure limiter

1) Adjust routing to prevent its slacking of
inspection hose J3 and insert the hose
end to the oil pan (saucer).
2) Referencing Measuring engine speed,
set up the condition necessary for checking the engine speed.
3) Start the engine and operate at the equivalent 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
If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed
(rpm)
Leaking amount
(cc/min)
Equivalent to rated
operation
Max. 10
After finishing testing, stop the engine.
Testing return rate from injector

a During testing injector return amount,
keep the end of hose J3 connected to
pressure limiter and insert the other end to
oil pan (receiver).
1) Disconnect fuel return hose (4) of return
block (2).
a Block the fuel hose side with plugs,
etc. and fix it to the frame.
Plug: 07376-70315
23
SEN00630-00
2)
3)
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.
Adjust routing to prevent its slacking of
inspection hose J4 and insert the hose
end to the oil pan (container).
7)
4.
4)
5)
6)
24
After finishing testing, stop the engine.
Work after finishing testing

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

set up the condition necessary for checking the engine speed.
Start the engine and operate at the equivalent to rated operation (torque converter
stall load).
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 injector is in the following range, it is normal.
Rated output speed
(rpm)
Return (Spill) limit

(cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
D85EX, PX-15E0
SEN00630-00
Bleeding air from fuel circuit
Bleed the air as follows if the engine has run

out of fuel or the fuel circuit equipment has
been removed and installed.
1.
Remove fuel pre-filter (1), fill up fuel inside and

reinstall.
a When filling, use clean fuel and be careful
not to let dirt get in.
a Add fuel through inlet port (a) areas (8
places) of the filter. Area (b) is the outlet
port after the fuel has been filtered (clean
side), so never add fuel from here.
a If clean fuel is not available, do not
remove the filter. Operate the priming
pump to fill the filter with fuel.
D85EX, PX-15E0
2.
Remove air bleeding plug (3) of fuel main filter

(2) and operate priming pump (4).
a Operate until fuel flows through plug hole
and when fuel is confirmed, install the
plug.
3 Air bleeding plug:
7.8 9.8 Nm {0.8 1.0 kgm}
3.
There can be following two cases concerning

the reason why the engine does not start up
easily after bleeding air from the common rail
fuel injection system (CRI) even after carrying
out the items 1 and 2 above.
a If the air has not been bled completely and
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 circuit, so the engine may be started
after bleeding air with the air bleeding
procedure introduced in the item 1
and 2 above.
25
SEN00630-00
2)
In the case that a number of fuel devices

have been removed and installed in
course of engine overhauling.
q
Since little fuel is left in the fuel circuit,
so air cannot be eliminated completely by the air bleeding methods
introduced in the item 1 and 2 above
(ordinary method). In that case,
bleed air in the following procedure.
1]
2]
3]
26
Remove air bleeding plug (3) of fuel

main filter (2) and operate priming
pump (4).
q
Bleed air
Operate the priming pump until
fuel flows through plug hole and
when fuel is confirmed, tighten
the plug.
3 Air bleeding plug:
7.8 9.8 Nm {0.8 1.0 kgm}
Remove fuel pressure measuring
plug (5) for the fuel filter and operate
priming pump (4).
q
fuel flows through plug hole and
when fuel is confirmed, tighten
the plug.
3 Fuel measuring plug:
3.9 6.9 Nm {0.4 0.7 kgm}
Loosen air bleeder (6) of fuel supply
pump (after loosening locknut) and
operate priming pump (4) from 90 to
100 times.
q
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}
Still continue to operate the priming pump until it becomes harder

to operate and a relief noise (a
high pitch noise) of overflow
valve (7) in the supply pump is
heard. It requires approx. 50
times of operation to reach that
stage.
Tighten bolt of priming pump (4) to fix.
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].
q
4]
5]
4.
Loosen air bleeder (6) of the fuel supply pump

and operate priming pump (4) 90 to 100 times.
a Operate priming pump until fuel flows
through air bleeder and when fuel is confirmed, tighten air bleeder and operate
several times more until priming pump
becomes stiff.
3 Air bleeder:
4.9 6.9 Nm {0.5 0.7 kgm}
5.
Crank the engine with the starting motor and

start the engine.
a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there still may
be air in the low-pressure circuit. In this
case, repeat the above procedure from
step 2.
D85EX, PX-15E0
Testing fuel circuit for leakage

k
SEN00630-00
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing
and installing its components, check for
fuel leakage according to the following procedure.
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.
5.

leakage.
6.
Run the engine at high idle.
7.

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
9.

leakage.
a If any fuel leakage is not detected, inspection is completed.
27
SEN00630-00
Testing and adjusting alternator

belt tension
1
2.
Loosen locknut (4), turn adjustment nut (5) to

move alternator (6) and adjust the belt tension.
Testing
q
Press the intermediate point between alternator pulley and drive pulley with a finger and
measure deflection (a).
a Pressing force: Approx. 59 N {Approx. 6 kg}
a Deflection (a): 13 16 mm
3.
After the adjustment, tighten nut (3) and bolt

(2) to fix alternator (6) and install cap (1).
3 Nut (3): 107.8 147 Nm {11 15 kgm}
3 Bolt (2): 28.4 32.4 Nm {2.9 3.3 kgm}
Adjusting
a If the deflection is out of range, adjust it
1.
28
Remove cap (1) and loosen bolt (2) and nut

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

conditioner compressor belt
tension
SEN00630-00
Testing
Press the intermediate point between air conditioner compressor pulley and drive pulley with a finger 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 compressor bracket mounting bolts (1).
D85EX, PX-15E0
29
SEN00630-00
Adjusting fuel control dial and

decelerator pedal
1.
2.
Outline of fuel control system

The following signals are inputted as rotation command signals to the engine controller.
q
Decelerator pedal potentiometer signal
q
3rd throttle signal
The engine controller controls the fuel
control system of the engine (CRI system)
according to the lowest engine speed signal among those input signals.
q
Adjust the deceleration slow speed by
adjusting the decelerator pedal linkage.
q
Preparatory work
1) Start the engine, set the monitor panel in
the Adjustment mode, and prepare to
measure the engine speed.
a For the operation method, see Special functions of monitor panel
(EMMS).
q
Adjustment code: 0007
(Engine deceleration cut mode)
a The engine speed is displayed by 1 rpm.
[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 position, 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 opening 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, perform 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
SEN00630-00
31
SEN00630-00
Measuring power train oil

pressure
a
Measuring tools for power train oil pressure
Symbol
K
1
2
a
a
a
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester
Stop the machine on a level place, lower

the work equipment to the ground, and set
the parking brake lever and work equipment lock lever in the lock position.
Measure the power train oil pressure under the
following condition.
q
The centralized power train oil pressure pickup
ports are installed inside the inspection cover
on the left outside of the operator cab.
A nipple for measuring oil pressure is not
installed as standard.
Measuring torque converter outlet pressure

(OUT)
1) Connect hydraulic tester K2 to oil pressure measurement nipple (1).
a Use an oil pressure gauge of 0.98
MPa {10 kg/cm2}.
List of oil pressure measuring points and

gauges to be used.
No. Mark
Oil pressure reading
Gauge
(MPa {kg/cm2})
OUT
Torque converter outlet

pressure
0.98 {10}
TM
Torque converter main

relief pressure
5.9 {60}
IN
Torque converter inlet

pressure
2.5 {25}
FWD
Transmission forward
clutch pressure
5.9 {60}
Transmission reverse
clutch pressure
5.9 {60}
1ST
Transmission 1st clutch

pressure
5.9 {60}
2ND
Transmission 2nd clutch

pressure
5.9 {60}
3RD
Transmission 3rd clutch

pressure
5.9 {60}
BR Steering brake pressure
5.9 {60}
1.
2)
3)
4)
32
Run the engine and set the PCCS lever in

the full neutral position.
Measure the oil pressure while the engine
is running at low idle and high idle.

removed parts.
D85EX, PX-15E0
2.
Measuring transmission main relief pressure

(TM)
1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure measurement
nipple (2).
a Use an oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
2)
3)

SEN00630-00
3.
Measuring torque converter inlet pressure

(IN)
nipple (3).
{25 kg/cm2}.
2)
3)
4)
4)

removed parts.
a For the oil pressure gauge, see
BPD11546.

removed parts.
D85EX, PX-15E0
33
SEN00630-00
4.
Measuring transmission forward clutch

pressure (FWD)
nipple (4).
{60 kg/cm2}.
2)
3)
4)
5)
34
Run the engine and set the parking brake

lever in free position.
With the brake pedal depressed, set the
PCCS lever in the forward and 3rd gear
speed position.
is running at high idle.
k Since the torque converter is
stalled, press th e b rake pedal
BPD11546.
After completing the measurement,
remove the measuring instrument and set
to the original condition.
5.
Measuring transmission reverse clutch

pressure (R)
nipple (5).
{60 kg/cm2}.
2)
3)
4)
5)
Start the engine and set the parking brake

lever in the free position.
PCCS lever in the reverse and 3rd gear
speed position.
is running at high idle.
stalled, press the brake pedal
BPD11546.
D85EX, PX-15E0
6.
Measuring transmission 1st clutch pressure (1ST)

nipple (6).
{60 kg/cm2}.
2)
3)
4)
5)

PCCS lever in the forward and 1st gear
speed position.
is running at low idle.
stalled, keep pressing the brake
pedal securely.
k Do not run the engine at high idle
while measuring.
BPD11546.
D85EX, PX-15E0
SEN00630-00
7.
Measuring transmission 2nd clutch pressure (2ND)

nipple (7).
{60 kg/cm2}.
2)
3)
4)
5)

PCCS lever in the forward and 2nd gear
speed position.
pedal securely.
while measuring.
BPD11546.
35
SEN00630-00
8.
Measuring transmission 3rd clutch pressure (3RD)

nipple (8).
{60 kg/cm2}.
9.
Measuring steering brake pressure (BR)

nipple (9).
{60 kg/cm2}.
2)
2)
3)
4)
5)
36

PCCS lever in the forward and 3rd gear
speed position.
pedal securely.
while measuring.
BPD11546.
3)
4)

a Check that the oil pressure lowers to
0 when the brake pedal is depressed
or the parking brake lever is set in the
lock position.
BPD11546.
D85EX, PX-15E0
Adjusting transmission speed

sensor
1.
SEN00630-00
6.
Taking care of the mounting direction of cover

(2), install cover (2) and sensor (1) as a unit
again to HSS case (4).
3 Surfaces of cover and case:
Gasket sealant (LG-5)
7.
After completing adjustment, set the monitor

panel in Monitoring display mode and check
that it displays the transmission speed normally.
a Monitoring code:
31400 (Transmission speed)
Remove the undercover of the fuel tank, then

remove transmission speed sensor assembly
(1) and cover (2) as a unit.
a Before adjusting transmission speed sensor (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).
2.
Install cover (2) to HSS case (4) temporarily.

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:
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
SEN00630-00
Simple method to test brake

performance
Implement simple method to test brake performance under the following condition.
q
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 position.
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 finished.
38
D85EX, PX-15E0
Adjusting brake pedal
SEN00630-00
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
SEN00630-00
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 assembly: 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})
8.
40
Brake
released
2.84 0.10 {29 1}
Brake applied
After adjusting the pedal, adjust the zero point

of the brake potentiometer (Adjustment mode:
0005).
D85EX, PX-15E0
Adjusting parking brake lever
SEN00630-00
1.
Assembling and installing lever assembly

1) Assemble lever assembly (9) and adjust
the operation of limit switch (10).
a When assembling the lever assembly,
disconnect the parking brake cable
from the lever.
q
When lever is pulled up: OFF,
lowered: ON
q
Operation stroke of limit switch: 3 mm
2) Install lever assembly (9).
2.
Adjusting installation length of parking

brake cable
1) Connect parking brake cable (11) to the
lever side and valve side, and adjust
installation dimensions (f) and (g).
q
Cable installation dimension (f): 88 mm
q
Cable installation dimension (g): 90 mm
2) Operate parking brake lever (12) between
the free and lock positions, and adjust rod
end (14) so that spool stroke (h) of brake
valve (13) is normal.
q
Spool stroke (h): 13 mm
D85EX, PX-15E0
3.
Checking brake oil pressure

Check that the brake oil pressure is as follows
when the parking brake lever is set in free and
lock positions.
a For the method of measuring the brake oil
pressure, see Measuring power train oil
pressure.
q
Lock position: 0,
Free position: Specified pressure
4.
Checking limit switch

Change the monitor panel to the monitoring
display mode and set the parking brake lever
in free and lock positions. Check that the limit
switch signal is normal at this time.
a For the operation method of the monitoring display mode, see Special functions
of monitor panel (EMMS).
q
Monitoring code:
40910 (Steering related controller switch
input 1)
41
SEN00630-00

a
Emergency escape method when

power train has trouble
1
a
Devices used for emergency escape
Symbol
1
L
2
3
1.
Part No.
Part name
19M-06-32820 Switch assembly

17M-06-41530 Wiring harness
799-101-5220
Nipple (10 x 1.25 mm)
07002-11023
O-ring
790-190-1601
Pump assembly
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,
gear speed, steering), carry out the emergency escape according to the following
procedure.
a The engine must be able to start during
implementing this procedure.
If the engine cannot be started, see
Emergency escape method with brake
releasing device.
1) Connect switch assembly [1] to wiring harness [2] of emergency escape device L1.
k To prevent the machine from starting suddenly, set all the gear speed
switches of switch assembly [1] to
OFF position and the direction
switch in P position.
2)
42
Put switch assembly [1] in the cab

through the cab window.
Open the left fender inspection cover and

connect wiring harness [2] to PL1 connector (1) and PL2 connector (2).
q
PL1 connector (1): Connect to male
side and female side.
q
PL2 connector (2): Connect to female
side.
a PL2 connector on the male side is
kept disconnected, mask it with a
vinyl sheet, etc.
3)
Disconnect neutral safety relay (NSF) in

the rear of the control box and connect
pins [3] and [5] of the connector on the
wiring harness side.
a When PL2 connector is disconnected, a model selection error is triggered and the neutral safety relay will
not be actuated. Above procedure is
implemented to avoid this condition.
k If the engine is started by this
method, the neutral safety function
does not work. Accordingly, before
starting the engine, set the parking
brake lever in lock position and set
the PCCS lever in full neutral position.
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.
4)

D85EX, PX-15E0
5)
Operate switch assembly [1] and move

the machine to a safe place.
a The electrical circuit of the gear
speed switches is configured so that
the switch on the lower gear speed is
operated first.
k Take care that the L.H. and R.H.
steering directions are opposite
when reverse.
SEN00630-00
2.
Emergency escape method with brake

releasing device (Use L3)
a If the engine cannot be started and the
parking brake cannot be released, carry
out the emergency escape according to
the following procedure.
1) Assemble pump assembly L3.
2)
D85EX, PX-15E0
Install volume pump [1] of pump assembly

L3 to the outside of the operator cab.
43
SEN00630-00
3)
4)
5)
6)
7)
8)
44
Remove inspection plug for measuring oil

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

parking brake lever in free position.
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 operated 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.
Tow the machine to a safe place.
a The brake releasing oil pressure lowers 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.
When disconnecting the hose after finishing the work, loosen the screw slowly and
do not stand in the spouting direction of
the oil.
D85EX, PX-15E0
Adjusting clearance of idler
SEN00630-00
If the lateral guide and vertical guide plates of

the idler have worn excessively and the idler
ran out slants, adjust the clearance of the idler
1.
Lateral adjustment
1) Drive the machine 1 2 m on flat ground,
then measure clearance (a) between the
track frame and guide plate (4 places; left,
right, inner and outer sides).
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
4)
5)
Pull up vertical guide (4) with a bar, etc.

and pull out shim (5) by the quantity of
adjustment obtained in 1).
Add shim (5) pulled out onto shim (6).
(8 places in total on both sides, inside, and
outside)
a The total number of shims (5) and (6)
before adjustment must be the same
as that after adjustment.
q
Sorts of shim thickness: 1 mm, 2 mm
45
SEN00630-00
Inspecting wear of sprocket

a
Use the Full-scale dimensions drawing of

sprocket profile in the topic Sprocket in the
chapter Structure, function and maintenance
standard as a gauge for measuring wear of
the sprocket.
Make a copy of the Full-scale dimensions
drawing of sprocket profile on a transparent
paper or sheet and apply it directly to the
sprocket to see if the sprocket can be used.
Testing and adjusting track shoe

tension
1
Testing
1. Move the machine slowly on a level place, then
stop it.
a Do not apply the brake when stopping.
2.
Place straight steel bar (1) between the idler

and front carrier roller and measure clearance
(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
46
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.
D85EX, PX-15E0
SEN00630-00
Testing and adjusting work

equipment and HSS oil pressure 1
a
Install nipple M2 and connect it to oil pressure gauge [1] of hydraulic tester M1.
a Use an oil pressure gauge of 39.2
MPa {400 kg/cm2}.
4)
Run the engine at high idle and set the

blade lever and ripper lever in neutral and
measure the oil pressure.
5)

removed parts.
Equipments for testing and adjusting work

equipment and HSS oil pressure
Symbol
1
M
2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-101-5220
07002-11023
O-ring
Measuring
k Stop the machine on a level place, lower
a Measure the work equipment and HSS oil
pressure under the following condition.
q
1.
3)
Measuring unload pressure

1) Remove main control valve cover (1) on
the right side of operator seat.
2)
Remove measurement plug (2).
D85EX, PX-15E0
47
SEN00630-00
2.
Measuring work equipment and HSS oil

pressure
1) Remove main control valve cover on the
right side of operator seat.
2) Remove pump discharge oil pressure
measurement plug (1) and LS oil pressure
(load sensing pressure) measurement
plug (2).
3)
48
Install nipples M2 and connect it to oil

pressure gauge [1] of hydraulic tester M1.
a Use the following oil pressure gauges
Work equipment oil pressure:
39.2 MPa {400 kg/cm2}
HSS oil pressure:
58.8 MPa {600 kg/cm2}

1] Run the engine and set the work equipment lock lever in the free position.
2] Run the engine at high idle and operate
the blade lever and ripper lever. When
each cylinder is relieved at the stroke end,
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
the right or left with the PCCS lever. When
the steering circuit is relieved, measure
the oil pressure.
3] After finishing measurement, remove the
measuring instrument and set to the original condition.
D85EX, PX-15E0

a
SEN00630-00
The unload pressure and relief pressure

also can be measured in the Pm clinic
auxiliary mode of the monitor panel.
D85EX, PX-15E0
49
SEN00630-00
3.
50
Adjusting
1) LS pressure (Load sensing pressure) of
work equipment
Loosen locknut (4) of work equipment LS
valve (3) and rotate adjustment screw (5)
to adjust the LS pressure.
a If the adjustment screw is
q
rotated to the right, the oil pressure is heightened.
q
rotated to the left, the oil pressure is lowered.
a If the adjustment screw is rotated 1
turn, the pressure is heightened or
lowered by 17.6 MPa {179 kg/cm2}.
3 Locknut:
29.4 39.2 Nm {3 4 kgm}
q
After adjusting, check the relief pressure and LS pressure of work equipment again.
2)
LS pressure (Load sensing pressure) of

HSS
Loosen locknut (7) of HSS LS valve (6)
and rotate adjustment screw (8) to adjust
the LS pressure.
a If the adjustment screw is
q
rotated to the right, the oil pressure is heightened.
q
rotated to the left, the oil pressure is lowered.
a If the adjustment screw is rotated 1
turn, the pressure is heightened or
lowered by 15.1 MPa {154 kg/cm2}.
3 Locknut:
68.6 78.5 Nm {7 8 kgm}
q
After adjusting, check the relief pressure and LS pressure of work equipment again.
D85EX, PX-15E0
SEN00630-00
Testing control circuit basic

pressure
a
1
2
Part No.
Install oil pressure pickup adapter N2 and connect the disconnected hose again.
4.
Install nipple [1] of hydraulic tester N1 and connect oil pressure gauge [2].
{60 kg/cm2}.
5.
Run the engine at high idle and set the blade

lever and ripper lever in neutral and measure
the oil pressure.
6.
parts.
Instruments for testing and adjusting control

circuit basic pressure
Symbol
3.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital type hydraulic tester
799-401-3200
Adapter (size 03)
The control circuit main pressure is the pressure lowered by the self pressure reducing
valve. It is used commonly for blade PPC, fan
pump control, steering EPC and ripper PPC.
Measuring
k Stop the machine on a level place, lower
a Measure the control circuit basic pressure
under the following condition.
q
1.
Remove main control valve cover on the right

side of operator seat.
2.
Disconnect hose (1).
Adjusting
a The self pressure reducing valve cannot be
adjusted.
D85EX, PX-15E0
51
SEN00630-00
Measuring PPC valve output

pressure
a
a
a
Part No.
Hydraulic tester
790-261-1204
Digital type hydraulic tester
799-401-3100
Adapter (size 02)
799-401-3200
Adapter (size 03)
parts.
Stop the machine on a level place, lower

Before measuring the PPC valve output pressure, check that the control circuit basic pressure is normal.
Measure the PPC valve output pressure under
the following condition.
q
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 connect oil pressure gauge [2].
4.
Run the engine and set the work equipment

lock lever in the free position.
52
6.
Part name
799-101-5002
Run the engine at high idle and operate the

control lever of the circuit to be measured and
a Measure the oil pressure with the lever at
full stroke.
a For the blade lower side, operate the lever
to the float position.
Measuring instruments for PPC valve output

pressure
Symbol
5.
D85EX, PX-15E0
1.
2.
3.
4.
5.
Main valve
PPC lock valve
Blade PPC valve
Ripper PPC valve
D85EX, PX-15E0
SEN00630-00
A.
B.
C.
D.
E.
F.
Blade LEFT TILT

Blade LOWER
Ripper RAISE
Ripper LOWER
Blade RAISE
Blade RIGHT TILT
53
SEN00630-00
Adjusting play of work equipment

PPC valve
1
a
a
The ripper valve is not adjustable.

If the end play of the blade lever is excessive,
adjust it with their PPC valves according to the
following procedure.
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
SEN00630-00
Checking parts which caused

hydraulic drift of blade and ripper1
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 procedure.
1.
Stop the engine with the cylinder at the following 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.
3)
2.
2)
Blade tilt cylinder

Retract the tilt cylinder to the stroke end
and tense blade further to push up the
right side of the machine.
D85EX, PX-15E0

Tens e r ipp er to pus h u p the re ar of
machine.
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 cylinder 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 reason why the drift speed becomes
faster by above mentioned operation
is as follows:
1) When work equipment is set in the above
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 press 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.
55
SEN00630-00
Measuring internal leakage of

work equipment cylinder
a
Measuring instruments for leakage of work

equipment cylinder
Symbol
Part No.
Commercial
item
a
a
1.
If the work equipment cylinder was removed

and installed or its piping was disconnected
and connected, bleed air from its circuit
1.
Run the engine at low idle for about 5 minutes.
2.
Running the engine at low idle, extend and

retract the cylinder to be bled 4 5 times.
a Move the piston rod to about 100 mm
before the stroke end and never relieve
the oil.
3.
Running the engine at high idle, carry out the

operation in 2.
4.
Running the engine at low idle, move the cylinder to the stroke end to relieve the oil.
Part name
Measuring cylinder
Measure the internal leakage of work equipment cylinder under the following condition.
q
Since the blade lift cylinder is equipped with a
piston valve, its internal leakage cannot be
measured.
Retract the cylinder to be measured to the
stroke end and set the machine in the measuring position.
1) Blade tilt cylinder
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 ripper.
4.
After 30 seconds, measure leakage for 1 minute.
5.
After finishing
removed parts.
56
Bleeding air from work equipment

cylinder
1
measurement,
return
the
D85EX, PX-15E0
Releasing residual pressure in

work equipment cylinder
SEN00630-00
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
SEN00630-00
Adjusting work equipment lock lever
1.
Adjust dimension (a) between pins of rod (1).

Dimension (a) between pins: 329 mm
2.
58
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.
D85EX, PX-15E0
SEN00630-00
Measuring fan motor speed

a
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
before starting the engine. Do not start
the engine with the radiator mask open.
7.
parts.
Measuring instruments for fan motor speed
Symbol
Part No.
799-205-1100
Part name
Tachometer KIT
1.
Open radiator mask (1).
2.
Remove fan guard (2).
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 position 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 adjustment mode, see Special functions of
monitor panel (EMMS).
a Adjustment code:
1005 (Fan 100% speed mode)
D85EX, PX-15E0
59
SEN00630-00
Measuring fan pump circuit

pressure
a
1
2
3
Part No.
6.
Measure the oil pressure of fan circuit while the

engine is running at high idle.
7.
parts.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-3400
Adapter (size 05)
799-101-5220
07002-11023
O-ring
1.
Open radiator mask (1).
2.
Remove fan guard (2).
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].
{400 kg/cm2}.
60
Run the engine, and turn the monitor panel to

the adjustment mode.
a For the operation method of the adjustment mode, see Special functions of
monitor panel (EMMS).
a Adjustment code:
1005 (Fan 100% speed mode)
Measuring instruments for fan pump circuit

pressure
Symbol
5.
D85EX, PX-15E0
Bleeding air from fan pump

a
SEN00630-00
If the fan pump was removed and installed or

its piping was disconnected and connected,
bleed air from the pump case according to the
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 minutes.
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
SEN00630-00
Adjusting blade
1.
If the blade was removed and installed or disassembled and assembled, adjust it according
to the following procedure.
Adjusting shims for assembly
1) Adjust the shim of center (1). (6 pieces)
Adjusted Adjusted
point clearance
1
Standard
clearance
Standard thickness
of shim
Refer to the
note.
4 mm
2)
Adjust the shim of lift (2). (2 pieces)
Adjusted Adjusted
point clearance
2
Standard
clearance
Standard thickness
of shim
Max. 1 mm
4 mm
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.
SEN00630-00
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 remarkably, adjust installation dimension (c) of
brace (3) according to the following procedure.
q
(e1) > (e2): Increase installation dimension (c) finely.
q
(e1) < (e2): Decrease installation dimension (c) finely.
D85EX, PX-15E0
63
SEN00630-00
Testing and adjusting operator

cab
Check after installing cab assembly

1.
Measuring pressure in cab

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
holes for wiring harnesses and optional
parts in the cab.
1) A simple method of measuring the internal
pressure is as follows.
1] Prepare a transparent vinyl hose.
q
Inside diameter: 6 mm,
Length: 3,000 mm
2] Secure the inside end of the hose to
the top of the back seat with a tape.
3] Remove bolt (1) under the left console box. Pass the other end of the
hose through the bolt hole and take it
out of inspection cover (2) on the left
side of the cab.
q
4]
5]
6]
7]
64
2.
Check of sealing performance

1) Close the all openings of the cab.
2) Splash water around the hatched part of
the cab at the rate of about 19 l/min. for
10 minutes.
q
At this time, it is not necessary to
splash pressurized water.
3) Splash water horizontally from a hose over
sealing surface (4).
4) Check around the dashboard carefully.
a If water leaks, caulk the leaking part and
check again.
Seal the hole of bolt (1) with tape (3).

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

Close the door and check the relationship
between the operator cab and door. If there is
any fault, repair it.
1) Check of current condition
1] Check the installed height to damper
rubber (1).
(Check both sides, 2 pieces on each.)
q
Stick adhesive tape [1], etc. to
the contact surface of damper
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 contact 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
SEN00630-00
2]
Check the relationship between the

door latch and striker (on both sides).
q
Close door (2) and check the
engaging condition of latch (3)
and striker (4).
Normal: Error of (a) must be 0.5
mm or less.
a Check deviation (a) of latch center
(y) and striker center (x) from each
other from the direction of (A).
65
SEN00630-00
2)
Adjusting
1] Adjusting height of damper rubber
q
Loosen the mounting bolts of
damper rubber (1).
a You can remove and install the
s h im s wi th o ut r e m ov i ng th e
mounting bolts.
q
Increase or decrease of shims
(5) under damper rubber (1) to
adjust the height of damper rubber (1) properly.
4.
Testing open lock

Lock the door open and check the relationship
between the operator cab and door. If there is
any fault, repair it.
1) Check of current condition
1] Check the relationship between open
lock latch (3) and striker (4) from the
direction of (B).
a
2]
3]
66
Adjusting height of latch and striker

1. Tighten the mounting bolt of
striker (4) temporarily and close
the door 2 3 times to align latch
(3) and striker (4) with each
other.
2. Check the engaging condition of
latch (3) and striker (4).
3. Tighten the mounting bolt of
striker (4) securely.
4. Open and close the door and
check that it is locked and
unlocked smoothly. If the door is
not locked and unlocked
smoothly (if the knob is heavy),
perform the adjustment procedure from the first.
a Operating effort of knob:
49 19.6 N {5 2 kg}
Apply grease (G2-LI) to latch (3).
a If latch (3) is not greased, the
knob becomes heavy. Accordingly, apply grease sufficiently.
2]
Move the door in the opening

direction to check the engagement of the latch and striker.
Check the installation height of stopper rubber.
(Check both sides, 2 pieces on each.)
1. Lock the door open and shake it
in the forward and reverse directions to see if it has any play.
2. Check that the operating effort of
unlock lever is not heavy.
3. Check that striker (4) does not
slant from center (d) of the latch.
4. Check that the latch is not shifted
from center (e) of the striker.
q
Normal: Error of (e) must be
less than 0.5 mm.
D85EX, PX-15E0
2)
Adjusting
1] Adjusting latch and striker
q
Loosen mounting bolt (7) of
striker (4), adjust striker (4)
upright, and tighten mounting
bolt (7).
SEN00630-00
2.
3.
2]
If there is any play, project

(heighten) the stopper rubber
until the play is eliminated.
a If the door is not locked easily or the unlock lever is
heavy, return (lower) the
stopper rubber in the range
that the door does not have
any play.
Tighten the locknut.
Adjusting installation height of stopper rubber

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

68
SEN00631-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

Testing and adjusting, Part 2........................................................................................................................... 2
Special functions of monitor panel (EMMS) ......................................................................................... 2
D85EX, PX-15E0
SEN00631-00
Special functions of monitor panel (EMMS)
Display section of special functions

1. Upper display section
(Gear speed display section)
2. Lower display section
(Multi-information section)
Operation section 1 of special functions (Basic

operation)
3. Service switch
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
EMMS: Equipment Management Monitoring

System
D85EX, PX-15E0
SEN00631-00
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
SEN00631-00
Operation and display of operator mode

(Outline)
a
information section (2). Reset after completion

of the replacement is done in this mode.
a Gear speed display section (1) remains
the normal display.
In this section, only the outline of operator

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 characters 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.
The items marked with a are displayed

but not used for this machine.
Replacement interval
Code
1st time
(Can not be
changed)
2nd time
and after
(Can be
changed)
ENG OIL Engine oil
500
500
02
ENG FILT Engine oil filter
500
500
1000
1000
250
2000
04
Maintenance mode
(1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replacement of oils and filters is displayed on multi-
Maintenance item
01
03
1.
Display
FUEL
FILT
Fuel main filter
HYD FILT Hydraulic oil filter
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 a HSS charge filter
19
POWL
OIL
Power train oil
250
1000
20
POWL
FILT
250
500
41
F.PREFLT
Fuel pre-filter
500
500
D85EX, PX-15E0
2.
Pm clinic auxiliary mode (2-PM CLINIC MODE)

In this mode, the condition of the machine is
displayed on multi-information section (2) as
an auxiliary function of the periodic diagnoses
such as the Pm clinic, even if any measuring
instrument is not connected.
the normal display.
No.
SEN00631-00
3.
Failure code display mode

(3-FAULT CODE DISPLAY MODE)
In this mode, the contents of each problem in
the machine are displayed by a 6-character
failure code on multi-information section (2).
When a user or an operator needs to be notified of the failure code of each problem, this
mode is applied.
the normal display.
Pm clinic auxiliary item
01
Engine speed
02
Coolant temperature
03
Engine oil pressure
05
Boost pressure
06
Boost temperature
07
08
Work equipment oil temperature
09
13
Battery voltage
D85EX, PX-15E0
When a serviceman needs to check the

failure codes for troubleshooting, Electrical system failure code display mode and
Mechanical system failure code display
mode is recommended to use for more
detailed information.
Method of checking failure code:
Turn buzzer cancel switch (4) to the [U ]
position on the screen shown on the
above, and all failure codes detected currently are displayed at the interval of about
2 seconds. (To finish displaying, turn the
buzzer cancel switch to the [t] position.)
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4.
Adjustment mode (4-USER ADJUST MODE)

In this mode, the display condition of the monitor panel can be adjusted on multi-information
section (2).
the normal display.
No.
1)
Brightness of LCD
This mode is to adjust brightness of the
backup lamp at the liquid crystal gauge
section. (See Operation and Maintenance
Manual.)
2)
Brightness of display
This mode is to adjust brightness of the
backup lamp at the multi-information section. (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 condition and the rotation speed of the
cooling fan is controlled to approximately 100% of the maximum speed.
a Exiting this mode disables the
function.
Adjustment item
01
Brightness of LCD
02
Brightness of display
03
Contrast of display
04
Fan 100% mode
05
No injection cranking mode
D85EX, PX-15E0
5)
No injection cranking mode

This mode is to circulate the engine oil
while applying no injection conditions to all
engine cylinders before staring engine
after an extended machine storage.
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] In this condition, turn the starting
switch to START position to apply no
injection cranking.
4] The mode is released by moving the
starting switch to ON position and
turning the buzzer cancel switch to
the [t] position.
k Do not continue no injection
cracking for more than 20 seconds in order to protect the
starting motor.
k For safety, this mode cannot be
operated while the engine is
running.
a Exiting from this mode disables
this function.
D85EX, PX-15E0
SEN00631-00
Action code display function

If a trouble which is to be notified to a operator
occurs during work, an action code and a phone
number are displayed on multi-information section
(2).
a Gear speed display section (1) remains the
normal display.
a The phone number is displayed only for important action codes. The display shown below is
an example. (The form of the displayed phone
number depends on the form of the input number.)
a If an important action code is displayed, the
caution lamp flashes and the alarm buzzer
sounds.
<Reference>
An action code is displayed only when a serious
abnormality occurs.
Even if an action code is not displayed, abnormality
may have occurred. Therefore, if you find any incident, be sure to check for a failure code in Electric al sy s te m fai l ur e c od e di s pl ay m od e an d
Mechanical system failure code display mode.
SEN00631-00
Action code table

Action
code
E01
E02
Display method of trouble
Only action code is displayed.
The action code is displayed.

Warning lamp flashes
Alarm buzzer sounds.
Remedy requested for an

operator
Examples of abnormality
Backup alarm does not turn on.

Fan speed is kept at maximum
level.
Gear is not shifted up or down.

Exhaust gas color is bad when
temperature is low.
Abnormal engine oil pressure
sensor
Automatic function stops or normal function stops partially, but

machine can work.
Contact your Komatsu distributor for repair.
Stop engine and start it again,

and you can operate machine
without limiting function. You
must take care, however.

CALL E03 Warning lamp flashes
Engine boost pressure is abnormal.

Move machine to safe place.
Usable gear speeds are limited.
Contact your Komatsu distribu Engine speed does not rise fully.
tor for repair.
Gear shift shocks become large.
Steering performance lowers.

CALL E04 Warning lamp flashes
Engine cannot be controlled.

Machine cannot travel.
Machine stops.
Immediately stop machine.

D85EX, PX-15E0
SEN00631-00
Operation and display in service mode

Method of changing to service mode
a When using the service mode, change the
screen by the following special operation.
1)
Special operation of switches

Set the monitor panel in the service mode by
operating service switch (3) and buzzer cancel
switch (4).
a Keeping the service switch in ON position,
hold the buzzer cancel switch in the [U]
position for more than 2.5 seconds.
a If the monitor panel is set in the service
mode, [1C] is displayed on gear speed
display section (1).
a Each time the monitor panel is set in the
service mode, Maintenance interval
change mode is displayed first.
D85EX, PX-15E0
No.
Gear speed
display section
1C
Maintenance interval change

mode
EE
Electrical system failure code

display mode
bE
Mechanical system failure code

display mode
Cb
Adjustment mode
Ld
10
5R
Real-time monitoring mode
11
dR
Dual display monitoring mode
Adjustment item
2)
Selecting and executing mode to be used

Select the mode to be used with information
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.
SEN00631-00
5.
Maintenance interval change mode

(5-EXCHG. INTVAL. SET MODE)
In this mode, you can check and set the maintenance interval times of various filters and oils
which are the bases of the maintenance display function in the operator mode.
1)
10
2)
Selecting and displaying maintenance item

1] Operate information switch (5) on the
maintenance item selection screen to
select a maintenance item.
q
[>]: Next code
q
[<]: Previous code
2] Display the maintenance item selection screen by operating buzzer cancel switch (4).
q
[U]: Execute item.
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 operation on this screen.
a If the replacement interval needs to
be changed, go to step 4).
Selecting and implementing a mode

1] Select Maintenance interval change
mode on the mode selection screen.
a If the mode is selected, code [1C]
is displayed on gear speed display section (1) and the title is
displayed on multi-information
section (2).
2] Display the maintenance item selection screen by operating buzzer cancel switch (4).
q
[U]: Execute mode
D85EX, PX-15E0
4)
Updating replacement interval

1] Change the set time by operating
information switch (5), shift-up switch
(6) and shift-down switch (7).
q
[>]: Move cursor to right.
q
[<]: Move cursor to left.
q
[UP]: Number increases.
q
[DOWN]: Number decreases.
a Cannot set the value beyond the
default setting time.
SEN00631-00
2]
If the input time is correct, enter the

change of setting by operating buzzer
cancel switch (4).
q
[U]: Enter change.
a If the change is finished normally,
the information display screen
appears after the screen shown
below.
a
a
D85EX, PX-15E0
If you do not use the maintenance function, set all times to 0.
If the change is not finished normally, the information display

screen before the change
appears after the screen shown
below. In this case, execute the
above operation again.
11
SEN00631-00
Maintenance items table

Replacement interval (H)
Code
Display
Maintenance item
1st time
(Can not be changed)
2nd time and after

(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
250
500
41
F.PRE-FLT
Fuel pre-filter
500
500
12
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.
D85EX, PX-15E0
6.
Electrical system failure code display mode

(6-ELEC. FAULT CODE MODE)
In this mode, you can check the electrical system failure codes among the information of the
troubles that occurred on the machine.
a Refer to the item of Troubleshooting for
the failure code list.
1)

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
SEN00631-00
2)
Display in case where no codes are

recorded
If the failure codes which occurred in the
past, and the current active failure codes
do not exist, the below display will be
shown.
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.
D85EX, PX-15E0
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.
13
SEN00631-00
a
14
Conditions for detecting and keeping

failure code
When a failure is detected, the failure
c ode other t han c omm unic ati on
related or engine-related keeps flashing until the starting switch is turned
off. After turning the starting switch
OFF temporarily, if the starting switch
is turn on or the engine is started
again, the failure code keeps lighting
until the same trouble is detected.
Communication related or engine
related failure code is switched to the
lighting when the problem is solved,
even if the starting switch is not
turned off.
4)
Operations in case that multiple codes are

recorded
When multiple codes are recorded, they
can be displayed one by one by operating
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 currently (code is flashing) cannot be
deleted.
7.
Mechanical system failure code display mode

(7-MACHINE FAULT CODE MODE)
In this mode, you can check the mechanical
system failure codes among the information of
the troubles that occurred on the machine.
a Refer to the item of Troubleshooting for
the failure code list.
1)

1] Select Mechanical system failure
code display mode on the mode
selection screen.
a If the mode is selected, code [bE]
section (2).
2] Display the failure code display
switch (4).
q
[U]: Executes mode.
D85EX, PX-15E0
2)
3)
Display in case where no codes are

recorded
If the failure codes which occurred in the
past, and the current active failure codes do
not exist, the below display will be shown.
SEN00631-00
4)
Operations in case that multiple codes are

recorded
When multiple codes are recorded, they
can be displayed one by one by operating
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 displayed in numerical order.
5)
Method of deleting failure code

The failure codes of the mechanical system cannot be deleted.
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.
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.
Conditions for detecting and keeping
failure code
A failure code of the mechanical system is switched to the lighting when
the problem is solved, even if the
starting switch is not turned off.
D85EX, PX-15E0
15
SEN00631-00
8.
Adjustment mode (8-SERVICE ADJUST MODE)

In this mode, you can adjust the control system
and various devices of the machine.
1)

1] Select Adjustment mode on the
mode selection screen.
a If the mode is selected, code [Cb]
section (2).
2] Display the adjustment code input
switch (4).
q
[U]: Executes mode.
2)
Selecting adjustment items

1] On the adjustment code input screen,
input the 4-digit code of the item to be
adjusted by operating information
switch (5), shift up switch (6) and shift
down switch (7).
q
[>]: Moves cursor rightward.
q
[<]: Moves cursor leftward.
q
[UP]: Increases number.
q
[DOWN]: Decreases number.
2] After inputting the code, operate
buzzer cancel switch (4) to display
the monitoring screen.
q
[U]: Enters input mode.
16
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.
D85EX, PX-15E0
3)
Contents of display on adjustment screen

1] : Code
2] : Adjustment item
3] : Related information
a For the detailed information and
adjustment procedure, see Adjustment mode table and adjustment procedure.
4)
In case of operating the machine in adjustment mode, if the parking brake lever is
set in the free position, gear speed display section (1) returns to the normal display 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 position temporarily and perform the necessary operation.
D85EX, PX-15E0
SEN00631-00
5)
Scrolling adjustment items in order (limited function)

For some adjustment items once the
adjustment item is selected, they can be
scrolled in order by the information switch
operation without inputting the codes
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 Adjustment mode
table and adjustment procedure, and
scrolled in the order of numeric character.
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
code for that item.
17
SEN00631-00
Adjustment mode table and adjustment procedure

No.
Code
Adjustment item
Related
information
Disassembly
and assembly
[1]
0001
INP TEL NO.
Phone No. input mode
a [2]
0002
S/T S.CODE
Steering and transmission controller specification set
Code
a [3]
0004
BODY TYPE
Machine specification set
Code
a [4]
0005
BRAKE BASE Brake potentiometer zero point adjustment
Voltage
a [5]
0007
ENG.FULL CH Engine deceleration-cut mode
Speed
[6]
0008
INJ -> 123456 Common rail reduced cylinder mode
a [7]
0009
PITCH SENS. Pitch angle sensor initial set
a [8]
0010
FAN 70%
MODE
Fan 70% speed mode
a [9]
0021
KMTRX INST
KOMTRAX specification set
a [10]
1005
FAN 100%
MODE
Fan 100% speed mode
[11]
1012
S/T N-SET
Steering control lever neutral set
Voltage
[12]
1013
S/T L-SET
Steering control lever left set
Voltage
Steering control lever right set
18
Figure/Symbol
Speed
Fuel injection
rate
q
Voltage
Adjustment
data
Symbol
Adjustment
data
[13]
1014
S/T R-SET
[14]
2222
HSS ADJUST HSS lever initial current set
Current
Voltage
[15]
9997
HI IDLE SET
High idle limit mode
Speed
[16]
9998
SFT INHIBIT
Gear speed limit mode
Symbol
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 procedure, 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.
D85EX, PX-15E0
[1] 0001: Phone No. input mode

q
This code inputs or changes a phone number
to be displayed simultaneously with when the
user code is displayed.
q
The lower part displays a phone number and
symbols.
q
Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ?
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 characters).
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.
a 16 digits of numeric characters are provided. To avoid confusion, input symbols
other than numeric characters at digits
you will not use.
a 0 (zero) is input at all places of the lower
part before shipment from our factory. (No
phone number is displayed under this condition.)
a Even if this code is turned off, the setting
is effective.
SEN00631-00
2)
a
a
Check that the displayed specification

code has changed from [4*4] to [444].
If specification code [444] is not displayed,
the controller wiring harness or the controller unit may be defective.
Even if this code is turned off, the setting
is effective.
[3] 0004: Machine specification code setting

q
This code is used to have the machine specification recognized by the controllers which
compose the system.
q
The machine specification code is displayed
on the lower line.
q
Adjustment method:
a Since this code is reset when Steering
and transmission controller specification
set is executed, adjust it after that.
1) Select the code of the machine specification 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 specification, is set.
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 transmission 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
SEN00631-00
No.
00
Specification
Standard specification
08
80
(Not used)
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).
q
Adjustment method:
With the brake pedal released, 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.
a This code is not for the adjustment of the
braking performance, etc..
[5] 0007: Engine deceleration-cut mode

q
This code is used to stop the auto-deceleration
function of the engine and check the high idle
speed of the engine unit.
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 disabled.
20
[6] 0008: Common rail reduced cylinder mode

a When the engine common rail system seems
to be defective, this code is used to stop injecting fuel into 1 or more cylinders (reduce the
number of effective cylinders) while the engine
is running and find out a defective cylinder
from the change of the engine speed and the
fuel injection rate.
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 operation, use this function while the engine is running.
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 cylinders again, too.
q
[>]: Moves cursor rightward.
q
[<]: Moves cursor leftward.
q
[U]: Executes or stops reduced cylinder
mode operation.
D85EX, PX-15E0

a
a
a
The below figure is an example that No. 2 cylinder is turned off for reduced cylinder mode
operation and turned on again (The cylinder
No. lamp is turned OFF in the reduced cylinder
mode operation and ON in the normal mode
operation).
Only one or more cylinders can be turned off

for the reduced cylinder mode operation.
If this code is turned off, its function is disabled.
D85EX, PX-15E0
SEN00631-00
[7] 0009: Pitch angle sensor standard value setting

q
This code is used to correct the installation
error of the pitch angle sensor by adjusting its
zero point.
q
The deviation from the standard neutral position is displayed by voltage on the lower line
(Display range: 2500 to 2500 mV).
q
Adjustment method:
Stop the machine on level ground, then set
buzzer cancel switch (4) in the [U] position
and check that the alarm buzzer sounds.
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
line.
q
How to use:
The function is effective with this code displayed to control the speed of cooling fan to
approximately 70% of the maximum speed.
a If this code is turned off, its function is disabled.
21
SEN00631-00
[9] 0021: KOMTRAX specification set

q
This code is used to select the installation setting 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 cancel switch (4) in the [U] position and
check that the alarm buzzer sounds.
is effective.
a If the controller is changed, be sure to
conduct (check) this setting, too.
[10] 0530: Stall speed check mode

q
This code is the function to make the cooling
fan speed maximum to check the torque converter stall speed.
k In this machine the cooling fan speed control 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

a
If this code is turned off, its function is disabled.
[11] 1005: Fan 100% mode

q
This code forcedly sets the speed of cooling fan
at approximately 100% of the maximum speed.
Also by this code, the adjustment value for the
maximum speed can be set.
q
The adjustment data is displayed on the lower line.
q
How to use:
a The function is effective with this code displayed 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] position and check that the alarm buzzer
sounds.
a If this code is turned off, its function is disabled. However, the adjustment value
once set is still effective.
D85EX, PX-15E0
[12] 1012: Swing lever neutral value setting

q
This code is used to adjust the steering potentiometer neutral position of the PCCS lever.
q
The output signal of the steering potentiometer
is displayed by voltage on the lower line (Display range: 0 5000 mV).
q
Adjustment method:
1) Shift the PCCS lever in the steering neutral position.
sounds.
is effective.
steering performance, etc..
SEN00631-00
[14] 1014: Swing lever right maximum value setting

q
This code is used to adjust the rightmost steering potentiometer position of the PCCS lever.
q
q
Adjustment method:
1) Shift the PCCS lever to the steering right
stroke end.
sounds.
is effective.
[13] 1013: Swing lever left maximum value setting

q
This code is used to adjust the leftmost steering potentiometer position of the PCCS lever.
q
q
Adjustment method:
1) Shift the PCCS lever to the steering left
stroke end.
sounds.
is effective.
D85EX, PX-15E0
23
SEN00631-00
[15] 2222: HSS initial current adjustment mode

q
When the steering start feeling is different by
the steering direction, this code is used to
adjust the turning radius at the start of steering.
q
The current to drive the HSS EPC solenoid is
displayed on the lower line [Display range:
350 mV (Left end) 0 350 mV (Right end)].
q
Adjustment method:
1) Gradually shifting the PCCS lever to the
left or right, display the current to be set
and keep it.
q
If the lever is shifted to the left, the current
becomes negative.
q
If the lever is shifted to the right, the current becomes positive.
sounds.
a
a
24
[16] 9997: High idle setting

This code is used to limit the high idle speed.
q
The limited speed (0 400 rpm) is displayed
on the lower line.
q
Possible limit range: High idle speed to 400 rpm
q
How to use:
1) Select a limit speed by setting information
switch (5) in the [>] position or [<] position.
sounds.
a If the high idle speed is limited, the engine
speed is not raised to the normal high idle
level even if the fuel control dial is controlled so.
is effective.
q
As the set current is increased in the positive or negative direction, the turning
radius at the start of steering is decreased
(the machine turns more quickly).
The below figure is an example that the
set current for steering to the left is
reduced to increase the turning radius.
Even if this code is turned off, the setting
is effective.
D85EX, PX-15E0
[17] 9998: 3rd gear speed cut setting

q
This code is used to restrict the shift to the 3rd
gear.
q
The usable gear speeds are displayed by bits
on the lower line (in the order of the 3rd, 2nd
and 1st from the left).
q
How to use:
Restrict or allow the use of the highest gear
speed by operating information switch (5) and
q
[>]: Restricts a shift to 3rd gear speed.
q
[<]: Does not restrict shift to 3rd gear
speed.
q
[U]: Determine the setting.
q
Display on lower line [o]: Gear speed is
effective.
q
Display on lower line [ ]: Gear speed is
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.
SEN00631-00
9.

(9-LOAD MEMORY DISPLAY MODE)
In this mode, the load on the machine, forward
odometer, and reverse odometer can be
checked.
1)

1] Select Load saving display mode on
the mode selection screen.
a If the mode is selected, code [Ld]
section (2).
2] Display the information screen by
operating buzzer cancel switch (4).
q
[U]: Execute mode
2)
Changing information screen

Change the information screen by operating information switch (5).
q
[>]: Next screen
q
[<]: Previous screen
No.
D85EX, PX-15E0
Displayed information
01
1000 rpm service meter
02
Forward odometer
03
Reverse odometer
25
SEN00631-00
26
3)
Displayed information of 1,000 rpm service meter (01)

This code is used to display the service
meter which integrates the operation
hours only while the engine speed is
higher than 1,000 rpm.
a The data cannot be reset.
4)
Displayed information of forward odometer (02)

On this screen, the integrated forward
travel distance of the machine is displayed.
5)
Displayed information of reverse odometer (03)

On this screen, the integrated reverse
travel distance of the machine is displayed.
6)
When operating machine in the load saving display mode

If the parking brake lever is set in the
free position, gear speed display section
(1) returns to the normal display and the
machine can be operated normally.
load saving display mode.)
traveling.
D85EX, PX-15E0
10. Real-time monitoring mode

(10-REAL TIME MONITORING MODE)
In this mode, the speeds, oil pressures, temperatures, currents, voltages, etc. can be monitored by using the signals from sensors,
switches, and solenoids installed to various
parts of the machine in real time.
a This mode is used to monitor the items
one by one. When monitoring two items
simultaneously, use the Dual display
monitoring mode.
1)

1] Select the Real-time monitoring
a If the mode is selected, code [5R]
section (2).
2] Display the monitoring code input
switch (4).
q
[U]: Select and decide mode.
D85EX, PX-15E0
SEN00631-00
2)
Selecting and entering monitored items

1] On the code input screen, input the 5digits code of the item to be monitored by operating information switch
(5), shift up switch (6), and shift down
switch (7).
q
[>]: Cursor moves rightward.
q
[<]: Cursor moves leftward.
q
q
2]
After inputting the code, operate

q
[U]: Determine input.
a If the input code is correct, the
monitoring screen shown below
appears.
27
SEN00631-00
a
If the input code is not correct, the code input

screen appears again after the screen shown
below.
5)
28
3)
Displayed information on monitoring

screen (Below figure shows examples)
1] : Code
2] : Monitored item
3] : Information
4] : Unit (Not displayed for some items)
a For the details, see the Monitoring
mode table.
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
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.
When operating machine with monitoring

display
If the parking brake lever is set in the
free position, gear speed display section
(1) returns to the normal display and the
machine can be operated normally.
monitoring mode.)
traveling.
D85EX, PX-15E0
6)
SEN00631-00
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 information 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
SEN00631-00
Monitoring mode table

No.
Remarks
Scroll
in
order
Monitored item
Unit
1 00201 ENG M ID
Engine controller model selection name
Character
2 01000 ENG REV
Engine speed
rpm
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
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.
16 08100 HSI BRAKE
HSI line brake point
rpm
17 08200 TQ Sel
Torque curve selection
Character
18 08300 Droop Type
Droop type selection
Character
19 08400 Droop SW
Droop switch selection
Character
20 08500 Droop Trim
Droop trim selection
Character
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
25 14201 FUEL TMP
Voltage of fuel temperature sensor
mV
26 17201 PCV TMG
Valve closing timing of PCV
CA
27 17500 ENG MODE
Selection of engine controller mode
Character
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
34 18300 ENG IVSW 1
Idle validation switch 1 of engine controller
bit
(See detailed
information)
35 18301 ENG IVSW 2
Idle validation switch 2 of engine controller
bit
(See detailed
information)
30
Code
D85EX, PX-15E0
No.
Code
SEN00631-00
Monitored item
Unit
Remarks
Scroll
in
order
36 18500 BOOST TMP
Boost temperature
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
41 20202 S/T.PROGRM
Program version of ST/TM controller
Character
42 20216 ENG BLD
Built version of engine controller
Character
43 20217 ENG CAL
Calibration data version of engine controller
Character
44 20300 KOMTRAX
KOMTRAX LED monitor
LED
33
45 20400 E-ECM SN
Engine controller ECM serial No.
Character
46 30100 T/C TEMP.
Torque converter oil temperature
47 31400 T/M OUT
rpm
48 31520 T/M-FILL
Fill switch input related to transmission
bit
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
62 31703 DECEL
Potentiometer voltage of decelerator pedal
mV
21
63 31706 F THROTTLE
Final accelerator opening angle
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
13
kPa
10
72 36700 ENG TORQUE Converted torque of engine

73 37200 EG OIL PRS
D85EX, PX-15E0
Engine oil pressure
(See detailed
information)
31
SEN00631-00
No.
Code
Monitored item
Unit
Remarks
Scroll
in
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
79 40905 T/M SW1
Controller switch 1 related to transmission
bit
(See detailed
information)
80 40906 T/M-SW2
Controller switch input 2 related to transmission
bit
(See detailed
information)
81 40909 T/M SOL.2
Controller on/off output 2 related to transmission
bit
(See detailed
information)
82 40910 S/T-SW1
Controller switch input 1 related to steering
bit
(See detailed
information)
83 40911 S/T-SW2
bit
(See detailed
information)
84 40913 S/T-SW5
bit
(See detailed
information)
85 40914 S/T SOL.1
Steering controller on/off output 1
bit
(See detailed
information)
86 40915 S/T SOL.2
Steering controller on/off output 2
bit
(See detailed
information)
87 43502 IdleCancel
Cancel flag of warming up
bit
(See detailed
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
103 60100 BODY ANGLE
Voltage of machine pitch angle sensor
mV
104 60400 S/T-SW6
Switch input 6 related to steering
bit
105 60500 ENG.CON.PW
Drive voltage of engine controller ACC cut relay
mV
106 60600 BR HOLD
Battery relay drive voltage
mV
107 60700 S/T MODE
Steering state variable
Character
32
(See detailed
information)
D85EX, PX-15E0
No.
Code
SEN00631-00
Monitored item
Unit
Remarks
Scroll
in
order
108 60800 FILL MODE
Variable for setting fill condition
Character
109 60909 MOD.MODE
Variable for setting modulation condition
Character
110 70000 CHG.P.MODE
Variable for setting condition of gear shift point
Character
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
118 99904 TRIG T 2
Trigger time 2
msec
119 99905 TRIG T 3
Trigger time 3
msec
120 99906 TM SFT
Transmission shift state
Character
121 99908 TM IN TRQ
Transmission input torque
Nm
122 99913 TC IN TRQ
Torque converter input torque
Nm
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
SEN00631-00
Detailed information on bit display codes

Display of bit information:
a The display position of the bit information in the
Real-time monitoring mode (Display of only 1
item) is different from that in the Dual display
monitoring mode (Simultaneous display of 2
items).
a The bit information is displayed by [_] for OFF
and [o] for ON in the places from 1 to 8.
a The state of each item shown in this section is
the condition for turning on the bit.
18300: Idle validation switch 1 of engine controller

1: Idle validation switch: When detecting
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
34
18301: Idle validation switch 2 of engine controller

1: Idle validation switch: When detecting
2: (Unused)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
31520: Fill switch input related to transmission

1: Forward clutch fill switch: ON
2: Reverse clutch fill switch: ON
3: 1st clutch fill switch: ON
4: 2nd clutch fill switch: ON
5: 3rd clutch fill switch: ON
6: (Unused)
7: (Unused)
8: (Unused)
D85EX, PX-15E0
SEN00631-00
40905:
1: Shift up switch: OFF
2: Shift up switch: ON
3: Shift down switch: OFF
4: Shift down switch: ON
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
40909:
Controller on/off output 2 related to transmission
1: (Unused)
2: (Unused)
3: (Unused)
4: Backup alarm relay: ON
5: Neutral safety relay: ON
6: (Unused)
7: (Unused)
8: (Unused)
40906:
1: Automatic shift down switch: ON
2: (Unused)
3. (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
40910: Controller switch input 1 related to steering

1: (Unused)
2: (Unused)
3: (Unused)
4: (Unused)
5: Parking brake lever switch: FREE
6: Parking brake lever switch: LOCK
7: (Unused)
8: (Unused)
D85EX, PX-15E0
35
SEN00631-00

1: Buzzer cancel switch: At t
2: Buzzer cancel switch: At U
3: Information switch: At >
4: Information switch: At <
5: Service switch: ON
6: (Unused)
7: (Unused)
8: (Unused)
40914: Controller on/off output 1 related to steering

1: (Unused)
2: (Unused)
3: Fan reverse solenoid: ON
4: (Unused)
5: Battery relay drive: ON
6: (Unused)
7: (Unused)
8: (Unused)

1: ACC signal: ON
2: (Unused)
3: R signal: ON
4: (Unused)
5: Fan speed selecting switch: COLD position (*)
6: Fan speed selecting switch: CLN position
7: (Unused)
8: (Unused)
40915: Controller on/off output 2 related to steering

1: (Unused)
2: Engine ACC cut relay drive: ON (*)
3: (Unused)
4: (Unused)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
*: 5 is only in case that OPT is equipped.
36
D85EX, PX-15E0
SEN00631-00
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)

1: (Unused)
2: (Unused)
3: (Unused)
4: Engine ACC cut signal: ON (*)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
D85EX, PX-15E0
37
SEN00631-00
11. Dual display monitoring mode

(11-DUAL DISPLAY MONITORING MODE)
In this mode, 2 monitored items can be displayed simultaneously.
a Note that only codes and monitoring information are displayed in this mode since
the available display columns are limited.
(Check item names and units cannot be
displayed.)
1)

1] Select the Dual display monitoring
a If the mode is selected, code [dR]
section (2).
2] Display the monitoring code input
switch (4).
q
[U]: Execute mode
2)
Selecting and entering monitored items

1] On the code input screen, input the 5digits codes of the items to be monitored by operating information switch
(5), shift up switch (6), and shift down
switch (7).
q
[>]: Cursor moves rightward.
q
[<]: Cursor moves leftward.
q
q
2] After inputting the code, operate
q
[U]: Determine input.
38
If the input codes are correct, the

monitoring screen shown below
appears.
D85EX, PX-15E0

a
If the input codes are not correct, the code

input screen appears again after the screen
shown below.
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 monitoring mode, if the parking brake lever is
set in the free position, gear speed display section (1) returns to the normal display and the machine can be operated
normally.
monitoring mode.)
traveling.
D85EX, PX-15E0
SEN00631-00
a
To select another screen, return the

39
SEN00631-00

40
SEN00632-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN00632-00
Testing and adjusting, Part3

Handling of voltage circuit of
engine controller
1.
2.
1
1
Adjustment method when

controller has been replaced
When disconnecting or connecting a connector, be sure to turn off the starting switch.
a Before connecting the harness connector,
be sure to completely remove sand, dust,
water, etc., from inside of controller side
connector.
Do not start the engine with T-adapter inserted

in or connected to a connector for troubleshooting.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
After the machine is assembled or steering

and transmission controller is replaced, adjust
the system according to the following procedure.
If the system is not adjusted, the machine
may not operate normally and may move
suddenly. Accordingly, be sure to adjust it.
Precautions for replacing a controller:
If a controller is replaced, the memory of the oil
and filter maintenance mode is reset. Accordingly, take a record of the next replacement
periods of the oils and filters.
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 controller

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

Turn starting switch OFF once and leave it for
approx. 1 minute after the battery relay shuts
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.
6.
Adjusting brake potentiometer

Select brake potentiometer initial set (0005)
and adjust the brake potentiometer.
7.
Adjusting pitch angle sensor

Select the initial setting (0009) of the pitch
angle sensor and adjust the pitch angle sensor.
D85EX, PX-15E0
SEN00632-00
8.
Adjusting KOMTRAX specification

Select KOMTRAX specification settings (0021)
and adjust the KOMTRAX 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
service mode.
2) Check if any active failure codes exist. If
not, delete all the failure codes recorded.
a If any active failure codes exist, eliminate the cause of the incident by troubleshooting, then carry out steps 9
and 10 again.
a Precautions after replacing controller:
If any controller is replaced, the service meter in the oil and filter maintenance 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, determine the first replacement periods of
the oils and filters after the replacement of the controller according to the
replacement periods recorded before
the replacement of the controller.
SEN00632-00
Preparation work for troubleshooting

for electrical system
1
a
When carrying out troubleshooting for an electrical 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.
Steering and transmission controller

1) Remove left console box inspection cover
(1).
2)
2)
Insert or connect T-adapters in or to connectors S03 and S04 on the back side of
monitor panel (2).
Insert or connect T-adapters in or to connectors PTC1, PTC2 and PTC3 of steering and transmission controller (2).
a If the connectors cannot be disconnected and connected easily, remove
the controller from the floor frame.
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: 2.8 Nm {0.29 kgm}
D85EX, PX-15E0
3.
SEN00632-00
Engine controller
1) Open the left upper side cover (1) of
engine and remove under side cover (2).
2)
Remove engine controller covers (3) and

(4).
3)
Insert or connect T-adapters in or to conne 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 disconnecting.
specified torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}
D85EX, PX-15E0
In order to prevent malfunction

and mistaken system error warning, be sure to completely remove
foreign object (b) such as sand,
dust, water, etc., from inside of
controller side connector (a) with
air blow etc., before connecting to
harness connector.
SEN00632-00
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.
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.
D85EX, PX-15E0
Inspection procedure of diode
SEN00632-00
The direction of continuity of diode is marked

on the surface of the diode.
1.
When using digital tester

1) Switch to diode range and check displayed value.
a Voltage of internal battery is displayed by normal tester.
2) Set red (+) test lead to diode anode (P)
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 displayed.
q
Displayed value becomes 0 or near 0 :
Short-circuiting of diode internal part
(defect)
D85EX, PX-15E0
2.
When using analog tester

1) Switch to resistance range.
2) Check the deflection of needle while connecting 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 connection i) but deflects with connection ii):
Normal. (However deflection range
(resistance value) varies depending
on the type of tester and measuring
range.)
q
Needle deflects with both connection
i) and ii): Defective (internal short circuit)
q
Needle does not deflect with either
connection i) or ii): Defective (internal
disconnection)
SEN00632-00
Pm Clinic service
Model
Serial No.
Service meter
T D85EX-15E0
T D85PX-15E0
User name
Date of clinic
/
Serviceman
Specifications
Blade
Attachment
T Semi U blade (EX)

T U blade (EX)
T Straight tilt blade (EX, PX)
T
Shoe width
T Multi-shank ripper
T Counterweight (
kg)
T
T
T 560 mm (EX)
T 610 mm (EX)
T 660 mm (EX)
T 910 mm (PX)
%
%
%
%
Operating conditions
Quarry, mine
Construction
T Coal
T Construction, civil engineerT Rock

ing
T Dozing
T Gold
T Roads
T Gravel
T Side cutting
T Limestone
T Tunnels
T Sand
T Ripping
T Clay
T Travel
Type of soil (specific gravity)
Type of work
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
Max.
Min.
Height above sea level

C
Operator's opinion
Visual check results
Failure code history

[
Content:
[
Content:
Content:
Content:
Engine coolant temperature: Max. range
Power train oil temperature: Max. range
D85EX, PX-15E0
SEN00632-00
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
SEN00632-00
Pm-clinic measuring points (2/2)
10
D85EX, PX-15E0
SEN00632-00
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
SEN00632-00
Pm clinic check sheet
Serial number
Work order
Date
/
Check item
Service meter
h
Unit
Deceleration pedal
depressed
Full throttle
Full throttle
rpm
Torque converter stall
Engine
Torque converter stall + Work equipment relief

kPa
{mmAq}
Blow-by pressure Torque converter stall
Torque converter
750 800
750 800
1,000 1,050
1,000 1,050
2,050 2,150
2,050 2,150
1,710 1,810
1,710 1,810
1,660 1,760
1,660 1,760
Max. 0.98
{Max. 100}
Max. 1.96
{Max. 200}
Min. 0.05
{Min. 0.5}
0.03
{0.3}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Boost pressure
Torque converter stall
kPa
{mmHg}
Min. 93
{Min. 700}
73
{550}
Max. 650
700
Unit
Standard value
for new machine
Service limit
value
0.1 0.5
{1 5}
0.1 0.5
{1 5}
0.1 0.31
{1 3}
0.1 0.31
{1 3}
Max. 1.02
{Max. 10}
Max. 1.02
{Max. 10}
0.61 0.81
{6 8}
0.61 0.81
{6 8}
Standard value
for new machine
Service limit
value
Engine at low idle
2.82 3.02
{28.8 30.8}
Min. 2.65
{Min. 24}
Engine at full throttle
3.24 3.53
{33.0 36.0}
Min. 3.04
{Min. 31.0}
0.1 0.25
{1.0 2.5}
0.1 0.25
{1.0 2.5}
2.16 2.45
{22.0 25.0}
Min. 1.96
{Min. 20}
Inlet oil pressure

Outlet oil pressure
Inlet oil pressure
Engine at low idle

Transmission: Neutral
Oil temperature: 70
90C
MPa
{kg/cm2}
Outlet oil pressure

Check item
Main relief
pressure
Unit
Transmission
Service limit
value
Engine oil pressure
Check item
Cooling fan
Standard value
for new machine
Engine at low idle

SAE0W30EOS
Oil temperature: Min 80C SAE5W40EOS
SAE10W30DH
SAE15W40DH
Oil temperature: Min 80C SAE30DH
Exhaust temperaTorque converter stall

ture
12
Serviceman
Low idle
Engine speed
T D85EX-15E0 #
T D85PX-15E0 #
Lubricating oil
pressure
(Reference)
Engine at low idle
F clutch pressure Transmission: F
Engine at low idle
R clutch pressure Transmission: R
Engine at low idle
2.75 3.02
{28.0 30.8}
Min. 2.55
{Min. 26.0}
1st clutch pressure
Transmission: F1
Engine at low idle
2.35 2.65
{24.0 27.0}
Min. 2.16
{Min. 22.0}
2nd clutch pressure
Transmission: F2
Engine at low idle
2.55 2.84
{26.0 29.0}
Min. 2.35
{Min. 24.0}
3rd clutch pressure
Transmission: F3
Engine at low idle
2.75 3.02
{28.0 30.8}
Min. 2.55
{Min. 26.0}
750 850
400
1,600 1,700
1,550
14.7 17.6
{150 180}
14.7 17.6
{150 180}
Fan speed
Fan pump
pressure
Fan 100% speed mode

Engine at low idle
Min.
speed
Fan 100% speed mode

Engine at high idle
Max.
speed
Fan 100% speed mode

Engine at high idle
MPa
{kg/cm2}
Measurement
Pass Fail
results
Measurement
Pass Fail
results
Measurement
Pass Fail
results
rpm
MPa
{kg/cm2}
D85EX, PX-15E0
SEN00632-00
Pm clinic check sheet
Serial number
Work order
Date
/
Service meter
h
Measurement
conditions
Unit
Brake pressure
Engine at low idle

Engine at full
throttle
Brake performance
Engine at full throttle, forward 2nd, brake applied
HSS
HSS main relief
pressure pressure
Travel lever right full

Travel lever left full
Check item
HSS and
work equipment
Hydraulic pump
system
Blade tilt
relief
MPa
{kg/cm2}
Unit
Engine at low idle
MPa
{kg/cm2}
Ripper lift
relief (EX)
Blade tilt
relief
PPC valve
output pressure
Engine at full
throttle
MPa
{kg/cm2}
Ripper lift
relief (EX)
Engine at full
throttle
Blade tilt
relief
Check item
Measurement
conditions
Unit
Engine at low idle

Blade RAISE
Work
equipment
speed
Engine at full
throttle
Engine at low idle
Single tilt (left o right)
Engine at full
throttle
Second
Engine at low idle

Ripper RAISE (EX)
Check item
Hydraulic
Blade lift cylinder
drift
Ripper lift cylinder (EX)
Check item
Visual inspection of final drive drain plug
Serviceman
Check item
Steering
brake
T D85EX-15E0 #
T D85PX-15E0 #
Engine at full
throttle
Measurement
conditions
Engine stopped
Unit
Standard
value for new
machine
Service limit
value
2.75 2.94
{28.0 30.0}
Min. 2.26
{Min. 23.0}
2.75 2.94
{28.0 30.0}
Min. 2.45
{Min. 25.0}
38.2 41.7
{390 425}
38.2 41.7
{390 425}
38.2 41.7
{390 425}
38.2 41.7
{390 425}
Standard
value for new
machine
Service limit
value
20.4 22.8
{208 232}
20.4 22.8
{208 232}
20.4 22.8
{208 232}
20.4 22.8
{208 232}
21.3 23.7
{218 242}
21.3 23.7
{218 242}
21.3 23.7
{218 242}
21.3 23.7
{218 242}
3.82 4.12
{39.0 42.0}
3.82 4.12
{39.0 42.0}
Standard
value for new
machine
Service limit
value
8 15
Max. 20
EX: 2.5 4.5

PX: 2.2 4.2
Max. 5.5
Max. 5.2
35
Max. 7
1.7 2.7
Max. 3.5
7 10
Max. 13
2.0 3.0
Max. 4.0
Standard
value for new
machine
Service limit
value
mm/15
min.
Max. 200
Max. 300
Max. 80
Max. 160
Standard
value for new
machine
Service limit
value
Engine stopped
Unit
Pass
Fail
Measurement
results
Pass
Fail
Measurement
results
Pass
Fail
Measurement
results
Pass
Fail
Measurement
results
Pass
Fail
Machine must not move
Measurement
conditions
Measurement
results
There must be no excessive

metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date
Service meter
D85EX, PX-15E0
Repair record
Date
Service meter
Repair record
13
SEN00632-00
Pm clinic
Undercarriage check sheet
Serial number
Work order
Date
/
T D85EX-15E0 #
Service meter
/
Serviceman
h
Measure the bushing temperature immediately after operations

Left side of machine
Right side of machine
Measurement results
Pass
Fail
Left side of
machine
Right side of
machine
q
14
Opening of track link

Left
track
A: Clearance between
links
Right
track
links
Pin No.
1.4
Pin No.
1.4
D85EX, PX-15E0
SEN00632-00
Pm clinic
Undercarriage check sheet
Serial number
Work order
Date
/
T D85EX-15E0 #
Service meter
/
Serviceman
h
Measure the bushing temperature immediately after operations

Left side of machine
Right side of machine
Measurement results
Pass
Fail
Left side of
machine
Right side of
machine
q
Opening of track link
D85EX, PX-15E0
Left
track
links
Right
track
links
Pin No.
1.4
Pin No.
1.4
15
SEN00632-00
Undercarriage troubleshooting report (Normal) (Program form NO.: SELA195001)
16
D85EX, PX-15E0
SEN00632-00
Undercarriage troubleshooting report (Impact) (Program form NO.: SELA195001)
D85EX, PX-15E0
17
SEN00632-00
How to start operation of

KOMTRAX terminal
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.
2.
Notification of model, model number and

serial number
Notify the model, model number and serial
number of the machine to the KOMTRAX operations administrator.
Registration of machine
The KOMTRAX operations administrator registers the machine using a KOMTRAX client personal computer.
a Refer to Manual for KOMTRAX operations administrator for the procedure.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is retrofitted on the machine after the shipment:
a Implement the following procedure in the case
where the KOMTRAX terminal is retrofitted
after shipment of the machine (retrofitted
machine)
1.
18
Sign-up test on the machine side

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 specification, and enable the KOMTRAX function.
q
Adjust code: 0021
q
Specification: ACTIVE
3) Switch the monitor panel display to Monitoring 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)
6)
7)
8)
Connect KACC connector (2). Keep that

condition for 5 seconds.
q
Check that display (b) on the monitor
panel or KOMTRAX terminal shows
the mark .
Disconnect test connector (1) and keep
that condition for 5 seconds.
Reconnect test connector (1) and keep
that condition for 5 seconds. [Dot (a)
blinks on and off]
q
Blinking of dot (a): When the terminal
detects insert
or removal of the connector, dot (a)
blinks on and off.
a
Complete procedure 6) 8) within 60

seconds.
Monitor panel
D85EX, PX-15E0
KOMTRAX terminal
SEN00632-00
a
a
9)
Check that the display (b) on the monitor

panel or KOMTRAX terminal is displayed
normally.
a The
normal
display
shows
d o 0 o repeatedly for 30 seconds on the monitor panel after 8) is
finished.
a Move on to the next step if you can
check that the display is [normal].
a If the display is [abnormal], start from
procedure 1) again.
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.
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.
If [D: GPS position data detection
trouble and reception trouble] is indicated, check if there is any abnormality on the GPS antenna/cable or
communication antenna/cable. If
there is any abnormality, repair it and
start from procedure 1) again.
If [E: Network trouble] is indicated,
check the display of [LED-C4] referring to Lamp display of KOMTRAX
terminal. If the CAN is not recognized, check the CAN harness of the
KOMTRAX terminal, and then if there
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 procedure 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
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 minutes before the display turns normal.)
D85EX, PX-15E0
19
SEN00632-00
13) Disconnect KACC connector (2).

14) Check that the display (b) on the monitor
normally in 5 seconds.
a If you can check that the display is
[normal], that is the end of sign-up
test.
a If the display shows [abnormal],
r ep eat fr om p ro ce dur e 1) a gai n
because the sign-up test has not
been completed successfully.
2.
Application for the start of use

a Application for the start of use should be
made only after the sign-up test is finished.
1) Notify to the KOMTRAX operations
administrator the following information
concerning the machine whose sign-up
test on the machine side is completed.
(1) Information on the machine whose
sign-up test on the machine side is
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)
20
The KOMTRAX operations administrator

registers the machine using a KOMTRAX
client personal computer.
a Refer to Manual for KOMTRAX operations administrator for the procedure.
a Now the terminal is ready for use.
D85EX, PX-15E0
SEN00632-00
Lamp display of KOMTRAX terminal
CPU LED
1. LED-C1 (R signal and ACC signal status)
2. LED-C2 (Engine control signal 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
7-segment and dot for CPU

7. 7-segment (number of mails not yet sent)
8. Dot (GPS positioning status)
21
SEN00632-00
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)
ON
Starting switch ACC signal

Fast blinking Starting switch ACC signal: OFF, alternator R signal: ON
LED-C1 status and alternator R signal
Slow blinking Starting switch ACC signal: ON, alternator R signal: OFF
status
OFF
Starting switch ACC signal: OFF, alternator R signal: OFF
LED-C2 Engine control signal status
LED-C3
ON
Engine control signal: ON
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

starting switch C signal status Slow blinking (Not used)
LED-C4 CAN connection status
OFF
S-NET: unconnected, starting switch C signal: OFF
ON
CAN: active (fuel sensor: no communication)
Fast blinking CAN: active (fuel sensor: in communication)

Slow blinking CAN: inactive (fuel sensor: in communication)
OFF
LED-C5
LED-C6
*1
a
22
Contents of display
Starting switch ACC signal: ON, alternator R signal: ON
Downloading and writing status
CAN: inactive (fuel sensor: no communication)
Either one is Downloading and writing status (special function for sysON
tem administrator)
Both are
OFF
Normal operation mode
Type and time of blinking

Fast blinking: blinking on an approximately 1 second cycle
Slow blinking: blinking on an approximately 4 seconds cycle
The LED displays can be checked in monitoring mode of the monitor panel.
D85EX, PX-15E0
2.
SEN00632-00
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
7-segment
Number of mails not

yet sent and satellite
acquisition condition
Dot
GPS positioning status
Display (*2)
09
ON
Contents of display
The numbers are numbers of mails not yet sent (If there is
more than 9 mails, 9 is displayed)
Lighting ON indicates satellite acquisition is in process.
09
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.
ON
GPS positioning has been completed. (Position has been recognized *3)
OFF
GPS positioning has not been completed. (Position has not

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

24
SEN00633-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
40 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
SEN00633-00
40 Troubleshooting
Points to remember when troubleshooting
k
k
k
k
k
k
Stop the machine on a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
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.
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.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
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 connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent 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 questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1.
2.
3.
4.
5.
6.
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 procedure.
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?
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.
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.
Troubleshooting
Use the results of the investigation and inspection in items 2 4 to narrow down the causes of failure, 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.
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.
D85EX, PX-15E0
40 Troubleshooting
SEN00633-00
How to proceed troubleshooting 1
D85EX, PX-15E0
SEN00633-00
40 Troubleshooting
Checks before troubleshooting
Hydraulic and
mechanical
equipment
Lubricating oil, coolant
Check item
Electrical equipment
Judgement value
Action
1. Check fuel level and type.
Add fuel
2. Check for impurities in fuel.
Clean and drain
Between H and L
Add oil
Add oil
3. Check hydraulic oil level.

4. Check oil level in damper case.
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
No red color
Clean or replace
9. Check brake pedal travel
Adjust
1. Check for abnormal noise and smell.
Repair
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 terminals.
3. Check for looseness and corrosion of starting motor harness terminals
8. Check dust indicator for clogging.
4. Check battery voltage (engine stopped)
20 30 V
Charge or replace
Between H and L
Add or replace
6. Check for discoloration, burnout of wiring, and peeling of harness

coating.
Repair or replace
7. Check for missing wiring clamps and a slack of wire.
Repair
8. Check for water leaking on wiring (pay particularly careful attention to water leaking on connectors or terminals)
Dry
9. Check for blown or corroded fuse
Replace
After running for

several minutes:
27.5 29.5 V
Replace
Replace
5. Check battery electrolyte level
10. Check alternator voltage (engine running at half speed or

above)
11. Check operating sound of battery relay (when turning the starting switch ON or OFF)
D85EX, PX-15E0
40 Troubleshooting
SEN00633-00
Classification and procedures of troubleshooting
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. according 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 troubleshooting in the [E-Mode], [H-Mode] or [S-Mode] related to the symptom.
D85EX, PX-15E0
SEN00633-00
40 Troubleshooting
Symptom supposed to be failure and troubleshooting No.

No.
Symptom that can be suspected to be a failure
Troubleshooting
Code display
E-mode
H-mode
S-mode
Symptom related to action code and failure code

Check failure
code.
Display action code on monitor panel.
Display failure code in failure code display mode.
Engine is hard to start. (Engine starting always takes time.)
q
Engine system
S-1
Engine does not crank.
Engine cranks but no exhaust smoke comes out.
S-2b)
Exhaust smoke comes out but engine does not

start.
S-2c)
Engine does not start.
E-1
S-2a)
Engine does not pick-up smoothly. (Poor follow-up performance)
S-3
Engine stops during operation.
S-4
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
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
S-6
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
D85EX, PX-15E0
40 Troubleshooting
No.
SEN00633-00
Symptom that can be suspected to be a failure
Troubleshooting
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.
41
When starting switch is turned ON, monitor panel completely remains lighted and
does not go out.
E-3
E-4
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
mode.
E-21
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
SEN00633-00
40 Troubleshooting
How to distinguish wire code
In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electrical circuit diagram.
Example: AEX
0.85
---
Indicates heat resistant low voltage wire for automobile application and nominal 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)
Type
Low voltage wire

for automobile
application
Thin-covered
low voltage wire
for automobile
application
Heat resistant
low voltage wire
for automobile
application
Symbol
Material
Conductor
Annealed copper wire for

electricity
Insulator
Plasticized type polyvinyl

chloride
Conductor

electricity
Insulator
Plasticized type polyvinyl

chloride
Conductor

electricity
AV
AVS
AEX
Insulator
Heat resistant crosslinked

polyethylene
Temperature range
(C) for
application
Reference
Applied sample
For ordinary wiring

(nominal No. is more than 5.)
30 +60
For ordinary wiring
(nominal No. is less than 3.)
50 +110
For ordinary wiring of extremely

cold region specification, wiring in
high ambient temperature
D85EX, PX-15E0
40 Troubleshooting
2.
SEN00633-00
Size
(Table 2)
Nominal No.
Coating D
Conductor
Number of
wires and
diameter of
element wire
Section area
(mm2)
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
3f
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
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
d (approximately)
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
AV
Standard
4.6
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
15
20
30
40
Number of
wires and
diameter of
element wire
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
Section area
(mm2)
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
d (approximately)
3.7
4.8
6.0
8.0
8.6
9.8
10.4
12.0
13.6
AVS
Standard
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
Conductor
Coating D
0.5f
50
60
85
100
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
D85EX, PX-15E0
SEN00633-00
3.
40 Troubleshooting
Color codes table
(Table 3)
Color code
Wire color
Color code
Wire color
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
Orange
BrY
Brown & Yellow
Pink
Ch
Charcoal
Red
Dg
Dark green
RB
Red & Black
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
White
GY
L
Green & Yellow
Yellow
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
40 Troubleshooting
Wiring table for connector pin numbers

a
SEN00633-00
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
SEN00633-00
12
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
13
SEN00633-00
14
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
15
SEN00633-00
16
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
17
SEN00633-00
18
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
19
SEN00633-00
20
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
21
SEN00633-00
22
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
23
SEN00633-00
24
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
25
SEN00633-00
26
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
27
SEN00633-00
28
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
29
SEN00633-00
30
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
31
SEN00633-00
32
40 Troubleshooting
D85EX, PX-15E0
40 Troubleshooting
D85EX, PX-15E0
SEN00633-00
33
SEN00633-00
40 Troubleshooting
T-adapter box and T-adapter table

a
The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of T-Branch.
37
799-601-3200 T-adapter box (for MS)
37
799-601-3300 T-adapter box (for ECONO)
24
799-601-3370 Plate for MS (17 pins)
799-601-3410 Adapter for BENDIX (MS)
24 MS-24P
24 MS-24P
17 MS-17P
17 MS-17P
10 MS-10P
MS-5P
MS-5S
17 MS-17P
19 MS-19P
14 MS-14P
out of kit
799-601-9300
799-601-3470 Case
799-601-2710 Adapter for MIC
MIC-5P
13
MIC13P
17
MIC17P
21
MIC21P
MIC-9P
799-601-2750 Adapter for ECONO
ECONO
q
2P
ECONO
q
3P
ECONO
q
4P
ECONO
q
8P
12
ECONO
q
12P
799-601-2810 Adapter for DLI
DLI-8P
12 DLI-12P q
16 DLI-16P q
12
ECONO
q
12P
799-601-4210 Adapter for DRC
50
DRC50
799-601-7010 Adapter for X (T adapter)
799-601-2850 Case
34
799-601-9200
Extension cable
(ECONO type)
799-601-9100
799-601-2840
799-601-9000
799-601-8000
799-601-7500
799-601-7000
799-601-6500
799-601-7400
799-601-3100 T-adapter box (for MS)
799-601-7100
21
799-601-6000
799-601-2600 T-adapter box (for ECONO)
799-601-5500
799-601-3000
799-601-2900
799-601-2800
799-601-2700
799-601-2500
Part name
Identification
code
Part No.
No. of pins
T-adapter kit
q
q
D85EX, PX-15E0
40 Troubleshooting
SEN00633-00
799-601-7060 Adapter for SWP
SW8P
12 SW12P
14 SW14P
16 SW16P
799-601-7080 Adapter for M (T-adapter)
799-601-7090 Adapter for M
q
q
q
q
M2P
M3P
M4P
M6P
M8P
799-601-7140 Adapter for S
S8P
799-601-7150 Adapter for S (white)
10
S10P
799-601-7160 Adapter for S (blue)
12
S12P
799-601-7170 Adapter for S (blue)
16
S16P
16 S16PW
12 S12PW
q
q
q
799-601-7180 Adapter for AMP040
A8P
12
A12P
16
A16P
20
A20P
799-601-7230 Short socket adapter for X
799-601-7240 Case
out of kit
799-601-9300
799-601-9200
SW6P
799-601-9100
X4P
799-601-9000
799-601-7400
799-601-8000
799-601-7100
799-601-7040 Adapter for X
799-601-7500
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
X3P
799-601-2900
X2P
799-601-2800
Part name
799-601-2700
Identification
code
Part No.
799-601-2500
No. of pins
T-adapter kit
799-601-7270 Case
799-601-7510 Adapter for 070
10
07-10
799-601-7520 Adapter for 070
12
07-12
799-601-7530 Adapter for 070
14
07-14
799-601-7540 Adapter for 070
18
07-18
799-601-7550 Adapter for 070
20
07-20
799-601-7360 Adapter for relay
REL-5P
799-601-7370 Adapter for relay
REL-6P
799-601-7380 Adapter for JFC
799-601-9010 Adapter for DTM
DTM2
799-601-9020 Adapter for DT
DT2
DT3
DT4
DT6
799-601-9060 Adapter for DT (gray)
DT8GR
799-601-9070 Adapter for DT (black)
DT8B
799-601-9080 Adapter for DT (green)
DT8G
799-601-9090 Adapter for DT (brown)
DT8BR
D85EX, PX-15E0
35
SEN00633-00
40 Troubleshooting
Part name
799-601-9110 Adapter for DT (gray)

799-601-9120 Adapter for DT (black)
799-601-9130 Adapter for DT (green)
12 DT12BR
799-601-9210 Adapter for HD30-18
D18-8
799-601-9220 Adapter for HD30-18
14
D18-14
799-601-9230 Adapter for HD30-18
20
D18-20
799-601-9240 Adapter for HD30-18
21
D18-21
799-601-9250 Adapter for HD30-24
D24-9
799-601-9260 Adapter for HD30-24
16
D24-16
799-601-9270 Adapter for HD30-24
21
D24-21
799-601-9280 Adapter for HD30-24
23
D24-23
799-601-9290 Adapter for HD30-24
31
D24-31
799-601-9310 Plate for HD30 (24 pins)

T-adapter box
799-601-9320
(for DT and HD)
12
out of kit
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
DT12G
799-601-6000
DT12B
12
799-601-5500
12
799-601-3000
799-601-2900
799-601-2800
DT12G
R
799-601-2700
12
799-601-2500
Identification
code
Part No.
No. of pins
T-adapter kit
799-601-9330 Case
799-601-9340 Case
40 DRC-40
24 DRC-24
799-601-9410 Adapter for engine (CRI-T2)
799-601-9420
Adapter for engine (CRI-T2)

A3
799-601-9430

1,2,3
795-799-5520 Adapter for engine (HPI-T2)
795-799-5530
Adapter for engine (HPI-T2)

795-799-5540
Adapter for engine (HPI-T2)

795-799-5460 Cable for engine (HPI-T2)

q
OIL
1,2,3
FCIN
FCIG
FCIB
FCIP3
1,2,3
1,2,3
1,2,3
1,2,3
1,2,3,4
36
D85EX, PX-15E0
40 Troubleshooting
SEN00633-00
out of kit
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
799-601-2900
799-601-2800
799-601-2700
799-601-2500
Part name
Identification
code
Part No.
No. of pins
T-adapter kit
799-601-4260 Adapter for controller (ENG)
DTP4
50
DRC50
60
DRC60
799-601-4280 Box for controller (PUMP)
121
799-601-9720 Adapter for controller (HST)
16 HST16A
16 HST16B
26 HST26A
D85EX, PX-15E0
37
SEN00633-00

38
SEN00634-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
40 Troubleshooting
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
SEN00634-00
40 Troubleshooting
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
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Failure code table
Action
code
Failure
code
CALL E03
1500L0
Transmission clutch
Dual engagement
S/T
Electrical
system
CALL E03
15SAL1
Forward clutch
Fill signal is ON when

command current is OFF.
S/T
Electrical
system
CALL E03
15SALH Forward clutch
Fill signal is OFF when

command current is ON.
S/T
Electrical
system
CALL E03
15SBL1

S/T
Electrical
system
CALL E03
15SBLH Reverse clutch

S/T
Electrical
system
CALL E03
15SEL1

S/T
Electrical
system
CALL E03
15SELH 1st clutch

S/T
Electrical
system
CALL E03
15SFL1
2nd clutch

S/T
Electrical
system
CALL E03
15SFLH
2nd clutch

S/T
Electrical
system
CALL E03
15SGL1
3rd clutch

S/T
Electrical
system

S/T
Electrical
system
MON
Mechanical
system
S/T
Mechanical
system
Failed section
Reverse clutch
1st clutch
CALL E03 15SGLH 3rd clutch
Symptom of failure
Alarm ConHistory
buzzer troller classification
AA10NX Air cleaner
Clogging
AB00MA Alternator
Malfunction
B@BAZG Engine oil
Oil pressure too low
ENG
Mechanical
system
B@BCNS Radiator coolant
Overheat
ENG
Mechanical
system
B@BCZK Radiator coolant level
Level too low
S/T
Mechanical
system
B@CENS Power train oil
Overheat
S/T
Mechanical
system
B@HANS Hydraulic oil
Overheat
S/T
Mechanical
system
CALL E04
CA111
Engine controller
Abnormality in controller
ENG
Electrical
system
CALL E04
CA115
Abnormal engine NE, Bkup

speed sensor
Abnormal speed sensor signal
ENG
Electrical
system
CALL E03
CA122
Charge pressure sensor too

high
Excessively high voltage

detected
ENG
Electrical
system
CALL E03
CA123
Charge pressure sensor too low
Excessively low voltage

detected
ENG
Electrical
system
CALL E03
CA131
Decelerator pedal sensor too

high

detected
ENG
Electrical
system
D85EX, PX-15E0
SEN00634-00
40 Troubleshooting
Action
code
Failure
code
CALL E03
CA132
Decelerator pedal sensor too

low

detected
ENG
Electrical
system
E02
CA135
Oil pressure sensor too high

detected
ENG
Electrical
system
E02
CA141
Oil pressure sensor too low

detected
ENG
Electrical
system
E01
CA144
Coolant temperature sensor too Excessively high voltage

high
detected
ENG
Electrical
system
E01
CA145
Coolant temperature sensor too Excessively low voltage

low
detected
ENG
Electrical
system
E01
CA153
Charge temperature sensor too Excessively high voltage

high
detected
ENG
Electrical
system
E01
CA154
Charge temperature sensor too Excessively low voltage

low
detected
ENG
Electrical
system
CALL E03
CA187
Sensor power source 2 too low

detected
ENG
Electrical
system
E01
CA221

too high

detected
ENG
Electrical
system
E01
CA222

too low

detected
ENG
Electrical
system
CALL E03
CA227
Sensor power source 2 too high

detected
ENG
Electrical
system
CA234
Engine overspeed
Excessively high speed
ENG
Mechanical
system
CALL E03
CA238
Abnormal power source for Ne Excessively low voltage

speed sensor
detected
ENG
Electrical
system
E01
CA263
Fuel temperature sensor too

high

detected
ENG
Electrical
system
E01
CA265
Fuel temperature sensor too

low

detected
ENG
Electrical
system
CALL E03
CA271
PCV1 short circuit
Short circuit
ENG
Electrical
system
CALL E03
CA272
PCV1 disconnection
Disconnection
ENG
Electrical
system
CALL E03
CA273
PCV2 short circuit
Short circuit
ENG
Electrical
system
CALL E03
CA274
PCV2 disconnection
Disconnection
ENG
Electrical
system
CALL E03
CA322
Disconnection and short circuit

in injector #1
ENG
Electrical
system
CALL E03
CA323

in injector #5
ENG
Electrical
system
CALL E03
CA324

in injector #3
ENG
Electrical
system
CALL E03
CA325

in injector #6
ENG
Electrical
system
CALL E03
CA331

in injector #2
ENG
Electrical
system
CALL E03
CA332

in injector #4
ENG
Electrical
system
Failed section
Symptom of failure
Alarm ConHistory
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Action
code
Failure
code
CALL E04
CA342
Abnormal engine controller data

Abnormal consistency
consistency
ENG
Electrical
system
CALL E03
CA351
Abnormal injector drive circuit
Abnormal circuit
ENG
Electrical
system
CALL E03
CA352
Sensor power source (1) too

low

detected
ENG
Electrical
system
CALL E03
CA386
Sensor power source (1) too

high

detected
ENG
Electrical
system
CALL E04
CA441
Power source voltage too low

detected
ENG
Electrical
system
CALL E04
CA442
Power source voltage too high

detected
ENG
Electrical
system
CALL E03
CA449
Common rail pressure too high Excessively high pressure

(2)
detected
ENG
Electrical
system
CALL E03
CA451

too high

detected
ENG
Electrical
system
CALL E03
CA452

too low

detected
ENG
Electrical
system
CALL E03
CA553
Common rail pressure too high Excessively high pressure

(1)
detected
ENG
Electrical
system
CALL E03
CA554
In-range error in common rail

pressure sensor
In-range error detected
ENG
Electrical
system
E02
CA559
Loss of pressure feed from

supply pump (1)
Loss of pressure feed detected
ENG
Electrical
system
CALL E03
CA689
Abnormal engine NE speed

sensor
Abnormal signal
ENG
Electrical
system
CALL E03
CA731
Abnormal engine Bkup speed

sensor phase
Abnormal phase
ENG
Electrical
system
CALL E04
CA757
Loss of all data of engine

controller
Loss of all data
ENG
Electrical
system
CALL E03
CA778
Abnormal engine Bkup speed

sensor
Abnormal Bkup signal
ENG
Electrical
system
E02
CA1228
Abnormal EGR valve servo (1) EGR cannot be controlled.
ENG
Electrical
system
CALL E03
CA1625
Abnormal EGR valve servo (2) EGR cannot be controlled.
ENG
Electrical
system
CALL E03
CA1633
Abnormal KOMNET
Abnormal communication
ENG
Electrical
system
CALL E03
CA2185
Decelerator sensor power

source too high

detected
ENG
Electrical
system
CALL E03
CA2186
Decelerator sensor power

source too low

detected
ENG
Electrical
system
CALL E03
CA2249
Loss of pressure feed from

supply pump (2)
ENG
Electrical
system
CALL E03
CA2271
EGR valve lift sensor too high

detected
ENG
Electrical
system
CALL E03
CA2272
EGR valve lift sensor too low

detected
ENG
Electrical
system
CALL E03
CA2351
Short circuit in EGR valve

solenoid drive
Short circuit
ENG
Electrical
system
D85EX, PX-15E0
Failed section
Symptom of failure
Alarm ConHistory
SEN00634-00
40 Troubleshooting
Action
code
Failure
code
CALL E03
CA2352
Disconnection in EGR valve

solenoid drive
Disconnection
E01
CA2555
Disconnection in intake air

heater relay
Disconnection
E01
CA2556
Short circuit in intake air heater

Short circuit
relay
Failed section
Symptom of failure
Alarm ConHistory
q
ENG
Electrical
system
ENG
Electrical
system
ENG
Electrical
system
D110KA Battery relay
Disconnection
S/T
Electrical
system
D110KB Battery relay
Short circuit
S/T
Electrical
system
E02
D130KA Neutral safety relay
Disconnection
S/T
Electrical
system
E02
D130KB Neutral safety relay
Short circuit
S/T
Electrical
system
E01
D161KA Backup alarm relay
Disconnection
S/T
Electrical
system
E01
D161KB Backup alarm relay
Short circuit
S/T
Electrical
system
D190KA
Engine controller ACC signal

cut relay
Disconnection
S/T
Electrical
system
D190KB
Engine controller ACC signal

cut relay
Short circuit
S/T
Electrical
system
D811KR
KOMTRAX controller CAN

communication
Defective communication
S/T
Electrical
system
Monitor panel CAN

communication
MON
Electrical
system
S/T
Electrical
system
CALL E03 DAFRKR
DAQ0KT Steering and transmission

(DB30KT) controller
Abnormal controller memory

information
CALL E04
DAQ1KK Main power source of steering

(DB31KK) and transmission controller
Power supply voltage drop and

input
S/T
Electrical
system
CALL E04
DAQ2KK Steering and transmission

(DB32KK) controller load power source

input
S/T
Electrical
system
CALL E03
5V power source of steering

DAQ5KK
and transmission controller
(DB35KK)
sensor (1)

input
S/T
Electrical
system
CALL E03

DAQ6KK
(DB36KK)
sensor

input
S/T
Electrical
system
E01

DAQ7KK
(DB37KK)
sensor (2)

input
S/T
Electrical
system
CALL E04
DAQ9KQ Steering and transmission

(DB39KQ) controller model selection
Inconsistent model selection

signal
S/T
Electrical
system
CALL E03
DAQRKR Steering and transmission

(DB3RKR) controller CAN communication
S/T
Electrical
system
(Abnormality in target
component system)
ENG
Electrical
system
S/T
Electrical
system
S/T
Electrical
system
E01
CALL E03 DB2RKR

E01
CALL E04
Engine controller CAN

communication
DB30KT Steering and transmission

(DAQ0KT) controller
Abnormal controller memory

information
DB31KK Main power source of steering

(DAQ1KK) and transmission controller

input
D85EX, PX-15E0
40 Troubleshooting
Action
code
Failure
code
SEN00634-00
Failed section
Symptom of failure
Alarm ConHistory
CALL E04
DB32KK Steering and transmission

(DAQ2KK) controller load power source

input
S/T
Electrical
system
CALL E03

DB35KK
(DAQ5KK)
sensor (1)

input
S/T
Electrical
system
CALL E03

DB36KK
(DAQ6KK)
sensor

input
S/T
Electrical
system
E01

DB37KK
(DAQ7KK)
sensor (2)

input
S/T
Electrical
system
CALL E04
DB39KQ Steering and transmission

(DAQ9KQ) controller model selection
Inconsistent model selection

signal
S/T
Electrical
system
CALL E03
DB3RKR Steering and transmission

(DAQRKR) controller CAN communication
S/T
Electrical
system
E02
DD12KA Shift up switch
Disconnection
S/T
Electrical
system
E02
DD12KB Shift up switch
Short circuit
S/T
Electrical
system
E02
DD13KA Shift down switch
Disconnection
S/T
Electrical
system
E02
DD13KB Shift down switch
Short circuit
S/T
Electrical
system
CALL E03
DD14KA
Parking lock switch
(DDQ2KA)
Disconnection
S/T
Electrical
system
CALL E03
DD14KB
Parking lock switch
(DDQ2KB)
Short circuit
S/T
Electrical
system
CALL E03
DDQ2KA
Parking lock switch
(DD14KA)
Disconnection
S/T
Electrical
system
CALL E03
DDQ2KB
Parking lock switch
(DD14KB)
Short circuit
S/T
Electrical
system
DGS1KX

sensor
Input signal out of range
S/T
Electrical
system
E01
DGT1KA

sensor
Abnormal input signal
S/T
Electrical
system
E01
DGT1KX

sensor
S/T
Electrical
system
DH22KA
HSS and work equipment pump

Disconnection
oil pressure sensor
S/T
Electrical
system
DH22KB
HSS and work equipment pump

Short circuit
oil pressure sensor
S/T
Electrical
system
CALL E03 DK10KA Fuel control dial
Disconnection
S/T
Electrical
system
CALL E03 DK10KB Fuel control dial
Short circuit
S/T
Electrical
system
CALL E03 DK30KA Steering potentiometer (1)
Disconnection
S/T
Electrical
system
CALL E03 DK30KB Steering potentiometer (1)
Short circuit
S/T
Electrical
system
CALL E04 DK30KX Steering potentiometer
S/T
Electrical
system
D85EX, PX-15E0
SEN00634-00
Action
code
Failure
code
40 Troubleshooting
Failed section
Symptom of failure
Alarm ConHistory
CALL E04 DK30KZ Steering potentiometer
Disconnection or Short circuit
S/T
Electrical
system
CALL E03
Inconsistent analog signals
S/T
Electrical
system
CALL E03 DK31KA Steering potentiometer (2)
Disconnection
S/T
Electrical
system
CALL E03 DK31KB Steering potentiometer (2)
Short circuit
S/T
Electrical
system
DK30L8
Steering potentiometer
E01
DK40KA Brake potentiometer
Disconnection
S/T
Electrical
system
E01
DK40KB Brake potentiometer
Short circuit
S/T
Electrical
system
CALL E04 DK55KX Forward-reverse potentiometer Input signal out of range
S/T
Electrical
system
CALL E04 DK55KZ Forward-reverse potentiometer Disconnection or short circuit
S/T
Electrical
system
CALL E03
Forward-reverse potentiometer Inconsistent analog signals
S/T
Electrical
system
CALL E03 DK56KA
Forward-reverse potentiometer
Disconnection
(1)
S/T
Electrical
system
CALL E03 DK56KB
Short circuit
(1)
S/T
Electrical
system
CALL E03 DK57KA
Disconnection
(2)
S/T
Electrical
system
CALL E03 DK57KB
Short circuit
(2)
S/T
Electrical
system
DK55L8
CALL E03
DKH1KA
Pitch angle sensor
(DKH1KX)
Short circuit
S/T
Electrical
system
CALL E03
DKH1KB
Pitch angle sensor
(DKH1KX)
Disconnection
S/T
Electrical
system
S/T
Electrical
system
DKH1KX
CALL E03 (DKH1KA) Pitch angle sensor
(DKH1KB)
E01
DLT3KA

sensor
Disconnection
S/T
Electrical
system
E01
DLT3KB

sensor
Short circuit
S/T
Electrical
system
E02
DV00KB Alarm buzzer
Short circuit
MON
Electrical
system
E01
DW7BKA Fan reverse solenoid
Disconnection
S/T
Electrical
system
E01
DW7BKB Fan reverse solenoid
Short circuit
S/T
Electrical
system
E02
DW7BKY Fan reverse solenoid
Hot short
S/T
Electrical
system
CALL E03 DWN1KA HSS EPC solenoid right
Disconnection
S/T
Electrical
system
CALL E03 DWN1KB HSS EPC solenoid right
Short circuit
S/T
Electrical
system
CALL E04 DWN1KY HSS EPC solenoid right
Hot short
S/T
Electrical
system
D85EX, PX-15E0
40 Troubleshooting
Action
code
Failure
code
SEN00634-00
Failed section
Symptom of failure
Alarm ConHistory
CALL E03 DWN2KA HSS EPC solenoid left
Disconnection
S/T
Electrical
system
CALL E03 DWN2KB HSS EPC solenoid left
Short circuit
S/T
Electrical
system
CALL E04 DWN2KY HSS EPC solenoid left
Hot short
S/T
Electrical
system
E01
DWN5KA Fan pump TVC solenoid
Disconnection
S/T
Electrical
system
E01
DWN5KB Fan pump TVC solenoid
Short circuit
S/T
Electrical
system
E02
DWN5KY Fan pump TVC solenoid
Hot short
S/T
Electrical
system
E01
DXA0KA HSS pump TVC solenoid
Disconnection
S/T
Electrical
system
E01
DXA0KB HSS pump TVC solenoid
Short circuit
S/T
Electrical
system
E01
DXA0KY HSS pump TVC solenoid
Hot short
S/T
Electrical
system
CALL E03 DXH4KA 1st clutch ECM solenoid
Disconnection
S/T
Electrical
system
CALL E03 DXH4KB 1st clutch ECM solenoid
Short circuit
S/T
Electrical
system
CALL E03 DXH4KY 1st clutch ECM solenoid
Hot short
S/T
Electrical
system
CALL E03 DXH5KA 2nd clutch ECM solenoid
Disconnection
S/T
Electrical
system
CALL E03 DXH5KB 2nd clutch ECM solenoid
Short circuit
S/T
Electrical
system
CALL E03 DXH5KY 2nd clutch ECM solenoid
Hot short
S/T
Electrical
system
CALL E03 DXH6KA 3rd clutch ECM solenoid
Disconnection
S/T
Electrical
system
CALL E03 DXH6KB 3rd clutch ECM solenoid
Short circuit
S/T
Electrical
system
CALL E03 DXH6KY 3rd clutch ECM solenoid
Hot short
S/T
Electrical
system
CALL E03 DXH7KA Reverse clutch ECM solenoid
Disconnection
S/T
Electrical
system
CALL E03 DXH7KB Reverse clutch ECM solenoid
Short circuit
S/T
Electrical
system
CALL E03 DXH7KY Reverse clutch ECM solenoid
Hot short
S/T
Electrical
system
CALL E03 DXH8KA Forward clutch ECM solenoid
Disconnection
S/T
Electrical
system
CALL E03 DXH8KB Forward clutch ECM solenoid
Short circuit
S/T
Electrical
system
CALL E03 DXH8KY Forward clutch ECM solenoid
Hot short
S/T
Electrical
system
D85EX, PX-15E0
SEN00634-00
40 Troubleshooting
Before troubleshooting by failure codes
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
No.
Electric supply
source
Fuse
capacity (A)
30
Standby electric power supply
Switched electric
power supply
20
Horn, Electrical intake air heater, Air suspension seat
20
Head lamp
20
Rear lamp
20
Transmission steering controller, Monitor panel,

KOMTRAX
3
4
5
Constant power
source
Destinations of electric power distribution
Fuse box B [FS2]

Fuse
No.
Electric supply
source
Fuse
capacity (A)
Constant power
source
20
Starting switch (B) (with 20 A circuit breaker in the subsequent circuit)
30
Steering and transmission controller (main electric power supply)
30
Backup alarm
30
Air conditioner (with 20 A circuit breaker in the subsequent circuit)
Starting switch (ACC), Engine controller
2
3
4
Switched electric
power supply
Cab fuse box C

Fuse
No.
Fuse
capacity (A)
10
Accessory electric power supply (12 V electric power supply)
20
Radio, Room lamp, Cigarette lighter, Additional light
20
Glass with heating wire
10
Rear wiper
10
Front wiper
10
Left and right door wipers
3
4
10
Electric supply
source
Switched electric
power supply
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Fuse installation position and No.
Circuit breaker
No.
Connector No.
Capacity (A)
Circuit
CB105
105
CB30H
30
Engine controller constant power source
CB105
105
Main power source for electrical intake air heater
CB30
30
Constant power source
CB1
20
Starting switch
CB2
20
Air conditioner
Main power source
Remarks
Installed in the
battery box
located at the left
side of the operator cab
Installed in the
dash board air
conditioner filter
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
SEN00634-00
40 Troubleshooting
Contents of troubleshooting table

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
Display of
panel
Display of panel
Failure
Trouble that appears in the machine
symptom
Failure content State where the monitor panel or controller detects the trouble
Controller's
action
Action to be taken to protect the system and equipment when the monitor panel or controller
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
Information related to troubles occurred or troubleshooting
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
Possible causes
and standard
value in normal
state
12
<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
A harness not connected to the power (24 V) circuit comes
2
into contact with the power (24 V) circuit.
Short circuit
Causes by which a trouble
A harness of an independent circuit abnormally comes into
is assumed to be defected
contact with one of another circuit.
(The order number indicates a serial number, not <Notes on troubleshooting>
(1) Method of indicating connector numbers and handling of Ta priority sequence.)
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 Tadapters 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 ()
leads as shown below unless especially specified.
4
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.
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
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
SEN00634-00
40 Troubleshooting
Failure code [1500L0] Transmission clutch: Dual engagement

Action code
Failure code
CALL E03
1500LO
Symptom Transmission clutch: Dual engagement

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
action
Flashes warning lamp and turns on alarm buzzer.

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
information
Duplication of failure code: Engine start + travel
Causes
Possible
causes and the
standard values
when normal
14
Standard values when normal and remarks for troubleshooting
Confirm the failure codes displayed at the same time, then carry out troubleshooting for the codes.
[15SAL1], [15SALH], [15SBL1], [15SBLH], [15SEL1], [15SELH], [15SFL1], [15SFLH], [15SGL1],
[15SGLH]
[DXH4KA], [DXH4KB], [DXH4KY], [DXH5KA, [DXH5KB], [DXH5KY], [DXH6KA], [DXH6KB],
[DXH6KY], [DXH7KA, [DXH7KB], [DXH7KY], [DXH8KA], [DXH8KB], [DXH8KY]
D85EX, PX-15E0
SEN00634-00
40 Troubleshooting
Failure code [15SAL1] Forward clutch: Fill signal is ON when command

current is OFF
1
Action code
Failure code
CALL E03
15SAL1
Failure content
Controller's
action
Symptom Forward clutch: Fill signal is ON when command current is OFF

The fill switch signal does not become off when the output of the transmission forward clutch solenoid circuit has stopped.
Even if operating the gear to the reverse, the gear is shifted to N (neutral).
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
General
information
The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
(Code 31520: Transmission fill switch input state)
Duplication of failure code: Engine start + travel neutral
Causes
Defective forward clutch
1 fill switch
(internal short circuit)
Possible
causes and the
standard values
when normal

a Prepare with starting switch OFF and start the engine to diagnose.
FFT (male)
PCCS lever
Resistance
Between (1) and

ground
Min. 1 Mz
F (Forward)
Max. 1 z
a Prepare with starting switch OFF and diagnose with starting

switch still OFF.
Defective harness grounding

(contact with ground circuit) Between ground and wiring harness
between PTC2 (female) (35) FFT (female)
(1)
Resistance
Min. 1 Mz
3
16
Defective steering and

transmission controller
PTC2
PCCS lever
Voltage
Between (35) and

ground
5 11 V
F (Forward)
Max. 1 V
When no fault is detected in the electrical system, the hydraulic

Defective hydraulic pressure
pressure system can be suspected to be abnormal. Carry out the
system
related troubleshooting (H mode).
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Circuit diagram related to transmission forward clutch ECMV
D85EX, PX-15E0
17
SEN00634-00
40 Troubleshooting
Failure code [15SALH] Forward clutch: Fill signal is OFF when

command current is ON
Action code
Failure code
CALL E03
15SALH
Failure content
Controller's
action
Symptom Forward clutch: Fill signal is OFF when command current is ON

The fill switch signal does not become ON when the output of the transmission forward clutch solenoid circuit is ON.
Even if operating the gear to the forward, the gear is shifted to N (neutral).
Symptoms that
appear on
Once machine is stopped, travel is limited to R1.
machine
General
information
The input state (ON/OFF) from the forward clutch fill switch can be checked in monitoring mode.
Duplication of failure code: Engine start + Forward travel
Causes
1 fill switch
Possible
causes and the
standard values
when normal
FFT (male)
PCCS lever
Resistance
Between (1) and

ground
Min. 1 Mz
F (Forward)
Max. 1 z

switch still OFF.
harness (Disconnection in
2
wiring or defective contact of Wiring harness between PTC2 (female) (35)
connectors)
FFT (female) (1)
Resistance
Max. 1 z
3
18

PTC2
PCCS lever
Voltage
Between (35) and

ground
5 11 V
F (Forward)
Max. 1 V

system
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
D85EX, PX-15E0
19
SEN00634-00
40 Troubleshooting
Failure code [15SBL1] Reverse clutch: Fill signal is ON when command

current is OFF
1
Action code
Failure code
CALL E03
15SBL1
Failure content
Controller's
action
Symptom Reverse clutch: Fill signal is ON when command current is OFF

The fill switch signal does not become off when the output of the transmission reverse clutch solenoid circuit has stopped.
Even if operating the gear to the forward, the gear is shifted to N (neutral).
Symptoms that
appear on
machine
General
information
The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Duplication of failure code: Engine start + travel neutral
Causes
Defective reverse clutch
1 fill switch
Possible
causes and the
standard values
when normal

FRT (male)
PCCS lever
Resistance
Between (1) and

ground
Min. 1 Mz
R (Reverse)
Max. 1 z

switch still OFF.

between PTC2 (female) (25) FRT (female)
(1)
Resistance
Min. 1 Mz
3
20

PTC2
PCCS lever
Voltage
Between (25) and

ground
5 11 V
R (Reverse)
Max. 1 V

system
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Circuit diagram related to transmission reverse clutch ECMV
D85EX, PX-15E0
21
SEN00634-00
40 Troubleshooting
Failure code [15SBLH] Reverse clutch: Fill signal is OFF when

command current is ON
Action code
Failure code
CALL E03
15SBLH
Failure content
Controller's
action
Symptom Reverse clutch: Fill signal is OFF when command current is ON

The fill switch signal does not become ON when the output of the transmission reverse clutch solenoid circuit is ON.
Even if operating the gear to the reverse, the gear is shifted to N (neutral).
Symptoms that
appear on
machine
General
information
The input state (ON/OFF) from the reverse clutch fill switch can be checked in monitoring mode.
Duplication of failure code: Engine start + reverse travel
Causes
1 fill switch
Possible
causes and the
standard values
when normal
harness
2
(disconnection or defective
contact of connectors)
FRT (male)
PCCS lever
Resistance
Between (1) and

ground
Min. 1 Mz
R (Reverse)
Max. 1 z

switch still OFF.
Wiring harness between PTC2 (female) (25)
FRT (female) (1)
Resistance
Max. 1 z
3
22

PTC2
PCCS lever
Voltage
Between (25) and

ground
5 11 V
R (Reverse)
Max. 1 V

system
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
D85EX, PX-15E0
23
SEN00634-00
40 Troubleshooting
Failure code [15SEL1] 1st clutch: Fill signal is ON when command

current is OFF
Action code
Failure code
CALL E03
15SEL1
Failure content
Controller's
action
Symptom 1st clutch: Fill signal is ON when command current is OFF

The fill switch signal does not become OFF when the output of the transmission 1st clutch solenoid
circuit has stopped.
Symptoms that
appear on
Once machine is stopped, travel is limited to F1 and R1.
machine
General
information
The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Duplication of failure code: Engine start + F1 or R1 o travel neutral
Causes
Defective 1st clutch
1 fill switch
Possible
causes and the
standard values
when normal

F1T (male)
PCCS lever
Resistance
Between (1) and

ground
Other than F1 and R1
Min. 1 Mz
F1 and R1
Max. 1 z

switch still OFF.

between PTC3 (female) (19) F1T (female)
(1)
Resistance
Min. 1 Mz
3
24

PTC3
PCCS lever
Voltage
Between (19) and

ground
5 11 V
F1 and R1
Max. 1 V

system
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Circuit diagram related to transmission 1st clutch ECMV
D85EX, PX-15E0
25
SEN00634-00
40 Troubleshooting
Failure code [15SELH] 1st clutch: Fill signal is OFF when command
current is ON
Action code
Failure code
CALL E03
15SELH
Failure content
Controller's
action
Symptom 1st clutch: Fill signal is OFF when command current is ON

The fill switch signal does not become ON when the output of the transmission 1st clutch solenoid
circuit is ON.
Symptoms that
appear on
machine
General
information
The input state (ON/OFF) from the 1st clutch fill switch can be checked in monitoring mode.
Duplication of failure code: Engine start + F1 or R1 travel
Causes
Defective 1st clutch
1 fill switch
Possible
causes and the
standard values
when normal
harness
2

F1T (male)
PCCS lever
Resistance
Between (1) and

ground
Min. 1 Mz
F1 and R1
Max. 1 z

switch still OFF.
F1T (female) (1)
Resistance
Max. 1 z
3

PTC3
PCCS lever
Voltage
Between (19) and

ground
5 11 V
F1 and R1
Max. 1 V

4
system
26
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
D85EX, PX-15E0
27
SEN00634-00
40 Troubleshooting
Failure code [15SFL1] 2nd clutch: Fill signal is ON when command

current is OFF
Action code
Failure code
CALL E03
15SFL1
Failure content
Controller's
action
Symptom 2nd clutch: Fill signal is ON when command current is OFF

The fill switch signal does not become off when the output of the transmission 2nd clutch solenoid
circuit has stopped.
Symptoms that
appear on
machine
General
information
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Causes
Defective 2nd clutch
1 fill switch
Possible
causes and the
standard values
when normal

F2T (male)
PCCS lever
Resistance
Between (1) and

ground
Min. 1 Mz
F2 and R2
Max. 1 z

switch still OFF.

(1)
Resistance
Min. 1 Mz
3
28

PTC3
PCCS lever
Voltage
Between (29) and

ground
5 11 V
F2 and R2
Max. 1 V

system
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Circuit diagram related to transmission 2nd clutch ECMV
D85EX, PX-15E0
29
SEN00634-00
40 Troubleshooting
Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command
current is ON
Action code
Failure code
CALL E03
15SFLH
Failure content
Controller's
action
Symptom 2nd clutch: Fill signal is OFF when command current is ON

The fill switch signal does not become ON when the output of the transmission 2nd clutch solenoid
circuit is ON.
Symptoms that
appear on
machine
General
information
The input state (ON/OFF) from the 2nd clutch fill switch can be checked in monitoring mode.
Causes
Defective 2nd clutch
1 fill switch
Possible
causes and the
standard values
when normal
harness
2

F2T (male)
PCCS lever
Resistance
Between (1) and

ground
Min. 1 Mz
F2 and R2
Max. 1 z

switch still OFF.
F2T (female) (1)
Resistance
Max. 1 z
3

PTC3
PCCS lever
Voltage
Between (29) and

ground
5 11 V
F2 and R2
Max. 1 V

4
system
30
D85EX, PX-15E0
40 Troubleshooting
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D85EX, PX-15E0
31
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40 Troubleshooting
Failure code [15SGL1] 3rd clutch: Fill signal is ON when command

current is OFF
Action code
Failure code
CALL E03
15SGL1
Failure content
Controller's
action
Symptom 3rd clutch: Fill signal is ON when command current is OFF

The fill switch signal does not become off when the output of the transmission 3rd clutch solenoid circuit has stopped.
Symptoms that
appear on
machine
General
information
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Causes
Defective 3rd clutch
1 fill switch
Possible
causes and the
standard values
when normal

F3T (male)
PCCS lever
Resistance
Between (1) and

ground
Min. 1 Mz
F3 and R3
Max. 1 z

switch still OFF.

(1)
Resistance
Min. 1 Mz
3
32

PTC3
PCCS lever
Voltage
Between (39) and

ground
5 11 V
F3 and R3
Max. 1 V

system
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Circuit diagram related to transmission 3rd clutch ECMV
D85EX, PX-15E0
33
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40 Troubleshooting
Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command
current is ON
Action code
Failure code
CALL E03
15SGLH
Failure content
Controller's
action
Symptom 3rd clutch: Fill signal is OFF when command current is ON

The fill switch signal does not become ON when the output of the transmission 3rd clutch solenoid
circuit is ON.
Symptoms that
appear on
machine
General
information
The input state (ON/OFF) from the 3rd clutch fill switch can be checked in monitoring mode.
Causes
Defective 3rd clutch
1 fill switch
Possible
causes and the
standard values
when normal
harness
2

F3T (male)
PCCS lever
Resistance
Between (1) and

ground
Min. 1 Mz
F3 and R3
Max. 1 z

switch still OFF.
F3T (female) (1)
Resistance
Max. 1 z
3

PTC3
PCCS lever
Voltage
Between (39) and

ground
5 11 V
F3 and R3
Max. 1 V

4
system
34
D85EX, PX-15E0
40 Troubleshooting
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D85EX, PX-15E0
35
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40 Troubleshooting
Failure code [AA10NX] Air cleaner: Clogged

Action code
Failure code
AA10NX
Symptom Air cleaner: Clogged

of failure (Mechanical system)
Failure content The air cleaner clogging state is detected during the engine running.
Controller's
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
information
The air cleaner clogging caution symbol on the monitor panel flashes and this failure code is
recorded.
Causes
1
Clogged air cleaner

(When system is normal)
Defective air cleaner

2 clogging switch (Internal
disconnection)
Possible
causes and the
standard values
when normal
harness
3

a Check the air cleaner, then clean and change if it is clogged.
AF2 (male)
Between (1) (2)
Air cleaner
Resistance
When normal
Max. 1 z
When clogged
Min. 1 Mz

switch still OFF.
Wiring harness between S03 (female) (13)
AF2 (female) (1)
Resistance
Max. 1 z
Wiring harness between AF2 (female) (2)

and ground
Resistance
Max. 1 z
4 Defective monitor panel
36
S03
Air cleaner
Voltage
Between (13) and

ground
When normal
Max. 1V
When clogged
Min. 7 V
D85EX, PX-15E0
40 Troubleshooting
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Circuit diagram related to clogged air cleaner
D85EX, PX-15E0
37
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40 Troubleshooting
Failure code [AB00MA] Abnormal battery charge: Malfunction

Action code
Failure code
AB00MA
Symptom Abnormal battery charge: Malfunction

Failure content The voltage of charge level circuit decreased during the engine running.
Controller's
action
Flashes warning lamp.
Symptoms that
appear on
If the machine is operated in such a condition, battery may be discharged.
machine
General
information
Possible
causes and the
standard values
when normal
The charge level caution symbol on the monitor panel flashes and this failure code is recorded.
Duplication of failure code: Start engine + fuel dial full
Causes
Defective battery charge

It can be suspected that the problem causing the detection of defective battery charge is currently occurring or occurred in the past.
Investigate the cause and damage condition, and correct it.
Defective charge level

caution lamp circuit
Carry out troubleshooting of charge level caution lamp system in

accordance with While engine is running, battery charge level caution lamp flashes in E mode.
Failure code [B@BAZG] Engine oil: Oil pressure too low

Action code
Failure code
B@BAZG
Symptom Engine oil: Oil pressure too low

Failure content The engine oil pressure abnormality takes place during the engine running.
Controller's
action
Flashes warning lamp and turns on alarm buzzer. (Function of monitor panel)
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).
General
information
The engine oil pressure caution symbol on the monitor panel flashes and this failure code is
recorded.
Duplication of failure code: Start the engine.
Causes
Possible
causes and the
standard values
when normal
Reduction of engine oil

1 pressure
2
38

It can be suspected that the problem causing the detection of
engine oil pressure reduction is currently occurring or occurred in
the past. Investigate the cause and damage condition, and correct
it.
Carry out troubleshooting of engine oil pressure caution lamp sysDefective engine oil pressure
tem in accordance with While engine is running, emergency warncaution lamp circuit
ing item flashes in E mode.
D85EX, PX-15E0
40 Troubleshooting
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Failure code [B@BCNS] Radiator coolant: Overheat

Action code
Failure code
B@BCNS
Symptom Radiator coolant: Overheat

Failure content The radiator coolant becomes overheated during the engine running.
Controller's
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
General
information
Possible
causes and the
standard values
when normal
The engine coolant temperature caution symbol on the monitor panel flashes and this failure code is
recorded.
Causes
Coolant overheats
It can be suspected that the problem causing a detection of coolant

overheat is currently occurring or occurred in the past. Investigate
the cause and damage condition, and correct it.
Defective engine coolant

2 temperature caution lamp
circuit
Carry out troubleshooting of coolant temperature caution lamp circuit in accordance with While engine is running, emergency warning item flashes in E mode.
Failure code [B@BCZK] Radiator coolant: Level too low

Action code
Failure code
B@BCZK
Symptom Radiator coolant: Level too low

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
General
information
Possible
causes and the
standard values
when normal
The radiator coolant level caution symbol on the monitor panel flashes and this failure code is
recorded.
Duplication of failure code: turn ON the starting switch.
Causes
Radiator coolant level is too

1 low.
It can be suspected that the problem causing the detection of radiator coolant level too low is currently occurring or occurred in the
past. Investigate the cause and damage condition, and correct it.
Defective radiator coolant

level caution lamp circuit
Carry out troubleshooting in accordance with When starting switch

is turned ON, radiator coolant level caution flashes in E mode.
D85EX, PX-15E0
39
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40 Troubleshooting
Failure code [B@CENS] Power train oil: Overheat

Action code
Failure code
B@CENS
Symptom Power train oil: Overheat

Failure content The power train oil becomes overheated during the engine running.
Controller's
action
Symptoms that
appear on
If the machine is operated in such a condition, power train may be damaged.
machine
General
information
The power train oil temperature caution symbol on the monitor panel flashes and this failure code is
recorded.
Causes
Possible
causes and the
standard values
when normal

1 overheat
It can be suspected that the problem causing a detection of power

train oil overheat is currently occurring or occurred in the past.
Defective caution lamp

2 circuit for power train oil
overheat
Carry out troubleshooting of power train oil temperature caution

lamp system in accordance with While engine is running, emergency warning item flashes in E mode.
Failure code [B@HANS] Hydraulic oil: Overheat

Action code
Failure code
B@HANS
Symptom Hydraulic oil: Overheat

Failure content The hydraulic oil temperature becomes overheated during the engine running.
Controller's
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
General
information
Possible
causes and the
standard values
when normal
40
The hydraulic oil temperature caution symbol on the monitor panel flashes and this failure code is
recorded.
Causes
Hydraulic oil overheat

It can be suspected that the problem causing a detection of

hydraulic oil overheat is currently occurring or occurred in the past.
Carry out troubleshooting of hydraulic oil temperature caution lamp

Defective hydraulic oil temcircuit in accordance with While engine is running, emergency
perature caution lamp circuit
warning item flashes in E mode.
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Failure code [CA111] Engine controller: Abnormality in controller

Action code
Failure code
CALL E04
CA111
Symptom Engine controller: Abnormality in controller

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
Causes
1 Defective breaker
Possible
causes and the
standard values
when normal
harness
2

Since the breaker can be suspected to be defective, inspect the
breaker.
(When the breaker is cut off, it is highly possible that a defective harness grounding has occurred in the circuit.)
switch still OFF.
Wiring harness between EGC3 (female) (3),
(4) battery (+)
Resistance
Max. 1 z

(2) and ground
Resistance
Max. 1 z

switch still OFF.
3
ResisMin. 1 Mz
between EGC3 (female) (3), (4) battery (+)
tance
4 Defective engine controller

switch ON.
EGC3
Voltage
Between (3), (4) (1), (2)
20 30 V
Circuit diagram related to controller power source
D85EX, PX-15E0
41
SEN00634-00
40 Troubleshooting

Abnormal speed sensor signal
Action code
Failure code
CALL E04
CA115
Failure content
Controller's
action
Symptom of Abnormal engine Ne and Bkup speed sensors: Abnormal speed

failure
sensor signal (Engine controller system)
Abnormality has occurred at the same time in Ne speed sensor circuit and Bkup speed sensor circuit.
Symptoms that
Engine does not start (during engine stop).
appear on
Engine stops (during engine running).
machine
General
information
Causes
Possible
causes and the
standard values
when normal
Defective Ne speed sensor

circuit
Carry out troubleshooting of [CA689].
Defective Bkup speed sensor

circuit

mounting section
Since a mounting section of Ne speed sensor can be suspected to

be defective, directly check the mounting section. (Defective
installation of sensor itself, internal defect of flywheel, etc.)
Bkup speed sensor mounting

section
Since a mounting section of Bkup speed sensor can be suspected

to be defective, directly check the mounting section. (Defective
installation of sensor itself, internal defect of supply pump, etc.)
Defective connection of sensor The defective (wrong) connections of Ne speed sensor and Bkup
(wrong connection)
speed sensor can be suspected. Directly check them.
42
Engine controller can be suspected to be defective if no problem

is found in causes 1 5 (since this is an internal defect, it cannot
be diagnosed).
D85EX, PX-15E0
SEN00634-00
40 Troubleshooting
Failure code [CA122] Charge pressure sensor too high: Excessively

high voltage detected
Action code
Failure code
CALL E03
CA122
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
action
Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
Symptoms that
appear on
Acceleration performance of engine deteriorates.
machine
General
information
The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
function. (Code: 36501 Boost pressure sensor voltage)
Causes
Defective sensor power
1
source circuit

If failure code [CA227] is displayed at the same time, carry out troubleshooting for it first.
a Prepare with starting switch OFF, and diagnose with starting
switch ON or with engine started.
Defective charge pressure

2 (boost pressure)
sensor (internal defect)
PIM
Between (1) (3)
Voltage
Power source
4.75 5.25 V
Since the sensor voltage is measured with the harness being connected, 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.
harness
3
Possible
causes and the
standard values
when normal
Wiring harness between EGC1 (female) (37)

PIM (female) (1)
Resistance
Max. 1 z

PIM (female) (2)
Resistance
Max. 1 z

PIM (female) (3)
Resistance
Max. 1 z

switch still OFF.
Between ground and wiring harness between
Defective harness grounding EGC1 (female) (37) PIM (female) (1)
4
(contact with ground circuit) Between ground and wiring harness between
EGC1 (female) (44) PIM (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

EGC1 (female) (47) PIM (female) (3)
Resistance
Min. 1 Mz

switch still OFF.
44
Harness short
(Harness internal short)
Between wiring harness from EGC1 (female)

(37) to PIM (female) (1) and wiring harness
from ENG (female) (44) to PIM (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
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Causes
Possible
causes and the
standard values
when normal

EGC1
Between (37) (47)
Voltage
Power source
4.75 5.25 V
Circuit diagram related to charge pressure sensor
D85EX, PX-15E0
45
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40 Troubleshooting
Failure code [CA123] Charge pressure sensor too low: Excessively low
voltage detected
1
Action code
Failure code
CALL E03
CA123
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
action
Operate with a fixed charge pressure (boost pressure) (400 kPa {4.1 kg/cm2}).
Symptoms that
appear on
Acceleration performance of engine deteriorates.
machine
General
information
Possible
causes and the
standard values
when normal
46
The signal voltage of the charge pressure (boost pressure) can be checked with the monitoring
function. (Code: 36501 Boost pressure sensor voltage)
Causes

source circuit
D85EX, PX-15E0
SEN00634-00
40 Troubleshooting
Failure code [CA131] Decelerator pedal sensor too high: Excessively

1
Action code
Failure code
CALL E03
CA131
Symptom Decelerator pedal sensor too high: Excessively high voltage

of failure detected (Engine controller system)
Failure content Excessively high voltage is detected at signal circuit of decelerator pedal.
Controller's
action
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.
If the starting switch is turned to the ON position in as-is abnormal condition, the controller operates
with 100% value.
Symptoms that
appear on
Engine speed cannot be controlled by decelerator pedal.
machine
General
information
The signal voltage of decelerator pedal can be checked in monitoring mode.

(Code: 31703 Decelerator voltage)
Causes
Defective throttle sensor
1
power supply circuit

If failure code [CA2185] is displayed at the same time, carry out
troubleshooting for it first.
switch ON.
DCL
2 Defective decelerator pedal
Between (A) (C)
Voltage
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.
Possible
causes and the
standard values
when normal
Hot short of harness

3 (a contact with 5V circuit or
24V circuit)
Harness short
Defective wiring harness

connector

switch ON.
Between ground and wiring harness
between EGC2 (female) (9) DCL (female)
(B)
Max. 1V

switch still OFF.
(9) to DCL (female) (B) and wiring harness
from EGC2 (female) (22) to DCL (female) (A)
Resistance
Min. 1 Mz
Since the connections among decelerator pedal body harness

engine controller are suspected to be defective, Check the connections directly.
Connector is loose, lock is broken, seal is broken
Pin is corroded, bent, broken, pushed in, expanded.
Moisture in connector, entry of dirt or sand, etc., and insufficient
insulation
switch ON.
EGC2
Between (22) (23)
48
Voltage
Voltage
Power source
4.75 5.25 V
D85EX, PX-15E0
40 Troubleshooting
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Circuit diagram related to decelerator pedal
D85EX, PX-15E0
49
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40 Troubleshooting
Failure code [CA132] Decelerator pedal sensor too low: Excessively low
voltage detected
1
Action code
Failure code
CALL E03
CA132
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
appear on
machine
General
information
The signal voltage of decelerator pedal can be checked in monitoring mode.

(Code: 31703 Decelerator voltage)
Causes
Defective throttle sensor
1
power supply circuit

If failure code [CA2186] is displayed at the same time, carry out
troubleshooting for it first.
switch ON.
DCL
2 Defective decelerator pedal
Between (A) (C)
Voltage
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.
3
Possible
causes and the
standard values
when normal
4

between EGC2 (female) (9) DCL (female)
(B)
Harness short

connector
Min. 1 Mz

switch still OFF.
from EGC2 (female) (23) to DCL (female) (C)
Resistance
Min. 1 Mz

insulation
switch ON.
EGC2
Between (22) (23)
50
Resistance
Voltage
Power source
4.75 5.25 V
D85EX, PX-15E0
40 Troubleshooting
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D85EX, PX-15E0
51
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40 Troubleshooting
Failure code [CA135] Oil pressure sensor too high: Excessively high
voltage detected
1
Action code
Failure code
E02
CA135
Symptom Oil pressure sensor too high: Excessively high voltage detected
Failure content Excessively high voltage is detected at oil pressure sensor circuit.
Controller's
action
Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Symptoms that
appear on
machine
General
information
The signal voltage of engine oil pressure sensor can be checked in monitoring function.
(Code: 37201 Engine oil pressure sensor voltage)
Causes
1
source circuit

If failure code [CA187] or [CA227] is displayed at the same time,
carry out troubleshooting for it first.
POIL
Defective oil pressure sensor

(internal defect)
Between (1) (2)
Voltage
Power source
4.75 5.25 V
switch still OFF.
harness
3
Possible
causes and the
standard values
when normal

POIL (female) (1)
Resistance
Max. 1 z

POIL (female) (2)
Resistance
Max. 1 z

POIL (female) (3)
Resistance
Max. 1 z

switch still OFF.
Defective harness grounding EGC1 (female) (37) POIL (female) (1)
4
EGC1 (female) (47) POIL (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

EGC1 (female) (13) POIL (female) (3)
Resistance
Min. 1 Mz

switch still OFF.
52
Harness short

(37) to POIL (female) (1) and wiring harness
from EGC1 (female) (47) to POIL (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Causes
Possible
causes and the
standard values
when normal

EGC1
Between (37) (47)
Voltage
Power source
4.75 5.25 V
Circuit diagram related to oil pressure sensor
D85EX, PX-15E0
53
SEN00634-00
40 Troubleshooting
Failure code [CA141] Oil pressure sensor too low: Excessively low
voltage detected
Action code
Failure code
E02
CA141
Symptom Oil pressure sensor too low: Excessively low voltage detected
Failure content Excessively low voltage is detected at oil pressure sensor circuit.
Controller's
action
Operates with oil pressure value defaulted to (250 kPa {2.5 kg/cm2})
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
54
The signal voltage of engine oil pressure sensor can be checked in monitoring function.
(Code: 37201 Engine oil pressure sensor voltage)
Causes

source circuit
D85EX, PX-15E0
SEN00634-00
40 Troubleshooting
Failure code [CA144] Coolant temperature sensor too high: Excessively

1
Action code
Failure code
E01
CA144
Symptom Coolant temperature sensor too high: Excessively high voltage

Failure content Excessively high voltage is detected at signal circuit of coolant temperature sensor.
Controller's
action
Operates with a fixed coolant temperature (90C).

Symptoms that
appear on
Exhaust gas color becomes white.
machine
General
information
The signal voltage of coolant temperature sensor can be checked in monitoring function.
(Code: 04105 Coolant temperature sensor voltage)
Causes
Defective coolant
temperature sensor
harness
2
Possible
causes and the
standard values
when normal
Harness short

connector
Defect in other locations than

5
engine controller
56

switch still OFF.
TWTR (male)
Resistance
Between (A) (B)
0.18 160 kz

switch still OFF.
TWTR (female) (A)
Resistance
Max. 1 z
Wiring harness among EGC1 (female) (38)

JM03 TWTR (female) (B)
Resistance
Max. 1 z

switch still OFF.
Between EGC1 (female) (15) all pins of
EGC1 (female) (with all connectors in the
harness disconnected)
Resistance
Min. 1 Mz
Since the connections among coolant temperature sensor engine

harness engine controller are suspected to be defective, check for
a defective connection.
insulation
switch still OFF.
EGC1 (female)
Resistance
Between (15) (38)
0.18 160 kz
Engine controller is possibly defective if no problem is found in

causes 1 5.
(Since this is an internal defect, it cannot be diagnosed.)
D85EX, PX-15E0
40 Troubleshooting
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Circuit diagram related to coolant temperature sensor
D85EX, PX-15E0
57
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40 Troubleshooting
Failure code [CA145] Coolant temperature sensor too low: Excessively

low voltage detected
1
Action code
Failure code
E01
CA145
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
action
Operates with a fixed coolant temperature (90C).

Symptoms that
appear on
machine
General
information
The signal voltage of coolant temperature sensor can be checked in monitoring function.
(Code: 04105 Coolant temperature sensor voltage)
Causes

switch still OFF.
Defective coolant
temperature sensor
TWTR (male)
Resistance
Between (A) (B)
0.18 160 kz
Between (A) and ground
Min. 1 Mz

switch still OFF.
2
ResisMin. 1 Mz
EGC1 (female) (15) TWTR (female) (A)
tance
Possible
causes and the
standard values
when normal
Harness short

connector

switch still OFF.
Resistance
Min. 1 Mz
Since the connections among coolant temperature sensor engine

harness engine controller are suspected to be defective, check for
a defective connection.
insulation
switch still OFF.

engine controller
58
EGC1 (female)
Resistance
Between (15) (38)
0.18 160 kz
Between (15) and ground
Min. 1 Mz

causes 1 5.
D85EX, PX-15E0
40 Troubleshooting
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Circuit diagram related to coolant temperature sensor
D85EX, PX-15E0
59
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40 Troubleshooting
Failure code [CA153] Charge temperature sensor too high: Excessively

1
Action code
Failure code
E01
CA153
Failure content
Controller's
action
Symptom Charge temperature sensor too high: Excessively high voltage

of failure detected. (Engine controller system)
Excessively high voltage is detected at signal circuit of charge temperature (boost temperature)
sensor.
Operates with a fixed charge temperature (boost temperature) (70C).
Symptoms that
appear on
machine
General
information
The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
monitoring function. (Code: 18501 Boost temperature sensor voltage)
Causes
Defective charge
temperature
1
(boost temperature) sensor
(internal defect)
harness
2
Possible
causes and the
standard values
when normal
Harness short

connector

switch still OFF.
TIM (male)
Resistance
Between (A) (B)
0.18 160 kz

switch still OFF.
TIM (female) (A)
Resistance
Max. 1 z

JM02 TIM (female) (B)
Resistance
Max. 1 z

switch still OFF.
Resistance
Min. 1 Mz
Since the connections among charge temperature (boost temperature) sensor engine harness engine controller are suspected to
be defective, check for a defective connection.
insulation

switch still OFF.
5
engine controller
EGC1 (female)
Resistance
Between (23) (47)
60
0.18 160 kz

causes 1 5.
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Circuit diagram related to charge temperature sensor
D85EX, PX-15E0
61
SEN00634-00
40 Troubleshooting
Failure code [CA154] Charge temperature sensor too low: Excessively

low voltage detected
1
Action code
Failure code
E01
CA154
Failure content
Controller's
action
Symptom Charge temperature sensor too low: Excessively low voltage

Excessively low voltage is detected at signal circuit of charge temperature (boost temperature)
sensor.
Operates with a fixed charge temperature (boost temperature) (70C).
Symptoms that
appear on
machine
General
information
The signal voltage of the charge temperature (boost temperature) sensor can be checked with the
monitoring function. (Code: 18501 Boost temperature sensor voltage)
Causes
Defective charge
temperature
1
(boost temperature) sensor
(internal defect)

switch still OFF.
TIM (male)
Resistance
Between (A) (B)
0.18 160 kz
Between (A) and ground
Min. 1 Mz

switch still OFF.
Possible
causes and the
standard values
when normal

between EGC1 (female) (23) TIM (female)
(A)
Harness short

connector
Resistance
Min. 1 Mz

switch still OFF.
Resistance
Min. 1 Mz
Since the connections among charge temperature (boost temperature) sensor engine harness engine controller are suspected to
be defective, check for a defective connection.
insulation
switch still OFF.

engine controller
62
EGC1 (female)
Resistance
Between (23) (47)
0.18 160 kz
Min. 1 Mz

causes 1 5.
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Circuit diagram related to charge temperature sensor
D85EX, PX-15E0
63
SEN00634-00
40 Troubleshooting
Failure code [CA187] Sensor power source 2 too low: Low voltage
detected
Action code
Failure code
CALL E03
CA187
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.
Controller's
action
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})
Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}).
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
appear on
Output decreases.
machine
General
information
Possible
causes and the
standard values
when normal
64
Causes

Carry out troubleshooting of failure code [CA227].
D85EX, PX-15E0
SEN00634-00
40 Troubleshooting
Failure code [CA221] Atmospheric pressure sensor too high:

Excessively high voltage detected
Action code
Failure code
CALL E03
CA221
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
action
Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Symptoms that
appear on
Output decreases.
machine
General
information
The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
(Code: 37401 Atmospheric pressure sensor voltage)
Causes
1
source circuit

If failure code [CA187] or [CA227] is displayed at the same time,
carry out troubleshooting for it first.
switch ON.
Defective atmospheric
2 pressure sensor
(internal defect)
PAMB
Between (1) (3)
Voltage
Power source
4.75 5.25 V
switch still OFF.
harness
3
Possible
causes and the
standard values
when normal

PAMB (female) (1)
Resistance
Max. 1 z

PAMB (female) (2)
Resistance
Max. 1 z

PAMB (female) (3)
Resistance
Max. 1 z

switch still OFF.
Defective harness grounding EGC1 (female) (37) PAMB (female) (1)
4
EGC1 (female) (3) PAMB (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

EGC1 (female) (38) PAMB (female) (3)
Resistance
Min. 1 Mz

switch still OFF.
66
Harness short

(37) to PAMB (female) (1) and wiring harness
from EGC1 (female) (3) to PAMB (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Causes
Possible
causes and the
standard values
when normal

EGC1
Voltage
Between (37) (38)
4.75 5.25 V
Circuit diagram related to atmospheric pressure sensor
D85EX, PX-15E0
67
SEN00634-00
40 Troubleshooting
Failure code [CA222] Atmospheric pressure sensor too low:

Excessively low voltage detected
Action code
Failure code
CALL E03
CA222
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
action
Operates with atmospheric pressure value defaulted to (52.44 kPa {0.5 kg/cm2}).
Symptoms that
appear on
Output decreases.
machine
General
information
Possible
causes and the
standard values
when normal
68
The signal voltage of the atmospheric pressure sensor can be checked in monitoring mode.
(Code: 37401 Atmospheric pressure sensor voltage)
Causes

D85EX, PX-15E0
SEN00634-00
40 Troubleshooting
Failure code [CA227] Sensor power source 2 too high: Excessively high
voltage detected
1
Action code
Failure code
CALL E03
CA227
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.
Controller's
action
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})
Operates with charge pressure sensor at fixed value (400 kPa {4.1 kg/cm2}).
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
appear on
Output decreases.
machine
General
information
Causes
1 Defective related circuits

Check the codes that are displayed at the same time. If any other
codes are displayed, carry out troubleshooting for those codes.
switch ON.
Defective sensor
2
(internal defect)
Possible
causes and the
standard values
when normal
harness
3
Disconnect the
devices on the right
one at a time.
If the code disappears, that device is
internally defective.
Bkup speed sensor
G connector
Oil pressure sensor
POIL connector
Atmospheric
pressure sensor
PAMB connector
Charge pressure
sensor
PIM connector
EGR valve
lift sensor
SEGR connector

switch still OFF.
each sensor (female)
Resistance
Max. 1 z

each sensor (female)
Resistance
Max. 1 z

switch still OFF.
Defective harness grounding between EGC1 (female) (37) each sensor
4
(contact with ground circuit) (female)
Resistance
Min. 1 Mz

between EGC1 (female) (47) each sensor
(female)
Resistance
Min. 1 Mz

switch still OFF.
5
70
Harness short

(37) to each sensor (female) and wiring harness from EGC1 (female) (47) to each sensor (female)
Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Causes
Possible
causes and the
standard values
when normal
Defective engine controller

switch ON.
EGC1
Voltage
Between (37) (47)
4.75 5.25 V
Circuit diagram related to sensor power source 2 (5V)
D85EX, PX-15E0
71
SEN00634-00
40 Troubleshooting
Failure code [CA234] Engine over speed: Excessively high speed

Action code
Failure code
CA234
Symptom Engine over speed: Excessively high speed

The engine speed exceeds upper control limit speed.

Failure content
Controller's
action
Stops operation of injector until the engine speed drops to the normal speed.
Symptoms that
appear on
Engine speed fluctuates.
machine
General
information
The engine speed can be checked in monitoring function.

(Code: 01000 Engine speed)
Duplication of failure code: Start engine and operate at high idle.
Causes
Possible
causes and the
standard values
when normal
72
2 Improper usage
The improper usage of equipped machine can be suspected.

Instruct the proper usage.
Engine controller can be suspected to be defective if no problem is

found in causes 1 2 (since this is an internal defect, it cannot be
diagnosed).
D85EX, PX-15E0
SEN00634-00
40 Troubleshooting

Action code
Failure code
CALL E03
CA238
Symptom Abnormal power source for Ne speed sensor: Excessively low voltof failure age detected (Engine controller system)
Failure content Excessively low voltage is detected at Ne speed sensor power supply (5V) circuit.
Controller's
action
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
Causes

switch still OFF.

(internal defect)
harness
2
Possible
causes and the
standard values
when normal
Ne speed sensor
NE connector

switch still OFF.
NE (female) (1)
Resistance
Max. 1 z

NE (female) (2)
Resistance
Max. 1 z

switch still OFF.
3
Defective harness grounding Between ground and wiring harness between

(contact with ground circuit) EGC1 (female) (16) NE (female) (1)
Resistance
Min. 1 Mz

EGC1 (female) (48) NE (female) (2)
Resistance
Min. 1 Mz
Harness short
74
Disconnect a device
shown on the right.
If the failure code disappears, that device
is internally defective.

switch still OFF.
(16) to NE (female) (1) and wiring harness
from EGC1 (female) (48) to NE (female) (2)
Resistance
Min. 1 Mz

switch ON.
EGC1
Voltage
Between (16) (48)
4.75 5.25 V
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Circuit diagram related to Ne speed sensor power source
D85EX, PX-15E0
75
SEN00634-00
40 Troubleshooting
Failure code [CA263] Fuel temperature sensor too high: Excessively

Action code
Failure code
E01
CA263
Symptom Fuel temperature sensor too high: Excessively high voltage

Failure content Excessively high voltage is detected at fuel temperature sensor circuit.
Controller's
action
Operates with a fixed fuel temperature (90C).
Symptoms that
appear on
machine
General
information
The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
(Code: 14201 Engine fuel temperature sensor voltage)
Causes
Possible
causes and the
standard values
when normal
Defective fuel temperature

sensor (internal defect)
harness
2

switch still OFF.
TFUEL (male)
Fuel temperature
Resistance
Between (A) (B)
10 100C
0.6 20 kz

switch still OFF.
TFUEL (female) (A)
Resistance
Max. 1 z

TFUEL (female) (B)
Resistance
Max. 1 z

switch still OFF.
3

(contact with ground circuit) EGC1 (female) (30) TFUEL (female) (A)
Resistance
Min. 1 Mz

switch still OFF.
4
76
EGC1 (female)
Fuel temperature
Resistance
Between (30) (47)
10 100C
0.6 20 kz
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Circuit diagram related to fuel temperature sensor
D85EX, PX-15E0
77
SEN00634-00
40 Troubleshooting
Failure code [CA265] Fuel temperature sensor too low: Excessively low
voltage detected
1
Action code
Failure code
E01
CA265
Symptom Fuel temperature sensor too low: Excessively low voltage detected
Failure content Excessively low voltage is detected at fuel temperature sensor circuit.
Controller's
action
Operates with a fixed fuel temperature (90C).
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
78
The signal voltage of engine fuel temperature sensor can be checked in monitoring function.
(Code: 14201 Engine fuel temperature sensor voltage)
Causes

D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Failure code [CA271] PCV1 short circuit: Short circuit

Action code
Failure code
CALL E03
CA271
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
Causes

switch still OFF.
Defective supply pump

PCV1 (internal short circuit)
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2) and ground
Min. 1 Mz

switch still OFF.
2
Possible
causes and the
standard values
when normal

(contact with ground circuit) EGC1 (female) (4) PCV1 (female) (1)
Resistance
Min. 1 Mz

EGC1 (female) (5) PCV1 (female) (2)
Resistance
Min. 1 Mz

switch ON.
3
Hot short of wiring harness

(contact with 24 V circuit)

Voltage
Max. 1V

Voltage
Max. 1V

switch still OFF.
4
EGC1 (female)
Resistance
Between (4) (5)
2.3 5.3 z
Min. 1 Mz
Circuit diagram related to supply pump PCV1
D85EX, PX-15E0
79
SEN00634-00
40 Troubleshooting
Failure code [CA272] PCV1 disconnection: Disconnection

Action code
Failure code
CALL E03
CA272
Symptom PCV1 disconnection: Disconnection

Failure content Disconnection has occurred in supply pump PCV1 circuit.

Controller's
action
Symptoms that
appear on
machine
General
information
Causes
1 PCV1 (internal disconnection)
Possible
causes and the
standard values
when normal
harness
2

switch still OFF.
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Min. 1 Mz

switch still OFF.
PCV1 (female) (1)
Resistance
Max. 1 z

PCV1 (female) (2)
Resistance
Max. 1 z

switch still OFF.
3

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

switch still OFF.
4
EGC1 (female)
Resistance
Between (4) (5)
2.3 5.3 z
Min. 1 Mz
80
D85EX, PX-15E0
40 Troubleshooting
SEN00634-00
Failure code [CA273] PCV2 short circuit: Short circuit

Action code
Failure code
CALL E03
CA273
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
Causes

switch still OFF.

PCV2 (internal short circuit)
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Min. 1 Mz

switch still OFF.
2
Possible
causes and the
standard values
when normal

Resistance
Min. 1 Mz

PCV2 (female) (2)
Resistance
Min. 1 Mz

switch ON.
3


Voltage
Max. 1V

Voltage
Max. 1V

switch still OFF.
4
EGC1 (female)
Resistance
Between (9) (10)
2.3 5.3 z
Min. 1 Mz
D85EX, PX-15E0
81
SEN00634-00
40 Troubleshooting
Failure code [CA274] PCV2 disconnection: Disconnection

Action code
Failure code
CALL E03
CA274
Symptom PCV2 disconnection: Disconnection

Failure content Disconnection has occurred in supply pump PCV2 circuit.

Controller's
action
Symptoms that
appear on
machine
General
information
Causes
1 PCV2
(internal disconnection)
Possible
causes and the
standard values
when normal
harness
2

switch still OFF.
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z

switch still OFF.
PCV2 (female) (1)
Resistance
Max. 1 z

PCV2 (female) (2)
Resistance
Max. 1 z

switch still OFF.
3

Resistance
Min.
1 Mz

Resistance
Min.
1 Mz

switch still OFF.
4
EGC1 (female)
Resistance
Between (9) (10)
2.3 5.3 z
Min. 1 Mz
82
D85EX, PX-15E0
SEN00634-00

84
SEN00635-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
40 Troubleshooting

Disconnection, short circuit ........................................................................................................... 3
Failure code [CA342] Engine controller data matching error: Matching error ...................................... 9
D85EX, PX-15E0
SEN00635-00
40 Troubleshooting
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
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00

Disconnection, short circuit
1
Action code
Failure code
CALL E03
CA322
Symptom Injector No. 1 system disconnection or short circuit: Disconnection,

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
Causes

switch still OFF.
Possible
causes and the
standard values
when normal
Defective injector No. 1

(internal defect)
harness
2
CN1 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Min. 1 Mz

switch still OFF.
CN1 (female) (1)
Resistance
Max. 1 z

CN1 (female) (2)
Resistance
Max. 1 z

switch still OFF.
3

(contact with ground circuit) EGC1 (female) (45) CN1 (female) (1)
Resistance
Min. 1 Mz

EGC1 (female) (53) CN1 (female) (2)
Resistance
Min. 1 Mz

switch still OFF.
4
EGC1 (female)
Resistance
Between (45) (53)
0.4 1.1 z
Min. 1 Mz
Circuit diagram related to injector No. 1
D85EX, PX-15E0
SEN00635-00
40 Troubleshooting
Failure code [CA323] Injector No. 5 system disconnection or short

circuit: Disconnection, short circuit
Action code
Failure code
CALL E03
CA323

Controller's
action
Symptoms that
Output decreases.
appear on
machine
General
information
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

(internal defect)
harness
2
CN5 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Min. 1 Mz

switch still OFF.
CN5 (female) (1)
Resistance
Max. 1 z

CN5 (female) (2)
Resistance
Max. 1 z

switch still OFF.
3

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

switch still OFF.
4
EGC1 (female)
Resistance
Between (46) (60)
0.4 1.1 z
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00

Action code
Failure code
CALL E03
CA324

Controller's
action
Symptoms that
Output decreases.
appear on
machine
General
information
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

(internal defect)
harness
2
CN3 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Min. 1 Mz

switch still OFF.
CN3 (female) (1)
Resistance
Max. 1 z

CN3 (female) (2)
Resistance
Max. 1 z

switch still OFF.
3

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

switch still OFF.
4
EGC1 (female)
Resistance
Between (55) (52)
0.4 1.1 z
Min. 1 Mz
D85EX, PX-15E0
SEN00635-00
40 Troubleshooting

Action code
Failure code
CALL E03
CA325

Controller's
action
Symptoms that
Output decreases.
appear on
machine
General
information
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

(internal defect)
harness
2
CN6 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Min. 1 Mz

switch still OFF.
CN6 (female) (1)
Resistance
Max. 1 z

CN6 (female) (2)
Resistance
Max. 1 z

switch still OFF.
3

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

switch still OFF.
4
EGC1 (female)
Resistance
Between (57) (59)
0.4 1.1 z
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00

Action code
Failure code
CALL E03
CA331

Controller's
action
Symptoms that
Output decreases.
appear on
machine
General
information
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

(internal defect)
harness
2
CN2 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Min. 1 Mz

switch still OFF.
CN2 (female) (1)
Resistance
Max. 1 z

CN2 (female) (2)
Resistance
Max. 1 z

switch still OFF.
3

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

switch still OFF.
4
EGC1 (female)
Resistance
Between (54) (51)
0.4 1.1 z
Min. 1 Mz
D85EX, PX-15E0
SEN00635-00
40 Troubleshooting

Action code
Failure code
CALL E03
CA332

Controller's
action
Symptoms that
Output decreases.
appear on
machine
General
information
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

(internal defect)
harness
2
CN4 (male)
Resistance
Between (1) (2)
0.4 1.1 z
Min. 1 Mz

switch still OFF.
CN4 (female) (1)
Resistance
Max. 1 z

CN4 (female) (2)
Resistance
Max. 1 z

switch still OFF.
3

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

switch still OFF.
4
EGC1 (female)
Resistance
Between (56) (58)
0.4 1.1 z
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Failure code [CA342] Engine controller data matching error: Matching

error
1
Action code
Failure code
CALL E04
CA342
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
Possible
causes and the
standard values
when normal
D85EX, PX-15E0
Causes

SEN00635-00
40 Troubleshooting
Failure code [CA351] Abnormal injector drive circuit: Abnormal circuit 1

Action code
Failure code
CALL E03
CA351
Symptom Abnormal injector drive circuit: Abnormal circuit

Failure content Abnormality has occurred in injector drive circuit.

Controller's
action
Operates with limited output. (Limits common rail pressure.)

Symptoms that
appear on
Output decreases.
machine
General
information
Causes
Possible
causes and the
standard values
when normal
Check the failure codes (codes for injector system trouble) that are
displayed at the same time. If any other codes are displayed, carry
out troubleshooting for those codes.
2 Defective breaker
Since a fuse or breaker of equipped machine side can be suspected

to be defective, directly check them.
(If fuse is blown, or breaker is shut off, it is highly possible that a
defective grounding, etc. has occurred in the circuit.)
harness
3

switch still OFF.
(4) battery (+)
Resistance
Max. 1 z

(2) and ground
Resistance
Max. 1 z

switch still OFF.
4
ResisMin. 1 Mz
between EGC3 (female) (3), (4) battery (+)
tance
10

switch ON.
EGC3
Voltage
Between (3), (4) (1), (2)
20 30V
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Circuit diagram related to controller power source
D85EX, PX-15E0
11
SEN00635-00
40 Troubleshooting
Failure code [CA352] Sensor power source (1) too low: Excessively low
voltage detected
1
Action code
Failure code
CALL E03
CA352
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
action
Common rail pressure sensor functions with limited output. (Limits common rail pressure.)
Symptoms that
appear on
Output decreases.
machine
General
information
Possible
causes and the
standard values
when normal
12
Causes

D85EX, PX-15E0
SEN00635-00
40 Troubleshooting
Failure code [CA386] Sensor power source (1) too high: Excessively
Action code
Failure code
CALL E03
CA386
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
action
Common rail pressure sensor functions with limited output. (Limits common rail pressure.)
Symptoms that
appear on
Output decreases.
machine
General
information
Causes

switch ON.
Possible
causes and the
standard values
when normal
Defective sensor
(internal defect)
harness
3
Disconnect a device
shown on the right.
If the failure code disappears, that device
is internally defective.
Common rail
pressure sensor
PFUEL connector

switch still OFF.
PFUEL (female) (1)
Resistance
Max. 1 z

PFUEL (female) (3)
Resistance
Max. 1 z

switch still OFF.
4

(contact with ground circuit) EGC1 (female) (33) PFUEL (female) (1)
Resistance
Min. 1 Mz

EGC1 (female) (47) PFUEL (female) (3)
Resistance
Min. 1 Mz

switch still OFF.
5
14
Harness short

(33) to PFUEL (female) (1) and wiring harness from EGC1 (female) (47) to PFUEL
(female) (3)
Resistance
Min. 1 Mz

switch ON.
EGC1
Voltage
Between (33) (47)
4.75 5.25 V
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Circuit diagram related to sensor power source 1 (5V)
D85EX, PX-15E0
15
SEN00635-00
40 Troubleshooting
Failure code [CA441] Power source voltage too low: Excessively low
voltage detected
1
Action code
Failure code
CALL E04
CA441
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
Possible
causes and the
standard values
when normal
Causes

Failure code [CA442] Power source voltage too high: Excessively high
voltage detected
1
Action code
Failure code
CALL E04
CA442
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
Possible
causes and the
standard values
when normal
16
Causes

D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Failure code [CA449] Common rail pressure too high (2): Excessively
high pressure trouble occurred
1
Action code
Failure code
CALL E03
CA449
Symptom Common rail pressure high trouble (2): Excessively high pressure
of failure trouble occurred (Engine controller system)
Failure content Excessively high pressure (level 2) has been detected with common rail pressure sensor circuit.
Controller's
action

Symptoms that
appear on
Output decreases.
machine
General
information
Possible
causes and the
standard values
when normal
D85EX, PX-15E0
Causes

17
SEN00635-00
40 Troubleshooting
Failure code [CA451] Common rail pressure sensor too high:

Action code
Failure code
CALL E03
CA451
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
action
Operates with limited output.(Limits common rail pressure.)

Symptoms that
appear on
Output decreases.
machine
General
information
The signal voltage of the common rail pressure sensor can be checked with the monitoring function.
(Code: 36401 Common rail pressure sensor voltage)
Causes
1
source circuit

If failure code [CA352] or [CA386] is displayed, carry out troubleshooting for it first.
PFUEL
Defective common rail

2 pressure sensor
(internal defect)
Possible
causes and the
standard values
when normal
Voltage
Between (1) (3)
Power source
4.75 5.25 V
Between (2) (3)
Signal
0.25 4.6 V
switch still OFF.
harness
3

PFUEL (female) (1)
Resistance
Max. 1 z

PFUEL (female) (2)
Resistance
Max. 1 z

PFUEL (female) (3)
Resistance
Max. 1 z

switch still OFF.
18

Defective harness grounding EGC1 (female) (33) PFUEL (female) (1)
4
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Causes

switch still OFF.
5
Possible
causes and the
standard values
when normal
Harness short

(female) (2)
Resistance
Min. 1 Mz

(female) (3)
Resistance
Min. 1 Mz

(female) (3)
Resistance
Min. 1 Mz

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
SEN00635-00
40 Troubleshooting
Failure code [CA452] Common rail pressure sensor too low:

Action code
Failure code
CALL E03
CA452
Symptom Common rail pressure sensor too low: Excessively low voltage
Failure content Excessively low voltage has occurred in the common rail pressure sensor circuit.
Controller's
action

Symptoms that
appear on
Output decreases.
machine
General
information
The signal voltage of the common rail pressure sensor can be checked with the monitoring function.
(Code: 36401 Common rail pressure sensor voltage)
Possible
causes and the
standard values
when normal
Causes

Failure code [CA553] Common rail pressure too high (1): Excessively
high pressure detected
1
Action code
Failure code
E02
CA553
Symptom Common rail pressure high trouble (1): high pressure trouble
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
appear on
Output decreases.
machine
General
information
Common rail pressure can be checked with the monitoring function.

(Code: 36400 Common rail pressure)
Causes
Possible
causes and the
standard values
when normal
20
2 Improper fuel has been used.
Since the use of improper fuel can be suspected, check the fuel.
(Viscosity is too high)
Since an electrical defect of common rail pressure sensor is susDefective electrical system of
pected, carry out troubleshooting for the following code.
common rail pressure sensor
[CA451]
Defective mechanical system

Since a mechanical defect of common rail pressure sensor is sus4 of common rail pressure
pected, directly check the sensor.
sensor
5 Defective overflow valve
Since a damage of spring, wear of seat or sticking of ball is suspected, directly check them.
6 Clogged overflow piping
Since an overflow piping is suspected to be clogged, directly check it.
7 Defective pressure limiter
Since a mechanical defect of pressure limiter is suspected, directly

check the limiter.
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Failure code [CA554] In-range error in common rail pressure sensor:

In-range error
1
Action code
Failure code
CALL E03
CA554
Symptom In-range error in common rail pressure sensor: In-range error

of failure occurred (Engine controller system)
Failure content In-range error has occurred in common rail pressure sensor circuit.
Controller's
action
Operates with limited output.(Limits common rail pressure.)

Symptoms that
appear on
Output decreases.
machine
General
information
Possible
causes and the
standard values
when normal
D85EX, PX-15E0
Causes

21
SEN00635-00
40 Troubleshooting
Failure code [CA559] Loss of pressure feed from supply pump (1): Loss
of pressure feed detected
1
Action code
Failure code
E02
CA559
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
action
Limits common rail pressure.
Symptoms that
Output decreases.
appear on
machine
General
information
Causes

2 Improper fuel has been used. Since the use of improper fuel is suspected, directly check the fuel.
Defective low pressure

circuit device
4 Clogged filter or strainer
Possible
causes and the
standard values
when normal
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.
Pressure in fuel low pressure
circuit
(At high idle or under the load
equivalent to rating (stalling))
Min. 0.15 MPa

{Min. 1.5 kg/cm2}
a See Note 2 for the contents of diagnosis.
Since an electrical defect of supply pump PCV is suspected, carry

Defective electrical system of
out troubleshooting for the following codes.
supply pump PCV
[CA271], [CA272], [CA273], and [CA274]
Defective common rail

pressure sensor
Since a defect of common rail pressure sensor is suspected, check

for a damage in harnesses.
a As for testing an amount of pressure limiter leak, see testing and
adjusting Testing fuel return and leak amount.
7 Defective pressure limiter

Pressure limiter leak amount
Max. 10 cc/min.
[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.
8 Defective injector
9 Defective supply pump
Speed under the conditions

which are equivalent to rated
operation (stalling)
Injector return (spill) limit amount
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

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 nopressure feed.
22
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
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
SEN00635-00
40 Troubleshooting
Check sheet for no-pressure feed

Model
Model and serial No.
Operation No.
#
Date inspected
Engine
Engine serial No.
Worker's name
A. Visual inspections
1
Fuel leakage to outside
Clogged fuel tank breather
Pass Fail
Pass Fail
B. Inspections with monitor panel (failure history, monitoring, and reduced cylinder mode operation)
3
Service meter
Checking failure codes
Checking monitoring information

Code
*1
Display item
Engine speed
Unit
Standard value
(reference value)
Low idle
rpm
750(+50/0)
High idle
rpm
2,100 50
Equivalent to rating
rpm
1,900
Condition for inspection
Measured value
Pass Fail
Low idle
High idle
100
mm3
Command for common

rail pressure
MPa
*5
Fuel pressure in
common rail
MPa
*6
Command for
fuel injection timing
*2
Throttle speed
*3
Command for fuel injection rate
*4
Low idle
CA
High idle
CA
CA
kPa
*7
Boost pressure
*8
Coolant temperature
(high temperature)
Low idle
*9
Coolant temperature
(low temperature)
Low idle
*10
Fuel temperature
Low idle
Unit
Standard value
(reference value)
Checking reduced cylinder mode operation (engine speed)

Function
5
*11
Cut-out cylinder
24
Measured value
Pass Fail
Cylinder No. 1
Low idle
rpm
Cylinder No. 2
Low idle
rpm
Cylinder No. 3
Low idle
rpm
Cylinder No. 4
Low idle
rpm
Cylinder No. 5
Low idle
rpm
Cylinder No. 6
Low idle
rpm
Unit
Standard value
(reference value)
At high idle or under the load equivalent to rating (stalling)
MPa
{kg/cm2}
Min. 0.15
{Min. 1.5}
C. Inspection of pressure in fuel circuit

6
Pressure in fuel low pressure circuit
Measured value
Pass Fail
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
D. Inspection of strainer and filter

7
Visual inspection of strainer
Visual inspection of gauze filter
Visual inspection of fuel filter
Pass Fail
10 Visual inspection of bypass valve
E. Inspection of fuel leak and return

amount
11
Pressure limiter
leak amount
12 Injector return amount
Unit
Standard value
(reference value)
Under the load equivalent to rating

(stalling)
cc/min
Max 10
Equivalent to rating: 1,600 rpm
cc/min
960
cc/min
1,020
cc/min
1,080
cc/min
1,140
cc/min
1,200
Measured value
Pass Fail
Rotation speed:
Return amount:
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
SEN00635-00
40 Troubleshooting
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal

signal
Action code
Failure code
CALL E03
CA689
Symptom Abnormal engine Ne speed sensor: Abnormal signal

Failure content Abnormal signal of the engine Ne speed sensor has been detected.
Controller's
action
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
Causes
1
source circuit

switch still OFF.
harness
2

NE (female) (1)
Resistance
Max. 1 z

NE (female) (2)
Resistance
Max. 1 z

NE (female) (3)
Resistance
Max. 1 z

switch still OFF.
Defective harness grounding EGC1 (female) (16) NE (female) (1)
3
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Possible causes
and the
standard values
when normal

switch still OFF.
Harness short

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
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.
Defective engine Ne speed
sensor
Engine Ne speed sensor can be suspected to be defective if no

problem is found in causes 1 5 (since this is an internal defect, it
cannot be diagnosed).

diagnosed).
26
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Circuit diagram related to engine Ne speed sensor
D85EX, PX-15E0
27
SEN00635-00
40 Troubleshooting
Failure code [CA731] Abnormal engine Bkup speed sensor phase:

Abnormal phase
Action code
Failure code
CALL E03
CA731
Symptom Abnormal engine Bkup speed sensor phase: Abnormal phase

Failure content Abnormal phase has been detected in the engine Bkup sensor circuit.
Controller's
action
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
Causes
Possible
causes and the
standard values
when normal
28
Defective engine Ne speed

sensor circuit
Since a defect of engine Ne speed sensor can be suspected, carry

out troubleshooting for the following code.
[CA689]
Defective engine Bkup

speed sensor system
Since a defect of engine Bkup speed sensor can be suspected,

carry out troubleshooting for the following code.
[CA778]
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Failure code [CA757] Loss of all engine controller data: Loss of all data1
Action code
Failure code
CALL E04
CA757
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
Possible
causes and the
standard values
when normal
D85EX, PX-15E0
Causes

29
SEN00635-00
40 Troubleshooting
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal

Bkup signal
1
Action code
Failure code
CALL E03
CA778
Symptom Abnormal engine Bkup speed sensor: Abnormal Bkup signal

Failure content Abnormal engine Bkup speed sensor signal has been detected.
Controller's
action
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
Causes
1
source circuit

switch still OFF.
harness
2

G (female) (1)
Resistance
Max. 1 z

G (female) (2)
Resistance
Max. 1 z

G (female) (3)
Resistance
Max. 1 z

switch still OFF.
Defective harness grounding EGC1 (female) (37) G (female) (1)
3
EGC1 (female) (47) G (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

EGC1 (female) (26) G (female) (3)
Resistance
Min. 1 Mz
Possible
causes and the
standard values
when normal

switch still OFF.
Harness short

(37) to G (female) (1) and wiring harness
from EGC1 (female) (47) to G (female) (2)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
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 susdetection
pected, directly check it.
Defective engine Bkup
speed sensor
Engine Bkup speed sensor can be suspected to be defective if no

problem is found in causes 1 5 (since this is an internal defect, it
cannot be diagnosed).

diagnosed).
30
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Circuit diagram related to engine Bkup speed sensor
D85EX, PX-15E0
31
SEN00635-00
40 Troubleshooting
Failure code [CA1228] Abnormal EGR valve servo (1): EGR out of
control
Action code
Failure code
E02
CA1228
Symptom Abnormal EGR valve servo (1): EGR out of control

Failure content An abnormality has occurred in EGR valve servo (level 1).
Controller's
action
Executes open loop control.

Symptoms that
appear on
machine
General
information
Causes

Check the failure codes that are displayed at the same time.
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.
Defective engine hydraulic

2
system (main circuit)
Possible
causes and the
standard values
when normal
32
Engine
Engine oil pressure
Low idle
0.03 MPa {0.3 kg/cm2}
High idle
0.18 MPa {1.8 kg/cm2}
If engine oil pressure is out of range, carry out troubleshooting for

mechanical system (S-12 Oil pressure drops).
3
Defective oil pump for EGR

valve
Since the oil pump relief valve for the EGR valve circuit can be suspected to be defective, directly check it.
Defective hydraulic feed

piping for EGR valve
Since the hydraulic feed piping for the EGR valve circuit can be suspected to be defective, directly check it.
Defective hydraulic return

piping for EGR valve
Since the hydraulic return piping for the EGR valve circuit can be
suspected to be defective, directly check it.
6 Defective EGR valve
Since a mechanical defect of EGR valve can be suspected, directly

check it.

diagnosed).
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Failure code [CA1625] Abnormal EGR valve servo (2): EGR out of
control
Action code
Failure code
CALL E03
CA1625
Symptom Abnormal EGR valve servo (2): EGR out of control

Failure content An abnormality has occurred in EGR valve servo (level 2).
Controller's
action
Operates by limiting output.

Closes the EGR valve.
Symptoms that
appear on
Output decreases.
machine
General
information
Possible
causes and the
standard values
when normal
D85EX, PX-15E0
Causes

33
SEN00635-00
40 Troubleshooting
Failure code [CA1633] Abnormal KOMNET: Abnormal communication 1

Action code
Failure code
CALL E03
CA1633
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.
Controller's
action
Operate in a default mode.

When the cause of the failure has been eliminated, it returns to normal.
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
Causes

switch still OFF.
harness
1
Wiring harness between S04 (female) (1) (2)

EGC2 (female) (46), S04 (female) (1) (2)
PTC2 (female) (32), S04 (female) (1) (2)
CA2 (female) (A) and S04 (female) (1) (2)
CA1 (female) (A)
Resistance
Max. 1 z

CA2 (female) (B) and S04 (female) (3) (4)
CA1 (female) (B)
Resistance
Max. 1 z

switch still OFF.
Possible
causes and the
standard values
when normal
Between ground and wiring harnesses

between S04 (female) (1) (2) EGC2
(female) (46), S04 (female) (1) (2) PTC2
(female) (32), S04 (female) (1) (2) CA2
(female) (A), S04 (female) (1) (2) CA1
Defective harness grounding (female) (A) and S04 (female) (1) (2) SRV
2
(contact with ground circuit) (male) (3)
Resistance
Min. 1 Mz

(female) (B), S04 (female) (3) (4) CA1
(female) (B) and S04 (female) (3) (4) SRV
(male) (10)
Resistance
Min. 1 Mz

switch ON.
3
34

(female) (A), S04 (female) (1) (2) CA1
(female) (A) and S04 (female) (1) (2) SRV
(male) (3)
Voltage
Max.
5.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Causes
3
Possible
causes and the
standard values
when normal


(female) (B) and S04 (female) (3) (4) SRV
(male) (10)
Voltage
Max.
5.5 V

Defective CAN terminal
switch still OFF.
resistance
4
(internal short circuit and disCA1 (male) and CA2 (male)
Resistance
connection)
Between (A) (B)
120 12 z

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
SEN00635-00
40 Troubleshooting
1
Action code
Failure code
CALL E03
CA2185
Decelerator pedal sensor power source too high: Excessively high

Symptom
voltage detected
of failure
(Engine controller system)
Failure content
Excessively high voltage (Min. 5.25 V) is detected in the decelerator pedal sensor power source circuit.
Controller's
action
with 100% value.
Symptoms that
appear on
machine
General
information
Causes

switch still OFF.
Harness short
Possible
causes and the
standard values
when normal

EGC2 (female) (with DCL disconnected)
Resistance
Min. 1 Mz

from EGC2 (female) (22) to DCL (female) (A)
Resistance
Min. 1 Mz

connector

insulation

diagnosed.)
36
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
1
Action code
Failure code
CALL E03
CA2186
Decelerator pedal sensor power source too low: Excessively low

Symptom
voltage detected
of failure
Failure content Excessively low voltage is detected in the decelerator pedal sensor (5V) power source circuit.
Controller's
action
with 100% value.
Symptoms that
appear on
machine
General
information
Causes

switch still OFF.
1
ResisMin. 1 Mz
EGC2 (female) (22) DCL (female) (A)
tance
Possible
causes and the
standard values
when normal
Harness short

switch still OFF.
CE02 (female) (with DCL also disconnected)
Resistance
Min. 1 Mz

connector

insulation

diagnosed.)
D85EX, PX-15E0
37
SEN00635-00
40 Troubleshooting
Action code
Failure code
CALL E03
CA2249
Loss of pressure feed from supply pump (2): Loss of pressure feed
Symptom
detected
of failure
Failure content Loss of pressure feed (2) occurred in the common rail circuit.
Controller's
action
Operates with limited output.

Symptoms that Engine is hard to start.

appear on
Exhaust gas color becomes black.
machine
Output decreases.
General
information
Possible
causes and the
standard values
when normal
38
Common rail pressure can be checked with the monitoring function.

(Code: 36400 Common rail pressure)
Causes
1

D85EX, PX-15E0
SEN00635-00
40 Troubleshooting
Failure code [CA2271] EGR valve lift sensor too high: Excessively high
voltage detected
1
Action code
Failure code
CALL E03
CA2271
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
appear on
Output decreases.
machine
General
information
Causes
1

source circuit

SEGR
Voltage
Defective EGR valve lift senBetween (1) (2)
Power source
4.75 5.25 V
2 sor
(internal defect)
Possible
causes and the
standard values
when normal

switch still OFF.
harness
3

SEGR (female) (1)
Resistance
Max. 1 z

SEGR (female) (2)
Resistance
Max. 1 z

SEGR (female) (3) (4)
Resistance
Max. 1 z

switch still OFF.
40

Defective harness grounding EGC1 (female) (37) SEGR (female) (1)
4
EGC1 (female) (47) SEGR (female) (2)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

EGC1 (female) (19) SEGR (female) (3) (4)
Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Causes

switch still OFF.
Possible
causes and the
standard values
when normal
Harness short

(37) to SEGR (female) (1) and wiring harness from EGC1 (female) (47) to SEGR
(female) (2)
Resistance
Min. 1 Mz

(female) (3) (4)
Resistance
Min. 1 Mz

(female) (3) (4)
Resistance
Min. 1 Mz

EGC1
Voltage
Between (37) (47)
4.75 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
D85EX, PX-15E0
41
SEN00635-00
40 Troubleshooting
Failure code [CA2272] EGR valve lift sensor too low: Excessively low
voltage detected
1
Action code
Failure code
CALL E03
CA2272
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
appear on
Output decreases.
machine
General
information
Possible
causes and the
standard values
when normal
42
Causes

D85EX, PX-15E0
SEN00635-00
40 Troubleshooting
Failure code [CA2351] EGR valve solenoid drive short circuit: Short
circuit
Action code
Failure code
CALL E03
CA2351
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
appear on
Output decreases.
machine
General
information
Causes
Defective EGR valve sole1 noid
(internal defect)
harness
2
Possible
causes and the
standard values
when normal

switch still OFF.
EGR (male)
Resistance
Between (1) (2)
10 21 z

switch still OFF.
EGR (female) (1)
Resistance
Max. 1 z

EGR (female) (2)
Resistance
Max. 1 z

switch still OFF.
3
Defective harness grounding Between ground and wiring harness EGC1

(contact with ground circuit) (female) (22) EGR (female) (1)
Resistance
Min. 1 Mz
Between ground and wiring harness EGC1

(female) (11) EGR (female) (2)
Resistance
Min. 1 Mz

switch ON.
4

(a contact with 24V circuit)
44

Voltage
Max. 1V

Voltage
Max. 1V

switch still OFF.
EGC1 (female)
Resistance
Between (22) (11)
10 21 z
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Circuit diagram related to EGR valve solenoid & lift sensor
D85EX, PX-15E0
45
SEN00635-00
40 Troubleshooting
Failure code [CA2352] EGR valve solenoid drive disconnection:

Disconnection
Action code
Failure code
CALL E03
CA2352
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
appear on
Output decreases.
machine
General
information
Possible
causes and the
standard values
when normal
46
Causes

D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Failure code [CA2555] Intake air heater relay disconnection:

Disconnection
Action code
Failure code
E01
CA2555
Symptom Intake air heater relay disconnection: Disconnection

Failure content Disconnection has occurred in intake air heater relay circuit.
Controller's
action
Takes no particular action.
Symptoms that
appear on
Startability of engine deteriorates in low temperature.
machine
General
information
Possible
causes and the
standard values
when normal
D85EX, PX-15E0
Causes

47
SEN00635-00
40 Troubleshooting
Failure code [CA2556] Intake air heater relay short circuit: Short circuit1
Action code
Failure code
E01
CA2556
Symptom Intake air heater relay short circuit: Short circuit

Failure content Short circuit has occurred in intake air heater relay circuit.
Controller's
action
Takes no particular action.
Symptoms that
appear on
Startability of engine deteriorates in low temperature.
machine
General
information
Causes
Defective intake air heater
1 relay
(internal defect)
Possible
causes and the
standard values
when normal
harness
2

switch still OFF.
RHR (male)
Resistance
Between (1) (2)
200 400 z

switch still OFF.
RHR (female) (1)
Resistance
Max. 1 z
Wiring harness between RHR (female) (2)

and ground
Resistance
Max. 1 z

switch still OFF.
3
(contact with ground circuit) Between ground and wiring harness EGC2
ResisMin. 1 Mz
(female) (40) RHR (female) (1)
tance
switch ON.
48
EGC2
Heater relay
Voltage
Between (40) and

ground
At working condition
20 30V
At stopping condition
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00635-00
Circuit diagram related to intake air heater relay
D85EX, PX-15E0
49
SEN00635-00

50
SEN00636-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
40 Troubleshooting

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
SEN00636-00
40 Troubleshooting
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
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
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
SEN00636-00
40 Troubleshooting
Failure code [D110KA] Battery relay: Disconnection
Action code
Failure code
D110KA
Symptom Battery relay: Disconnection

Failure content Current does not flow during output to battery relay circuit.
Controller's
action
Stops output to battery relay circuit.
Symptoms that
appear on
Problem may occur in data writing to ROM (non volatile memory) of each controller.
machine
General
information
Output state (voltage) to battery relay can be checked in monitoring mode.

(Code 60600: Battery relay drive voltage)
Causes
Possible
causes and the
standard values
when normal
Defective battery relay

harness
2

switch still OFF.
Battery relay
Continuity
Between SW terminal and

ground BRE terminal
Continue

switch still OFF.
Wiring harnesses between PTC3 (female)
(4) battery relay SW terminal
Resistance
Max. 1 z
Wiring harnesses between ground BRE terminal and ground
Resistance
Max. 1 z

switch ON.
3



between PTC3 (female) (4) battery relay
SW terminal and DS1 (female) (8) RSD
(female) (1)
Voltage
Max. 1V
Since this is an internal defect, it cannot be diagnosed.
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to battery relay
D85EX, PX-15E0
SEN00636-00
40 Troubleshooting
Failure code [D110KB] Battery relay: Short circuit

Action code
Failure code
D110KB
Symptom Battery relay: Short circuit

Failure content Abnormal current flowed during the output to battery relay circuit.
Controller's
action
Stop output to battery relay circuit.
Symptoms that
appear on
Problem may occur in data writing to ROM (non volatile memory) of each controller.
machine
General
information
Output state (voltage) to battery relay can be checked in monitoring mode.

(Code 60600: Battery relay drive voltage)
Duplication of failure code: turn starting switch from ON o OFF.
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

harness
2
Battery relay
Continuity
Between SW terminal and BRE

terminal
Continue
Between SW terminal and

ground
Min. 1 Mz

switch still OFF.
between PTC3 (female) (4) battery relay
SW terminal and DS1 (female) (8) RSD
(female) (1)
Resistance
Min. 1 Mz
Defective diode
(Internal short circuit)
See Inspection procedure of diode (Testing and adjusting).

D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to battery relay
D85EX, PX-15E0
SEN00636-00
40 Troubleshooting
Failure code [D130KA] Neutral safety relay: Disconnection

Action code
Failure code
E02
D130KA
Symptom Neutral safety relay: Disconnection

Failure content The voltage of the neutral safety relay circuit is inconsistent with the output state of the controller.
Controller's
action
Flashes warning lamp and turns on alarm buzzer

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
General
information
Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Duplication of failure code: Turn starting switch ON + operate parking brake lever (to free or lock position)
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.
Causes

switch still OFF.
Defective neutral safety relay
1
NSF (male)
Resistance
200 400 z
Between (1) (2)

harness
2
Possible
causes and the
standard values
when normal

switch still OFF.
NSF (female) (2)
Resistance
Max. 1 z
Wiring harness between NSF (female) (1)

starting switch ACC (270)
Resistance
Max. 1 z

switch still OFF.
3
ResisMin. 1 Mz
PTC2 (female) (8) NSF (female) (2)
tance
4

switch ON, parking brake lever lock position.
PCT2 (female) (8) NSF (female) (2)
Voltage
Max. 1V

switch ON.
5

PTC2
Parking lever
Voltage
Between (8) and

ground
Free position
20 30 V
Lock position
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to neutral safety relay
D85EX, PX-15E0
SEN00636-00
40 Troubleshooting
Failure code [D130KB] Neutral safety relay: Short circuit

Action code
Failure code
E02
D130KB
Symptom Neutral safety relay: Short circuit

Failure content Abnormal current flowed when neutral safety relay circuit is output.
Controller's
action

Stops ground output to neutral safety relay circuit.
Symptoms that
appear on
Engine does not start.
machine
General
information
Output state (voltage) to neutral safety relay can be checked in monitoring mode.
(Code 50900: Neutral safety relay drive voltage)
Duplication of failure code: Turn starting switch ON + operate parking brake lever (to lock position)
a This failure code identifies a detected abnormality in primary side (coil side) of neutral safety relay,
Causes

switch still OFF.
Defective neutral safety relay
1
NSF (male)
Resistance
200 400 z
Between (1) (2)

Possible
causes and the
standard values
when normal

switch still OFF.
2
ResisMin. 1 Mz
tance
PTC2 (female) (8) NSF (female) (2)
switch ON.
3
10

PTC2
Parking lever
Voltage
Between (8) and

ground
Free position
20 30 V
Lock position
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to neutral safety relay
D85EX, PX-15E0
11
SEN00636-00
40 Troubleshooting
Failure code [D161KA] Back-up alarm relay: Disconnection

Action code
Failure code
E01
D161KA
Symptom Backup alarm relay: Disconnection

Failure content The voltage of the backup alarm relay circuit is inconsistent with the output state of the controller.
Controller's
action
Stops ground output to backup alarm relay circuit.
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
General
information
Output state (voltage) to backup alarm relay can be checked in monitoring mode.
(Code 70400: Backup alarm relay drive voltage)
Duplication of failure code: Turn starting switch ON + shift steering, directional and gear shift lever to
neutral
a This failure code identifies a detected abnormality in primary side (coil side) of backup alarm relay,
Causes
1 Defective fuse FS2-3

If fuse is blown, it is highly possible that a defective harness grounding, etc. has occurred in the circuit.

switch still OFF.
Defective backup alarm relay
2
BKA (male)
Resistance
200 400 z
Between (1) (2)

harness
3
Possible
causes and the
standard values
when normal

switch still OFF.
BKA (female) (2)
Resistance
Max. 1 z
Wiring harnesses between BKA (female) (1)

FS2-3 outlet
Resistance
Max. 1 z

switch still OFF.
4

(contact with ground circuit) PTC2 (female) (18) BKA (female) (2)
Between ground and wiring harnesses of
BKA (female) (1) FS2-3 outlet

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch ON, PCCS lever in reverse position.
PTC2 (female) (18) BKA (female) (2)
Voltage
Max. 1V

switch ON.
6
12

PTC2
PCCS lever
Voltage
Between (18) and

ground
At neutral
20 30 V
At reverse
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to back-up alarm relay
D85EX, PX-15E0
13
SEN00636-00
40 Troubleshooting
Failure code [D161KB] Back-up alarm relay: Short circuit

Action code
Failure code
E01
D161KB
Symptom Backup alarm relay: Short circuit

Failure content Abnormal current flowed when backup alarm relay circuit is output.
Controller's
action
Stops ground output to backup alarm relay circuit.
Symptoms that
appear on
Backup alarm does not turn on.
machine
General
information
Output state (voltage) to backup alarm relay can be checked in monitoring mode.
(Code 70400: Backup alarm relay drive voltage)
Duplication of failure code: Turn starting switch ON + Shift steering, directional and gear shift lever
(to reverse)
a This failure code identifies a detected abnormality in primary side (coil side) of backup alarm relay,
Causes

switch still OFF.
Defective backup alarm relay
1
BKA (male)
Resistance
200 400 z
Between (1) (2)

Possible
causes and the
standard values
when normal

switch still OFF.
2
ResisMin. 1 Mz
PTC2 (female) (18) BKA (female) (2)
tance
switch ON.
3
14

PTC2
PCCS lever
Voltage
Between (18) and

ground
At neutral
20 30 V
At reverse
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to back-up alarm relay
D85EX, PX-15E0
15
SEN00636-00
40 Troubleshooting
Failure code [D190KA] Engine controller ACC signal cutout relay:

Disconnection
Action code
Failure code
D190KA
Failure content
Controller's
action
Symptom Engine controller ACC signal cutout relay: Disconnection

The voltage of the engine controller ACC signal cutout relay circuit is not inconsistent with the output
state of the controller.
No particular action
Symptoms that
appear on
Engine cannot be stopped (option function) by steering and transmission controller.
machine
General
information
a This failure code identifies a detected abnormality in primary side (coil side) of engine controller ACC
signal cutout relay, but an abnormality in secondary side (contact side) can not be detected.
Causes
1 ACC signal cutout relay
harness
2
Possible
causes and the
standard values
when normal

switch still OFF.
ACT (male)
Resistance
Between (1) (2)
200 400 z

switch still OFF.
ACT (female) (2)
Resistance
Max. 1 z
Wiring harness between ACT (female) (1)

starting switch ACC (270)
Resistance
Max. 1 z

switch still OFF.
Defective harness grounding between PTC2 (female) (19) ACT (female)
3
(contact with ground circuit) (2)
between ACT (female) (1) starting switch
ACC (270)

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch ON, when the stop signal is input.
between PTC2 (female) (19) ACT (female)
(2)
Voltage
Max. 1 V

switch ON.
5
16

PTC2
Stop signal
Voltage
Between (19) and

ground
Input
Max. 1 V
No input
20 30 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to engine controller ACC signal cutout relay
D85EX, PX-15E0
17
SEN00636-00
40 Troubleshooting
Failure code [D190KB] Engine controller ACC signal cutout relay: Short
circuit
1
Action code
Failure code
D190KB
Symptom Engine controller ACC signal cutout relay: Short circuit

Failure content Abnormal current flowed in the engine controller ACC signal cutout relay circuit.
Controller's
action
Stops the ground output of the engine controller ACC signal cutout relay circuit.
Symptoms that
appear on
Engine cannot be stopped (option function) by steering and transmission controller.
machine
General
information
a This failure code identifies a detected abnormality in primary side (coil side) of engine controller ACC
signal cutout relay, but an abnormality in secondary side (contact side) can not be detected.
Causes
1 ACC signal cutout relay
Possible
causes and the
standard values
when normal

switch still OFF.
ACT (male)
Resistance
Between (1) (2)
200 400 z

switch still OFF.

between PTC2 (female) (19) ACT (female)
(2)
Resistance
Min. 1 Mz

switch ON.
3
18

PTC2
Stop signal
Voltage
Between (19) and

ground
Input
Max. 1V
No input
20 30 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to engine controller ACC signal cutout relay
D85EX, PX-15E0
19
SEN00636-00
40 Troubleshooting
Failure code [D811KR] KOMTRAX controller CAN communication:

Action code
Failure code
D811KR
Failure content
Controller's
action
KOMTRAX controller CAN communication: Defective communicaSymptom

tion
of failure
(Steering and transmission controller system)
Steering and transmission controller cannot identify KOMTRAX controller with CAN communication
circuit.
Symptoms that
appear on
KOMTRAX LED information (Code: 20300) cannot be correctly displayed in monitoring mode.
machine
General
information
Duplication of failure code: Turn starting switch ON and then select Code: 20300 in monitoring mode.
Causes

switch still OFF.
harness
1
Possible
causes and the
standard values
when normal
20

(2)-PT2 (female) (32), S04 (female) (1) (2)
EGC2 (female) (46) and S04 (female) (1) (2)
CA1 (female) (A) and among S04 (female)
(1) (2) CA2 (female) (A) KOM1 (female)
(8) and between S04 (female) (1) (2) SRV
(male) (3)
Resistance
Max. 1 z
Wiring harnesses between S04 (female) (3)

(4) PTC2 (female) (22), S04 (female) (3)
(4) EGC2 (female) (47), S04 (female) (3)
(4) CA1 (female) (B), S04 (female) (3) (4)
CA2 (female) (B), S04 (female) (3) (4)
KOM1 (female) (7) and S04 (female) (3) (4)
SRV (male) (10)
Resistance
Max. 1 z

switch still OFF.
between S04 (female) (1) (2) PTC2
(female) (32), S04 (female) (1) (2) EGC2
(female) (46) and S04 (female) (1) (2) CA1
(female) (A) and among S04 (female) (1) (2)
CA2 (female) (A) KOM1 (female) (8) and
Defective harness grounding between S04 (female) (1) (2) SRV (male)
2
Resistance
Min. 1 Mz

(female) (B), S04 (female) (3) (4) KOM1
(female) (7) and S04 (female) (3) (4) SRV
(male) (10)
Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Causes

switch ON.

Possible
causes and the
standard values
when normal

resistance
Defective KOMTRAX con5 troller or defective steering

D85EX, PX-15E0

(female) (46) and S04 (female) (1) (2) CA1
(female) (A) and among S04 (female) (1) (2)
CA2 (female) (A) KOM1 (female) (8) and
between S04 (female) (1) (2) SRV (male)
(3)
Voltage
Max. 1V

(male) (10)
Voltage
Max. 1V

switch still OFF.
CA1 (male), CA2 (male)
Resistance
Between (A)-(B)
100 140 z
When Causes 1 to 4 are not applicable, it can be suspected that

KOMTRAX controller or steering and transmission controller is
defective. (Since this is an internal defect, it cannot be diagnosed.)
21
SEN00636-00
40 Troubleshooting
Circuit diagram related CAN communication
22
D85EX, PX-15E0
SEN00636-00
40 Troubleshooting
Failure code [DAFRKR] Monitor panel CAN communication: Defective

communication
1
Action code
Failure code
CALL E03
DAFRKR
Symptom Monitor panel CAN communication: Defective communication

of failure (Monitor panel circuit)
Failure content Monitor panel cannot identify steering and transmission controller with CAN communication circuit.
Controller's
action

Symptoms that System may not operate normally.

appear on
machine
General
information
Causes

switch still OFF.
harness
1
Possible
causes and the
standard values
when normal

PT2 (female) (32), S04 (female) (1) (2)
CA1 (female) (A), S04 (female) (1) (2) CA2
(female) (A), S04 (female) (1) (2) KOM1
(male) (3)
Resistance
Max. 1 z

SRV (male) (10)
Resistance
Max. 1 z

switch still OFF.
between S04 (female) (1) (2) PT2 (female)
(32), S04 (female) (1) (2) EGC2 (female)
(46), S04 (female) (1) (2) CA1 (female) (A),
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)
(male) (10)
24
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Causes

switch ON.

Possible
causes and the
standard values
when norma

resistance

Voltage
Max. 1V

(male) (10)
Voltage
Max. 1V

switch still OFF.
Resistance
Between (A) (B)
100 140 z
Defective monitor panel or

5 defective steering and trans- monitor panel or steering and transmission controller is defective.
mission controller
D85EX, PX-15E0
25
SEN00636-00
40 Troubleshooting
26
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Failure codes [DAQ0KT] and [DB30KT] Steering and transmission

controller: Abnormal controller memory information
Action code
Failure code
E01
DAQ0KT
DB30KT
Steering and transmission controller: Abnormal controller memory

Symptom
information
of failure
Failure content Information of ROM (non volatile memory) of steering and transmission controller is not normal.
Controller's
action
Defaults the memory information value.
Symptoms that
appear on
Gear shift feeling of transmission may become worse.
machine
General
information
Possible
causes and the
standard values
when normal
Both of DAQ0KT and DB30KT are displayed.

Causes

Defective steering and trans- Adjust once in adjustment mode (Code 0002).
1
mission controller
(It is no problem to keep using controller unless any visible trouble
symptom appears on machine.)
D85EX, PX-15E0
27
SEN00636-00
40 Troubleshooting
Failure code [DAQ1KK] [DB31KK] Main power source of steering and

transmission controller: Power source voltage drop and input
1
Action code
Failure code
CALL E04
DAQ1KK
DB31KK
Main power supply of steering and transmission controller: Power

Symptom
source voltage drop and input
of failure
Failure content Power source voltage of steering and transmission controller is below 17V.
Controller's
action

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.
General
information
Both of DAQ1KK and DB31KK are displayed.

Battery charge state (voltage) can be checked in monitoring mode.
(Code 03200: Battery voltage)
Causes
2
Defective circuit breaker

CB30

If fuse FS1-5 is blown, it is highly possible that a defective grounding, etc. has occurred in the circuit.
When the circuit breaker is cut off, it is highly possible that a defective harness grounding has occurred in the circuit.
switch still OFF.
Possible
causes and the
standard values
when normal
harness
3

(11) FS1-5
Resistance
Max. 1 z
Wiring harness between FS1-5 battery

relay BRB terminal
Resistance
Max. 1 z

(31) (32) (33) and ground GND02
Resistance
Max. 1 z

switch still OFF.
4
Defective harness grounding Between ground and wiring harness

(contact with ground circuit) between PTC3 (female) (1) (11) FS1-5
between FS1-5 battery relay BRB terminal
28
Defective steering and transmission controller
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch ON.
PTC3
Voltage
Between (1) (11) (21) (31) (32)

(33)
20 30V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to steering and transmission power source
D85EX, PX-15E0
29
SEN00636-00
40 Troubleshooting
Failure code [DAQ2KK] [DB32KK] Load power source of steering and

1
Action code
Failure code
CALL E04
DAQ2KK
DB32KK
Failure content
Controller's
action
Load power supply of steering and transmission controller: Power

Symptom
source voltage drop and input
of failure
Power source voltage of load (relay, solenoid, etc.) on steering and transmission controller is below
17V.
Symptoms that Relay and solenoid may not be driven and therefore system may not operate properly.
appear on
machine
General
information

Battery charge state (voltage) can be checked in monitoring mode.
(Code 03200: Battery voltage)
Causes
2

CB105

If fuse FS2-2 is blown, it is highly possible that a defective grounding, etc. has occurred in the circuit.
When the circuit breaker is cut off, it is highly possible that a defective harness grounding has occurred in the circuit.
switch still OFF.
Possible
causes and the
standard values
when normal
harness
3
Resistance
Max. 1 z
Wiring harness between FS2-2 battery

relay BRC terminal
Resistance
Max. 1 z

(31) (32) (33) and ground
Resistance
Max. 1 z

switch still OFF.
4
30

(12) (22) FS2-2

(contact with ground circuit) between PTC3 (female) (2) (12) (22) FS2-2
Resistance
Min. 1 Mz

between FS2-2 battery relay BRC terminal
Resistance
Min. 1 Mz
Defective steering and transmission controller

switch ON.
PTC3
Voltage
Between (2) (12) (22) (21) (31)

(32) (33)
20 30 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to steering and transmission power source
D85EX, PX-15E0
31
SEN00636-00
40 Troubleshooting
Failure codes [DAQ5KK] and [DB35KK] Steering and transmission

controller sensor 5 V power source (1): Power source voltage drop and
input
1
Action code
Failure code
CALL E03
DAQ5KK
DB35KK
Failure content
Controller's
action
Symptom Steering and transmission controller sensor 5 V power source(1):

of failure Power source voltage drop and input
Voltage of 5 V power source circuit of steering and transmission controller sensor is less than 4.5 V
or more than 5.5 V.
Abnormal current flowed in 5 V power source circuit of steering and transmission controller sensor.
Stops output of 5 V power source circuit if abnormal voltage has flowed.

appear on
machine
General
information

Causes

switch still OFF.
BRK (male)
Defective brake potentiometer (Internal short circuit)

Sensor
Resistance
Between (C) (A)
5 kz 20%
Between (C) and

ground
Min. 1 Mz

switch still OFF.
2
DIAL (male)
Defective fuel dial potentiometer (Internal short circuit)

Sensor
Possible
causes and the
standard values
when normal
Resistance
Between (1) (3)
5 kz 15%
Between (1) and

ground
Min. 1 Mz

switch still OFF.
Defective forward and
3 reverse potentiometer
TL2 (male)
Sensor
Resistance
Between (4) (1)
3.2 kz 20%
Between (4) and

ground
Min. 1 Mz

switch still OFF.
Defective steering
4 potentiometer
TL2 (male)
Sensor
Resistance
Between (5) (8)
3.2 kz 20%
Between (5) and

ground
Min. 1 Mz

switch still OFF.
5
32
Defective harness grounding Between ground and wiring harnesses

(contact with ground circuit) between PTC1 (female) (22) TL2 (female)
(5), PTC1 (female) (22) TL2 (female) (4),
PTC1 (female) (22) DIAL (female) (1) and
PTC1 (female) (22) BRK (female) (C)
Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Causes

switch ON.
Possible
causes and the
standard values
when normal



between PTC1 (female) (22) TL2 (female)
(5), PTC1 (female) (22) TL2 (female) (4),
PTC1 (female) (22) DIAL (female) (1) and
Voltage
Max. 1V

switch ON.
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
SEN00636-00
40 Troubleshooting
Failure code [DAQ6KK] [DB36KK] Steering and transmission controller

sensor 24 V power source: Power source voltage drop and input
1
Action code
Failure code
CALL E03
DAQ6KK
DB36KK
Failure content
Controller's
action
Steering and transmission controller sensor 24 V power source:

Symptom
Power source voltage drop and input
of failure
Voltage of 24 V power source circuit of steering and transmission controller sensor is less than 12 V
or more than 30 V.
Stops output of 24 V power source circuit if abnormal voltage has flowed.

appear on
machine
General
information

Causes
If service code lights up steadily (reset display) when

Defective pitch angle sensor right connector is disconnected, the defect is internal.
1
a Disconnect connector with starting switch OFF and
turn the switch ON to diagnose.
Possible
causes and the
standard values
when normal
PT2
connector

switch still OFF.

between PTC1 (female) (16) PT2 (female)
(C)
Resistance
Min. 1 Mz

switch ON.
PTC1
Voltage
Between (16) (21)
20 30V
Circuit diagram related to steering and transmission controller sensor 24 V power source
34
D85EX, PX-15E0
SEN00636-00
40 Troubleshooting
Failure codes [DAQ7KK] and [DB37KK] Steering and transmission

input
1
Action code
Failure code
E01
DAQ7KK
DB37KK
Failure content
Controller's
action
Symptom Steering and transmission controller sensor 5 V power source (2):

of failure Power source voltage drop and input
Voltage of 5 V power source (2) circuit of steering and transmission controller sensor is less than 4.5
V or more than 5.5 V.
Stops output of 5 V power source (2) circuit if abnormal voltage has flowed.
Symptoms that
appear on
System may not operate normally.
machine
General
information

Causes
If service code lights up steadily (reset display) when

Defective work equipment oil
right connector is disconnected, the defect is internal.
1 pressure sensor
a Disconnect connector with starting switch OFF and
turn the switch ON to diagnose.
HHP
connector

switch still OFF.
2
Possible
causes and the
standard values
when normal
3
36

between PTC3 (female) (34) HHP (female)
(B)


Resistance
Min. 1 Mz

switch ON.
(B)
Voltage
Max. 1V

switch ON.
PTC3, PTC1
Voltage
Between PTC3 (34)

PTC1(21)
4.5 5.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to steering and transmission controller sensor 5 V power source (2)
D85EX, PX-15E0
37
SEN00636-00
40 Troubleshooting
Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller

model selection: Inconsistency in model select signal
1
Action code
Failure code
CALL E04
DAQ9KQ
DB39KQ
Failure content
Controller's
action
Steering and transmission controller model selection: Inconsistent

Symptom
model selection signal
of failure
Internal specification setting of steering and transmission controller is inconsistent with specification
setting signal.
(Steering and transmission controller cannot be recognized properly.)
Stops all outputs of steering and transmission controller.
Restricts the operation of engine, transmission and brake.
Symptoms that Machine does not operate at all.

appear on
machine
General
information
Both of DAQ9KQ and DB39KQ are displayed.

Causes
1 transmission
controller adjustment
Possible
causes and the
standard values
when normal

It is normal if failure code lights up steadily (reset display) after
adjustment mode is carried out.
Adjustment code 0002: Steering and transmission controller
specification set
harness
switch still OFF.
2 (Disconnection in wiring,
Resisdefective contact of connec- Wiring harnesses between PTC3 (female)
Max. 1 z
(30) GND02
tance
tors)
switch still OFF.
3
ResisMin. 1 Mz
between PTC3 (female) (40) PL2 (18)
tance
switch ON.
4
38

PTC3
Voltage
Max. 1V
5 11 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to steering and transmission controller model selection
D85EX, PX-15E0
39
SEN00636-00
40 Troubleshooting
Failure codes [DAQRKR] and [DB3RKR] Steering and transmission

controller CAN communication: Defective communication
Action code
Failure code
CALL E03
DBQRKR
DB3RKR
Failure content
Controller's
action
Steering and transmission controller CAN communication: Defective

Symptom
communication
of failure
Steering and transmission controller cannot identify monitor panel or engine controller with CAN
communication circuit.

appear on
machine
General
information
Both of DAQRKR and DB3RKR are displayed.

Causes

switch still OFF.
harness
1
Possible
causes and the
standard values
when normal

(male) (3)
Resistance
Max. 1 z

SRV (male) (10)
Resistance
Max. 1 z

switch still OFF.
2
(male) (10)
40
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Causes

switch ON.

Possible
causes and the
standard values
when normal

resistance
Defective monitor panel or

engine controller, or defec5
tive steering and transmission controller
D85EX, PX-15E0

Voltage
Max. 1V

(male) (10)
Voltage
Max. 1V

switch still OFF.
Resistance
Between (A) (B)
100 140 z

monitor panel or steering and transmission controller is defective.
41
SEN00636-00
40 Troubleshooting
42
D85EX, PX-15E0
SEN00636-00
40 Troubleshooting
Failure code [DB2RKR] Engine controller CAN communication:

Action code
Failure code
CALL E03
DB2RKR
Failure content
Controller's
action
Symptom Engine controller CAN communication: Communication disabled

Engine controller cannot identify steering and transmission controller with CAN communication circuit.

appear on
machine
General
information
Causes

switch still OFF.
harness
1
Possible
causes and the
standard values
when normal

PT2 (female) (32), S04 (female) (1) (2)
(male) (3)
Resistance
Max. 1 z

SRV (male) (10)
Resistance
Max. 1 z

switch still OFF.
2
(male) (10)
44
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Causes

switch ON.

Possible
causes and the
standard values
when normal

resistance

5 or defective steering and
D85EX, PX-15E0

Voltage
Max. 1V

(male) (10)
Voltage
Max. 1V

switch still OFF.
Resistance
Between (A) (B)
100 140 z
If no problem is found in causes 1 4, it can be suspected that

engine controller or steering and transmission controller is defective. (Since this is an internal defect, it cannot be diagnosed.)
45
SEN00636-00
40 Troubleshooting
46
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00

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

1
a
See DAQ1KK
Failure code [DB32KK] [DAQ2KK] Load power source of steering and

1
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
a
See DAQ9KQ
Failure codes [DB3RKR] and [DAQRKR] Steering and transmission

controller CAN communication: Defective communication
a
See DAQRKR
D85EX, PX-15E0
47
SEN00636-00
40 Troubleshooting
Failure code [DD12KA] Shift up switch: Disconnection

Action code
Failure code
E02
DD12KA
Symptom Shift up switch: Disconnection

Failure content 2 circuit signals of shift up switch circuit were turned OFF (OPEN) at the same time.
Controller's
action

Recognizes that switch is not pressed.
Symptoms that
Cannot shift up.
appear on
Auto shift down function does not work.
machine
General
information
As for two circuit signals of switch, NO is for an operation detection and NC is for an error detection.
The input state (ON or OFF) from shift up switch can be checked in monitoring mode.
(Code 40905: Transmission-related controller input signal 1)
Duplication of failure code: Turn starting switch ON +Operate shift up switch
Causes

switch still OFF.
Defective shift up switch

SFTU (male)
Shift up switch
OFF (Release)
ON (Press)
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(2) (1)
Min. 1 Mz
Max. 1 z

switch still OFF.
harness
2
Possible
causes and the
standard values
when normal

SFTU (female) (3)
Resistance
Max. 1 z

SFTU (female) (1)
Resistance
Max. 1 z

SFTU (female) (2)
Resistance
Max. 1 z

switch ON.


between PTC1 (female) (12) SFTU
(female) (3)
Voltage
Max. 1V

between PTC3 (female) (9) SFTU (female)
(1)
Voltage
Max. 1V

(2)
Voltage
Max. 1V

switch ON.
48

PTC1, PTC3
Shift up switch
OFF (Release)
ON (Press)
Voltage between
PTC1 (12) PTC1 (4)
Max. 1V
5 11 V
Voltage between
PTC3 (9) PTC1 (4)
5 11 V
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to shift up & shift down switch
D85EX, PX-15E0
49
SEN00636-00
40 Troubleshooting
Failure code [DD12KB] Shift up switch: Short circuit

Action code
Failure code
E02
DD12KB
Symptom Shift up switch: Short circuit

Failure content 2 circuit signals of shift up switch circuit were turned ON (CLOSE) at the same time.
Controller's
action

Symptoms that
Cannot shift up.
appear on
machine
General
information
Duplication of failure code: Turn starting switch ON +Operate shift up switch
Causes

switch still OFF.
Possible
causes and the
standard values
when normal
Defective shift up switch

SFTU (male)
Shift up switch
OFF (Release)
ON (Press)
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(2) (1)
Min. 1 Mz
Max. 1 z

switch still OFF.
Defective harness grounding between PTC1 (female) (12) SFTU
2
(contact with ground circuit) (female) (3)
(1)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch ON.
50

PTC1, PTC3
Shift up switch
OFF (Release)
ON (Press)
Voltage between
PTC1 (12) PTC1 (4)
Max. 1V
5 11 V
Voltage between
PTC3 (9) PTC1 (4)
5 11 V
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
D85EX, PX-15E0
51
SEN00636-00
40 Troubleshooting
Failure code [DD13KA] Shift down switch: Disconnection

Action code
Failure code
E02
DD13KA
Symptom Shift down switch: Disconnection

Failure content 2 circuit signals of shift down switch circuit were turned OFF (OPEN) at the same time.
Controller's
action

Symptoms that
Cannot shift down.
appear on
machine
General
information
Duplication of failure code: Turn starting switch ON + Operate shift down switch
Causes

switch still OFF.
Defective shift down switch

SFTD (female)
Shift down switch

OFF (Release)
ON (Press)
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(2) (1)
Min. 1 Mz
Max. 1 z

switch still OFF.
harness
2
Possible
causes and the
standard values
when normal

SFTD (male) (3)
Resistance
Max. 1 z

SFTD (male) (1)
Resistance
Max. 1 z

SFTD (male) (2)
Resistance
Max. 1 z

switch ON.


between PTC1 (female) (24) SFTD (male)
(3)
Voltage
Max. 1V

(1)
Voltage
Max. 1V

(2)
Voltage
Max. 1V

switch ON.
52

PTC1
Shift down switch

OFF (Release)
ON (Press)
Voltage between
PTC1 (24) PTC1 (4)
Max. 1V
5 11 V
Voltage between
PTC1 (18) PTC1 (4)
5 11 V
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
D85EX, PX-15E0
53
SEN00636-00
40 Troubleshooting
Failure code [DD13KB] Shift down switch: Short circuit

Action code
Failure code
E02
DD13KB
Symptom Shift down switch: Short circuit

Failure content 2 circuit signals of shift down switch circuit were turned ON (CLOSE) at the same time.
Controller's
action

Symptoms that
Cannot shift down.
appear on
machine
General
information
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
Causes

switch still OFF.
Possible
causes and the
standard values
when normal
Defective shift down switch

SFTD (female)
Shift down switch

OFF (Release)
ON (Press)
Resistance between
(2) (3)
Max. 1 z
Min. 1 Mz
Resistance between
(2) (1)
Min. 1 Mz
Max. 1 z

switch still OFF.
Defective harness grounding between PTC1 (female) (24) SFTD (male)
2
Resistance
Min. 1 Mz

(1)
Resistance
Min. 1 Mz

switch ON.
54

PTC1
Shift down switch

OFF (Release)
ON (Press)
Voltage between
PTC1 (24) PTC1 (4)
Max. 1V
5 11 V
Voltage between
PTC1 (18) PTC1 (4)
5 11 V
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
D85EX, PX-15E0
55
SEN00636-00
40 Troubleshooting
Failure codes [DD14KA] and [DDQ2KA] Parking lock switch:

Disconnection
Action code
Failure code
CALL E03
DD14KA
DDQ2KA
Symptom Parking lock switch: Disconnection

Failure content 2 circuit signals of parking lock switch circuit were turned OFF (OPEN) at the same time.
Controller's
action

Recognizes that parking brake lever is in free position.
appear on
machine
Engine can not start.
General
information
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.
The input state (ON or OFF) from parking lock switch can be checked in monitoring mode.
(Code 40910: Steering-related controller input signal 1)
Duplication of failure code: Turn starting switch ON + operate parking brake lever.
Causes

switch still OFF.
Defective parking lock switch

(Internal disconnection)
NSW (male)
Parking lever
Free position
Lock position
Resistance
between (A) (B)
Max. 1 z
Min. 1 Mz
Resistance
between (A) (C)
Min. 1 Mz
Max. 1 z

switch still OFF.
harness
2
Possible
causes and the
standard values
when normal

NSW (female) (C)
Resistance
Max. 1 z

NSW (female) (B)
Resistance
Max. 1 z

NSW (female) (A)
Resistance
Max. 1 z

switch ON.
Hot short circuiting in wiring
harness
3
(a defective contact with 24
V circuit)

PTC2 (female) (15) NSW (female) (C)
Voltage
Max. 1V

PTC2 (female) (5) NSW (female) (B)
Voltage
Max. 1V

PTC1 (female) (4) NSW (female) (A)
Voltage
Max. 1V

switch ON.
PTC2, PTC1
4
56
Parking lever
Free position
Lock position
Voltage between
PTC2 (5) and
PTC1 (4)
5 11 V
Max. 1V
Voltage between
PTC2 (15) and
PTC1 (4)
Max. 1V
5 11 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to parking brake switch
D85EX, PX-15E0
57
SEN00636-00
40 Troubleshooting
Failure codes [DD14KB] and [DDQ2KB] Parking lock switch: Short

circuit
Action code
Failure code
CALL E03
DD14KB
DDQ2KB
Symptom Parking lock switch: Short circuit

Failure content 2 circuit signals of parking lock switch circuit were turned ON (CLOSE) at the same time.
Controller's
action

Recognizes that parking brake lever is in free position.
appear on
machine
Engine can not start.
General
information
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.
The input state (ON or OFF) from parking lock switch can be checked in monitoring mode.
(Code 40910: Steering-related controller input signal 1)
Duplication of failure code: Turn starting switch ON + operate parking brake lever.
Causes

switch still OFF.
Defective parking lock

1
switch (internal short circuit)
NSW (male)
Parking lever
Free position
Lock position
Resistance between
(A) (B)
Max. 1 z
Min. 1 Mz
Resistance between
(A) (C)
Min. 1 Mz
Max. 1 z

switch still OFF.
Possible
causes and the
standard values
when normal

Defective harness grounding NSW (female) (A) PTC1 (female) (4)
2
NSW (female) (B) PTC2 (female) (5)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

NSW (female) (C) PTC2 (female) (15)
Resistance
Min. 1 Mz

switch ON.
PTC2, PTC1
3
58
Parking lever
Free position
Lock position
Voltage between
PTC2 (5) and
PTC (4)
5 11 V
Max. 1V
Voltage between
PTC2 (15) and
PTC1 (4)
Max. 1V
5 11 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to parking brake switch
D85EX, PX-15E0
59
SEN00636-00
40 Troubleshooting
Failure codes [DDQ2KA] and [DD14KA] Parking lock switch:

Disconnection
a
See DD14KA
Failure codes [DDQ2KB] and [DD14KB] Parking lock switch: Short

circuit
a
60
See DD14KB
D85EX, PX-15E0
SEN00636-00
40 Troubleshooting
Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is

out of normal range
1
Action code
Failure code
DGS1KX
Symptom Hydraulic oil temperature sensor: Input signal out of range

Failure content Hydraulic oil temperature sensor signal is out of normal range.
Controller's
action
Only memorizes the trouble. Does not turn on a particular alarm.

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
General
information
Hydraulic oil temperature state (temperature) can be checked in monitoring mode.

(Code 04401: Hydraulic oil temperature)
Duplication of failure code: Turn starting switch ON or start engine.
Causes
Defective hydraulic oil temperature sensor
1
(internal disconnection and
short circuit)
harness
2
Possible
causes and the
standard values
when normal

switch still OFF.
SDS (male)
Resistance
Between (1) (2)
3.5 kz 90 kz (10 100C)
Min. 1 Mz

switch still OFF.
SDS (female) (1)
Resistance
Max. 1 z

SDS (female) (2)
Resistance
Max. 1 z

switch still OFF.

between PTC1 (female) (9) SDS (female)
(1)
Resistance
Min. 1 Mz

switch ON.
4
62


(1)
Voltage
Max. 1V

(2)
Voltage
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to hydraulic oil temperature sensor
D85EX, PX-15E0
63
SEN00636-00
40 Troubleshooting
Failure code [DGT1KA] Power train oil temperature sensor:

Disconnection
Action code
Failure code
E01
DGT1KA
Symptom Power train oil temperature sensor: Disconnection

Failure content The power train temperature sensor signal is lower than the specified value.
Controller's
action
Nothing particular.
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.
General
information
Power train temperature state (temperature) can be checked in monitoring mode.

(Code 30100: Power train oil temperature)
Causes
Defective power train oil tem1 perature sensor
(Short circuit)

switch still OFF.
453 (male)
Resistance
Between (1) (2)
3.5 kz 90 kz (10 100C)
Min. 1 Mz

switch still OFF.
Possible
causes and the
standard values
when normal

Defective harness grounding 453 (female) (1)
2
(contact with ground circuit) Wiring harness between S03 (female) (3)
453 (female) (2)
453 (female) (2)
3
64
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

switch still OFF.
S04 (female) (12) 453 (female) (1)
Voltage
Max. 1V

switch ON.
S04 (female) (12) 453 (female) (1)
Voltage
Max. 1V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to power train oil temperature sensor
D85EX, PX-15E0
65
SEN00636-00
40 Troubleshooting
Failure code [DGT1KX] Power train oil temperature sensor: Input signal
is out of normal range
1
Action code
Failure code
E01
DGT1KX
Symptom Power train oil temperature sensor: Input signal out of range
Failure content Power train temperature sensor signal is out of normal range.
Controller's
action
Nothing particular.
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.
General
information
Power train temperature state (temperature) can be checked in monitoring mode.

Causes
Defective power train oil tem1 perature sensor
(Short circuit)
Possible
causes and the
standard values
when normal

switch still OFF.
453 (male)
Resistance
Between (1) (2)
3.5 kz 90 kz (10 100C)
Min. 1 Mz

switch still OFF.

between S04 (female) (12) 453 (female)
(1)

Resistance
Min. 1 Mz

switch ON.
(1)
Voltage
Max. 1V
66
D85EX, PX-15E0
SEN00636-00
40 Troubleshooting
Failure code [DH22KA] HSS and work equipment pump oil pressure
sensor: Disconnection
Action code
Failure code
DH22KA
Symptom HSS and work equipment pump oil pressure sensor: Disconnection
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
General
information
Input state (voltage) from work equipment pump oil pressure sensor can be checked in monitoring
mode.
(Code 70701: Voltage of work equipment oil pressure sensor)
Causes
1
Defective sensor 5 V power

supply circuit
Defective work equipment

2 pump oil pressure sensor
(internal defect)

Check if failure code [DAQ7KK] or [DB37KK] is displayed. If it is
displayed, carry out troubleshooting for it first.
switch ON.
HHP
Voltage
Between (C) (A)
0.5 6.0 V

switch still OFF.
Possible
causes and the
standard values
when normal
harness
3

HHP (female) (B)
Resistance
Max. 1 z

HHP (female) (C)
Resistance
Max. 1 z

HHP (female) (A)
Resistance
Max. 1 z

switch still OFF.
68

(C)
Resistance
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to work equipment pump oil pressure sensor
D85EX, PX-15E0
69
SEN00636-00
40 Troubleshooting
Failure code [DH22KB] HSS and work equipment pump oil pressure
sensor: Short circuit
Action code
Failure code
DH22KB
Symptom HSS and work equipment pump oil pressure sensor: Short circuit
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
General
information
Input state (voltage) from work equipment pump oil pressure sensor can be checked in monitoring
mode.
(Code 70701: Voltage of work equipment oil pressure sensor)
Causes
1

supply circuit
Defective work equipment

2 pump oil pressure sensor
(internal defect)
Possible
causes and the
standard values
when normal

switch ON.
HHP
Voltage
Between (C) (A)
0.5 6.0 V

switch ON.
3


(C)
Voltage
Max. 1V

(B)
Voltage
Max. 1V
Circuit diagram related to work equipment pump oil pressure sensor
70
D85EX, PX-15E0
SEN00636-00
40 Troubleshooting
Failure code [DK10KA] Fuel dial: Disconnection

Action code
Failure code
CALL E03
DK10KA
Symptom Fuel dial: Disconnection

Failure content Signal voltage of fuel dial circuit is lower than the specified value.
Controller's
action

Continues to control with decelerator pedal potentiometer signal.
Operation of engine and transmission is limited.
Symptoms that
appear on
machine
General
information
Input state (voltage) from fuel dial can be checked in monitoring mode.
(Code 03000: Fuel dial voltage)
Causes
Defective sensor 5V power
1
supply circuit

switch still OFF.
Defective fuel dial

2 (internal disconnection and
short circuit)
DIAL (male)
Resistance
Between (1) (3)
4.0 6.0 kz
Between (1) (2)
0.5 4.5 kz
Between (2) (3)
0.5 4.5 kz

switch still OFF.
Possible
causes and the
standard values
when normal
harness
3

DIAL (female) (1)
Resistance
Max. 1 z

DIAL (female) (2)
Resistance
Max. 1 z

DIAL (female) (3)
Resistance
Max. 1 z

switch still OFF.
4

(contact with ground circuit) PTC1 (female) (22) DIAL (female) (1)
Resistance
Min. 1 Mz

PTC1 (female) (20) DIAL (female) (2)
Resistance
Min. 1 Mz

switch ON.
5
72

PTC1
Voltage
Between (22) (21)
4.6 5.4 V
Between (20) (21)
0.5 4.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to fuel dial
D85EX, PX-15E0
73
SEN00636-00
40 Troubleshooting
Failure code [DK10KB] Fuel dial: Short circuit

Action code
Failure code
CALL E03
DK10KB
Symptom Fuel dial: Short circuit

Failure content Signal voltage of fuel dial circuit is higher than the specified value.
Controller's
action

Continues to control with decelerator pedal potentiometer signal.
Operation of engine and transmission is limited.
Symptoms that
appear on
machine
General
information
Input state (voltage) from fuel dial can be checked in monitoring mode.
(Code 03000: Fuel dial voltage)
Causes
1
supply circuit

switch still OFF.
Defective fuel dial

short circuit)
Possible
causes and the
standard values
when normal
harness
3
DIAL (male)
Resistance
Between (1) (3)
4.0 6.0 kz
Between (1) (2)
0.5 4.5 kz
Between (2) (3)
0.5 4.5 kz

switch still OFF.
DIAL (female) (3)
Resistance
Max. 1 z

switch ON.


between PTC1 (female) (22) DIAL (female)
(1)
Voltage
Max. 1V

(2)
Voltage
Max. 1V

(3)
Voltage
Max. 1V

switch ON.
5
74

PTC1
Voltage
Between (22) (21)
4.6 5.4 V
Between (20) (21)
0.5 4.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to fuel dial
D85EX, PX-15E0
75
SEN00636-00
40 Troubleshooting
Failure code [DK30KA] Steering potentiometer (1): Disconnection

Action code
Failure code
CALL E03
DK30KA
Symptom Steering potentiometer (1): Disconnection

Failure content Signal voltage of steering potentiometer (1) circuit is higher than the specified value.
Controller's
action

Continues to control with signal of steering potentiometer (2) circuit.
Symptoms that
appear on
machine
General
information
Input state (voltage) from steering potentiometer (1) can be checked in monitoring mode.
(Code 50300: Steering potentiometer (1) voltage)
Duplication of failure code: Turn starting switch ON+(operate PCCS lever (steering))
Causes
1
supply circuit

switch still OFF.
Defective
steering potentiometer (1)
2
short circuit)
Possible
causes and the
standard values
when normal
harness
3
Resistance
Between (5) (8)
3.2 kz 20%
Between (7) (5)
1 6 kz
(for steering to right and left)
Between (7) (8)
6 1 kz

switch still OFF.
TL2 (female) (8)
Resistance
Max. 1 z

TL2 (female) (7)
Resistance
Max. 1 z

switch ON.


5
76
TL2 (male)

(7)
Voltage
Max. 1V

(5)
Voltage
Max. 1V

(8)
Voltage
Max. 1V

switch ON.
PTC1
Voltage
Between (2) (21)
0.5 4.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to steering potentiometer
D85EX, PX-15E0
77
SEN00636-00
40 Troubleshooting
Failure code [DK30KB] Steering potentiometer (1): Short circuit

Action code
Failure code
CALL E03
DK30KB
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
Causes
1
supply circuit

switch still OFF.
Defective steering potentiometer (1)

2
short circuit)
Possible
causes and the
standard values
when normal
TL2 (male)
Resistance
Between (5) (8)
3.2 kz 20%
Between (7) (5)
1 6 kz
Between (7) (8)
6 1 kz

switch still OFF.
Defective harness grounding between PTC1 (female) (2) TL2 (female)
3
(5)
harness
4
78

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch still OFF.
TL2 (female) (5)
Resistance
Max. 1 z

switch ON.
PTC1
Voltage
Between (2) (21)
0.5 4.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
D85EX, PX-15E0
79
SEN00636-00
40 Troubleshooting
Failure code [DK30KX] Steering potentiometer: Input signal is out of

normal range
Action code
Failure code
CALL E04
DK30KX
Failure content
Controller's
action
Symptom Steering potentiometer: Input signal out of normal range

Either failure code [DK30KA] or [DK30KB] and either failure code [DK31KA] or [DK31KB] occurred
at the same time at steering potentiometer circuits 1 and 2.
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
Input state (voltage) from steering potentiometer can be checked in monitoring mode.
(Code 50300: Steering potentiometer 1 voltage)
Causes
Diagnose the failure codes [DK30KA], [DK30KB], [DK31KA], and [DK31KB].
Failure code [DK30KZ] Steering potentiometer: Disconnection or short

circuit (Double failure)
1
Action code
Failure code
CALL E04
DK30KZ
Failure content
Controller's
action
Symptom Steering potentiometer: Disconnection or short circuit

With starting switch ON, an abnormality existed in only one of the steering potentiometer circuit 1 or
2. After that, either failure code [DK30KA] or [DK30KB] and either failure code [DK31KA] or
[DK31KB] occurred at the same time.
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
80
Causes
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Failure code [DK30L8] Steering potentiometer: Inconsistent analog

signal
Action code
Failure code
CALL E03
DK30L8
Symptom Steering potentiometer: Inconsistent analog signal

Failure content Total signal voltage of steering potentiometer circuits 1 and 2 is beyond the specified range.
Controller's
action

Continues to control with the normal signal of either steering potentiometer circuit 1 or 2.
Symptoms that
appear on
machine
General
information
Duplication of failure code: Turn starting switch ON +(operate PCCS lever (forward-reverse))
Possible
causes and the
standard values
when normal
D85EX, PX-15E0
Causes
81
SEN00636-00
40 Troubleshooting
Failure code [DK31KA] Steering potentiometer (2): Disconnection

Action code
Failure code
CALL E03
DK31KA
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
Causes
1
source circuit

switch still OFF.
Defective steering
potentiometer (2)
2
short circuit)
Possible
causes and the
standard values
when normal
harness
3
TL2 (male)
Resistance
Between (5) (8)
3.2 kz 20%
Between (6) (5)
61z
Between (6) (8)
16z

switch still OFF.
TL2 (female) (5)
Resistance
Max. 1 z

TL2 (female) (6)
Resistance
Max. 1 z

switch still OFF.
4
Resistance
Min. 1 Mz

(5)
Resistance
Min. 1 Mz
82


switch ON.
PTC1
Voltage
Between (19) (21)
0.5 4.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
D85EX, PX-15E0
83
SEN00636-00
40 Troubleshooting
Failure code [DK31KB] Steering potentiometer (2): Short circuit

Action code
Failure code
CALL E03
DK31KB
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
Causes
1
supply circuit

switch still OFF.
Defective steering
potentiometer (2)
2
short circuit)
TL2 (male)
Resistance
Between (5) (8)
3.2 kz 20%
Between (6) (5)
1 6 kz (for steering to right and

left)
Between (6) (8)
6 1 kz (for steering to right and

left)

switch ON.
Possible
causes and the
standard values
when normal

harness
4
84


(6)
Voltage
Max. 1V

(5)
Voltage
Max. 1V

(8)
Voltage
Max. 1V

switch still OFF.
TL2 (female) (8)
Resistance
Max. 1 z

switch ON.
PTC1
Voltage
Between (19) (21)
0.5 4.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
D85EX, PX-15E0
85
SEN00636-00
40 Troubleshooting
Failure code [DK40KA] Brake potentiometer: Disconnection

Action code
Failure code
E01
DK40KA
Symptom Brake potentiometer: Disconnection

Failure content Signal voltage of brake potentiometer circuit is lower than the specified value.
Controller's
action
Nothing particular.
Symptoms that
appear on
Automatic shift-down does not function properly.
machine
General
information
Input state (voltage) from brake potentiometer can be checked in monitoring mode.
(Code 50400: Brake potentiometer voltage value)
Duplication of failure code: Turn starting switch ON + (operate brake pedal)
Causes
1

source circuit
Defective brake potentiometer. (internal discon2

nection and short circuit)
Defective potentiometer
mounting
Possible
causes and the
standard values
when normal
harness
3

switch still OFF.
BRK (male)
Resistance
Between (A) (C)
4.0 6.0 kz
Between (A) (B)
1.5 4.5 kz (free full stroke)
Between (B) (C)

switch still OFF.
BRK (female) (C)
Resistance
Max. 1 z

BRK (female) (B)
Resistance
Max. 1 z

switch still OFF.
4

(contact with ground circuit) PTC1 (female) (3) BRK (female) (B)
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

5

switch ON.
PTC1
Voltage
Between (3) (21)
1.5 4.5 V
Circuit diagram related to brake potentiometer
86
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Failure code [DK40KB] Brake potentiometer: Short circuit

Action code
Failure code
E01
DK40KB
Symptom Brake potentiometer: Short circuit

Failure content Signal voltage of brake potentiometer circuit is higher than the specified value.
Controller's
action
Nothing particular.
Symptoms that
appear on
machine
General
information
Input state (voltage) from brake potentiometer can be checked in monitoring mode.
(Code 50400: Brake potentiometer voltage value)
Duplication of failure code: Turn starting switch ON + (operate brake pedal)
Causes
1

supply circuit
Defective brake potentiometer. (internal discon2

nection and short circuit)
Defective potentiometer
mounting
Possible
causes and the
standard values
when normal

switch still OFF.
BRK (male)
Resistance
Between (A) (C)
4.0 6.0 kz
Between (A) (B)
Between (B) (C)

switch ON.
3
harness
4
5

PTC1 (female) (3) BRK (female) (B)
Voltage
Max. 1V

Voltage
Max. 1V

PTC1 (female) (21) BRK (female) (A)
Voltage
Max. 1V

switch still OFF.
BRK (female) (A)
Resistance
Min. 1 z

switch ON.
PTC1
Voltage
Between (3) (21)
1.5 4.5 V
Circuit diagram related to brake potentiometer
D85EX, PX-15E0
87
SEN00636-00
40 Troubleshooting
Failure code [DK55KX] Forward-reverse potentiometer: Input signal is

out of normal range
1
Action code
Failure code
CALL E04
DK55KX
Failure content
Controller's
action
Symptom Forward-reverse potentiometer: Input signal out of range

Either failure code [DK56KA] or [DK56KB] and either failure code [DK57KA] or [DK57KB] occurred
at the same time at forward-reverse potentiometer circuits 1 and 2.
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
Input state (voltage) from forward-reverse potentiometer can be checked in monitoring mode.
(Code 50200: Forward-reverse potentiometer 1 voltage)
Duplication of failure code: Turn starting switch ON + (operate PCCS lever (forward-reverse))
Causes
Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection

or short circuit (Double failure)
1
Action code
Failure code
CALL E04
DK55KZ
Failure content
Controller's
action
Forward-reverse potentiometer: Disconnection or short circuit (douSymptom

ble failure)
of failure
With starting switch ON, an abnormality existed in only one of the forward-reverse potentiometer circuit 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
General
information
Possible
causes and the
standard values
when normal
88
Causes
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent

analog signal
Action code
Failure code
CALL E03
DK55L8
Symptom Forward-reverse potentiometer: Inconsistent analog signals

Failure content Total signal voltage of forward-reverse potentiometer circuits 1 and 2 is beyond the specified range.
Controller's
action

Continues to control with the normal signal of either forward-reverse potentiometer circuit 1 or 2.
Symptoms that
appear on
machine
General
information
Possible
causes and the
standard values
when normal
D85EX, PX-15E0
Causes
89
SEN00636-00
40 Troubleshooting
Failure code [DK56KA] Forward-reverse potentiometer (1):

Disconnection
Action code
Failure code
CALL E03
DK56KA
Symptom Forward-reverse potentiometer (1): Disconnection

Failure content Signal voltage of forward-reverse potentiometer (1) circuit is lower than the specified value.
Controller's
action

Continues to control with signal of forward-reverse potentiometer (2) circuit.
Symptoms that
appear on
machine
General
information
Input state (voltage) from forward-reverse potentiometer (1) can be checked in monitoring mode.
(Code 50200: Forward-reverse potentiometer (1) voltage)
Causes
1

supply circuit
Defective forward-reverse
potentiometer (1)
2
(Internal disconnection or
short circuit)
Possible
causes and the
standard values
when normal
harness
3

switch still OFF.
TL2 (male)
Resistance
Between (4) (1)
3.2 kz 20%
Between (3) (4)
5.5 1.5 kz (forward reverse)
Between (3) (1)

switch still OFF.
TL2 (female) (4)
Resistance
Max. 1 z

TL2 (female) (3)
Resistance
Max. 1 z

switch still OFF.
4
Resistance
Min. 1 Mz

(4)
Resistance
Min. 1 Mz
90


switch ON.
PTC1
Voltage
Between (13) (21)
0.5 4.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
Circuit diagram related to forward-reverse potentiometer
D85EX, PX-15E0
91
SEN00636-00
40 Troubleshooting
Failure code [DK56KB] Forward-reverse potentiometer (1): Short

circuit
Action code
Failure code
CALL E03
DK56KB
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
Causes
1

supply circuit
potentiometer (1)
2
short circuit)

switch still OFF.
TL2 (male)
Resistance
Between (4) (1)
3.2 kz 20%
Between (3) (4)
Between (3) (1)

switch ON.
Possible
causes and the
standard values
when normal

harness
4
92


(3)
Voltage
Max. 1V

(4)
Voltage
Max. 1V

(1)
Voltage
Max. 1V

switch still OFF.
TL2 (female) (1)
Resistance
Max. 1 z

switch ON.
PTC1
Voltage
Between (13) (21)
0.5 4.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
D85EX, PX-15E0
93
SEN00636-00
40 Troubleshooting
Failure code [DK57KA] Forward-reverse potentiometer (2):

Disconnection
Action code
Failure code
CALL E03
DK57KA
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
Causes
1

supply circuit
potentiometer (2)
2
short circuit)
Possible
causes and the
standard values
when normal
harness
3

switch still OFF.
TL2 (male)
Resistance
Between (4) (1)
3.2 kz 20%
Between (2) (4)
Between (2) (1)

switch still OFF.
TL2 (female) (4)
Resistance
Max. 1 z

TL2 (female) (2)
Resistance
Max. 1 z

switch still OFF.
4
(4)
94

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch ON.
PTC1
Voltage
Between (7) (21)
0.5 4.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
D85EX, PX-15E0
95
SEN00636-00
40 Troubleshooting
Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit

Action code
Failure code
CALL E03
DK57KB
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
Causes
1
supply circuit
potentiometer (2)
2
short circuit)

switch still OFF.
TL2 (male)
Resistance
Between (4) (1)
3.2 kz 20%
Between (2) (4)
Between (2) (1)

switch ON.
Possible
causes and the
standard values
when normal

harness
4
5
96

(2)
Voltage
Max. 1V

(4)
Voltage
Max. 1V

(1)
Voltage
Max. 1V

switch still OFF.
TL2 (female) (1)
Resistance
Max. 1 z

switch ON.
PTC1
Voltage
Between (7) (21)
0.5 4.5 V
D85EX, PX-15E0
40 Troubleshooting
SEN00636-00
D85EX, PX-15E0
97
SEN00636-00

98
SEN00637-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
40 Troubleshooting

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
SEN00637-00
40 Troubleshooting
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
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit
Action code
Failure code
CALL E03
DKH1KA
DKH1KX
Symptom Pitch angle sensor: Short circuit

Failure content Signal voltage of pitch angle sensor is higher than specified value.
Controller's
action

Cannot recognize pitch angle.
Symptoms that Gear shift shocks become large.

appear on
machine
General
information
Both DKH1KA and DKH1KX are displayed

Input state (voltage) from pitch angle sensor can be checked in monitoring mode.
(Code 60100: Voltage of pitch angle sensor)
Causes
1
Defective sensor 24 V power Check if failure code [DAQ6KK] or [DB36KK] is displayed. If it is

supply circuit

switch ON.
Defective pitch angle sensor
2
(internal defect)
PT2
Voltage
Between (B) (A)
Possible
causes and the
standard values
when normal
0.15 4.85 V

switch ON.
3
Disconnection in wiring harness

4
5


between PTC1(female) (8) PT2 (female)
(B)
Voltage
Max. 1V

between PTC1 (female) (21) PT2 (female)
(A)
Voltage
Max. 1V

switch still OFF.
PT2 (female) (A)
Resistance
Max. 1 z
Circuit diagram related to pitch angle sensor
D85EX, PX-15E0
SEN00637-00
40 Troubleshooting
Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection 1

Action code
Failure code
CALL E03
DKH1KB
DKH1KX
Symptom Pitch angle sensor: Disconnection

Failure content Signal voltage of pitch angle sensor is lower than specified value.
Controller's
action

Cannot recognize pitch angle.
Symptoms that Gear shift shocks become large.

appear on
machine
General
information
Both DKH1KB and DKH1KX are displayed.

Input state (voltage) from pitch angle sensor can be checked in monitoring mode.
(Code 60100: Voltage of pitch angle sensor)
Causes
1
Defective sensor 24V power Check if failure code [DAQ6KK] or [DB36KK] is displayed. If it is
supply circuit

switch ON.
Defective pitch angle sensor
2
(internal defect)
PT2
Voltage
Between (B) (A)
Possible
causes and the
standard values
when normal
harness
3
0.15 4.85 V

switch still OFF.
PT2 (female) (C)
Resistance
Max. 1 z

PT2 (female) (B)
Resistance
Max. 1 z

switch still OFF.
4

(contact with ground circuit) PTC1(female) (8) PT2 (female) (B)
Resistance
Min. 1 Mz

PTC1 (female) (16) PT2 (female) (C)
Resistance
Min. 1 Mz

Circuit diagram related to pitch angle sensor
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor:

a
Refer to DKH1KA or DKH1KB
D85EX, PX-15E0
SEN00637-00
40 Troubleshooting
Failure code [DLT3KA] Transmission output speed sensor: Disconnection1

Action code
Failure code
E01
DLT3KA
Symptom Transmission output speed sensor: Disconnection

Failure content Signal is not input from transmission output speed sensor.
Controller's
action
Assumes that transmission output speed is 0 rpm.
Transmission speed cannot be monitored.

Symptoms that
Traction force cannot be calculated.
appear on
Automatic shift-down does not function properly
machine
General
information
Transmission output speed can be checked in monitoring mode.

(Code 31400: Transmission speed)
Duplication of failure code: Start engine and travel machine actually.
Causes
Defective transmission
1 output speed sensor
Possible
causes and the
standard values
when normal
harness
2

switch still OFF.
TM1 (male)
Resistance
Between (1) (2)
400 1,000 z

switch still OFF.
TM1 (female) (1)
Resistance
Max. 1 z

TM1 (female) (2)
Resistance
Max. 1 z

switch ON.
3


between PTC2 (female) (30) TM1 (female)
(1)
Voltage
Max. 1V

(2)
Voltage
Max. 1V
Circuit diagram related to transmission output speed sensor
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DLT3KB] Transmission output speed sensor: Short circuit1

Action code
Failure code
E01
DLT3KB
Symptom Transmission output speed sensor: Short circuit

Signal from transmission output speed sensor does not change even though the machine is
Failure content
traveling.
Controller's
action
Assumes that transmission output speed is 0 rpm.
Transmission speed cannot be monitored.

Symptoms that
Traction force cannot be calculated.
appear on
machine
General
information
Transmission output speed can be checked in monitoring mode.

(Code 31400: Transmission speed)
Duplication of failure code: Start engine and travel machine actually.
Causes
1
Defective mounting of trans- Make adjustment according to Testing and adjusting Adjusting
mission output speed sensor transmission speed sensor.
Defective transmission
2 output speed sensor
Possible
causes and the
standard values
when normal

switch still OFF.
TM1 (male)
Resistance
Between (1) (2)
400 1,000 z
Min. 1 Mz

switch still OFF.
Defective harness grounding between PTC2 (female) (30) TM1 (female)
3
Resistance
Min. 1 Mz

(2)
Resistance
Min. 1 Mz

Circuit diagram related to transmission output speed sensor
D85EX, PX-15E0
SEN00637-00
40 Troubleshooting
Failure code [DV00KB] Alarm buzzer: Short circuit

Action code
Failure code
E02
DV00KB
Symptom
Alarm buzzer: Short circuit (monitor panel circuit)
of failure
Failure content Abnormal current flowed in the alarm buzzer circuit.

Controller's
action
Stops the GND output for alarm buzzer circuit.
Symptoms that
appear on
Alarm buzzer does not sound.
machine
General
information
Duplication of failure code: Turn starting switch ON

(When it is turned ON, buzzer sounds for 1 second).
Causes
Defective alarm buzzer


2
Possible
causes and the
standard values
when normal

switch still OFF.
217 (male)
Continuity
Between (2) (1)
Continue

switch ON.
217 (female) (1) S03 (female) (18)
Voltage
Max. 1V

switch still OFF.

between 217 (female) (1) S03 (female)
(18)
Resistance
Min. 1 Mz

switch ON.
S03
Between (18) and
ground
Alarm buzzer
Voltage
When stopping
20 30 V
When turned ON
(sounding)
Max. 3V
Circuit diagram related to alarm buzzer
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DW7BKA] Fan reverse solenoid: Disconnection

Action code
Failure code
E01
DW7BKA
Symptom Fan reverse solenoid: Disconnection

Failure content Current does not flow when power is output to fan reverse solenoid circuit.
Controller's
action
Stops outputting power to fan reverse solenoid circuit.
Symptoms that
appear on
The fan reversing function cannot be used.
machine
General
information
Output state (ON/OFF) to fan reverse solenoid can be checked in monitoring mode.
(Code 40914: Steering-related controller output signal)
Duplication of failure code: Turn starting switch ON and operate cleaning.
Causes
Defective fan reverse
1 solenoid
Possible
causes and the
standard values
when normal
harness
2



switch still OFF.
FAR2 (male)
Resistance
Between (1) (2)
34 44 z

switch still OFF.
FAR2 (female) (1)
Resistance
Max. 1 z

FAR2 (female) (2)
Resistance
Max. 1 z

switch ON.
between PTC3 (female) (18) FAR2
(female) (1)
Voltage
Max. 1V
Circuit diagram related to fan reverse solenoid
D85EX, PX-15E0
SEN00637-00
40 Troubleshooting
Failure code [DW7BKB] Fan reverse solenoid: Short circuit

Action code
Failure code
E01
DW7BKB
Symptom Fan reverse solenoid: Short circuit

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.
Causes
1 solenoid
Possible
causes and the
standard values
when normal

switch still OFF.
FAR2 (male)
Resistance
Between (1) (2)
34 44 z
Min. 1 Mz

switch still OFF.

(female) (1)
Harness short

Resistance
Min. 1 Mz

switch still OFF.
Between PTC3 (female) (18) FAR2
(female) (1) and ST3. Wiring harness
between (female) (13) FAR2 (female) (2)
Resistance
Min. 1 Mz
10
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DW7BKY] Fan reverse solenoid: Hot short circuit

Action code
Failure code
E02
DW7BKY
Symptom Fan reverse solenoid: Hot short circuit

Failure content Current flows constantly to fan reverse solenoid circuit.

Controller's
action
Symptoms that
appear on
Fan remains in reverse.
machine
General
information
Causes
1 solenoid
Possible
causes and the
standard values
when normal



switch still OFF.
FAR2 (male)
Resistance
Between (1) (2)
34 44 z

switch ON.
(female) (1)
Voltage
Max. 1V
Steering and transmission controller can be suspected to be defective if no problem is found in causes 1 2 (since this is an internal
defect, it cannot be diagnosed).
D85EX, PX-15E0
11
SEN00637-00
40 Troubleshooting
Failure code [DWN1KA] HSS EPC solenoid right: Disconnection

Action code
Failure code
CALL E03
DWN1KA
Symptom HSS EPC solenoid right: Disconnection

Failure content Current does not flow when power is output to HSS EPC solenoid right circuit.
Controller's
action

Stops outputting to HSS EPC solenoid right circuit.
Symptoms that Can not turn to the right.

appear on
machine
General
information
Output state (current) to HSS EPS solenoid right can be checked in monitoring mode.
(Code 50603: Right HSS solenoid output current value)
Duplication of failure code: Turn starting switch ON and operate PCCS lever (for steering to right).
Causes

switch still OFF.
Defective HSS EPC solenoid
1
right (internal disconnection)
HSB (male)
Resistance
Possible
causes and the
standard values
when normal
Between (1) (2)

harness
2

5 15 z

switch still OFF.
HSB (female) (1)
Resistance
Max. 1 z

HSB (female) (2)
Resistance
Max. 1 z
Circuit diagram related to HSS EPC solenoid right
12
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DWN1KB] HSS EPC solenoid right: Short circuit

Action code
Failure code
CALL E03
DWN1KB
Symptom HSS EPC solenoid right: Short circuit

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.

appear on
machine
General
information
Duplication of failure code: Turn starting switch ON and operate PCCS lever (for steering to right).
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

right (internal short circuit)
HSB (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

switch still OFF.

between PTC3 (female) (35) HSB (female)
(1)
Harness short

Resistance
Min. 1 Mz

switch still OFF.
HSB (female) (1) and PTC3 (female) (3)
HSB (female) (2)
Resistance
Min. 1 Mz
D85EX, PX-15E0
13
SEN00637-00
40 Troubleshooting
Failure code [DWN1KY] HSS EPC solenoid right: Hot short circuit
Action code
Failure code
CALL E04
DWN1KY
Symptom HSS EPC solenoid right: Hot short circuit

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)
appear on
machine
General
information
Causes
1
Possible
causes and the
standard values
when normal
Defective HSS EPC solenoid a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
right
short circuit)


HSB (male)
Resistance
Between (1) (2)
5 15 z

switch ON.
between PTC3 (female) (35) HSB (female)
(1)
Voltage
Max. 1V
Steering and transmission controller can be suspected to be defective if no problem is found in causes 1 2.
14
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DWN2KA] HSS EPC solenoid left: Disconnection

Action code
Failure code
CALL E03
DWN2KA
Symptom HSS EPC solenoid left: Disconnection

Failure content Current does not flow when power is output to HSS EPC solenoid left circuit.
Controller's
action

Stops outputting to HSS EPC solenoid left circuit.
Symptoms that Cannot turn to the left.

appear on
machine
General
information
Output state (current) to HSS EPS solenoid left can be checked in monitoring mode.
(Code 50602: Left HSS solenoid output current value)
Duplication of failure code: Turn starting switch ON and operate PCCS lever (for steering to left).
Causes
Possible
causes and the
standard values
when normal

switch still OFF.
1 left
HSA (male)
Resistance
Between (1) (2)
5 15 z
harness
2


switch still OFF.
HSA (female) (1)
Resistance
Max. 1 z

HSA (female) (2)
Resistance
Max. 1 z
Circuit diagram related to HSS EPC solenoid left
D85EX, PX-15E0
15
SEN00637-00
40 Troubleshooting
Failure code [DWN2KB] HSS EPC solenoid left: Short circuit

Action code
Failure code
CALL E03
DWN2KB
Symptom HSS EPC solenoid left: Short circuit

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.

appear on
machine
General
information
Duplication of failure code: Turn starting switch ON and operate PCCS lever (for steering to left).
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

left (internal short circuit)
HSA (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

switch still OFF.

between PTC3 (female) (25) HSA (female)
(1)
Harness short

Resistance
Min. 1 Mz

switch still OFF.
HSA (female) (1) and PTC3 (female) (3)
HSA (female) (2)
Resistance
Min. 1 Mz
16
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DWN2KY] HSS EPC solenoid left: Hot short circuit
Action code
Failure code
CALL E04
DWN2KY
Symptom HSS EPC solenoid left: Hot short circuit

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)
appear on
machine
General
information
Causes
1
Possible
causes and the
standard values
when normal
Defective HSS EPC solenoid a Prepare with starting switch OFF and diagnose with starting
switch still OFF.
left
short circuit)


HSA (male)
Resistance
Between (1) (2)
5 15 z

switch ON.
between PTC3 (female) (25) HSA (female)
(1)
Voltage
Max. 1V
D85EX, PX-15E0
17
SEN00637-00
40 Troubleshooting
Failure code [DWN5KA] Fan pump EPC solenoid: Disconnection

Action code
Failure code
E01
DWN5KA
Symptom Fan pump EPC solenoid: Disconnection

Failure content Current does not flow when power is output to fan pump EPC solenoid circuit.
Controller's
action
Stops outputting power to fan pump EPC solenoid circuit.
Symptoms that
appear on
Fan speed is kept at maximum level
machine
General
information
Output state (current) to fan pump EPC solenoid can be checked in monitoring mode.
(Code 31623, 31624: Cooling fan solenoid output current)
Causes
Defective fan pump solenoid
1
Possible
causes and the
standard values
when normal
harness
2


switch still OFF.
FAC (male)
Resistance
Between (1) (2)
15 25 z

switch still OFF.
FAC (female) (1)
Resistance
Max. 1 z

FAC (female) (2)
Resistance
Max. 1 z
Circuit diagram related to fan pump EPC solenoid
18
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DWN5KB] Fan pump EPC solenoid: Short circuit

Action code
Failure code
E01
DWN5KB
Symptom Fan pump EPC solenoid: Short circuit

Failure content Abnormal current flowed when power is output to fan pump EPC solenoid circuit.
Controller's
action
Symptoms that
appear on
Fan speed is kept at maximum level
machine
General
information
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

FAC (male)
Resistance
Between (1) (2)
15 25 z
Min. 1 Mz

switch still OFF.

between PTC3 (female) (36) FAC (female)
(1)
Harness short

Resistance
Min. 1 Mz

switch still OFF.
FAC (female) (1) and PTC3 (female) (23)
FAC (female) (2)
Resistance
Min. 1 Mz
D85EX, PX-15E0
19
SEN00637-00
40 Troubleshooting
Failure code [DWN5KY] Fan pump EPC solenoid: Hot short circuit
Action code
Failure code
E02
DWN5KY
Symptom Fan pump EPC solenoid: Hot short circuit

Failure content Current flows constantly to fan pump EPC solenoid circuit.
Controller's
action

Symptoms that
Fan speed is kept at minimum level.
appear on
Overheat easily.
machine
General
information
Causes
1 (Internal disconnection and
short circuit)
Possible
causes and the
standard values
when normal



switch still OFF.
FAC (male)
Resistance
Between (1) (2)
15 25 z

switch ON.
between PTC3 (female) (36) FAC (female)
(1)
Voltage
Max. 1V
20
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DXA0KA] HSS and work equipment pump TVC solenoid:
Disconnection
1
Action code
Failure code
E01
DXA0KA
Failure content
Controller's
action
Symptom HSS and work equipment pump TVC solenoid: Disconnection

Any current does not flow when power is output to HSS and work equipment pump TVC solenoid circuit.
Stops outputting power to HSS and work equipment TVC solenoid circuit.
Symptoms that
appear on
When load is applied while engine is running at low speed, engine may tend to stall.
machine
General
information
Output state (current) to HSS and work equipment pump TVC solenoid left can be checked in monitoring mode.
(Code 01300, 01301: Output current of TVC solenoid)
Causes
Defective HSS and work
1 equipment pump TVC solenoid (Internal disconnection)
Possible
causes and the
standard values
when normal
harness
2


switch still OFF.
TVC (male)
Resistance
Between (1) (2)
9 19 z

switch still OFF.
TVC (female) (1)
Resistance
Max. 1 z

TVC (female) (2)
Resistance
Max. 1 z
Circuit diagram related to and work equipment HSS pump TVC solenoid
D85EX, PX-15E0
21
SEN00637-00
40 Troubleshooting
Failure code [DXA0KB] HSS and work equipment pump TVC solenoid:
Short circuit
1
Action code
Failure code
E01
DXA0KB
Failure content
Controller's
action
Symptom HSS and work equipment pump TVC solenoid: Short circuit
Abnormal current flowed when power is outputted to HSS and work equipment pump TVC solenoid
circuit.
Stops outputting power to HSS and work equipment TVC solenoid.
Symptoms that
appear on
When load is applied while engine is running at low speed, engine may tend to stall.
machine
General
information
Causes
1 equipment pump TVC solenoid (Internal short circuit)
Possible
causes and the
standard values
when normal

switch still OFF.
TVC (male)
Resistance
Between (1) (2)
9 19 z
Min. 1 Mz

switch still OFF.

between PTC3 (female) (17) TVC (female)
(1)
Harness short

Resistance
Min. 1 Mz

switch still OFF.
Between wiring harness from PTC3 (female)
(17) to TVC (female) (1) and wiring harness
from PTC3 (female) (3) to TVC (female) (2)
Resistance
Min. 1 Mz
Circuit diagram related to HSS and work equipment pump TVC solenoid
22
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DXA0KY] HSS and work equipment pump TVC solenoid:
Hot short circuit
1
Action code
Failure code
E01
DXA0KY
Symptom HSS and work equipment pump TVC solenoid: Hot short circuit
Failure content Current flows constantly to HSS and work equipment pump TVC solenoid circuit.
Controller's
action
Stops outputting power to HSS and work equipment TVC solenoid circuit.
Symptoms that
Large turning radius
appear on
Work equipment speed is slow.
machine
General
information
Causes
1 equipment pump TVC solenoid (Internal disconnection)
Possible
causes and the
standard values
when normal



switch still OFF.
TVC (male)
Resistance
Between (1) (2)
9 19 z

switch ON.
between PTC3 (female) (17) TVC (female)
(1)
Voltage
Max. 1V
Circuit diagram related to HSS and work equipment pump TVC solenoid
D85EX, PX-15E0
23
SEN00637-00
40 Troubleshooting
Failure code [DXH4KA] 1st clutch ECMV: Disconnection

Action code
Failure code
CALL E03
DXH4KA
Symptom 1st clutch ECMV: Disconnection

Failure content Current does not flow when power is output to transmission 1st clutch solenoid circuit.
Controller's
action

Stops outputting to transmission 1st clutch solenoid circuit.
Symptoms that Auto shift down function does not work.

appear on
machine
General
information
Output state (current) to 1st clutch solenoid can be checked in monitoring mode.
(Code 31602, 31612: 1st clutch ECMV output current value)
Causes
1
Possible
causes and the
standard values
when normal
Defective 1st clutch ECMV

harness
2


switch still OFF.
S1T (male)
Resistance
Between (1) (2)
5 25 z

switch still OFF.
S1T (female) (1)
Resistance
Max. 1 z

S1T (female) (2)
Resistance
Max. 1 z
24
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DXH4KB] 1st clutch ECMV: Short circuit

Action code
Failure code
CALL E03
DXH4KB
Symptom 1st clutch ECMV: Short circuit

Failure content Abnormal current flowed when power was output to transmission 1st clutch solenoid circuit.
Controller's
action


appear on
machine
General
information
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

S1T (male)
Resistance
Between (1) (2)
5 25 z
Min. 1 Mz

switch still OFF.

between PTC3 (female) (6) S1T (female)
(1)
Harness short

Resistance
Min. 1 Mz

switch still OFF.
(6) to S1T (female) (1) and wiring harness
from PTC3 (female) (23) to S1T (female) (2)
Resistance
Min. 1 Mz
D85EX, PX-15E0
25
SEN00637-00
40 Troubleshooting
Failure code [DXH4KY] 1st clutch ECMV: Hot short circuit

Action code
Failure code
CALL E03
DXH4KY
Symptom 1st clutch ECMV: Hot short circuit

Failure content Current flows constantly to transmission 1st clutch solenoid circuit.
Controller's
action


appear on
machine
General
information
Causes
short circuit)
Possible
causes and the
standard values
when normal



switch still OFF.
S1T (male)
Resistance
Between (1) (2)
5 25 z

switch ON.
(1)
Voltage
Max. 1V
Circuit diagram related to transmission 1st clutch ECMV solenoid
26
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection

Action code
Failure code
CALL E03
DXH5KA
Symptom 2nd clutch ECMV: Disconnection

Failure content Current does not flow when power is output to transmission 2nd clutch solenoid circuit.
Controller's
action

Stops outputting to transmission 2nd clutch solenoid circuit.

appear on
machine
General
information
Output state (current) to 2nd clutch solenoid can be checked in monitoring mode.
(Code 31603, 31613: 2nd clutch ECMV output current value)
Causes

switch still OFF.
Defective 2nd clutch ECMV.
1
S2T (male)
Resistance
Possible
causes and the
standard values
when normal
Between (1) (2)

harness
2

5 25 z

switch still OFF.
S2T (female) (1)
Resistance
Max. 1 z

S2T (female) (2)
Resistance
Max. 1 z
D85EX, PX-15E0
27
SEN00637-00
40 Troubleshooting
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit

Action code
Failure code
CALL E03
DXH5KB
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
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

S2T (male)
Resistance
Between (1) (2)
5 25 z
Min. 1 Mz

switch still OFF.

(1)
Harness short

Resistance
Min. 1 Mz

switch still OFF.
Resistance
Min. 1 Mz
28
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DXH5KY] 2nd clutch ECMV: Hot short circuit

Action code
Failure code
CALL E03
DXH5KY
Symptom 2nd clutch ECMV: Hot short circuit

Failure content Current flows constantly to transmission 2nd clutch solenoid circuit.
Controller's
action


appear on
machine
General
information
Causes
Possible
causes and the
standard values
when normal

switch still OFF.
S2T (male)
Resistance
short circuit)
Between (1) (2)
5 25 z



switch ON.
(1)
Voltage
Max. 1V
D85EX, PX-15E0
29
SEN00637-00
40 Troubleshooting
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection

Action code
Failure code
CALL E03
DXH6KA
Symptom 3rd clutch ECMV: Disconnection

Failure content Current does not flow when power is output to transmission 3rd clutch solenoid circuit.
Controller's
action

Stops outputting to transmission 3rd clutch solenoid circuit.

appear on
machine
General
information
Output state (current) to 3rd clutch solenoid can be checked in monitoring mode.
(Code 31604, 31614: 3rd clutch ECMV output current value)
Causes
1
Possible
causes and the
standard values
when normal
Defective 3rd clutch ECMV

harness
2


switch still OFF.
S3T (male)
Resistance
Between (1) (2)
5 25 z

switch still OFF.
S3T (female) (1)
Resistance
Max. 1 z

S3T (female) (2)
Resistance
Max. 1 z
30
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit

Action code
Failure code
CALL E03
DXH6KB
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
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

S3T (male)
Resistance
Between (1) (2)
5 25 z
Min. 1 Mz

switch still OFF.

(1)
Harness short

Resistance
Min. 1 Mz

switch still OFF.
Resistance
Min. 1 Mz
D85EX, PX-15E0
31
SEN00637-00
40 Troubleshooting
Failure code [DXH6KY] 3rd clutch ECMV: Hot short circuit

Action code
Failure code
CALL E03
DXH6KY
Symptom 3rd clutch ECMV: Hot short circuit

Failure content Current flows constantly to transmission 3rd clutch solenoid circuit.
Controller's
action


appear on
machine
General
information
Causes
short circuit)
Possible
causes and the
standard values
when normal



switch still OFF.
S3T (male)
Resistance
Between (1) (2)
5 25 z

switch ON.
(1)
Voltage
Max. 1V
32
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DXH7KA] Reverse clutch ECMV: Disconnection

Action code
Failure code
CALL E03
DXH7KA
Symptom Reverse clutch ECMV: Disconnection

Failure content Current does not flow when power is output to transmission reverse clutch solenoid circuit.
Controller's
action

Stops outputting to transmission reverse clutch solenoid circuit.
Symptoms that
appear on
machine
General
information
Output state (current) to reverse clutch solenoid can be checked in monitoring mode.
(Code 31606, 31616: Output current of reverse clutch ECMV)
Causes
1 ECMV
Possible
causes and the
standard values
when normal
harness
2


switch still OFF.
SRT (male)
Resistance
Between (1) (2)
5 25 z

switch still OFF.
SRT (female) (1)
Resistance
Max. 1 z

SRT (female) (2)
Resistance
Max. 1 z
D85EX, PX-15E0
33
SEN00637-00
40 Troubleshooting
Failure code [DXH7KB] Reverse clutch ECMV: Short circuit

Action code
Failure code
CALL E03
DXH7KB
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
Causes
1 solenoid
Possible
causes and the
standard values
when normal

switch still OFF.
SRT (male)
Resistance
Between (1) (2)
5 25 z
Min. 1 Mz

switch still OFF.

between PTC3 (female) (37) SRT (female)
(1)
Harness short

Resistance
Min. 1 Mz

switch still OFF.
(37) to SRT (female) (1) and wiring harness
from PTC3 (female) (13) to SRT (female) (2)
Resistance
Min. 1 Mz
34
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DXH7KY] Reverse clutch ECMV: Hot short circuit

Action code
Failure code
CALL E03
DXH7KY
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
Causes
Possible
causes and the
standard values
when normal

ECMV
1
short circuit)



switch still OFF.
SRT (male)
Resistance
Between (1) (2)
5 25 z

switch ON.
between PTC3 (female) (37) SRT (female)
(1)
Voltage
Max. 1V
D85EX, PX-15E0
35
SEN00637-00
40 Troubleshooting
Failure code [DXH8KA] Forward clutch ECMV: Disconnection

Action code
Failure code
CALL E03
DXH8KA
Symptom Forward clutch ECMV: Disconnection

Failure content Current does not flow when power is output to transmission forward clutch solenoid circuit.
Controller's
action

Stops outputting to transmission forward clutch solenoid circuit.
Symptoms that
appear on
machine
General
information
Output state (current) to forward clutch solenoid can be checked in monitoring mode.
(Code 31608, 31622: Output current of forward clutch ECMV)
Causes
1 ECMV
Possible
causes and the
standard values
when normal
harness
2


switch still OFF.
SFT (male)
Resistance
Between (1) (2)
5 25 z

switch still OFF.
SFT (female) (1)
Resistance
Max. 1 z

SFT (female) (2)
Resistance
Max. 1 z
36
D85EX, PX-15E0
40 Troubleshooting
SEN00637-00
Failure code [DXH8KB] Forward clutch ECMV: Short circuit

Action code
Failure code
CALL E03
DXH8KB
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
Causes
1 ECMV
Possible
causes and the
standard values
when normal

switch still OFF.
SFT (male)
Resistance
Between (1) (2)
5 25 z
Min. 1 Mz

switch still OFF.

between PTC3 (female) (27) SFT (female)
(1)
Harness short

Resistance
Min. 1 Mz

switch still OFF.
(27) to SFT (female) (1) and wiring harness
from PTC3 (female) (13) to SFT (female) (2)
Min. 1 Mz
D85EX, PX-15E0
37
SEN00637-00
40 Troubleshooting
Failure code [DXH8KY] Forward clutch ECMV: Hot short circuit

Action code
Failure code
CALL E03
DXH8KY
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
Causes
Possible
causes and the
standard values
when normal

ECMV
1
short circuit)



switch still OFF.
SFT (male)
Resistance
Between (1) (2)
5 25 z

switch ON.
between PTC3 (female) (27) SFT (female)
(1)
Voltage
Max. 1V
38
D85EX, PX-15E0
SEN00637-00

40
SEN00638-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
40 Troubleshooting
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
SEN00638-00
40 Troubleshooting
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
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Before troubleshooting of electrical system
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
source
Fuse
capacity (A)
30
Standby electric power supply
Switched electric
power supply
20
Horn, Electrical intake air heater, Air suspension seat
20
Head lamp
20
Rear lamp
20
Transmission and steering controller, Monitor panel,

KOMTRAX
Fuse No.
3
4
5
Constant power
source
Fuse box B [FS2]

Fuse No.
Electric supply
source
Fuse
capacity (A)
Constant power
source
20
Starting switch (B) (with 20 A circuit breaker in the subsequent circuit)
30
Steering and transmission controller (main electric power supply)
30
Backup alarm
30
Air conditioner (with 20 A circuit breaker in the subsequent circuit)
30
Starting switch (ACC), Engine controller
2
3
4
Switched electric
power supply
Cab fuse box C

Fuse No.
Electric supply
source
Fuse
capacity (A)
10
Accessory electric power supply (12 V electric power supply)
20
Radio, Room lamp, Cigarette lighter, Additional light
20
Glass with heating wire
10
Rear wiper
10
Front wiper
10
Left and right door wipers
3
4
Switched electric
power supply
D85EX, PX-15E0
SEN00638-00
40 Troubleshooting
Fuse installation position and No.
Circuit breaker
No.
Connector No.
Capacity (A)
Circuit
CB105
105
Main power source
CB30H
30
Engine controller constant power source
CB105
105
Main power source for electrical intake air heater
CB30
30
Constant power source
CB1
20
Starting switch
CB2
20
Air conditioner
Remarks
Installed in the
battery box
located at the left
side of the operator cab
Installed in the
dash board air
conditioner filter
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
40 Troubleshooting
SEN00638-00

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
Related
information
Problem that appears on machine

Information related to detected trouble or troubleshooting
Cause
Standard value in normal state required to judge the
assumed cause (good or not)
Remarks required to judge whether the cause is good
Possible causes
and standard
value in normal
state
Standard value in normal state/Remarks on troubleshooting
<Phenomenon of defective harness>

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
A harness not connected to the power (24 V) circuit comes
2
into contact with the power (24 V) circuit.
Short circuit
Causes by which a trouble
A harness of an independent circuit abnormally comes into
is assumed to be defected
contact with one of another circuit.
(The order number indicates a serial number, not <Notes on troubleshooting>
(1) Method of indicating connector numbers and handling of Ta priority sequence.)
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 Tadapters 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 ()
leads as shown below unless especially specified.
4
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: indicate 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
SEN00638-00
40 Troubleshooting
E-1 Engine does not start.
Symptom of
failure
The starting motor does not turn and accordingly the engine does not start.
General
information
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
turning the starting switch ON, the main electric power supply system can be suspected to be defective. 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.)
Causes
1 Insufficient battery capacity

Battery voltage
Battery specific gravity
Min. 24 V
Min. 1.26

switch still OFF.
2
Defective starting switch

Defective parking lever

switch
3
(internal defect or defective
adjustment)
Possible
causes and the
standard values
when normal
Starting switch
Switch position
Resistance
Between 250 (B) and

280 (C)
OFF
Min. 1 Mz
START
Max. 1 z

switch ON.
Parking lever
Monitor panel
Free position
Lock position
Other than P is
displayed.
P is displayed.
4
Defective neutral safety relay If the engine starts in accordance with the engine starting operation
after the neutral safety relay (NSF) is replaced with another one
while the starting switch is set to OFF, the neutral safety relay is
defective.
Defective alternator

switch ON.
Alternator
Voltage
Between terminal R and ground
Max. 1 V
Detective starting motor

(internal defect)
Starting motor
Voltage
Electric power supply: between

terminal ST/B and ground
20 30 V
Charge: between ST (2) and

ground
Max. 1 V
Starting: between ST (1) and

ground
20 30 V
When each voltage of electric power supply, charging, and starting

is normal but the starting motor does not rotate, the starting motor is
defective.
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Causes
Possible
causes and the
standard values
when normal
Defective diode
harness
8

switch still OFF.
Diagnose diode RSD (male)
See the Inspection procedure of diode in the Testing and
adjusting section.
switch still OFF.
Wiring harness between 280 (C) NSF
(female) (3)
Resistance
Max. 1 z
Wiring harness between NSF (female) (5)

ST (female) (1)
Resistance
Max. 1 z

switch ON.
9


between alternator R terminal ST (female)
(2), alternator R terminal PTC1 (female)
(15) and alternator R terminal S04 (female)
(9)
Voltage
Max. 1V

switch still OFF.
10

(contact with ground circuit) between 280 (C) NSF (female) (3)
between NSF (female) (5) ST (female) (1)
D85EX, PX-15E0
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
SEN00638-00
40 Troubleshooting
Circuit diagram related to engine start and charge
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
E-2 The preheater does not operate.
Symptom of
failure
The preheater does not operate.
General
information
a This troubleshooting describes the procedures to be followed when the automatic and manual preheating 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 available. When either function is performed, the preheating lamp comes on.
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 defective. So, check the main electric power supply system.
(If the failure code [CA153], [CA154], [CA2555] or [CA2556] is displayed, firstly conduct this troubleshooting.)
Causes

switch still OFF.

Starting switch
Switch position
Resistance
Between 250 (B)

255 (R1)
OFF
Min. 1 Mz
HEAT (R1)
Max. 1 z
Defective fuse
(FS1, FS2)
If the fuse is burnt, it is highly possible that a defective grounding,

etc. has occurred in the circuit.

(CB105H)
If the breaker is cutout, it is highly possible that a defective grounding, etc. has occurred in the circuit.
Defective preheater relay

Possible
causes and the
standard values
when normal

switch ON.
If preheating starts normally at the intake air temperature below
minus 5C after the preheater relay RHR is replaced with another
one, the preheater relay RHR is defective.
a Prepare with the starting switch OFF and diagnose with the starting switch HEAT.
Defective heater relay

(internal defect)
Heater relay
Voltage
Electric power supply: between

terminal HT/B and ground
20 30V
Signal: between terminal HT/C

and ground
20 30V
When the both voltages of electric power supply and signal are normal and no operating noise is heard, the heater relay is defective.
Defective diode

switch still OFF.
Diagnose diode HDT (male)
adjusting section.

switch still OFF.
Defective electrical intake air
7
heater (internal defect)
Electrical intake air heater
Continuity
Between terminals
D85EX, PX-15E0
Continue
SEN00638-00
40 Troubleshooting
Causes

switch still OFF.
harness
8
Possible
causes and the
standard values
when normal
Wiring harnesses between starting switch

255 (R1) RHR (female) (3) and between
starting switch 255 (R1) HT/C
Resistance
Max. 1 z
Wiring harness between RHR (female) (5)

FS1 (2)
Resistance
Max. 1 z
Wiring harness between battery relay BRC

terminal HT/B terminal
Resistance
Max. 1 z
Wiring harness between heater relay HT/A

terminal electrical intake air heater
Resistance
Max. 1 z

switch still OFF.
between starting switch 255 (R1) RHR (3)
and starting switch 255 (R1) HT/C
9
10
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

between battery relay BRC terminal HT/B
Resistance
Min. 1 Mz

between heater relay HT/A electrical intake
air heater terminal
Resistance
Min. 1 Mz

(contact with ground circuit) between RHR (female) (5) FS1 (2)
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related engine preheat
D85EX, PX-15E0
11
SEN00638-00
40 Troubleshooting
E-3 The monitor panel does not light up at all when the starting switch is
turned ON.
1
Symptom of
failure
If the battery relay does not make operating sound when the starting switch is turned on, the main
electric power supply system can be suspected to be defective. So, check the main electric power
supply system.
The monitor panel does not light up at all when the starting switch is turned ON.
General
information
When the starting switch is turned ON, the gear speed indicator, multi-information section, gauge
section, and lamp section light up for approximately 2 sec. and then go out.
Causes

When the fuse FS1-5 is blown, the circuit probably has a ground
fault.
switch still OFF.
harness
2
Possible
causes and the
standard values
when normal

starting switch 270 (ACC)
Resistance
Max. 1 z

fuse FS1-5
Resistance
Max. 1 z

GND02
Resistance
Max. 1 z

switch still OFF.
3
Between ground wiring harness between

S03 (female) (1) (2) starting switch 270
(ACC)
between S03 (female) (5) (6) and fuse FS1-5
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch ON.
12
S03
Voltage
Between (1) (2) (3) (4)
20 30 V
Between (5) (6) (3) (4)
20 30 V
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to electric power supply to monitor panel
D85EX, PX-15E0
13
SEN00638-00
40 Troubleshooting
E-4 When the starting switch is turned ON, the monitor panel
completely remains lighted and does not go out.
Symptom of
failure
When the starting switch is turned ON, the monitor panel completely remains lighted and does not go
out.
General
information
When the starting switch is turned ON, the gear speed indicator, multi-information section, gauge
section, and lamp section light up for approximately 2 sec. and then go out.
Possible
causes and the
standard values
when normal
14
Cause
Standard value when normal and remarks for troubleshooting

D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
E-5 When the starting switch is turned ON, the radiator coolant level
caution lamp flashes.
Symptom of
failure
Radiator coolant level caution lamp flashes.
General
information
Regarding basic check items, the caution lamp flashes if any abnormality is detected before engine
starting.
Causes
Radiator coolant level is too

1 low.
Since the low radiator coolant level is detected, check the radiator
coolant level.
(The lamp flashes in case that the level is lower than the specification.)
switch still OFF.
2
Possible
causes and the
standard values
when normal
Defective radiator coolant

level sensor
WLD (male)
Between (1) (2)
harness
3
Resistance
When normal
Max. 1 z
When level is too low.
Min. 1 Mz

switch still OFF.
WLD (female) (1)
Resistance
Max. 1 z
Wiring harness between WLD (female) (2)

and ground GND03
Resistance
Max. 1 z

switch ON.
S03
Voltage
Between (11) and

ground
When normal
Max. 1V
When level is too low.
Min. approx. 7 V
Circuit diagram related to electric power supply to monitor panel
D85EX, PX-15E0
15
SEN00638-00
40 Troubleshooting
E-6 While the engine is running, the battery charge level caution lamp
flashes.
1
Symptom of
failure
The battery charge level caution lamp flashes.
General
information
When any abnormality is detected during engine operating, the battery charge level caution lamp
flashes.
Causes
Defective alternator
1 (insufficient power generation)

Alternator
Engine speed
Voltage
Between terminal R
and ground
Min. medium speed

(half)
20 30 V

switch still OFF.
Possible
causes and the
standard values
when normal
harness
2

alternator terminal AL/R
Resistance
Max. 1 z
Wiring harness between alternator terminal

AL/E and ground
Resistance
Max. 1 z

alternator terminal AL/R
Resistance
Max. 1 z

switch still OFF.
between S04 (female) (9) alternator termiDefective harness grounding nal AL/R and S04 (female) (9) PTC1
3
(contact with ground circuit) (female) (15)
Resistance
Min. 1 Mz

between PTC3 (female) (4) starting switch
260 (BR) and PTC3 (female) (4) SW (battery relay)
Resistance
Min. 1 Mz
16
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to engine start and charge
D85EX, PX-15E0
17
SEN00638-00
40 Troubleshooting
E-7 While the engine is running, the emergency warning item flashes. 1
Symptom of
failure
(1) The engine oil pressure caution lamp flashes.
General
information
When any abnormality is detected during engine running, the engine oil pressure caution lamp
flashes and the alarm buzzer sounds.
The engine oil pressure sensor signal is used to communicate with the engine controller.
Causes
Possible
causes and the
standard values
when normal
Reduction of engine oil pres- Check the engine oil pressure, as the drop of engine oil pressure is
1 sure
detected.
Carry out the troubleshooting of S-12 Oil pressure drops.
Defective engine hydraulic
2
system
If no problem is found in cause 1, the engine oil pressure sensor circuit can be suspected to be defective. So, carry out the troubleshooting of Failure codes [CA135] and [CA141] Abnormal engine
oil pressure sensor.
Symptom of
failure
(2) The coolant temperature caution lamp flashes.
General
information
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
engine water temperature gauge.
The input state (temperature) from the coolant temperature sensor can be checked in the monitoring
mode.
(Code 04104: Coolant temperature)
Possible
causes and the
standard values
when normal
18
Causes
Coolant overheats
Since the coolant overheat is detected, check the coolant temperature. (At the coolant temperature over 105C, the lamp flashes and
the buzzer sounds. Over 102C, just the lamp flashes.)
Defective coolant tempera2 ture sensor system

(Engine controller circuit)
When the cause 1 is not the real cause, the coolant temperature
sensor circuit can be suspected to be defective. So, carry out the
troubleshooting of E-9 The coolant temperature gauge does not
indicate correctly.
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Symptom of
failure
(3) The power train oil temperature caution lamp flashes.
General
information
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.
The input state (temperature) from the power train oil temperature sensor can be checked in the
monitoring mode.
(If the failure code [DGT1KA] or [DGT1KX] is displayed, firstly diagnose the displayed code.)
Possible
causes and the
standard values
when normal
Causes

1 overheat
Since the power train oil overheat is detected, check the power train
oil temperature.
(At the oil temperature over 130C, the lamp flashes and the buzzer
sounds. Over 120C, just the lamp flashes.)
If no problem is found in cause 1, the power train oil temperature

Defective power train oil temsensor 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
failure
(4) The hydraulic oil temperature caution lamp flashes.
General
information
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.
The input state (temperature) from the hydraulic oil temperature sensor can be checked at monitoring mode.
(If the failure code [DGS1KX] is displayed, firstly diagnose the displayed code.)
Possible
causes and the
standard values
when normal
Causes
Hydraulic oil overheat

Since the hydraulic oil overheat is detected, check the hydraulic oil
temperature. (At the hydraulic oil temperature over 110C, the lamp
flashes and the buzzer sounds. Over 100C, just the lamp flashes.)
Defective hydraulic oil tem2 perature sensor circuit

(Monitor panel circuit)
When the cause 1 is not the real cause, the hydraulic oil temperature sensor circuit can be suspected to be defective. So, carry out
the troubleshooting of E-11 The hydraulic oil temperature gauge
does not indicate correctly.
D85EX, PX-15E0
19
SEN00638-00
40 Troubleshooting
E-8 While the preheater is operating, the preheating pilot lamp does not
light up.
1
Symptom of
failure
While the preheater is operating, the preheating pilot lamp does not light up.
General
information
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 troubleshooting of E-2 The preheater does not operate.)
For preheating, both the Automatic preheating function and Manual preheating function are available. When either function is performed, the preheating lamp comes on.
Cause
harness
1
(Disconnection or defective
Possible
causes and the
standard values
when normal

switch still OFF.
RHR (female) (3)
Resistance
Max. 1 z

switch still OFF.

(Contact with ground circuit) Between ground and wiring harness
between S03 (female) (9) RHR (female)
(3)
Resistance
Min. 1 Mz

switch ON.
S03
Between (9) ground
20
Starting switch
Voltage
ON
Min. 1 V
HEAT
Min. 7 V
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to engine preheat
D85EX, PX-15E0
21
SEN00638-00
40 Troubleshooting
E-9 The coolant temperature gauge does not indicate correctly.
Symptom of
failure
(1) Although the coolant temperature is rising normally, the indication of the coolant temperature stays
in white range (a).
(2) Although the coolant temperature is stabilized normally, the indication of the coolant temperature
rises to red range (c).
General
information
Signals of the coolant temperature sensor are input into the engine controller and that information is
transmitted to the monitor panel through communication system.
mode.
Cause
Possible
causes and the
standard values
when normal
Defective coolant temperature sensor circuit

Since the coolant temperature sensor circuit is supposed to be
defective, carry out the troubleshooting of failure codes [CA144]
and [CA145].
When the possible cause 1 is not the real cause, the monitor panel
is supposed to be defective. (As it is an internal defect, it cannot be
diagnosed.)
Symptom of
failure
(3) The coolant temperature does not match to the indication of coolant temperature gauge.
(4) The coolant temperature gauge does not match with the indication of coolant temperature monitor.
General
information
Signals of the coolant temperature sensor are input into the engine controller and that information is
transmitted to the monitor panel through communication system.
mode.
Cause
Possible
causes and the
standard values
when normal

a Diagnose with starting switch ON or with engine started.
Caution lamp (d)
OFF
Flashing
White range (a)

Green range (b)
Red range (c)
Coolant temperature gauge and caution lamp
22
D85EX, PX-15E0
SEN00638-00
40 Troubleshooting
E-10 Power train oil temperature gauge does not indicate correctly.
Symptom of
failure
(1) Although the power train oil temperature is rising normally, the indication of the power train oil temperature stays in white range (a).
(2) Although the power train oil temperature is stabilized normally, the indication of the power train oil
temperature rises to red range (c).
General
information
monitoring mode.
If an abnormality takes place in the power train oil temperature sensor circuit, the failure code
[DGT1KA] or [DGT1KX] may be displayed.
Causes

switch still OFF.
Defective power train oil

temperature sensor
1
(internal disconnection or
short circuit)
453 (male)
Between (1) (2)
Between (1) and
ground
harness
2
Possible
causes and the
standard values
when normal
Torque converter
oil temperature
Resistance
3.5 90 kz
10 100C
Min. 1 Mz

switch still OFF.
453 (female) (1)
Resistance
Max. 1 z
Wiring harness between 453 (female) (2)

S03 (female) (3)
Resistance
Max. 1 z

switch still OFF.
Defective grounding of wiring
3 harness
Resis(contact with GND circuit)
Min. 1 Mz
tance
(1)
switch ON.
4


(1)
Voltage
Max. 1V

between 453 (female) (2) S03 (female) (3)
Voltage
Max. 1V

switch still OFF.
24
S04 (female)
Resistance
Between (12) and

ground
10 100C
3.5 kz 90 kz
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Symptom of
failure
(3) The power train oil temperature does not match with the indication of oil temperature gauge.
(4) The power train oil temperature gauge does not match with the indication of the power train oil temperature monitor.
General
information
monitoring mode.
Cause
Possible
causes and the
standard values
when normal

Caution lamp (d)
OFF
Flashing
White range (a)

Green range (b)
Red range (c)
Power train oil temperature gauge and caution lamp
D85EX, PX-15E0
25
SEN00638-00
40 Troubleshooting
E-11 Hydraulic oil temperature gauge does not indicate properly.
Symptom of
failure
(1) Though the hydraulic oil temperature rises normally, the gauge indication does not rise from white
range (a).
(2) Although the hydraulic oil temperature is stabilized normally, but gauge indication rises to red range
(c).
General
information
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
[DGS1KX] may be displayed.
The input state (temperature) from the hydraulic oil temperature sensor can be checked in monitoring mode.
(Code: 04401 hydraulic oil temperature)
Causes
Defective hydraulic oil temperature sensor
1
short circuit)
harness
2
Possible
causes and the
standard values
when normal

switch still OFF.
SDS (male)
Resistance
Between (1) (2)
3.5 kz 90 kz
Min. 1 Mz

switch still OFF.
SDS (female) (1)
Resistance
Max. 1 z

SDS (female) (2)
Resistance
Max. 1 z

switch still OFF.
3 harness
Resis(contact with GND circuit)
Min. 1 Mz
tance
(1)
switch ON.
4

(1)
Voltage
Max. 1V

(2)
Voltage
Max. 1V

switch still OFF.
5

26
PTC1 (female)
Resistance
Between (9) (21)
3.5 kz 90 kz
Min. 1 Mz
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to hydraulic oil temperature sensor
Symptom of
failure
(3) Actual temperature of the hydraulic oil and the indication of the oil temperature gauge do not match.
(4) Indication of hydraulic oil temperature gauge and hydraulic oil temperature monitor do not match.
General
information
The input state (temperature) from the hydraulic oil temperature sensor can be checked at monitoring mode.
Cause
Possible
causes and the
standard values
when normal

Caution lamp (d)
OFF
Flashing
White range (a)

Green range (b)
Red range (c)
Hydraulic oil temperature gauge and caution lamp
D85EX, PX-15E0
27
SEN00638-00
40 Troubleshooting
E-12 Fuel gauge does not indicate properly.
Symptom of
failure
Fuel gauge does not indicate properly.
General
information
The input state (voltage signal) from the fuel level sensor can be checked in monitoring mode.
(Code: 04200 fuel level sensor voltage)
Cause
Defective fuel level sensor
short circuit)
harness
2
Possible
causes and the
standard values
when normal

switch still OFF.
423 (male)
Fuel level
Resistance
Between (1) (2)

ground
Full
Approx. 4 z
Empty
Approx. 85 z

switch still OFF.
423 (female) (1)
Resistance
Max. 1 z
Wiring harness among 423 (female) (2)

S03 (female) (3), (4) ground
Resistance
Max. 1 z

switch still OFF.
3 harness
Resis(Contact with GND circuit)
Min. 1 Mz
tance
(1)
switch ON.
4
(Contact with 24 V circuit)

(1)
Voltage
Max. 1V

between 423 (female) (2) S03 (female) (3)
(4)
Voltage
Max. 1V
Circuit diagram related to fuel level sensor
28
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
E-13 Gear speed and engine speed are not indicated properly.
Symptom of
failure
Gear speed and engine speed are not indicated properly.
General
information
Signals of gear speed and engine speed are sent and received through communication by steering
transmission controller and engine controller.
Possible
causes and the
standard values
when normal
Cause

E-14 The preset mode and service meter do not indicate properly.
Symptom of
failure
(1) While engine is running, the service meter does not advance.
General
information
The service meter accumulates time while the monitor panel is receiving engine run signals (alternator signals).
The display data of the preset mode and service meter is received from the S/T and T/M controller
through communication system.
Causes
Possible
causes and the
standard values
when normal
Defective alternator signal

circuit
When the battery charge level caution lamp flashes during engine
operation, carry out the troubleshooting of "E-6 While engine is running, battery charge level caution lamp flashes."
Defective monitor panel

(Gauge or lamp module)
Symptom of
failure
(2) Shift mode and service meter are not displayed at all.
General
information
The display data are sent and received through communication by the steering and transmission
controller.
Possible
causes and the
standard values
when normal
Cause
D85EX, PX-15E0

29
SEN00638-00
40 Troubleshooting
E-15 The warning lamp does not flash or does not go out.
Symptom of
failure
The warning lamp does not flash or does not go out.
General
information
Possible
causes and the
standard values
when normal
30
Cause

D85EX, PX-15E0
SEN00638-00
40 Troubleshooting
E-16 The alarm buzzer does not sound or does not stop.
Symptom of
failure
The alarm buzzer does not sound or does not stop.
General
information
When a short circuit occurs in the alarm buzzer system, the failure code [DV00KB] is displayed but
no other failure codes are displayed.
Cause

a Prepare with the starting switch OFF, then carry out troubleshooting without turning the starting switch ON.

Defective alarm buzzer

short circuit)
Possible
causes and the
standard values
when normal
harness
3
Starting switch
Switch position
Resistance
Between (B) 270

(ACC)
OFF
Min. 1 Mz
ON(ACC)
Max. 1 z

switch still OFF.
217 (male)
Continuity
Between (2) (1)
Continue
Between (1), (2) ground
No continuity

switch still OFF.
217 (female) (1)
Resistance
Max. 1 z

starting switch 270 (ACC)
Resistance
Max. 1 z

switch still OFF.
between starting switch 270 (ACC) 271
4 harness
(female) (2)
(Contact with GND circuit)
between 217 (female) (1) S03 (female)
(18)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch ON.
5
32
Defective monitor panel

(Gauge or lamp module)
S03
Between (18)
ground
Alarm buzzer
Voltage
When stopping
20 30V
When turned ON
(sounding)
Max. 3V
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to alarm buzzer
D85EX, PX-15E0
33
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40 Troubleshooting
E-17 Auto shift down does not operate or does not release.
Symptom of
failure
The auto shift down does not operate or does not release.
General
information
Causes
Defective auto shift down
switch
1
short circuit)
Possible
causes and the
standard values
when normal
harness
2

switch still OFF.
ASD (male)
Between (2) (3)
Auto shift down

switch
Resistance
OFF(0)
Min. 1 Mz
ON(1)
Max. 1 z

switch still OFF.
ASD (female) (2)
Resistance
Max. 1 z
Wiring harness between ASD (female) (3)

and ground
Resistance
Max. 1 z

switch ON.
3 harness
(contact with GND circuit)
between PTC2 (female) (37) ASD (female) Voltage
Max. 1V
(2)
switch ON.
4
34

Limitation of function by
controller
Between PTC2 (37)

PTC3 (21), (31), (32),
(33)
Auto shift down

switch
Voltage
OFF(0)
5 11 V
ON(1)
Max. 1 V
If no problem is found in causes 1 4, the steering and transmission

controller may be restricting the function because of other causes.
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to auto shift down switch
D85EX, PX-15E0
35
SEN00638-00
40 Troubleshooting
E-18 Buzzer cancel switch does not work.

Symptom of
failure
Buzzer cancel switch does not work.
General
information
Causes

switch still OFF.
Defective buzzer cancel

1 switch (internal disconnection or short circuit)
BUZ (male)
Between (1) (2)
Between (1) (3)
Buzzer cancel
switch
Resistance
OFF (Center)
Min. 1 Mz
t (Right)
Max. 1 z
OFF (Center)
Min. 1 Mz
U (Left)
Max. 1 z

switch still OFF.
harness
2
Possible
causes and the
standard values
when normal

BUZ (female) (2)
Resistance
Max. 1 z

BUZ (female) (3)
Resistance
Max. 1 z
Wiring harness between BUZ (female) (1)

GND01
Resistance
Max. 1 z

switch still OFF.
Defective harness grounding between PTC2 (female) (36) BUZ (female)
3
Resistance
Min. 1 Mz

between PTC2 (female) (26) BUZ (female)
(3)
Resistance
Min. 1 Mz

switch ON.
36

Steering and transmission controller
Buzzer cancel
switch
Voltage
Between PTC2 (36)

PTC3 (21), (31), (32),
(33)
OFF (Center)
5 11 V
t (Right)
Max. 1 V
Between PTC2 (26)

PTC3 (21), (31), (32),
(33)
OFF (Center)
5 11 V
U (Left)
Max. 1 V
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to buzzer cancel switch
D85EX, PX-15E0
37
SEN00638-00
40 Troubleshooting
E-19 The information switch does not work.

Symptom of
failure
Information switch does not work.
General
information
Causes

switch still OFF.
Defective information switch

short circuit)
CUR (male)
Between (1) (2)
Between (1) (3)
Information
switch
Resistance
OFF (Center)
Min. 1 Mz
> (Right)
Max. 1 z
OFF (Center)
Min. 1 Mz
< (Left)
Max. 1 z

switch still OFF.
harness
2
Possible
causes and the
standard values
when normal

CUR (female) (2)
Resistance
Max. 1 z

CUR (female) (3)
Resistance
Max. 1 z
Wiring harness between CUR (female) (1)

GND01
Resistance
Max. 1 z

switch still OFF.
Defective harness grounding between PTC2 (female) (16) CUR (female)
3
between PTC2 (female) (6) CUR (female)
(3)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch ON.
38

Steering and transmission

controller
Information
switch
Voltage
Between PTC2 (16)

PTC3 (21), (31), (32),
(33)
OFF (Center)
5 11 V
> (Right)
Max. 1 V
Between PTC2 (6)

PTC3 (21), (31), (32),
(33)
OFF (Center)
5 11 V
< (Left)
Max. 1 V
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to information switch
D85EX, PX-15E0
39
SEN00638-00
40 Troubleshooting
E-20 The manual mode does not operate or does not release.
Symptom of
failure
The manual mode or preset mode does not operate or does not release.
General
information
Causes
Defective manual mode
1 switch

switch still OFF.
MAM (male)
Between (2) (3)
Manual mode switch
Resistance
Manual (O)
Min. 1 Mz
Preset (I)
Max. 1 z

switch still OFF.
Possible
causes and the
standard values
when normal

2 (disconnection or defective
MAM (female) (2)
contact)
Wiring harness between MAM (female) (3)
and ground
Resistance
Max. 1 z
Resistance
Max. 1 z

switch still OFF.

between PTC2 (female) (10) MAM
(female) (2)
Resistance
Max. 1 Mz

switch ON.
4
40

Limitation of function by
controller
PTC2
Manual mode switch
Voltage
Between (10) and

ground
Manual (0)
5 11 V
Preset (I)
Max. 1V
If no problem is found in causes 1 4, the steering and transmission

controller may be restricting the function because of other causes.
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to manual mode
D85EX, PX-15E0
41
SEN00638-00
40 Troubleshooting
E-21 The monitor panel cannot be set in the service mode or cannot be
set out of the service mode.
1
Symptom of
failure
The monitor panel cannot be set in the service mode or cannot be set out of the service mode.
General
information
Causes

Since the buzzer cancel switch system can be suspected to be
defective, carry out the troubleshooting of "E-18 Buzzer cancel
switch does not work."
Defective buzzer cancel

switch circuit
Since the information switch system can be suspected to be defecDefective information switch
tive, carry out the troubleshooting of "E-19 Information switch does
circuit
not work".
3 Defective fuse FS1 (5)
Defective service switch

4 (Internal short circuit or disconnection)
When the fuse FS1 (5) is blown, the circuit probably has a ground
fault.
switch still OFF.
S24
Service switch
Resistance
Between (1) (2)

Between (5) (4)
OFF
Min. 1 Mz
ON
Max. 1 z

switch still OFF.
Possible
causes and the
standard values
when normal
harness
5
Wiring harness between FS1 (5) outlet S24

(1)
Resistance
Max. 1 z
Wiring harness between S24(4) and ground
Resistance
Max. 1 z

S24 (2)
Resistance
Max. 1 z

S24 (5)
Resistance
Max. 1 z

switch still OFF.
6

between FS1 (5) S24 (1) and FS1 (5)
S03 (female) (5) (6)
between S24 (5) PTC1 (female) (6)

Resistance
Max.
1 Mz
Resistance
Max.
1 Mz

switch ON.
between S24 (2) S03 (female) (16)
Voltage
Max. 1V

switch ON.
42
S03
Service switch
Voltage
Between (16) and

ground
OFF
Max. 1 V
ON
20 30 V
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Causes
Possible
causes and the
standard values
when normal

switch ON.

PTC1
Service switch
Voltage
Between (6) and

ground
OFF
5 11 V
ON
Max. 1 V
Circuit diagram related to service switch
D85EX, PX-15E0
43
SEN00638-00
40 Troubleshooting
E-22 The back-up alarm does not sound.
Symptom of
failure
Back-up alarm does not turn on.
General
information
When a failure occurs on the primary side (coil side) of the back-up alarm relay, relevant failure code
[D161KA] or [D161KB] is displayed, but in case of failure on the secondary side (contact side), no
failure code is displayed.
Causes
1 Blown fuse (FS2-3)
Defective back-up alarm

2 relay

If fuse is blown, it is highly possible that a defective harness grounding, etc. has occurred in the circuit.
switch ON.
If alarm sounds when the starting switch is turned on and the
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.
Possible
causes and the
standard values
when normal
harness
3
Wiring harness between FS2-3 BKA

(female) (1) (3)
Resistance
Max. 1 z
Wiring harness between BKA (female) (2)

PTC2 (female) (18)
Resistance
Max. 1 z
Wiring harness between BKA (female) (5)

back-up alarm positive (+) terminal
Resistance
Max. 1 z
Wiring harness between back-up alarm negative () terminal and GND03
Resistance
Max. 1 z

switch still OFF.
4
44
Between ground and wiring harness FS2-3

BKA (female) (1) (3)
between BKA (female) (5) back-up alarm
positive (+) terminal
Defective back-up alarm
(internal defect)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
If no problem is found in causes 1 4, the back-up alarm can be

suspected to be defective.
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to back-up alarm
D85EX, PX-15E0
45
SEN00638-00
40 Troubleshooting
E-23 The head lamp and rear lamp do not light up.
Symptom of
failure
(1) Head lamp does not light up.
General
information
Causes
Defective head lamp

1
(burned-out bulb)
Since the head lamp can be suspected to be defective, check for

burned-out bulb.
2 Defective fuse (FS1-3)
If the fuse is blown, the circuit probably has a defective grounding,

etc.
switch still OFF.
Defective head lamp switch

FWL (male)
Between (2) (3)
Possible
causes and the
standard values
when normal
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z
Defective left head lamp

relay
4
short circuit)

switch ON.
Defective right head lamp

relay
5
short circuit)

switch ON.
If the left head lamp becomes normal after replacing left head lamp
relay (LMFL) with new one, the previous relay is defective.
If the right head lamp becomes normal after replacing right head
lamp relay (LMFR) with new one, the previous relay is defective.
switch still OFF.
harness
6
46
Switch
Wiring harness between FS1 (3) FWL

(female) (3)
Resistance
Max. 1 z
Wiring harnesses between FWL (female) (2)

LMFR (female) (1) and FWL (female) (2)
LMFL (female) (1)
Resistance
Max. 1 z
Wiring harnesses between FS1 (3) LMFR

(female) (3) and FS1 (3) LMFL (female) (3)
Resistance
Max. 1 z
Wiring harness between LMFR (female) (5)

203 (female) (1)
Resistance
Max. 1 z
Wiring harness between LMFL (female) (5)

204 (female) (1)
Resistance
Max. 1 z
Wiring harnesses between LMFR (female)

(2) GND03 and LMFL (female) (2)
GND03
Resistance
Max. 1 z
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Causes

switch still OFF.
Possible
causes and the
standard values
when normal
Symptom of
failure

between FS1 (3) FWL (female) (3), FS1 (3)
LMFR (female) (3) and FS1 (3) LMFL
(female) (3)
Resistance
Min. 1 Mz

Defective harness grounding between FWL (female) (2) LMFR (female)
7
(contact with ground circuit) (1) and FWL (female) (2) LMFL (female)
(1)
Resistance
Min. 1 Mz

between LMFR (female) (5) 203 (female)
(1)
Resistance
Min. 1 Mz

between LMFL (female) (5) 204 (female)
(1)
Resistance
Min. 1 Mz
(2) The rear lamp and ripper point lamp do not light up.
General
information
Causes
Defective rear lamp

(burned-out bulb)
Since a defect of the rear lamp can be suspected, check for burnedout bulb directly.
Defective ripper point lamp

(burned-out bulb)
Since a defect of the ripper point lamp can be suspected, check for
burned-out bulb directly.
If the fuse is blown, the circuit probably has a defective grounding,

etc.
switch still OFF.
4
Possible
causes and the
standard values
when normal
Defective rear lamp switch

RWL (male)
Between (2) (3)
harness
5
Switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z

switch still OFF.
Wiring harness between FS1-4 RWL
(female) (3)
Resistance
Max. 1 z
Wiring harnesses between RWL (female) (2)

224 (female) (1) and RWL (female) (2)
226 (female) (1)
Resistance
Max. 1 z

switch still OFF.
6
D85EX, PX-15E0

between FS1-4 RWL (female) (3)
between RWL (female) (2) 224 (female) (1)
and RWL (female) (2) 226 (female) (1)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
47
SEN00638-00
40 Troubleshooting
Circuit diagram related to panel illumination, head lamp and rear lamp
48
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
E-24 The horn does not sound or does not stop.

Symptom of
failure
Horn does not sound or does not stop.
General
information
Causes
1 Blown fuse (FS1-2)
Defective horn switch

2 (internal short circuit and disconnection)
Possible
causes and the
standard values
when normal
harness
3

If the fuse is burnt, it is highly possible that a defective grounding,
etc. has occurred in the circuit.
switch still OFF.
Terminal (switch)
265 266
Horn switch
Resistance
OFF
Min. 1 Mz
ON
Max. 1 z

switch still OFF.
Wiring harness between FS1-2 266
Resistance
Max. 1 z
Wiring harness between 265 205 (female)

(1)
Resistance
Max. 1 z

switch still OFF.

4 harness
between FS1-2 266
(contact with GND circuit)
between 265 205 (female) (1)
5
Defective horn
(internal defect)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

switch ON.
between 265 205 (female) (1)
Voltage
Max. 1 V
If no problem is found in causes 1 5, the horn can be suspected to

be defective.
Circuit diagram related to horn
D85EX, PX-15E0
49
SEN00638-00
40 Troubleshooting
E-25 Malfunction of wipers
Symptom of
failure
(1) The front wiper does not operate. (Continuous operation is defective.)
General
information
When only the front wiper is defective

If fuse (5) in the cab is blown, intermittent operation of the all wipers becomes defective.
If all wipers do not operate, check circuit breaker (CB105).
Diagnose with intermittent switch OFF and with wiper switch ON.
Causes

(CB105)
When the circuit breaker is cut off, a defective grounding may have
possibly occurred in the circuit.
Defective fuse (5)

in cab
Since fuse (5) in the cab is used for the front wiper circuit and intermittent switch circuit, either circuit of those two probably have a
ground fault, etc.
switch ON.
Between CN23 (6) and ground
3 Defective front wiper motor
Voltage
20 30 V

switch still OFF.
Wiring harness between CN23 (female) (1)
and ground
Resistance
Max. 1 z

switch still OFF.
Possible
causes and the
standard values
when normal
4 Defective front wiper switch
CN14 (male)
Position of switch
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz
Between (3) (4)
If the problem is eliminated by replacing the relay (CN27), (CN31)

or (CN33) with another one, the relay is defective.
Defective front wiper
5
intermittent selector relay

switch ON.
Voltage
20 30 V
Voltage
20 30 V
Voltage
Max. 1 V

Defective front wiper
6
intermittent relay
50

switch ON.
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

CN29 (female) (3)
Resistance
Max. 1 z

between CN14 (female) (4) CN29 (female)
(3)
Resistance
Min. 1 Mz

CN28 (female) (4)
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Max. 1 z
Resistance
Min. 1 Mz

CN23 (female) (6)
Resistance
Max. 1 z

(6)
Resistance
Min. 1 Mz

and ground
Resistance
Max. 1 z

and ground
Resistance
Max. 1 z

Disconnection or short circuit (4)
with ground in wiring harness Wiring harnesses between fuse (5) CN14
(Disconnection in wiring or
(female) (2) (3), fuse (5) CN23 (female) (3)
7
defective contact of connec- and fuse (5) CN28 (female) (3)
tors or contact with ground
circuit)
between fuse (5)-CN14 (female) (2) (3), fuse
(5)-CN23 (female) (3) and fuse (5)-CN28
(female) (3)
D85EX, PX-15E0
51
SEN00638-00
40 Troubleshooting
Symptom of
failure
(2) Front wiper malfunctions in the intermittent mode.
General
information
When the ordinary operation is normal.

When carrying out the troubleshooting, turn the wiper switch and intermittent switch ON.
The wiper stops for about 5 seconds after a single wiping operation.
Cause

If the ordinary operation is normal and the other wiper also malfunctions in the intermittent mode, the intermittent switch is probably defective.
1 Defective intermittent switch

switch still OFF.
CN11 (male)
Position of switch
Between (1) (2)
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz

2
Possible
causes and the
standard values
when normal
Defective front wiper intermittent selector relay
Defective front wiper intermittent relay

switch ON.
Between CN29 (1) ground
Voltage
20 30 V
Voltage
20 30 V

switch ON.
Voltage
20 30 V

switch still OFF.
Disconnection or short circuit

with ground in wiring harness
4
defective contact of connectors or contact with ground
circuit)
52

CN29 (female) (1)
Resistance
Max. 1 z

(1)
Resistance
Min. 1 Mz

CN28 (female) (2)
Resistance
Max. 1 z

(2)
Resistance
Min. 1 Mz

ground
Resistance
Max. 1 z
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to wiper system
D85EX, PX-15E0
53
SEN00638-00
40 Troubleshooting
Symptom of
failure
(3) The rear wiper does not operate (Continuous operation is defective)
General
information
When only the rear wiper is defective

Diagnose with intermittent switch OFF and with wiper switch ON.
Causes

(CB105)
2 Defective fuse (4) in cab
Since fuse (4) in the cab is used only for the rear wiper circuit, the
rear wiper circuit probably has a ground fault, etc.
switch ON.
3 Defective rear wiper motor
Voltage
20 30 V

switch still OFF.
and ground
Resistance
Max. 1 z

switch still OFF.
Possible
causes and the
standard values
when normal
4 Defective rear wiper switch
CN12 (male)
Position of switch
Between (3) (4)
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz

5
Defective rear wiper


switch ON.
Voltage
20 30 V
Voltage
20 30 V
Voltage
Max. 1V

6
intermittent relay
54

switch ON.
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

7
defective contact of connectors or contact with ground
circuit)
D85EX, PX-15E0

CN33 (female) (3)
Resistance
Max. 1 z

(3)
Resistance
Min. 1 Mz

CN32 (female) (4)
Resistance
Max. 1 z

(4)
Resistance
Min. 1 Mz
Wiring harness between fuse (4) CN12

(female) (2) (3)
Resistance
Max. 1 z

between fuse (4) CN12 (female) (2) (3)
Resistance
Min. 1 Mz
Wiring harnesses between fuse (4) CN32

(female) (3) and fuse (4) CN37 (female) (3)
Resistance
Max. 1 z

between fuse (4)-CN32 (female) (3) and fuse
(4)-CN37 (female) (3)
Resistance
Min. 1 Mz

CN37 (female) (1)
Resistance
Max. 1 z

(1)
Resistance
Min. 1 Mz

and ground
Resistance
Max. 1 z

and ground
Resistance
Max. 1 z
55
SEN00638-00
40 Troubleshooting
Symptom of
failure
(4) Rear wiper malfunctions in the intermittent mode.
General
information

Cause


switch still OFF.
CN11 (male)
Position of switch
Between (1) (2)
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz

2
Possible
causes and the
standard values
when normal


intermittent relay

switch ON.
Voltage
20 30 V
Voltage
20 30 V

switch ON.
Voltage
20 30 V

switch still OFF.

4
defective contact in connector or contact with ground circuit)
56

CN33 (female) (1)
Resistance
Max. 1 z

(1)
Resistance
Min. 1 Mz

CN32 (female) (2)
Resistance
Max. 1 z

(2)
Resistance
Min. 1 Mz

ground
Resistance
Max. 1 z
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
D85EX, PX-15E0
57
SEN00638-00
40 Troubleshooting
Symptom of
failure
(5) The right door wiper does not operate. (Continuous operation is defective.)
General
information
When only the right door wiper is defective (If fuse (6) in the cab is blown, the left door wiper does not
operate either.)
When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch
ON.
Causes

(CB105)
If the circuit breaker is cut off, a defective grounding may have possibly 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.
Defective right door wiper
3
motor
Between connector (3) just before motor and

ground
Voltage
20 30 V

switch still OFF.
Wiring harness between connector (1) just
before motor and ground
Resistance
Max. 1 z

switch still OFF.
Possible
causes and the
standard values
when normal

switch
CN13 (male)
Position of switch
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz
Between (3) (4)

5

switch ON.
Voltage
20 30 V
Voltage
20 30 V
Voltage
Max. 1 V

6
intermittent relay
58

switch ON.
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

CN31 (female) (3)
Resistance
Max. 1 z

(3)
Resistance
Min. 1 Mz

CN30 (female) (4)
Resistance
Max. 1 z

(4)
Resistance
Min. 1 Mz
Resistance
Max. 1 z
Resistance
Min. 1 Mz

(female) (3)
Resistance
Max. 1 z

between fuse (6) CN30 (female) (3)
Resistance
Min. 1 Mz
Wiring harness among connector (female)

(3) just before motor CN17 (3) CN30
(female) (5)
Resistance
Max. 1 z
Between ground and wiring harness among

connector (female) (3) just before motor
CN17 (3) CN30 (female)(5)
Resistance
Min. 1 Mz

and ground
Resistance
Max. 1 z

(1) just before motor CN17(1) ground
Resistance
Max. 1 z

(female) (2) (3) and among fuse (6) CN17
(4) connector (female) (4) just before motor
Disconnection or short circuit CN15 (female) (2) (3)
7
between fuse (6) CN13 (female) (2) (3) and
defective contact of connecamong fuse (6) CN17 (4) connector
(female) (4) just before motor CN15
circuit)
(female) (2) (3)
D85EX, PX-15E0
59
SEN00638-00
40 Troubleshooting
Symptom of
failure
(6) Right door wiper malfunctions in the intermittent mode.
General
information

Cause


switch still OFF.
CN11 (female)
Position of switch
Between (1) (2)
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz

2
Possible
causes and the
standard values
when normal


intermittent relay

switch ON.
Voltage
20 30 V
Voltage
20 30 V

switch ON.
Voltage
20 30 V

switch still OFF.

4
60

CN31 (female) (1)
Resistance
Max. 1 z

(1)
Resistance
Min. 1 Mz

CN30 (female) (2)
Resistance
Max. 1 z

(2)
Resistance
Min. 1 Mz

ground
Resistance
Max. 1 z
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
D85EX, PX-15E0
61
SEN00638-00
40 Troubleshooting
Symptom of
failure
(7) The left door wiper does not operate (continuous operation is defective.)
General
information
When only the left door wiper is defective (If fuse (6) in the cab is blown, the right door wiper does not
operate either.)
When carrying out the troubleshooting, turn the intermittent switch OFF and turn the wiper switch
ON.
Causes

(CB105)
If the circuit breaker is cut off, a defective grounding may have possibly 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.
Defective left door wiper
3
motor
Between connector (3) just before motor and

ground
Voltage
20 30 V

switch still OFF.
Wiring harness between connector (1) just
before motor and ground
Resistance
Max. 1 z

switch still OFF.
Possible
causes and the
standard values
when normal

switch
CN15 (male)
Position of switch
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz
Between (3) (4)

5

switch ON.
Voltage
20 30 V
Voltage
20 30 V
Voltage
Max. 1 V

6
intermittent relay
62

switch ON.
Voltage
20 30 V
Voltage
20 30 V
Voltage
20 30 V
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Causes

switch still OFF.
Possible
causes and the
standard values
when normal

CN27 (female) (3)
Resistance
Max. 1 z

(3)
Resistance
Min. 1 Mz

CN26 (female) (4)
Resistance
Max. 1 z

(4)
Resistance
Min. 1 Mz
Resistance
Max. 1 z
Resistance
Min. 1 Mz
Resistance
Max. 1 z

between fuse (6) CN15 (female) (2) (3)
Resistance
Min. 1 Mz

(3) just before motor CN24(3) CN26
(female) (5)
Resistance
Max. 1 z

connector (female) (3) just before motor
CN24 (3) CN26 (female) (5)
Resistance
Min. 1 Mz

and ground
Resistance
Max. 1 z

(1) just before motor CN24 (1) ground
Resistance
Max. 1 z

(female)(3) and among fuse (6) CN24 (4)
Disconnection or short circuit connector just before motor (female)(4)
7
between fuse (6) CN26 (female)(3) and
defective contact of connecamong fuse (6) CN24 (4) connector just
before motor (female)(4)
circuit)
(female) (2) (3)
D85EX, PX-15E0
63
SEN00638-00
40 Troubleshooting
Symptom of
failure
(8) Left door wiper malfunctions in the intermittent mode.
General
information

Cause


switch still OFF.
CN11 (male)
Position of switch
Between (1) (2)
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz

2
Possible
causes and the
standard values
when normal


intermittent relay

switch ON.
Voltage
20 30 V
Voltage
20 30 V

switch ON.
Voltage
20 30 V

switch still OFF.

4
64

CN27 (female) (1)
Resistance
Max. 1 z

(1)
Resistance
Min. 1 Mz

CN26 (female) (2)
Resistance
Max. 1 z

(2)
Resistance
Min. 1 Mz

ground
Resistance
Max. 1 z
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
D85EX, PX-15E0
65
SEN00638-00
40 Troubleshooting
E-26 Washer does not spray water
Symptom of
failure
(1) Front washer does not spray water.
General
information
When the front wiper operates normally

(If the wiper does not operate either, carry out troubleshooting in E-25 (1) The front wiper does not
operate. first.)
Causes

switch still OFF.

ResisMax. 1 z
tance
1 Defective front washer motor and ground
switch ON. (Switch position: W/I or W/II)
Between 362 (1) and ground
Voltage
20 30 V

switch still OFF.
Possible
causes and the
standard values
when normal
2 Defective front wiper switch
Between (2) (1)
Position of switch
Resistance
W/I or W/II
Max. 1 z
OFF
Min. 1 Mz

switch still OFF.
(disconnection in wiring har3
ness or defective contact of
connectors or contact with
ground circuit)
66
CN14 (female)

(female) (2)
Resistance
Max. 1 z

Resistance
Min. 1 Mz
Wiring harness among CN14 (female) (1)

19 (3) 362 (female) (1)
Resistance
Max. 1 z

CN14 (female) (1) 19 (3) 362 (female) (1)
Resistance
Min. 1 Mz

and ground
Resistance
Max. 1 z
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to washer system
D85EX, PX-15E0
67
SEN00638-00
40 Troubleshooting
Symptom of
failure
(2) Rear washer does not spray water
General
information
When the rear wiper operates normally

(If the wiper does not operate either, carry out troubleshooting in E-25 (3) The rear wiper does not
operate. first.)
Causes

switch still OFF.

ResisMax. 1 z
tance
1 Defective rear washer motor and ground
Voltage
20 30 V

switch still OFF.
Possible
causes and the
standard values
when normal
2 Defective rear wiper switch
CN12 (female)
Between (2)-(1)
Position of switch
Resistance
W/I or W/II
Max. 1 z
OFF
Min. 1 Mz

switch still OFF.
ground circuit)

(female) (2)
Resistance
Max. 1 z

Resistance
Min. 1 Mz

19 (4) 364 (female) (1)
Resistance
Max. 1 z

CN12 (female) (6) 19 (4) 364 (female) (1)
Resistance
Min. 1 Mz

and ground
Resistance
Max. 1 z
* For the electrical diagram of each system, see Symptom of failure (1).
68
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Symptom of
failure
(3) Left door washer does not spray water
General
information
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
operate. first.)
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.
Causes

switch still OFF.
Defective left door washer

motor

and ground
Resistance
Max. 1 z

Voltage
20 30 V

switch still OFF.
Possible
causes and the
standard values
when normal

switch
CN15 (female)
Between (2) (1)
Position of switch
Resistance
W/I or W/II
Max. 1 z
OFF
Min. 1 Mz

switch still OFF.
ground circuit)

(female) (2)
Resistance
Max. 1 z

Resistance
Min. 1 Mz

19 (1) 361 (female) (1)
Resistance
Max. 1 z

CN15 (female) (6) 19 (1) 361 (female) (1)
Resistance
Min. 1 Mz

and ground
Resistance
Max. 1 z
D85EX, PX-15E0
69
SEN00638-00
40 Troubleshooting
Symptom of
failure
(4) Right door washer does not spray water
General
information
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
operate. first.)
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.
Causes

switch still OFF.
Defective right door washer

motor

and ground
Resistance
Max. 1 z

switch ON.
Voltage
20 30 V

switch still OFF.
Possible
causes and the
standard values
when normal

switch
CN13 (female)
Between (2) (1)
Position of switch
Resistance
W/I or W/II
Max. 1 z
OFF
Min. 1 Mz

switch still OFF.
ground circuit)

(female) (2)
Resistance
Max. 1 z

Resistance
Min. 1 Mz

19 (2) 363 (female) (1)
Resistance
Max. 1 z

CN13 (female) (1) 19 (2) 363 (female) (1)
Resistance
Min. 1 Mz

and ground
Resistance
Max. 1 z
70
D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
E-27 The air conditioner does not operate

Symptom of
failure
Air does not blow out
General
information
Causes
2

(CB2)
Defective blower main relay

3
(coil side)
Defective blower main relay

4
(contact side)
Defective blower Hi relay

5
(coil side)
Possible
causes and the
standard values
when normal
Defective blower Hi relay

6
(contact side)
Defective blower Mi1 relay

7
(coil side)

8
(contact side)

9
(coil side)

10
(contact side)
11 Defective blower motor
D85EX, PX-15E0

If the fuse is burnout, the circuit probably has a ground fault, etc.
switch still OFF.
CN-R1 (male)
Resistance
Between (1) (2)
240 40 z

switch ON.
CN-R1
Voltage
Between (8C) and ground
20 30 V

switch still OFF.
CN-R2 (male)
Resistance
Between (1) (2)
240 40 z

switch ON.
It is normal if the motor rotates with the starting switch and the
blower Hi switch turned ON.
switch still OFF.
CN-R3 (male)
Resistance
Between (1) (2)
240 40 z

switch ON.
blower Mi switch turned ON.
switch still OFF.
CN-R4 (male)
Resistance
Between (1) (2)
240 40 z

switch ON.
blower Lo switch turned ON.
switch ON.
blower Lo switch turned ON.
71
SEN00638-00
40 Troubleshooting
Causes

switch still OFF.

12 (disconnection in wiring or
Possible
defective contact of conneccauses and the
tors)
standard values
when normal
13 Defective control panel

14
72
Symptom of failure is
incorrect.
Wiring harnesses between CN-R4 (female)

(14C) AC1 (female) (14A), CN-R4 (female)
(14C) CN-R (female) (S141), CN-R4
(female) (14C) CN-R2 (female) (14E) and
CN-R4 (female) (14C) CN-R3 (female)
(14N)-ground
Resistance
Max. 1 z
Wiring harness between CN-B (female)

(11B) CN-R1(female) (11A)
Resistance
Max. 1 z
Wiring harnesses between CN-B (female)

(12A) CN-R2 (female) (12B) and CN-B
(female) (12A) CN-R (female) (12C)
Resistance
Max. 1 z
Wiring harnesses between CB2 outlet AC1

(female) (1A),CB2 outlet CN-R1 (female)
(1D), CB2 outlet CN-R2 (female) (1E), CB2
outlet CN-R3 (female) (1N) and CB2 outlet
CN-R4 (female) (1I)
Resistance
Max. 1 z
Wiring harness between CN-R1 (female)

(2B) AC1 (female) (2A)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
Control panel can be suspected to be defective if no problem is

When the cause cannot be identified, the symptom of failure may be
incorrect. Carry out the troubleshooting of It does not get cool.
D85EX, PX-15E0
40 Troubleshooting
Symptom of
failure
SEN00638-00
It does not get cool.
General
information
Causes

switch ON.
1 Defective pressure switch
CN-P
Blower switch
Voltage
Between (6B) and

ground
ON
20 30 V

switch still OFF.
Defective compressor clutch
2
relay (coil side)
CN-R5 (male)
Resistance
Between (1) (2)
240 40 z
a Prepare with starting switch OFF and diagnose starting switch

and air conditioner switch ON.
Defective compressor clutch
3
relay (contact side)
CN-R5
Voltage
Possible
causes and the
standard values
when normal
Between (18A) and ground
4 Defective thermistor
5 Defective blower resister
Defective compressor
magnet clutch.
20 30 V

switch still OFF.
CN-T (male)
Resistance
Between (1) (2)
Max. 3,500 z

switch still OFF.
Blower resister
Resistance
Between terminals
2.8 z 5 %
a Start the engine to diagnose.

Since the compressor magnet clutch can be suspected to be defective, check it directly.
7 Defective compressor
D85EX, PX-15E0
Defective diode
Since the compressor can be suspected to be defective, check it

directly.
Diagnose diode ACS (male).
adjusting section.
73
SEN00638-00
40 Troubleshooting
Causes

switch still OFF.
Possible
causes and the
standard values
when normal
Wiring harnesses between CB2 outlet AC1

(female) (1A), CB2 outlet CN-R1 (female)
(1D), CB2 outlet CN-R2 (female) (1E), CB2
outlet CN-R3 (female) (1N), CB2 outlet
CN-R4 (female) (1I) and CB2 outlet CN-R5
(female) (1K)
Max. 1 z
Resistance
Max. 1 z
Wiring harness between CN-T (female) (9B)

AC1 (female) (9A)
Resistance
Max. 1 z
Wiring harness between CN-P (female) (7B)

CN-R5 (female) (7A)
Resistance
Max. 1 z
Wiring harness between CN-P (female) (6B)

AC1 (female) (6A)
Resistance
Max. 1 z
harness (Disconnection in
Wiring harnesses between CN-T (female)
9
wiring or defective contact of (13B) AC1 (female) (13A) and CN-T
connectors)
(female) (13B) CN-W (female) (13C)
10 Defective control panel
74
Resistance
Control panel can be suspected to be defective if no problem is

D85EX, PX-15E0
40 Troubleshooting
SEN00638-00
Circuit diagram related to air conditioner
D85EX, PX-15E0
75
SEN00638-00
40 Troubleshooting
E-28 KOMTRAX system does not operate normally.
Symptom of
failure
KOMTRAX system does not operate properly.
General
information
If KOMTRAX system administrator makes request for checking system on machine side for trouble,
carry out the following troubleshooting.
Even if KOMTRAX system has a trouble, it does not particularly appear on machine.
Causes
1
Defective specification
setting
Defective electric power

supply

Check the code 0021: KOMTRAX specification setting in adjustment mode and set to ACTIVE.
switch still OFF.
KOM1
Signal
Voltage
Between (39) (40)

(37) (38)
Constant power
source
20 30 V
a Diagnose with starting switch ON and with the engine started.

3 ACC signal and alternator R
signal
Possible
causes and the
standard values
when normal
Defective starting switch C

signal
LED(1)
Normal condition
LED-C1
ON
KOM1
Signal
Voltage
Between (36)
(37) (38)
Starting switch ACC
20 30 V
Between (28)
(37) (38)
Alternator R
20 30 V

switch ON.
KOM1
Signal
Voltage
Between (27)
(37) (38)
Starting switch C
20 30 V
a Diagnose with starting switch ON.
Defective CAN connecting

condition
LED(4)
Normal condition
LED-C4
ON

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
09

Defective GPS positioning
7
status
76
LED(8)
Normal condition
Dot
ON
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.
D85EX, PX-15E0
40 Troubleshooting
LED display section of KOMTRAX terminal
SEN00638-00
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

78
SEN00639-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
40 Troubleshooting
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
SEN00639-00
40 Troubleshooting
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
40 Troubleshooting
SEN00639-00
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
failure
Symptom of failure that has appeared in the machine
General
information
Information related to troubles occurred or troubleshooting
Cause
Possible
causes and the
standard values
when normal
Cause by which a trouble

is assumed to be caused
(The order number indicates a serial number, not
a priority sequence.)
Standard value when normal required to judge the possible
cause
Remarks required to judge whether the cause is right or not
D85EX, PX-15E0
SEN00639-00
40 Troubleshooting
H-1 There is no travel power (no drawbar pull)
Symptom of
failure
There is no travel power (no drawbar pull).
General
information
Check that the power train oil level is normal before troubleshooting.
Causes
1 Defective engine
2 Defective power train pump

a Prepare with the starting switch OFF, and diagnose by measuring
the torque converter stall speed according to item 5 of Measuring engine speed in Testing and adjusting.
Engine speed
F3 stall
1,760rpm
The power train pump can be suspected to be defective; visually

check it.
a Prepare with the starting switch OFF, and then run the engine at
high idle for troubleshooting.
Internally defective torque

converter
PCCS lever
Torque converter
inlet pressure
Torque converter
outlet pressure
Full neutral
Max. 1.02 MPa

{Max. 10 kg/cm2}
0.61 0.81 MPa

{6 8 kg/cm2}
Possible
causes and the
standard values
when normal
Defective set pressure or

4 internal defect of transmission main relief valve
PCCS lever
Transmission main relief

pressure
Full neutral
Min. 2.81 MPa {Min. 29 kg/cm2}

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
low idle for troubleshooting.
Defective operation of
5 transmission valve
(ECMV)
Transmission clutch
Clutch pressure
FWD
REV
1ST
2ND
3RD
6 Defective brake valve
Parking lever
Brake pressure
Free
Defective parking lever and

brake pedal linkage
If any problem has been found in the troubleshooting for cause 6,

improper adjustment of parking lever or brake pedal linkage can be
suspected. Therefore check the adjustment directly.
Internally defective
transmission
Since the transmission is suspected to be internally defective, check

it directly.
D85EX, PX-15E0
40 Troubleshooting
SEN00639-00
H-2 Machine does not move (at 2nd or 3rd speed)
Symptom of
failure
Machine does not travel (at 2nd or 3rd speed)
General
information
Check that the transmission main relief pressure is normal before troubleshooting.
(See H-1 There is no travel power.)
Causes


converter
PCCS lever
Torque converter
inlet pressure
Torque converter
outlet pressure
Full neutral
Max. 1.02 MPa

{Max. 10 kg/cm2}
0.61 0.81 MPa

{6 8 kg/cm2}
low idle for troubleshooting.
Possible
causes and the
standard values
when normal
transmission valve (ECMV)
Transmission clutch
Clutch pressure
2ND
3RD
transmission clutch
Since the transmission clutch (2nd or 3rd speed) can be suspected

to be internally defective, check it directly.
parking brake (dragging)
Since the defective operation of parking brake (dragging) can be

suspected, inspect the linkage valves.
a Move to a flat ground (with a firm surface), and start the engine to
diagnose.
Defective operation of brake
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.").
6
D85EX, PX-15E0
transmission
Since the transmission is suspected to be internally defective, check

it directly.
SEN00639-00
40 Troubleshooting
H-3 Machine does not move at any gear speed
Symptom of
failure
Machine does not start at any gear speed.
General
information
Causes
Defective power train
1
pump

Since the power train pump can be suspected to be defective,
check it directly.

PCCS lever

pressure
Full neutral

switch still OFF.
Free length of small spring: 108 mm
Number of shims: 6 pieces
Possible
causes and the
standard values
when normal
a Prepare with the starting switch OFF, and diagnose with the
engine running at low idle.
(After checking that the transmission main relief pressure is normal.)
3
transmission
Transmission clutch
Clutch pressure
FWD
REV
1ST
2ND
3RD
Since the transmission clutch can be suspected to be internally

defective, check it directly.
a Move to a flat ground, and diagnose with the engine running at
high idle.
5 Defective brake valve
Brake pedal
Brake oil pressure (left and right)
Release
Depress
0 {0}
When the oil pressure is abnormal, carry out troubleshooting "H-8

Brake does not work".
D85EX, PX-15E0
40 Troubleshooting
SEN00639-00
H-4 Machine travels only in one direction, forward or reverse

Symptom of
failure
Machine travels only in one direction, forward or reverse.
General
information
Causes
1 Defective power train pump

check it directly.

PCCS lever

pressure
Full neutral

switch still OFF.
Possible
causes and the
standard values
when normal
Transmission clutch
Clutch pressure
FWD
REV

Defective transmission clutch
the clutch seal can be suspected to be defective. Therefore check
seal
the clutch seal directly.
transmission clutch
D85EX, PX-15E0
Since the transmission clutch (forward or reverse) can be suspected

to be internally defective, directly check it.
SEN00639-00
40 Troubleshooting
H-5 When gear is shifted or travel direction is changed, large time lag is
made
1
Symptom of
failure
Time lag is excessive at shifting gear speed or shifting forward-reverse.
General
information
Causes
1
Defective power train

pump

check it directly.

PCCS lever

pressure
Full neutral

switch still OFF.
Possible
causes and the
standard values
when normal
3
Transmission clutch
Clutch pressure
FWD
REV
1ST
2ND
3RD

Defective transmission clutch
the clutch seal can be suspected to be defective. Therefore check
seal
the clutch seal directly.
transmission clutch

defective, check it directly.
a Move the machine to a flat ground (with a firm surface), and start
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.").
D85EX, PX-15E0
40 Troubleshooting
SEN00639-00
H-6 Machine cannot be steered (Machine does not turn leftward or

rightward)
Symptom of
failure
Machine cannot be steered. (Machine does not turn leftward or rightward.)
General
information
Check that the hydraulic oil level is normal before troubleshooting.
Causes
Possible
causes and the
standard values
when normal
Incorrect set pressure or

defective operation of self
1
pressure reducing valve
(PPC basic pressure)
Abnormal noise from HSS

peripheral equipment

a Prepare with the engine started, and then run the engine at high
idle for troubleshooting.
PCCS lever
Control circuit basic pressure
Neutral
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
If an abnormal noise occurs in the HSS peripheral equipment, carry

out troubleshooting "Abnormal noise comes out around HSS and
work equipment pump or HSS motor."
H-7 Steering speed or power is low
Symptom of
failure
Steering speed or power is insufficient.
General
information
Causes
1 defective operation of HSS
main relief valve
Possible
causes and the
standard values
when normal

defective operation of self
2
pressure reducing valve
D85EX, PX-15E0
Abnormal noise from HSS

peripheral equipment

PCCS lever
HSS relief pressure
Left or right stroke end
Min. 38.2 41.7 MPa

{Min. 390 425 kg/cm2}
PCCS lever
Neutral
3.78 4.46 MPa

{38.5 45.5 kg/cm2}
If an abnormal noise occurs in the HSS peripheral equipment, carry

out troubleshooting "Abnormal noise comes out around HSS and
work equipment pump or HSS motor."
SEN00639-00
40 Troubleshooting
H-8 Brake does not work
Symptom of
failure
Brake does not work.
General
information
Causes

1
Possible
causes and the
standard values
when normal

valve
Improper adjustment of
brake pedal linkage
3 Defective brake seal

4
10
A slip or wear of brake disc

plate
Brake pedal
Brake oil pressure
When released
Min. 2.45 MPa

{Min. 25 kg/cm2}
When depressed
0 MPa {0 kg/cm2}

the improper adjustment of the brake pedal linkage can be also suspected, directly check it.
the brake seal can be also suspected to be improper. Therefore
check the brake seal directly.
Slip or wear of the brake disc plate can be suspected; directly check
it.
D85EX, PX-15E0
40 Troubleshooting
SEN00639-00
H-9 Overheat of power train oil
Symptom of
failure
Power train oil overheats.
General
information
Check that the reading on the power train oil temperature gauge matches the actual oil temperature
before troubleshooting. (If they do not match, carry out troubleshooting E-10 Power train oil temperature gauge does not indicate correctly.)
Causes
1 Defective engine system
Since the engine cooling system can be suspected to be defective

or the engine output can be suspected to be increased, see the
engine section of shop manual.
Defective power train pump

2 or residual air in the suction
circuit
The power train pump can be suspected to be defective or residual

air in the suction circuit can be suspected, directly check them.
Possible
causes and the
standard values
when normal

converter
transmission clutch (Slip)
PCCS lever
Torque converter
inlet pressure
Torque converter
outlet pressure
Full neutral
Max. 1.02 MPa

{Max. 10 kg/cm2}
0.61 0.81 MPa

{6 8 kg/cm2}

defective (slip), directly check it.
D85EX, PX-15E0
Defective operation of brake 1. Raise the machine with blade and ripper.
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)
If the machine cannot be stopped completely while performing F3
(Slip)
stall, the brake is slipping.
11
SEN00639-00
40 Troubleshooting
H-10 Abnormal sound comes out from around HSS and work equipment
pump or HSS motor
1
Symptom of
failure
Abnormal sound comes out around HSS and hydraulic pump or HSS motor.
General
information
Causes
1 Inappropriate oil is used.
Possible
causes and the
standard values
when normal
12
Clogged hydraulic oil tank

strainer
3 Air inhaled in suction circuit

The oil used can be suspected to be inappropriate, directly check it.
The hydraulic oil tank strainer can be suspected to be clogged,
directly check it.
Since the air can be suspected to be inhaled in the suction circuit of
the HSS and work equipment pump, directly check the pipes.
Internally defective HSS and Since the HSS and work equipment pump can be suspected to be
work equipment pump
internally defective, directly check it.
Internally defective HSS

motor
Since the HSS motor can be suspected to be internally defective,

directly check it.
D85EX, PX-15E0
40 Troubleshooting
SEN00639-00
H-11 All work equipment speeds are slow
Symptom of
failure
Speed of all work equipments is slow.
General
information
Check that the oil level in the hydraulic tank is normal before troubleshooting.
Causes
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)
2

equipment pump
Since the HSS and work equipment pump can be suspected to be

defective, directly check it.
3
Possible
causes and the
standard values
when normal
unload valve

4 defective operation of main
relief valve
Defective operation of self

5 pressure reducing valve
D85EX, PX-15E0
Internally defective PPC

valve
Work equipment control lever
Unload pressure
Full neutral
2.45 3.82 MPa

{25 39 kg/cm2}
Main relief pressure
Stroke end
22.54 1.18 MPa

{230 12 kg/cm2}
Full neutral
3.77 4.46 MPa

{38.5 45.5 kg/cm2}

the PPC valve can be suspected to be internally defective. Therefore directly check the PPC valve.
13
SEN00639-00
40 Troubleshooting
H-12 All work equipments do not move
Symptom of
failure
All work equipments do not move.
General
information
Causes
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)
2

equipment pump
Since the HSS and work equipment pump can be suspected to be

3
Possible
causes and the
standard values
when normal
unload valve

4 defective operation of main
relief valve
Defective operation of self

5 pressure reducing valve
Unload pressure
Full neutral
2.45 3.82 MPa

{25 39 kg/cm2}
Main relief pressure
Stroke end
22.54 1.18 MPa

{230 12 kg/cm2}
Full neutral
3.77 4.46 MPa

{38.5 45.5 kg/cm2}
H-13 Blade lift speed is slow or lacks power
Symptom of
failure
Blade lift moves slowly or lacks power.
General
information
Check for modifications to the blade.
If the hydraulic drift of blade lift is also excessive, carry out the troubleshooting of H-16 Excessive
hydraulic drift of blade lift first.
Causes

Possible
causes and the
standard values
when normal
14
Defective operation of PPC

valve
Blade control lever
PPC valve output pressure
Lift stroke end
3.82 4.12 MPa

{39 42 kg/cm2}
Defective operation of blade Since the operation of the blade lift control valve spool can be suslift control valve (spool)
pected to be defective, directly check it.
Residual air in blade lift

cylinder
Since the air can be suspected to reside in the blade lift cylinder,
bleed air and observe how the symptom changes.
D85EX, PX-15E0
40 Troubleshooting
SEN00639-00
H-14 Blade tilt speed is slow or lacks power
Symptom of
failure
Blade tilt speed or power is insufficient.
General
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.
Causes

Possible
causes and the
standard values
when normal

valve
Blade control lever
Tilt stroke end
3.82 4.12 MPa

{39 42 kg/cm2}
Since the operation of the blade tilt control valve spool can be susblade tilt control valve (spool) pected to be defective, directly check it.
Residual air in blade tilt

cylinder
Since the air can be suspected to reside in the blade tilt cylinder,
H-15 Ripper lift speed is slow or lacks power
Symptom of
failure
Ripper lift speed or power is insufficient.
General
information
Check for modifications to the ripper.
If the hydraulic drift of ripper lift is also excessive, carry out the troubleshooting of H-18 Excessive
hydraulic drift of ripper lift first.
Causes

1
Possible
causes and the
standard values
when normal

valve
Lift stroke end
3.82 4.12 MPa

{39 42 kg/cm2}
Defective operation of ripper Since the operation of the ripper lift control valve spool can be suslift control valve (spool)
pected to be defective, directly check it.
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.
4
D85EX, PX-15E0
Residual air in ripper lift

cylinder
Since the air can be suspected to reside in the ripper lift cylinder,
15
SEN00639-00
40 Troubleshooting
H-16 Excessive hydraulic drift of blade lift
Symptom of
failure
Excessive hydraulic drift of blade lift.
General
information

Check for oil leak in the hydraulic circuit of the work equipment before troubleshooting.
Causes

a Prepare with the engine started, and diagnose with the engine
stopped.
Possible
causes and the
standard values
when normal
If the hydraulic drift speed becomes faster when diagnosing in the

following procedure, the seal of the blade lift control valve spool is
defective.
1. Tense the blade lift against the ground to push up the front of the
machine.
2. Stop the engine and release the work equipment lock lever.
3. Check symptoms when the blade control lever is shifted to the liftlowering position.
Defective seal of blade lift

control valve (spool)
Defective seal of blade lift

cylinder
Raise the blade approximately 1,000 mm and check hydraulic drift

Defective fitting of quick drop
of the tip of blade cutting edge.
valve
300 mm/15 min
Since the seal of the blade lift cylinder can be suspected to be

H-17 Excessive hydraulic drift of blade tilt
Symptom of
failure
Excessive hydraulic drift of blade tilt
General
information

Causes

stopped.
Possible
causes and the
standard values
when normal
Defective seal of blade tilt

Defective seal of blade tilt

2
cylinder
16

following procedure, the seal of the blade tilt control valve spool is
defective.
1. Tense the blade tilt against the ground to push up the right side of
the machine.
3. Check symptoms when the blade control lever is shifted to the
right-tilt position.
Blade tilt cylinder
Right tilt stroke end
16 cc/min
D85EX, PX-15E0
40 Troubleshooting
SEN00639-00
H-18 Excessive hydraulic drift of ripper lift
Symptom of
failure
Hydraulic drift of ripper lift is excessive.
General
information
Check for modifications to the ripper.

Causes

stopped.
Possible
causes and the
standard values
when normal
D85EX, PX-15E0
Defective seal of ripper lift

Defective seal of ripper lift

cylinder

following procedure, the seal of the ripper lift control valve (Hi) spool
is defective.
1. Tense the ripper lift against the ground to push up the rear of the
machine.
3. Check symptoms when the ripper control lever is shifted to the
lift-lowering position.
Lower stroke end
16 cc/min
17
SEN00639-00

18
SEN00640-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up
40 Troubleshooting

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
SEN00640-00
40 Troubleshooting
S-15 Abnormal noise is made. ........................................................................................................... 25

S-16 Vibration is excessive ................................................................................................................ 26
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00
Method of using troubleshooting charts
This troubleshooting chart is divided into three sections: 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 determine the causes. C in the chart to the right corresponds to them.
Causes:
The contents to be determined after asking questions and checking items.
The serviceman determines causes of high probability 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
SEN00640-00
40 Troubleshooting
<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].
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00
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
SEN00640-00
40 Troubleshooting
S-1 Starting performance is poor.
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Stuck, seized supply pump plunger
Clogged feed pump gauze filter
Clogged fuel filter, element
Leaking or clogged fuel piping, entry of air
Worn piston ring, cylinder
Defective contact of valve and valve seat
Clogged air breather hole of fuel tank cap
E E
Q Q
E
w
Q Q Q Q
w
w w Q Q
w
w
w w
w
w
w
Q
w Q Q
Q
w
w w
w
w
Q Q
w
Q w Q Q
q
q
q
q
q
q
q
q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
q
Clean
Replace
Correct
Clean
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
Inspect fuel filter, strainer directly
Inspect gauze filter of feed pump directly
Carry out troubleshooting by failure code Loss of pressure feed from supply
pump (*2)
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change with some cylinders
When starting switch is turned to HEAT, intake air heater mount does not become
warm
Yes
Is voltage 20 30 V between alternator terminal R and terminal E
with engine at low idle?
No
When specific gravity of electrolyte and voltage of battery are measured, they are
low
Remedy
E E
Q Q w w
Correct
Confirm recent repair history

Degree of use of machine Operated for long period
Became worse gradually
Starting performance
Engine starts easily when warm
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation and Maintenance Manual
Engine oil must be added more frequently
When engine is preheated or when temperature is low, preheating monitor does
not indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is
installed)
Dust indicator is red (if indicator is installed)
Air breather hole of fuel tank cap is clogged
Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
Starting motor cranks engine slowly
If air bleeding plug of fuel filter is removed, fuel does
not flow out
While engine is cranked
with starting motor
If spill hose from injector is disconnected, little fuel
spills
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Engine does not pick up smoothly and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Cracked EGR cooler (Coolant in exhaust piping)
Clogged air cleaner element
Cause
Replace
Troubleshooting
Check items
Questions
General causes why starting performance is poor

q
q
Insufficient supply of fuel
q
Insufficient intake of air
q
Improper selection of fuel
q
Coolant in exhaust piping
a The common rail fuel injection system (CRI) recognizes the fuel injection timing electrically. Accordingly,
even if the starting operation is carried out, the engine
may not start until the crankshaft revolves 2 turns at
maximum. This phenomenon does not indicate a trouble, however.
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00
*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
SEN00640-00
40 Troubleshooting
S-2 Engine does not start
a) Engine does not turn
Cracked EGR cooler (Coolant in exhaust piping)

Broken flywheel ring gear
Defective connection of battery terminal
Defective starting motor (safety relay section)
Defective starting motor (motor section)
Defective starting circuit wiring
Defective hydraulic pump
Cause

Horn does not sound
Condition of horn when
starting switch is turned ON Horn volume is low
Battery electrolyte is low
Battery terminal is loose
When starting switch is turned ON, there is no operating sound from battery relay
When starting switch is turned to START, starting pinion does not move out
Speed of rotation is low
When starting switch is
Makes grating noise
turned to START, starting
Soon disengages again
pinion moves out, but
Makes rattling noise and does not turn
When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze flows
out (*1)
Inspect flywheel ring gear directly
When specific gravity of electrolyte and voltage of battery are measured, they are
low
There is not voltage (20 30 V) between battery relay
terminal M and terminal E
When terminal B and terminal C of starting switch are
Turn starting switch OFF, connected, engine starts
connect cord, and carry out When terminal B and terminal C at safety relay outlet
troubleshooting at ON
are connected, engine starts
Even if terminal B and terminal C at safety relay outlet
are connected, engine does not start
Remedy
EEE
Q
w
w
w
Q
Q
w
w
w
w
w
Q w
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Carry out troubleshooting in E-mode.
Carry out troubleshooting in H-mode.
Troubleshooting
Check items
Questions
General causes why engine does not turn

q
Internal parts of engine seized
o See S-4 Engine stops during operations
q
Coolant entered in cylinder, producing water hammer
q
q
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00

D85EX, PX-15E0
SEN00640-00
40 Troubleshooting
b) Engine cranks but no exhaust smoke comes out.
Use of improper fuel

Insufficient fuel in tank
Clogged air breather hole in fuel tank cap
Clogged fuel filter element
Seized or abnormally worn feed pump
Broken supply pump shaft or key
Stuck or seized supply pump plunger
Defective supply pump PCV
Wrong connection of supply pump PCV
Defective operation of overflow valve (does not close)
Defective operation of flow damper
Defective fuel injector
Causes
General causes why engine cranks but no exhaust smoke

comes out:
q
Fuel is not being supplied.
q
Supply of fuel is extremely small.
q
Improper selection of fuel (particularly in winter)
Questions
Confirm recent repair history.

Degree of use of machine
EEE
Operated for long period
w Q w w w
Exhaust smoke suddenly stopped coming out (when restarting).

Replacement of filters has not been carried out according to Operation
and Maintenance Manual.
Rust or water are observed when fuel tank is drained.

w
When fuel filter is removed, there is no fuel in filter.
Q Q Q
Q Q
Fuel is leaking from fuel piping.
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,

fuel does not flow out.
When spill hose from injector is disconnected, little fuel spills.
w Q
w w w w
q q
Inspect fuel filter directly.
Inspect feed pump gauze filter directly
Check feed pump directly.

Carry out troubleshooting by failure code Loss of pressure feed from
supply pump (*1).
Carry out troubleshooting by failure code Abnormal PCV1 (*2) or
Abnormal PCV2 (*3).
q
q
q
Inspect overflow valve directly.
q q
Engine can be started in reduced cylinder mode.

Remedy
Replace
Refill
Correct
Correct
Replace
Clean
Replace
Replace
Replace
Replace
Correct
Replace
Replace
Replace
While engine is cranked

with starting motor,
Air breather hole in fuel tank cap is clogged.
Check items
When fuel tank is inspected, it is found to be empty.
Troubleshooting
w w
EE

10
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00
c) Exhaust smoke comes out but engine does not start

(fuel is being injected).

Worn valve system (valve, rocker lever, etc.)
Worn piston ring or cylinder liner
Leaking or clogged fuel system, entry of air
Clogged fuel filter or strainer
Clogged injector, defective spray
Defective coolant temperature sensor or wiring harness
Defective intake air heater system
Causes

E
E E
E
Suddenly failed to start
w
w
Q
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
Q
w w
When fuel filter is removed, there is no fuel in filter.
w
w
w Q Q
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
Q
w w
While engine is cranked with does not flow out.
starting motor,
When spill hose from injector is disconnected, litw
tle fuel spills.
When exhaust manifold is touched immediately after starting engine, temperaw
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
Inspect fuel filter and strainer directly.
pump (*1).
When injector unit is tested, spray condition is bad.
When electrolyte specific gravity and voltage of battery are measured, they are
too low.
Coolant temperature gauge does not indicate properly (if coolant temperature
gauge is installed).
Intake air heater mount does not become warm during operation of preheating.
Remedy
q
q
q
q
q
q
q
q
Clean
Replace
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Clean
Replace
Replace
Replace
Troubleshooting
Check items
Questions
General causes why exhaust smoke comes out but engine

does not start:
q
Lack of rotating force due to defective electrical system
q
q
q

D85EX, PX-15E0
11
SEN00640-00
40 Troubleshooting
S-3 Engine does not pick up smoothly
E E E
Q
E
w
Clogged injector, defective spray

Q
w
w w w
w
w w
w
w
w
w w
w
w Q Q
Q
w
w
w
w
Q
w w
Q w
q
q
q
q
q
q
Correct

q
Carry out troubleshooting by failure code Abnormal EGR valve servo (*1).
q
q
q
Inspect valve clearance directly.
q
When turbocharger is rotated by hand, it is found to be heavy.
q
Carry out troubleshooting by failure code Loss of pressure feed from supply pump (*2).
When a specific cylinder is cut out for reduced cylinder mode operation,
engine speed does not change with some cylinders.
Remedy
E E
Q Q
Replace

Engine pick-up suddenly becomes worse.
Maintenance Manual.
More engine oil is required for refill than before.
Rust and water are observed when fuel tank is drained.
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Blue under light load
Color of exhaust gas is
Black
When engine is cranked, abnormal noise comes out around cylinder head.
When engine is running, interference noise comes out around turbocharger.
High idle speed under no load is normal, but speed suddenly drops when
load is applied.
Engine hunts (rotation is irregular).
Blow-by gas is excessive.
Defective operation of flow damper

(Excessive leakage from injector)

Stuck EGR valve
Improper valve clearance
Seized turbocharger or interference of turbocharger
Causes
Clean
Replace
Replace
Adjust
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Troubleshooting
Check items
Questions
General causes why engine does not pick up smoothly:

q
q
q
Defective condition of fuel injection
q
q
Controller is controlling in derate mode.
(limiting injection rate (output) because of an error in
electrical system)
q
EGR valve is stuck open.
(There is much EGR gas and intake of air is insufficient.)

12
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00
S-4 Engine stops during operations

Abnormal noise was heard and engine
w w w w
stopped suddenly.
Condition when engine
Engine overheated and stopped.
w Q
stopped
Engine stopped slowly.
There was hunting and engine stopped.
and Maintenance Manual.
Fuel level monitor indicates low level (if monitor is installed).
Metal particles are observed when oil in oil pan is drained.
w w
Does not turn at all
w w
w
When engine is cranked Turns in opposite direction
by hand
Moves by amount of gear backlash
w
Supply pump shaft does not turn
Engine turns, but stops when load is applied to machine.
Remedy
EE
Q w Q
w
w Q
Q Q
Q Q Q
Q Q Q
w w
w
w
w
w
w Q Q
w w
Q Q
w
w
q
q
q
q
q
q
q q
Carry out troubleshooting in H-mode

Inspect piston and connecting rod directly.
Inspect crankshaft bearing directly
Inspect gear train directly.
Check feed pump directly.
supply pump (*1).
Broken valve system (valve, rocker lever, etc.)

Broken or seized piston or connecting rod
Broken or seized crankshaft bearing
Broken or seized gear train
Leaking or clogged fuel piping
Broken or seized feed pump
Broken supply pump shaft or key
Causes
Replace
Replace
Replace
Replace
Refill
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Troubleshooting
Check items
Questions
General causes why engine stops during operations:

q
Seized parts inside engine
q
q
Engine is overheating.
q
D85EX, PX-15E0
13
SEN00640-00
40 Troubleshooting
S-5 Engine does not rotate smoothly
1
Low idle speed is set too low.
Defective operation of EGR valve
Defective operation of flow damper (Excessive leakage from injector)
Clogged injector, defective spray (dirt in injector)
Defective Ne speed sensor or wiring harness
Defective Bkup speed sensor or wiring harness
Causes

E
E
Occurs at a certain speed range
Q Q
Occurs at low idle.
w
Q Q
Condition of hunting
Occurs even when speed is raised
Q
Q
Occurs on slopes
w
Replacement of filters has not been carried out according to Operation and Mainw
tenance Manual.
w
w
Q
w
w Q
When a specific cylinder is cut out for reduced cylinder mode operation, engine
speed does not change.
Carry out troubleshooting by failure code Abnormal engine Ne speed sensor
(*2)
Carry out troubleshooting by failure code Abnormal engine Bkup speed sensor
(*3)
Remedy
E
Q
Q Q Q Q
Q
Q
Q
Q
Q
Q
Q
Q
q
q
q
q
q q
q
q
Correct
Replace
Refill
Clean
Correct
Clean
Clean
Replace
Correct
Correct
Correct
Troubleshooting
Check items
Questions
General causes why engine does not rotate smoothly:

q
Air in fuel system
q
Defective speed sensor (Error at degree that it is not indicated)
q
Defective EGR valve

*2: Failure code [CA689]
*3: Failure code [CA778]
14
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output
q
q
q
Defective condition of fuel spray
q
q
There is overheating
o See S-14 Coolant temperature becomes
too high (Overheating).
q
Controller is controlling in derate mode
(limiting injection rate (output) because of an
error in electrical system)
E E
Q Q
Q Q
Q
Q

w
and Maintenance Manual
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
Black
w w
Color of exhaust gas
w
When exhaust manifold is touched immediately after starting engine, temw
perature of some cylinders is low
When engine is cranked, interference sound is generated around turbow
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
q
q q q
q
q
q
q
q

supply pump (*1)
When a cylinder is cut out for reduced cylinder mode operation, engine
speed does not change
Inspect boost pressure sensor mount directly
Carry out troubleshooting for Charge pressure sensor too high. (*2)
See *2 for code.
Carry out troubleshooting for Fuel temperature sensor too high. (*3)
See *3 for code.
q q
q
q
Replace
Correct
Replace
Replace
Replace
Clean
Replace
Correct
Clean
Replace
Adjustment
Replace
Replace
q
Clean
Remedy
D85EX, PX-15E0
Inspect air cleaner directly

Inspect air intake piping directly
When boost pressure is measured, it is found to be low
Inspect valve clearance directly
Inspect fuel filter, strainer directly
Inspect gauze filter of feed pump directly

Defective fuel temperature sensor, wiring harness
Defective charge air pressure sensor, wiring harness
Defective installation of charge air pressure sensor

(air leakage)
Defective drive of injector (signal, solenoid)
Clogged injector, defective spray (dirt in injector)
Stuck, seized supply pump plunger
Clogged fuel filter, strainer
Leaking, clogged fuel piping
Clogged air breather hole of fuel tank cap
Excessive wear of piston ring, cylinder liner
Seized turbocharger, interference of turbocharger
Air leakage from air intake piping

E

Suddenly
Gradually
Replace
Power was lost
Cause
Correct
Troubleshooting
Check items
Questions

15
SEN00640-00
40 Troubleshooting
S-7 Exhaust smoke is black (incomplete combustion)
E
w
Improper fuel injection pressure
Improper fuel injection timing
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Clogged or seized injector

E
E
Q Q
Q Q
w
Q Q
w
w
Q
w
Q Q
Q
w
w
Q Q Q
Q w
w
w
Q Q
Q
Q Q
w
Q Q Q
Q
Q w
w
w
q
q
q
q
q
Replace
Adjust
Adjust
Correct
Replace
Replace
Replace
q
Replace
Adjust
Correct
Replace
Replace
Clean

q
q
q
q
q
When muffler is removed, exhaust gas color improves.
pump (*2).
When a specific cylinder is cut out for reduced cylinder mode operation,
engine speed does not change with some cylinders.
Inspect fuel spill piping (on cylinder head side) visually.
Carry out troubleshooting by failure code Abnormal coolant temperature
sensor (*3).
Remedy
Crushed or clogged muffler
Leakage of air between turbocharger and cylinder head
Stuck EGR valve
E E
w Q
Replace

Suddenly became black
Gradually became black
More oil is required for refill than before.
Suddenly
Power was lost
Gradually
Muffler is crushed.
Leakage of air in piping between turbocharger and cylinder head or loose clamp
Engine is running in low-temperature mode at normal temperature.
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low.
When engine is running, abnormal noise comes out around cylinder head.
Pump relief speed is too high (excessive fuel is injected).
Exhaust noise is abnormal.
Engine does not pick up smoothly and combustion is irregular.
When spill hose from injector is disconnected, abnormally much fuel spills.
Seized turbocharger or interference of turbocharger
Causes
Replace
Troubleshooting
Check items
Questions
General causes why exhaust gas color is black:

q
q
Excessive fuel is supplied.
q
Defective condition of fuel injection
q
q
Engine is overheating
o See S-14 Coolant temperature becomes too
high (overheating).
q
Controller is controlling in derate mode.
(limiting injection rate (output) because of an error
in electrical system)
q
EGR valve is stuck open.
(There is much EGR gas and intake of air is insufficient.)

16
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive:
q
Abnormal combustion of oil
q
Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
minutes continuously.)
q
External leakage of oil
q
Wear of parts in lubrication system
Dust sucked in from air intake system.

Worn or damaged valve (stem, guide or seal)
Worn seal at turbine end
Turbocharger
Worn seal at blower end
Oil leakage from EGR valve stem
Clogged breather or breather hose
Broken piston ring
Worn or damaged rear oil seal
Broken oil cooler
Oil leakage from oil cooler
Oil leakage from oil filter
Oil leakage from oil piping
Oil leakage from oil drain plug
Oil leakage from oil pan, cylinder head, etc.
Causes
Questions

EEEE
E
w
Oil consumption suddenly increased.

Q
Q
w
Q Q w
Oil gets contaminated prematurely.
w w w w w
Smear of oil is observed on the outside of engine.

w
There are loose piping clamps in air intake system.
Inside of turbocharger exhaust gas outlet pipe has been smeared

with oil.
Q w
w
Oil has been mixed into the coolant.

w
Oil level in damper chamber has risen.

Q
Exhaust gas color is blue under light load.

Amount of blow-by gas
Excessive
w w
w
When intake manifold is removed, excessive dirt is observed on the

inside.
q
q q
Excessive play of turbocharger shaft

When EGR valve is removed, exhaust port is found to be smeared
with oil.
q
q
Inspect breather and breather hose visually.

q q
q
Inspect rear oil seal visually.

A leakage has been detected during a pressure tightness test of the
oil cooler.
q q
q q q q
Oil is leaking to the outside of the engine.

Remedy
D85EX, PX-15E0
w w
No
When intake manifold is removed, dust is observed inside.
Troubleshooting
Correct
Correct
Replace
Replace
Replace
Clean
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Check items
Inside of turbocharger intake air outlet pipe has been smeared with
oil.
17
SEN00640-00
40 Troubleshooting
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

q
Entry of exhaust gas into oil due to internal wear
q
Clogging of lubrication passage
q
q
Use of improper oil
q
Operation under excessive load
Defective seal at turbocharger turbine end

Worn EGR valve guide
Worn valve, valve guide
Excessive wear of piston ring, cylinder liner
Clogged breather, breather hose
Clogged oil cooler
Clogged oil filter
Defective oil filter safety valve
Clogged turbocharger lubrication drain tube
Exhaust smoke is bad
Cause
EEEE

Q
Oil filter clogging monitor indicates error even when oil temperature is high (if monitor is installed)
w Q
Metal particles are found when oil filter is drained
Q Q
Inside of exhaust pipe is dirty with oil
w
w
Color of exhaust gas

Amount of blow-by gas
Black
Q
Excessive
Troubleshooting
Q
w
None
q
Excessive play of turbocharger shaft
When EGR valve is removed, exhaust port is found to be dirty with oil
q q
Check breather and breather hose directly
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
Inspect turbocharger lubrication drain tube directly

Remedy
18
Q w
Replace
Replace
Replace
Replace
Clean
Clean
Replace
Replace
Clean
Check items
Engine oil temperature rises quickly
See S-7
Questions
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive:

q
Leakage of fuel
q
Defective condition of fuel injection (fuel pressure, injection timing)
q
Excessive injection of fuel
Fuel leakage inside head cover

Fuel leakage from fuel filter, piping, etc.
Defective feed pump oil seal
Defective supply pump plunger
Defective common rail fuel pressure
Defective spray by injector
Defective operation of injector
Causes
Questions

EE
Is excessive when compared with others of same model

Fuel consumption
Gradually increased
Q Q
Suddenly increased
Fuel is leaking to the outside of the engine.
Combustion is irregular.
w
Check items
Oil level rises and oil smells of diesel fuel.
When exhaust manifold is touched immediately after starting engine, temperature of

some cylinders are low.
Low idle speed is too high.
Hydraulic pump relief speed is high.
Q Q
Black
Q Q
White
Remove head cover and inspect visually.
Inspect feed pump oil seal visually.

Troubleshooting
Q Q Q
Carry out troubleshooting by failure code Loss of pressure feed from supply pump
(*1).
When a specific cylinder is cut out for reduced cylinder mode operation, engine speed
does not change with some cylinders.
q
q
When spill hose from injector is disconnected, the spill measures too much.
Carry out troubleshooting by failure code Abnormal coolant temperature sensor (*2).
Remedy
Correct
Correct
Replace
Replace
Correct
Replace
Replace
Correct
Correct
Confirm with monitoring function of monitor.

D85EX, PX-15E0
19
SEN00640-00
40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) 1
General causes why oil is in coolant:
q
Internal leakage in lubrication system
q
Internal leakage in cooling system
Broken cylinder head or head gasket

Cracks inside of cylinder block
Damaged cylinder liner O-ring or holes caused by pitting
Insufficient protrusion of cylinder liner
Broken oil cooler core or O-ring
Causes
Questions

E

Oil level rose
Suddenly
Gradually
Q Q
Q
Q Q
Excessive air bubbles are trapped in the radiator and coolant spurts back.
A leakage has been detected during a pressure tightness test of the cylinder head.
q q
Inspect cylinder block and liner visually.
Inspect cylinder liner visually.
A leakage has been detected during a pressure tightness test of the oil cooler.
Remedy
Replace
Replace
Replace
Correct
Replace
Check
items
Troubleshooting
Hard water is being used as coolant.

Oil level has risen and oil is milky.
20
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00
S-12 Oil pressure drops
General causes why oil pressure drops:

q
Leakage, clogging or worn part in lubrication system
q
Defective oil pressure control
q
Improper selection of oil (improper viscosity)
q
Deterioration of oil due to overheat
Worn bearing journal

Lack of oil in oil pan
Coolant or fuel in oil
Clogged strainer in oil pan
Clogged or broken pipe in oil pan
Defective oil pump
Defective oil pump relief valve
Clogged oil filter
Leaking, crushed, clogged hydraulic piping
Defective EGR oil pump
Leaking EGR hydraulic piping
Defective oil pressure sensor or wiring harness
Defective oil level sensor or wiring harness
Causes
Questions

E
Non-specified oil is used.
Maintenance Manual.
Oil pressure monitor
(if monitor is installed)
w
w
Indicates pressure drop at low and high idle
Indicates pressure drop on slopes
w w w Q
Q Q
Sometimes indicates pressure drop
Check items
Q w
Oil pressure monitor indicates oil pressure is too low (if monitor is installed)
Indicates pressure drop at low idle
Oil level monitor indicates oil level drop (if monitor is installed).
Oil level in oil pan is low.
Q Q
w
w
External hydraulic piping is leaking or crushed.
Oil is milky or smells of diesel oil.

Metal particles are observed when oil pan is drained.
Metal particles are observed when oil filter is drained.
Metal particles are observed in oil filter.
q q
Inspect oil pan strainer and pipe visually.
Oil pump rotation is heavy, or there is excessive play in oil pump.

See S-13.
Valve or spring of oil pump relief valve is fatigued or damaged.

Inspect oil filter visually
Relief valve of EGR oil pump is damaged or oil leaks from it.
Inspect EGR hydraulic piping visually.
Carry out troubleshooting by failure code Abnormal oil pressure sensor
(*1)
If oil level sensor is replaced, oil pressure monitor indicates properly.
Remedy
q
q
q
q
q
q
Replace
Refill
Clean
Clean
Replace
Adjust
Replace
Correct
Replace
Replace
Replace
Replace
Troubleshooting
D85EX, PX-15E0
21
SEN00640-00
40 Troubleshooting
S-13 Oil level rises (water, fuel in oil)
1
Cracked EGR cooler (entry of coolant)
Broken cylinder head or head gasket
Fuel leakage inside head cover
Cracks inside of cylinder block
Damaged cylinder liner O-ring or holes caused by pitting
Worn or damaged rear oil seal
Broken oil cooler core or O-ring
Clogged water pump drain hole (breather hole) or defective seal
Defective thermostat seat
Internally defective supply pump
Defective seal of auxiliary equipment (pump or air compressor)
Causes

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 bubw
Q
bles come out or coolant spurts back.
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
flows out (*1).
Remove head cover and inspect visually.
Inspect cylinder block and liner visually.
Inspect rear oil seal visually.
A leakage has been detected during a pressure tightness test of the oil cooler.
Remove water pump and inspect visually.
Remove thermostat cover and inspect visually.
Remove supply pump and inspect visually.
Directly check seal of auxiliary equipment.
Remedy
22
q
q
q
q q
q
q
q
q
q
q
Replace
Replace
Correct
Replace
Replace
Replace
Replace
Replace
Correct
Replace
Replace
Troubleshooting
Check items
Questions
General causes why oil level rises:

q
Coolant in oil (milky)
q
Fuel in oil (smells of diluted diesel fuel)
a If oil in coolant, carry out troubleshooting for S-11 Oil is in
coolant.
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00

D85EX, PX-15E0
23
SEN00640-00
40 Troubleshooting
S-14 Coolant temperature becomes too high (overheating)
External water leakage from EGR cooler

Broken cylinder head, head gasket
Broken O-ring of cylinder liner, holes caused by pitting
Clogged, broken oil cooler
Lack of coolant
Broken water pump
Defective operation of thermostat
Clogged, crushed radiator fins
Clogged radiator core
Defective radiator cap (pressure valve)
Slipping fan belt, worn fan pulley
Defective coolant temperature gauge
Cause

Suddenly overheated
Condition of overheating
Always tends to overheat
Rises quickly
Coolant temperature
gauge (if installed)
Does not go down from red range
Radiator coolant level monitor indicates drop of coolant level (if monitor is
installed)
Engine oil level has risen and oil is milky
Fan belt tension is low
When fan belt is turned, it has play
Milky oil is floating on coolant
There are excessive air bubbles in radiator, coolant spurts back
When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard on applicable machine side are
clogged with dirt or mud
Coolant is leaking because of cracks in hose or loose clamps
Coolant flows out from radiator overflow hose
Fan belt whines under sudden acceleration
EE
Q w
Q
Q
Q w w
w
w
Q
w
w Q
w
w
w
w
w
w
w
w
w
Inspect EGR cooler for leakage of coolant directly

q
q
Inspect cylinder liner directly
q
Inspect oil cooler directly
q
Temperature difference between upper and lower tanks of radiator is large
When operation of thermostat is carried out, it does not open at cracking temperature
Temperature difference between upper and lower tanks of radiator is slight
Inspect radiator core directly
When operation of radiator cap is carried out, its cracking pressure is low
Inspect fan belt, pulley directly
When coolant temperature is measured, it is fount to be normal
Remedy
24
EEE
Q
q
q
q
q
q
q
q
Replace
Replace
Replace
Replace
Add
Replace
Replace
Correct
Correct
Replace
Correct
Replace
Troubleshooting
Check items
Questions
General causes why coolant temperature becomes too high

q
Lack of cooling air (deformation, damage of fan)
q
Drop in heat dissipation efficiency
q
Problem in coolant circulation system
q
Rise in hydraulic oil temperature
D85EX, PX-15E0
40 Troubleshooting
SEN00640-00
S-15 Abnormal noise is made.
1
Leakage of air between turbocharger and cylinder head
Interference of turbocharger or seized turbocharger
Cracked or leaking EGR gas piping
Broken valve system (valve, rocker lever)
Internally defective muffler (partition plate out of position)
Excessive wear of piston ring or cylinder liner
Improper gear train backlash
Removed or seized gear train bushing
Deformed fan, loose fan belt or interference of fan belt
Clogged or seized injector
Dirt caught in injector
Improper fuel injection timing (abnormal coolant temperature sensor)
Causes

E
Gradually
Q
Q
Abnormal noise appeared
Suddenly
Q Q Q
Q
Q
w
Metal particles are observed when oil in oil filter is drained.
w
w
Air leaks between turbocharger and cylinder head.
w
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
When exhaust manifold is touched immediately after starting engine, temperaQ
ture of some cylinders is low.
w
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
w
Inspect EGR gas piping visually.
When muffler is removed, abnormal noise disappears.
Inspect fan and fan belt visually.
When a specific cylinder is cut out for reduced cylinder mode operation, engine
speed does not change with some cylinders.
Abnormal noise comes out only when engine is started.
Remedy
D85EX, PX-15E0
q
q
q
q
q
q
q q
q
q q
q
q
Replace
Replace
Replace
Replace
Replace
Adjust
Replace
Replace
Replace
Correct
Replace
Correct
Correct
Troubleshooting
Check items
Questions
General causes why abnormal noise comes out.

q
Abnormality due to defective parts
q
Abnormal combustion
q
Air sucked in from air intake system
a Judge if the noise is an internal noise or an external
noise, before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently.
Accordingly, the engine noise becomes a little larger.
This does not indicate abnormality, however.
a When the engine is accelerated, it is operated in the
acceleration mode and its sound becomes a little larger
for up to about 3 seconds. This does not indicate abnormality, however.
25
SEN00640-00
40 Troubleshooting
S-16 Vibration is excessive
General causes why vibration is excessive:

q
Defective parts (abnormal wear, breakage, etc.)
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"
Stuck valve system (valve, rocker lever, etc.)

Worn main bearings or connecting rod bearings
Improper gear train backlash
Worn camshaft bushing
Loose engine mounting bolts, broken cushions
Misalignment between engine and devices on the machine side
Broken parts inside the damper
Causes

Condition of vibration
Suddenly increased
Q
Q
Metal particles are observed when oil in oil filter is drained.
Metal particles are observed when oil pan is drained.
Oil pressure is low when running at low idle.
Gradually increased
Vibration occurs when running at a medium speed.

Q
Vibration follows engine speed.

Exhaust gas color is black.
Q Q Q
Inspect main bearings and connecting rod bearings visually.
Inspect camshaft bushing visually.
Inspect engine mounting bolts and cushions visually.
When alignment is checked, radial runout or facial runout is detected.
Inspect inside of damper directly.

Remedy
26
Replace
Replace
Replace
Replace
Adjust
Replace
Adjust
Replace
Troubleshooting
Check items
Questions
D85EX, PX-15E0
SEN00640-00

28
SEN01263-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN01263-00

How to read this manual
1.
Removal and installation of assemblies

Special tools
q
Special tools which are deemed necessary for removal or installation of parts are
described as A1,X1 etc. and their part
names, part numbers and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
(installed).
q : Special tools that will be useful if available and are substitutable with commercially available tools.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They respectively have a
new part number.
R:
Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of "Sketches of
special tools".
q
Part No. of special tools starting with
79 T:
means that they can not be supplied
from Komatsu in Japan (i.e. locally
made parts).
* *** ****
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.
Removal
q
The [Removal] section contains procedures
and precautions for implementing the work,
know how and the amount of oil or coolant to
be drained.
q
Various symbols used in the Removal Section
are explained and listed below.
k: This mark indicates safety-related precautions that must be followed when implementing the work.
a: Know-how or precautions for work
[*1] : This mark shows that there are instructions or
precautions for installing parts.
6: This mark shows the amount of oil or coolant
to be drained.
4: Weight of part or component
Installation
q
Except where otherwise instructed, installation
of parts is done in the reverse order of
removal.
q
Instructions and precautions for installing parts
are shown with [*1] mark in the Installation section, identifying which step the instructions are
intended for.
q
Marks shown in the Installation section stand
for the following.
k: Precautions related to safety in execution
of work.
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
5
: Quantity of oil or coolant to be added
Sketches of special tools

q
Various special tools are illustrated for the convenience of local manufacture.
D85EX, PX-15E0
2.
Disassembly and assembly of assemblies

Special tools
q
Special tools which are deemed necessary for removal or installation of parts are
described as A1,X1 etc. and their part
names, part numbers and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
(installed).
q : Special tools that will be useful if available and are substitutable with commercially available tools.
2) Distinction of new and existing special
tools
N
: Tools newly developed for this
model. They respectively have a
new part number.
R
: Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of "Sketches of
special tools".
q
Part No. of special tools starting with
79 T:
means that they can not be supplied
from Komatsu in Japan (i.e. locally
made parts).
* *** ****
SEN01263-00
Disassembly
q
In Disassembly section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q
The meanings of the symbols used in Disassembly section are as follows.
k: This mark indicates safety-related precautions that must be followed when implementing the work.
a : Know-how or precautions for work
6: Quantity of oil or coolant drained
Assembly
q
In Assembly section, the work procedures, precautions and know-how for carrying out those
procedures, and quantity of the oil and coolant
added are described.
q
The meanings of the symbols used in Assembly section are as follows.
k: Precautions related to safety in execution
of work
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
5
: Quantity of oil or coolant to be added
Sketches of special tools

Various special tools are illustrated for the convenience of local manufacture.
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
SEN01263-00
Coating materials list

a
a
The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu
code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Used for plastic (except polyethylene,

polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene Features: Resistance to heat and chemicals.

container Used to fix and seal bolts and plugs.
Adhesive
LT-3
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
790-129-9140
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
LG-1
790-129-9010
200 g
790-129-9080
Can
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Aron-alpha
201
LG-5
Gasket sealant
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
LT-4
ThreeBond
1735
Features: Resistance to heat and chemicals.

Polyethylene
Used for fitted portions used at high temperacontainer
tures.
Tube
Used to stick or seal gaskets and packings of

power train case, etc.
1 kg
Used to seal various threaded portions, pipe

Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-6
790-129-9020
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant.

Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
LG-7
790-129-9070
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
ThreeBond
1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
ThreeBond
1207B
419-15-18131
100 g
D85EX, PX-15E0
LM-G
Part number
Q'ty
Container
09940-00051
60 g
Can
Used to lubricate sliding portions.

(to prevent squeaking)
200 g
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
LM-P
09940-00040
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
Various
Various
General purpose type.
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
Various
Various
Used for bearings used at normal temperature

under light load in contact with water or steam.
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
GLASS
PRIMER 580
SUPER
Primer
SUNSTAR
PAINT PRIMER
435-95
400 g x 10 Bellows-type
400 g x 20 container Used for parts under heavy load.
16 kg
Can
400 g
16 kg
400 g
16 kg
Seizure resistance and heat resistance higher

Bellows-type
than molybdenum disulfide grease.
container
Not conspicuous on machine since color is
Can
white.
Bellows-type Since this grease is decomposed by natural baccontainer
teria in short period, it has less effects on microCan
organisms, animals, and plants.
20 ml
Glass
container
Used as primer for cab side.

(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
Used as primer for glass side.

20 ml
Glass
container
417-926-3910
22M-54-27230
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
D85EX, PX-15E0
Adhesive for cab glass
Grease
Molybdenum
disulfide lubricant
CateKomatsu code
gory
SEN01263-00
Used as primer for painted surface on cab

side.
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
Used as primer for sash (Almite).
SEN01263-00
Part number
Q'ty
Container
SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
S is used for high-temperature season

(April October) and W for low-temperature season (November April) as adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Used as adhesive for glass.

SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window.

Cartridge
Used to seal joint of glasses.

Translucent white seal.
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Caulking material
Adhesive
CateKomatsu code
gory
Used as adhesive for glass.

Used to seal joints of glass parts.
D85EX, PX-15E0
SEN01263-00
Special tool list

a
a
Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufactured).
Necessity:t: Cannot be substituted, should always be installed (used).
q: Extremely useful if available, can be substituted with commercially available part.
1 795-630-5500
A1 2 01010-81080
Bolt
Washer
Push tool
790-101-5221
Grip
01010-81225 Bolt
01050-31640 Bolt
795-931-1210
1 01050-31625 Bolt
01050-31645 Bolt
795-931-1220
A2
Engine assembly
A3
Push tool
Removal of fuel supply pump

Q
Installation of engine front seal
Installation of engine rear seal
A4
790-331-1120
Wrench
A5
795T-471-1550
Wrench
791-612-1100
Installer
790-101-4200
Puller (294kN {30ton}) t
790-101-1102
Hydraulic pump
D1
791-415-1300
Puller assembly
Removal, installation of snap

ring of carrier
D2
799-301-1600
Oil leak tester
Operation check of piston
E1
791T-422-1320
Hanger
E2
790-302-1500
Wrench set
E3
796-730-2300
Wrench assembly
E4
795-630-1810 or
Torque wrench
purchased tool
Push tool
HSS case assembly
D85EX, PX-15E0
Nature of work, remarks
01050-31645 Bolt
TORQFLOW
transmission
assembly
Part name
795T-521-1140
3 01643-31032
Damper assembly
Standard puller
Part number
Sketch
Component
New/Remodel
Tools marked Q in the Sketch column are tools introduced in special sketches (See Sketches of special
tools).
Q'ty
Necessity
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.
Symbol
Tightening of cylinder head bolt

Q
Removal, installation of nozzle

tip
Press fitting of bearing
Removal, installation of brake

assembly
Removal, installation of bearing
nut
Check of bevel gear rotating
torque
J2
J3
Lifting tool
791T-627-2110
Plate
Part name
01643-32060
Washer
790-431-1031
Block
791-520-4140
Screw
790-101-2360
Plate
791-112-1180
Nut
791-546-1110
Adapter
790-201-2690
Plate
790-101-2102
Puller
Removal of sprocket hub bearing
790-101-1102
Hydraulic pump
790-431-1031
Block
791-520-4140
Screw
791-112-1180
Nut
01643-32460
Washer
791T-627-2130
Plate
Press fitting of sprocket hub

Q bearing inner race
791T-627-2120
Push tool
790-101-2102
Puller
Hydraulic pump
Installer
790-101-5201
Push tool KIT
790-101-5281 Plate
790-101-5221 Grip
01010-51225 Bolt
L1
791-530-1510
Installer
Press fitting of floating seal of

idler assembly
L2
791-601-1000
Oil pump
Adding oil
791-685-8006
Compressor
791-635-3160
Extension
791T-630-2610
Spacer
790-101-1300
Cylinder
790-101-1102
Hydraulic pump
N1
791-651-1510
Installer
Press fitting of floating seals of

track roller and carrier roller
assemblies
N2
791-601-1000
Oil pump
Adding oil
Idler assembly
Q Slinging of final drive assembly
790-101-1102
J5
Track roller and

carrier roller
assemblies
791-580-1510
J4
Recoil spring
assembly
Sketch
790-337-1032
Part number
New/Remodel
Q'ty
J1
Necessity
Component
Symbol
SEN01263-00
M1
Press fitting of floating seal
Press fitting of oil seal
Disassembly, assembly of recoil

spring assembly
D85EX, PX-15E0
Necessity
Q'ty
794-650-3000
Remover and installer
790-101-1300
Cylinder assembly
790-105-2300
Jack assembly
790-101-1102
Hydraulic pump
791-650-3500
Remover and installer
791-675-5542
Adapter
791-675-5571
Adapter
790-101-1300
Cylinder assembly
790-105-2300
Jack assembly
790-101-1102
Hydraulic pump
assembly
R3
791-646-7531
Push tool
Removal of track pin plug
R4
791-660-7460
Pin brush
Cleaning of track pin plug
791-646-7900
Plug push tool
R1
R2
Track shoe
assembly
R5
Part number
790-434-1210 Bar
790-434-1220 Guide
791-932-1110
Plug push tool
791-646-7523 Bar
Disassembly, assembly of track

(Master link type)
Disassembly, assembly of track

(Lubricated type)
Installation of track pin plug
R6
791-632-1060
Installer
Installation of track link seal
R7
790-701-3000
Seal checker
Check of sealing of track link
R8
791-601-1000
Oil pump
Adding track link oil
790-502-1003
Cylinder repair stand
790-101-1102
Hydraulic pump
Disassembly, assembly of
hydraulic cylinder
790-102-3802
Wrench
790-302-1310
Socket
790-302-1350
Socket
790-302-1340
Socket
790-201-1702
Push tool KIT
U1
U2
U3
U4
01010-50816 Bolt
790-201-1791 Push tool
790-201-1821 Push tool
790-201-1811 Push tool
Push tool KIT
790-101-5021 Grip
U5
U6
790-101-5021 Grip
790-201-1500
D85EX, PX-15E0
791-646-7590 Guide
Hydraulic cylinder
assembly
Sketch
Part name
Symbol
Component
SEN01263-00
New/Remodel
1
1
01010-50816 Bolt
790-201-1610 Plate
790-201-1630 Plate
790-201-1620 Plate
790-720-1000
Expander
Removal, installation of hydraulic cylinder head

Removal, installation of nut
(Blade lift)
(Blade tilt)
(Ripper lift)
Press fitting of cylinder head
bushing
(Blade lift)
(Blade tilt)
(Ripper lift)
(Ripper tilt)
Press fitting of cylinder head

dust seal
(Blade lift)
(Blade tilt)
(Ripper lift)
(Ripper tilt)
Installation of piston ring
Operator's cab
assembly
Air compressor
10
U7
X1
X2
Ring
07281-01159
Clamp
796-720-1680
Ring
07281-01589
Clamp
796-720-1670
Ring
07281-01279
Clamp
793-498-1210
Lifter (Suction cup)
799-703-1200
Service tool kit
799-703-1100
Vacuum pump
799-703-1110
Vacuum pump
799-703-1120
Vacuum pump
799-703-1401
Gas leak detector
Part name
Sketch
796-720-1660
Part number
New/Remodel
Q'ty
Hydraulic cylinder
assembly
Necessity
Component
Symbol
SEN01263-00
Installation of piston ring

(Blade lift)
(Blade tilt)
(Ripper lift)
(Ripper tilt)
Removal, installation of operator's
cab glass (stuck glass)
Adding air conditioner refrigerant

(R134a)
D85EX, PX-15E0
Sketch of special tool
SEN01263-00
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A2: Push tool
A5: Wrench
D85EX, PX-15E0
11
SEN01263-00
E1: Hanger
J1: Plate
12
D85EX, PX-15E0
SEN01263-00
J3: Plate
J3: Plate
D85EX, PX-15E0
13
SEN01263-00
M1: Spacer
14
D85EX, PX-15E0
SEN01263-00

16
SEN01264-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

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
SEN01264-00

Removal and installation of fuel
supply pump assembly
1
4.
Open engine left side cover (2).
5.
Remove side cover (3).
6.
Remove the air conditioner compressor as follows.

1) Disconnect air conditioner wirings (4) and
(5).
2) Disconnect air conditioner hoses (6) and
(7).
[*1]
a Before disconnecting the air conditioner hoses, collect the new Freon
gas (R134a).
3) Remove the compressor belt and compressor (8).
4) Remove compressor mounting bracket
(9).
1 795-630-5500
Standard puller
t 2
Washer
t 2
799-703-1200
Service tool kit
t 1
799-703-1100
Vacuum pump
(100 V)
t 1
799-703-1110
Vacuum pump
(220 V)
t 1
799-703-1120
Vacuum pump
(240 V)
t 1
799-703-1401
Gas leak detector t 1
3 01643-31032
Sketch
New/Remodel
t 1
Bolt
A1 2 01010-81080
X2
Part name
Q'ty
Part number
Necessity
Symbol
Special tools
Removal
k
Disconnect the cable from the negative ()

terminal of the battery.
1.
Release the residual pressure from the fuel system. 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).
D85EX, PX-15E0
SEN01264-00
7.
Disconnect fuel supply pump wiring connectors PCV1 (10), PCV2 (11), and G (12).
8.
Disconnect fuel return hose (13).
9.
Remove high-pressure pipe clamp (14) and 2

high-pressure pipes (15).
[*3]
10. Disconnect lubrication tube (16).
[*2]
12. Remove fuel supply pump assembly as follows.

1) Remove cover (1).
2) Rotate the crankshaft forward and set
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 forcing 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.
[*4]
3)
Remove mounting nut (4) and then remove

washer (5).
a Use a magnet or the like in this operation 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
SEN01264-00
4)
5)
6)
Remove pump mounting bolts (6) and

bracket (7).
a Leave bolts (6) tightened by 2 3
threads to prevent the pump from falling down.
Install tool A1-1 with A1-2 and A1-3 and
then screw in the center bolt of A1-2 to
remove the gear from the shaft.
Remove remaining bolts and then remove
fuel supply pump assembly (8).
a Leave tools A1-1, A1-2 and A1-3 in
the installed condition.
Installation
Carry out installation in the reverse order to
removal.
[*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 conditioner hose, check that O-ring (43) is fitted to it.
a Apply sufficient compressor oil (Showa-Shell
Suniso 4G or 5G) to each O-ring.
Tightening torque of air conditioner refrigerant

piping
Thread size
Tightening torque
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}
Charging air conditioner circuit refrigerant

gas
Using tool X2, charge the air conditioner circuit
with air conditioner refrigerant gas (R134a).
[*2]
Fuel return hose: 54 93 Nm {5.5 9.5 kgm}
D85EX, PX-15E0
[*3]
1.
SEN01264-00
4)
Install bracket (6).

3 Mounting bolt (supply pump side):
19.6 29.4 Nm {2.0 3.0 kgm}
a Leave the cylinder block side mounting bolt in temporarily tightened state
(it is to be tightened permanently in
the following Step 2).
5)
Make sure that match marks (A to C) of

drive gears and idler gears are matched.
Do not correct the high-pressure pipe by

bending before installing it.
Be sure to use the genuine high-pressure
pipe clamp and observe the tightening
torque.
Install the high-pressure pipe and wiring
harness at least 10 mm apart from each
other.
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.
Install the fuel supply pump and the high-pressure

pipe between it and common rail according to the
Installation of fuel supply pump assembly
1) Set fuel supply pump assembly (3) and
then tighten it temporarily using 4 mounting 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 aligning 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
SEN01264-00
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 permanently.
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 downward 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
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}
D85EX, PX-15E0
SEN01264-00
[*4]
3
3
Joint bolt on supply pump side:

7.9 12.7 Nm {0.8 1.3 kgm}
Joint bolt on engine side:
9.8 12.7 Nm {1.0 1.3 kgm}
[*5]
3
3
Fuel hose (24):

14.8 19.6 Nm {1.5 2.0 kgm}
Eyebolts (21), (22), and (23):
24.5 34.3 Nm {2.5 3.5 kgm}
Checking for fuel leakage

Check for fuel leakage. For details, see Testing
and adjusting, Checking fuel system for leakage.
Bleeding air
Bleed air from the fuel circuit. For details, see
Testing and adjusting, Bleeding air from fuel
circuit.
D85EX, PX-15E0
SEN01264-00
Removal and installation of

cylinder head assembly
Wrench (angle)
Sketch
790-331-1120
New/Remodel
A4
Part name
Qty
Part number
Necessity
Symbol
Special tools
q 1
Removal
k

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
3.
Remove cover (1).
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).
D85EX, PX-15E0
SEN01264-00
6.
Disconnect dust indicator hose (3A).
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).
12. Disconnect wiring harness clamps (9).
10. Remove the mounting bolts and lift off muffler

assembly (7).
4
Muffler assembly: 33 kg
15. Remove heat insulation cover and bracket

assembly (13).
16. Disconnect harness clamps (14).
11. Remove air cleaner bracket (8).
D85EX, PX-15E0
SEN01264-00
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]
27. Remove exhaust tube (26).
[*9]
19. Remove filter and bracket assembly (18).

20. Disconnect heater terminal (19).
[*5]
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
10
Turbocharger and exhaust manifold

assembly: 40 kg
D85EX, PX-15E0
SEN01264-00
31. Remove bracket (29).
37. Disconnect 6 injector connectors (35).
32. Disconnect EGR tube (30).
38. Disconnect wiring harness and bracket assembly (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).

36. Remove bracket (34).
D85EX, PX-15E0
Air intake manifold: 25 kg
11
SEN01264-00
43. Remove the air conditioner compressor. For

details, see Removal and installation of fuel
supply pump assembly. (Do not remove the
air conditioner hoses.)
48. Disconnect 2 capture nuts (45).

a The capture nuts are so installed that they
will not fall.
49. Loosen locknut (46) and adjustment screw (47).
44. Using the pulley mounting bolt, set intermediate point (L) between stamps 2.5 TOP and 3.4
TOP of damper (D) to pointer (P).
a Rotate the crankshaft. For details, see
Testing and adjusting, Testing and adjusting valve clearance.
50. Remove mounting bolts (48) and rocker arm

and shaft assembly (49).
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
SEN01264-00
53. Remove 12 crossheads (54).
Installation
54. Remove rocker arm housing (55).
55. Remove cylinder head assembly (56).
1.
2.
D85EX, PX-15E0
Cylinder head assembly

Check that the cylinder head mounting surface
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.
Check the following items of the cylinder head

mounting bolts. If any bolt is out of the standard, 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.
13
SEN01264-00
3.
Using sling [1], lift up cylinder head assembly

(56) and set it on the cylinder block.
4
Cylinder head assembly: 20 kg
4.
14
Tighten the cylinder head assembly mounting

bolts in the order of 1 6 and then tighten auxiliary bolt 7.
2 Mounting bolt (1 6 in following figure):
Molybdenum disulfide grease (LM-P) or
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}
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).
1] Make a punch mark (c) on the mounting bolt head to indicate the number
of tightening times.
a When a new bolt is used, do not
make a punch mark on its head.
D85EX, PX-15E0
5.
Fit the gasket to cylinder head assembly (56)

and install rocker arm housing (55).
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
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 crosshead (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}
SEN01264-00
6.
Fuel injector assembly

Install gasket (103) and O-rings (104) and
(105) to fuel injector assembly (53).
2 O-ring: Engine oil (EO30)
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).

58.8 73.5 Nm {6.0 7.5 kgm}
10. Install the 12 push rods.
D85EX, PX-15E0
15
SEN01264-00
Rocker arm and shaft assembly

11. Set rocker arm and shaft assembly (49).
a When installing the rocker arm shaft, direct
its larger mounting hole end down and its
ball plug (108) end forward of the engine.
15. Fit the O-ring and install cylinder head cover

(44).
a When installing the O-ring, do not twist it.
3 Mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
12. Check that the ball of adjustment screw (47) is

fitted in push rod socket (109) and tighten
mounting bolts (48).
a Before installing, clean the oil holes.
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
16. Fit the gaskets to both sides, and install air

vent tube (43).
3 Joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
13. Adjust the valve clearance. For details, see

Testing and adjusting, Testing and adjusting
valve clearance.
3 Locknut (46):
58.8 73.5 Nm {6 7.5 kgm}
17. Fit the gaskets to both sides, and install spill

tube (42).
3 Joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
Fuel injector wiring harness

14. Tighten 2 capture nuts (45) of the wiring harness into injector assembly (53).
3 Capture nut:
2.0 2.4 Nm {0.2 0.24 kgm}
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
SEN01264-00
Carry out the rest of installation in the reverse

order to removal.
For the photos corresponding to the Nos., see
Removal.
[*1]
a Use a new MIKALOR clamp.
a Set the hose to the original (marked) position.
(For the insertion depth of air hose: see the
table below.)
a Set the bridge (BR) at the bottom of clamp bolt
and it will be lapped over band (BD) by at least
min. 5 mm.
2 Threads of clamp bolt: Lubricating oil:
THREEBOND, PANDO 18B
a Do not use an impact wrench.
q
When reusing the hose
a Set the clamp to its original position.
3 MIKALOR clamp: Min. 6 Nm (0.6 kgm}
q
When using a new hose
a Tighten until band gap (BDG) is as shown in
the table below.
MIKALOR clamp
Insertion depth of
air hose (mm)
Band gap
(BDG) (mm)
MC5
60
7 10
MC6
80
17 20
[*2]
(For the insertion depth of air hose: see the
table below.)
min. 5 mm.
q
q
a Tighten until band gap (BDG) is as shown in
the table below.
MIKALOR clamp
Insertion depth of
air hose (mm)
Band gap
(BDG) (mm)
MC1
60
7 10
MC2
80
17 20
MC3
80
17 20
MC4
55
17 20
[*3]
Air hose clamp:

8.8 0.5 Nm {0.9 0.05 kgm}
[*4]
D85EX, PX-15E0
Air cleaner band:

9.8 11.8 Nm {1 1.2 kgm}
17
SEN01264-00
[*5]
Heater terminal:
5.88 7.48 Nm {0.6 0.8 kgm}
[*6]
Joint bolt on filter (upper) side of tube and

clamp assembly (20):
24.5 34.3 Nm {2.5 3.5 kgm}
Joint bolt on fuel supply pump (lower) side of
tube and clamp assembly (20):
14.8 19.6 Nm {1.5 2.0 kgm}
Sleeve nut on engine controller (lower) side
of tube and clamp assembly (20):
84 132 Nm {8.5 13.5 kgm}
Clamp of tube and clamp assembly (20):
27 34 Nm {2.8 3.5 kgm}
[*11]
(Insertion depth of air hose: 80 mm)
min. 5 mm.
q
3 MIKALOR clamp: Min. 6 Nm {0.6 kgm}
q
a Tighten until band gap (BDG) is 17 20 mm.
[*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 assembly (23).
[*8]
Sleeve nut: 40 44 Nm {4.1 4.5 kgm}
[*9]
Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
[*10]
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]
q
High-pressure pipe assembly
k Do not bend the high-pressure pipe to collect before installing.
k Be sure to use the genuine high-pressure
pipe clamps and observe the tightening
torque.
a

taper seal: Part at 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.
1.
Finger tighten high-pressure pipe assembly

(40).
a Loosen all of the high-pressure pipe clamps.
2.
Permanently tighten high-pressure pipe assembly (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.
a When installing each bellows, take care of
the direction of the slit.
q
Fuel injector side: To be directed down.
q
Common rail side:
To be dir ec ted to cylinder block
(upper) side.
a The bellows are installed so that fuel will not
spout over the hot parts of the engine and
catch fire when it leaks for some reason.
D85EX, PX-15E0
SEN01264-00
4.
Installation procedure for clamps and brackets.

3 Mounting bolt of clamp and bracket
(Permanently tightening):
11.8 14.7 Nm {1.2 1.5 kgm}
1) Finger tighten 6 clamps (110) and 6 brackets (37).
2) Permanently tighten clamps (110) and
brackets (37) in order.
3) Finger tighten 4 hollow clamps (111).
4) Finger tighten clamp (112) to bracket (34)
and then permanently tighten it.
5) Permanently tighten bracket (34).
6) Permanently tighten 4 hollow clamps (111).
Check that each high-pressure pipe and

wiring harness are at least 10 mm apart
from each other.
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.
5
19
SEN01264-00

injector assembly
1
7.
Remove turbocharger lubrication tube clamp

plates (6).
Removal
8.
Disconnect wiring harness clamps (7).
9.
Disconnect tubes (8) at the inlet and outlet of

the engine oil filter and remove filter and
bracket assembly (9).

1.
Remove the engine hood. For details, see

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
SEN01264-00
12. Remove 6 clamps (12) and 6 splash prevention covers (13) on the injector side.
13. Remove spill tube (19).
17. Remove the injector.

Remove holder mounting bolt (26) of injector
(24) and then remove injector (24) and holder
(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
SEN01264-00
Installation
[*3]
a Install high-pressure pipes between the fuel
injector and common rail according to the following procedure.
1) Install high-pressure pipes (3), (4), (5), (6),
(7) and (8).
a Mounting angle of the high-pressure
injection pipe is adjusted before the
installation of the injector.
3 Sleeve nut (on both sides):
39.2 49 Nm {4 5 kgm}
2) Tighten bracket (9) and clamp (10) by
3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
3) Install clamps (11), (12), (13) and (14) by
tightening them by hand.
4) Install 6 each of the splash prevention
covers (15) and (16).
Direct the slit on the injector side downward and that on the common rail side
toward the cylinder block.
k
k

removal.
Do not bend the high-pressure pipes before
using them.
Be sure to use the genuine high-pressure
pipe clamps and tighten them to the specified torque.
Install the high-pressure pipes and wiring
harness at least 10 mm apart.
taper seal: Part of 2 mm from the end) for
stepped-type wear (fatigue) which your nail
can feel. If any of those defects may cause fuel
leakage, replace the high-pressure pipe.
[*1]
Hose clamp: 8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
22
Band clamp: 9.8 11.76 Nm {1.0 1.2 kgm}
D85EX, PX-15E0
5)
6)
Install bracket (17).

3 Clamp tightening torque:
11.8 14.7 Nm {1.2 1.5 kgm}
Tighten clamps (11), (12), (13), and (14)
permanently.
3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
SEN01264-00
2)
Insert holder (2) to injector (1). Continue

from that state, insert inlet connector (5) to
the high-pressure pipe insertion hole
through the rocker housing.
3)
Fit the ball washer to bolt (3) and tighten

holder (2) temporarily.
2 Spherical part of washer:
Engine oil (EO30)
Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them temporarily.
a Tighten the common rail side sleeve
nut temporarily, too.
Tighten holder (2) with bolt (3) permanently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the opposite direction of the injector.
58.8 73.5 Nm {6.0 7.5 kgm}
After tightening the holder, remove the
high-pressure sleeve from the inlet connector and then install the other injectors
in order according to the above procedure.
[*4]
Head cover mounting bolt:

9.8 1 Nm {1.0 0.1 kgm}
4)
[*5]
Wiring harness capture nut:

2.0 2.4 Nm {0.2 0.24 kgm}
5)
[*6]
a Install the fuel injector assembly according to
1) Install gasket (6) and O-rings (7) and (8) to
injector (1).
2 O-ring: Engine oil (EO30)
6)
D85EX, PX-15E0
23
SEN01264-00
Checking for fuel leakage

Check for fuel leakage. For details, see Testing
and adjusting, Releasing residual pressure
from fuel system.
Bleeding air
Bleed air from the fuel circuit. For details, see
Testing and adjusting, Bleeding air from fuel
circuit.
24
D85EX, PX-15E0
SEN01264-00

engine front seal
4.
Remove alternator belt (7) and air compressor

belt (8).
5.
Remove 6 pulley mounting bolts (9) and (10)

and pulley (11).
a One of mounting bolts (10) has a different
diameter.
[*3]
6.
Remove front seal (12).
A2
795T-521-1140
Push tool
t 1
790-101-5221
Grip
t 1
01010-81225 Bolt
t 1
01050-31640 Bolt
t 3
Sketch
Q'ty
Part name
New/Remodel
Part number
Necessity
Symbol
Special tools
Removal
k
1.

Open undercover (1).
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 compressor assembly and adjustment bolt (6). [*2]
D85EX, PX-15E0
[*4]
25
SEN01264-00
Installation
[*1]
q
Strain the belt according to the following procedure.

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
with finger to about 98 N {10 kg})
ii)
[*3]
iii)
3
3
Mounting bolt (9):

245 309 Nm {25 31.5 kgm}
Mounting bolt (10):
157 196 Nm {16 20 kgm}
Evenly push in the metallic ring of seal (12)

with both hands, getting over the large diameter side of the internal plastic cylinder.
After pushing in seal (12), remove internal
plastic cylinder (13).
a When removing, take care not to
damage the seal lip.
[*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 cylinder of the spare seal before installing the seal.
iv) Tighten the bolt of tool A2 evenly until the
end of tool A2 touches the end of crankshaft (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
26
Lip: Lithium grease (G2-LI)
D85EX, PX-15E0
SEN01264-00

engine rear seal
3.
Lift off flywheel assembly (1).

4
Flywheel assembly: 58 kg
795-931-1210
Push tool
t 1
1 01050-31625 Bolt
t 3
01050-31645 Bolt
t 3
795-931-1220
t 1
A3
2
Push tool
01050-31645 Bolt
Sketch
Q'ty
Part name
New/Remodel
Part number
Necessity
Symbol
Special tools
t 3
4.
Remove rear seal (2).
[*2]
Removal
k

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
SEN01264-00
Installation
q

removal.
[*1]
a Apply clean lubricating oil (EO30-CD) all over
the threads, seats, and washers of the bolts.
a Tighten the 6 flywheel mounting bolts in the
order of 1 6 as shown in the following figure.
a Tighten each mounting bolt twice.
3 Mounting bolt:
1st tightening torque:
147 19.6 Nm {15 2.0 kgm}
2nd tightening torque:
289.1 19.6 Nm {29.5 2.0 kgm}
Procedure for installing standard seal (A)

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 cylinder (3) of the spare seal before installing
the seal.
1)
[*2]
q
28
Put the large inside diameter side (b) of

internal plastic cylinder (3) to the end of
crankshaft (4).
of the plastic internal cylinder.
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 m or less)
and it does not have a flaw, install the
standard seal (A). In other cases, install
the seal with sleeve (B).
D85EX, PX-15E0
2)
3)
4)
SEN01264-00
Evenly push in the metallic ring of seal (2)

with both hands, getting over the large
diameter side of the internal plastic cylinder.
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:
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).
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.
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 thoroughly from the shaft.
a Handle the seal and sleeve as an assembly. Never separate them from each other.
D85EX, PX-15E0
29
SEN01264-00
3)
4)
30
Remove tool A3-2 and install tool A3-1.

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 with sleeve (2).
D85EX, PX-15E0

engine oil pan
SEN01264-00
5.
Disconnect oil hoses (6) and (7) of the power

train oil cooler.
6.
Disconnect hoses (8), (9), and (10) between

the power train oil cooler and radiator.
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.
Removal
k
1.
2.

Open undercovers (1), (2) and (3).
Drain the engine oil.

6
a
3.
Engine oil: Approx. 44 l
Remove the engine oil level gauge.
Drain the radiator coolant.

6
4.
[*1]
Open both engine side covers (4) and remove

both side covers (5).
10. Loosen mounting bolt (14) and remove power

train oil cooler (15).
D85EX, PX-15E0
31
SEN01264-00
11. Disconnect fuel return circuit block (16) on the

left side of the engine.
14. Set jack [1] under damper (20) to push up the

damper.
12. Disconnect universal joint assembly (17).
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.
[*3]
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
cap (22) of No. 6 engine cylinder.
SEN01264-00
Installation
q

removal.
[*1]
Drain plug: 127.4 176.4 Nm {13 18 kgm}
[*2]
Length of spacer: (L) = 98.5 mm (2 pieces)
[*3]
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
[*4]
18. Pull out oil pan (21) forward and remove.

4
Oil pan: 26 kg
Mating face of oil pan:


5
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
D85EX, PX-15E0
Oil pan: Approx. 44 l
33
SEN01264-00

34
SEN01265-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

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
SEN01265-00

engine assembly
5.
Open undercovers (1), (2) and (3).
6.
Remove engine side covers (4) and plates (5)

on both sides.
7.
Disconnect wirings (6), (7), (8), (9), and (10).
8.
Remove external air suction tube (11).
X2
799-703-1200
Service tool KIT t 1
799-703-1100
Vacuum pump
(100 V)
t 1
799-703-1110
Vacuum pump
(220 V)
t 1
799-703-1120
Vacuum pump
(240 V)
t 1
799-703-1401
Sketch
New/Remodel
Part name
Q'ty
Part number
Necessity
Symbol
Special tools
Removal
k

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.

6
2.

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.
D85EX, PX-15E0
9.
Disconnect engine ground wire (12).
10. Disconnect fuel return hoses (13) and (14).
SEN01265-00
13. Disconnect fuel supply hose (18).
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
SEN01265-00
16. Remove universal joint assembly (23).
[*2]
17. Disconnect tubes (24) and (25) at the outlet

and inlet of the power train oil filter.
a Cover the flange to prevent dirt from
entering it.
18. Remove power train oil filter (26) and mounting
bracket together.
20. Remove 2 bolts each from both sides of rear

engine mount (28).
21. Lift off engine assembly (34).

a Before lifting off the engine assembly,
check that all the wires and pipes are disconnected.
4
Engine assembly: 1,465 kg
19. Remove 2 bolts each from both sides of front

engine mount (27).
D85EX, PX-15E0
SEN01265-00
Installation
q

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]
them.
Tightening torque of air conditioner refrigerant piping
Thread size
Tightening torque
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]
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}

5
Charging air conditioner with refrigerant gas

with new Freon gas (R134a).
D85EX, PX-15E0
SEN01265-00

radiator assembly
5.
Disconnect hoses (4), (5), and (6) for the

power train oil cooler from the bottom of the
radiator.
6.
Disconnect the aeration hose from the top of

the power train oil cooler.
7.
Disconnect wiring connector (7) of the radiator

coolant level sensor, remove clamp (8), and
separate wiring harness (9) from the radiator.
X2
799-703-1200
Service tool KIT t 1
799-703-1100
Vacuum pump
(100 V)
t 1
799-703-1110
Vacuum pump
(220 V)
t 1
799-703-1120
Vacuum pump
(240 V)
t 1
799-703-1401
Sketch
New/Remodel
Part name
Q'ty
Part number
Necessity
Symbol
Special tools
Removal
k

1.
Remove the fan drive assembly. For details,

see Removal and installation of fan drive
assembly.
2.

assembly.
3.
Remove undercovers (1) and (2).
4.
Drain the radiator coolant.

5
D85EX, PX-15E0
SEN01265-00
8.
Disconnect hose (10) of the reserve circuit and

remove tank (11).
9.
Remove the corrosion resistor and mounting

bracket (12) together and disconnect the hose
clamp.
14. Disconnect bypass valve outlet hose (19) of

the hydraulic oil cooler circuit.
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
SEN01265-00
17. Lift off the radiator assembly (22).

4
Radiator assembly: Approx. 242 kg
[*2]
them.
Installation
q

removal.
[*1]
(Insertion depth of air hose: 80 mm)
min. 5 mm.
q
q
a Tighten until band gap (BDG) is 7 10 mm.
Thread size
Tightening torque
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}

5
Charging air conditioner with refrigerant gas

with new Freon gas (R134a).
D85EX, PX-15E0
Removal and installation of fan

drive assembly
1
SEN01265-00
4.
Disconnect fan motor solenoid wiring connector (3).
5.
Disconnect 3 fan motor hoses (4), (5) and (6).

a Plug the hoses to prevent dirt from entering them.
6.
Remove 2 lower mounting bolts of the fan drive

assembly and spring (7).
7.
Sling the fan drive assembly temporarily and

remove 3 upper mounting bolts (8).
Removal
k
1.

Drain the hydraulic oil.
6
2.
3.
Hydraulic tank:
D85EX-15E0; Approx. 120 l
D85PX-15E0; Approx. 106 l
Remove the mounting bolt and open fan guard

(1).
Remove fan net (2).
D85EX, PX-15E0
SEN01265-00
8.
Lift off fan drive assembly (9).

4
Fan drive assembly: 73 kg
Installation
q

removal.
Refilling with oil

Add oil to the specified level. Run the engine to
circulate the oil through the system. Then,
check the oil level again.
5
10
Hydraulic tank:
Bleeding air
Bleed air from the piping. For details, see Testing and adjusting, Bleeding air from work
equipment cylinders.
D85EX, PX-15E0
SEN01265-00

motor assembly
1
Removal
1.
Remove the fan drive assembly. For details, see

Removal and installation of fan drive assembly.
2.
Remove mounting bolt (1) and lock plate (2).
3.
Remove nut (3).
4.
Using puller [1], remove fan (4).
5.
Remove the 4 mounting bolts and fan motor

assembly (5).
D85EX, PX-15E0
[*1]
Installation
q

removal.
[*1]
a Tighten the nut to 142.2 Nm {14.5 kgm}. Then,
align the holes on the front and back sides of
the lock plate by retightening the nut by the
minimum angle.
3 Mounting nut:
132.4 156.9 Nm {13.5 16 kgm}
11
SEN01265-00

tank assembly
1
5.
Disconnect fuel level sensor wiring connector

423 (5).
6.
Disconnect 2 fuel return hoses (6) and (7).
7.
Remove 6 fuel tank mounting bolts (8).
Removal
k
1.

Remove rear cover (1).
2.
Close fuel supply valve (2).
3.
Disconnect fuel supply hose (3).
4.
12
Remove operator seat rear cover (4).
D85EX, PX-15E0
8.
SEN01265-00
Lift off fuel tank assembly (9).

4
Fuel tank assembly:

215 kg (When empty)
618 kg (When full)
Installation
q

removal.
D85EX, PX-15E0
13
SEN01265-00

damper assembly
7.
Remove rubber cover (3).
8.
Loosen clamp (4) of damper oil level detection

pipe.
9.
Disconnect breather hose (5) and remove oil

level detection pipe (6) and breather hose
together.
a Move the oil level detection pipe aside.
Removal
k

1.

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
assembly.
4.
5.
Drain the oil from the damper chamber.

6
6.
14
Oil in damper chamber: Approx. 1.5 l
Remove universal joint assembly (2).
[*1]
D85EX, PX-15E0
SEN01265-00
10. Using a eyebolt, sling damper cover assembly

(7) temporarily and remove the mounting bolts.
[*2]
Installation
11. Using 2 forcing screws, lift off damper cover

assembly (7).
[*3]
a Lower the damper cover assembly to the
floor.
[*1]
Damper cover assembly: 57 kg

removal.
Mounting bolt:
98.1 122.6 Nm {10 12.5 kgm}
[*2]
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 lubricant (A) and leave it as it is for 2 3 minutes.
Then, apply extreme pressure lithium grease
containing molybdenum (B) to the shaft spline.
A
Molybdenum disulfide dry lubricant
Sumiko lubricant: Rocol Dry

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) temporarily and remove the mounting bolts.
[*4]
13. Using 2 guide bolts, lift off damper assembly (8).
a Lift up the damper assembly, and then
lower it to the floor.
4
Damper assembly: 74 kg
[*4]
Damper assembly mounting bolt:

98.1 122.6 Nm {10 12.5 kgm}
Refilling with oil

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
3
D85EX, PX-15E0
Oil in damper chamber: Approx. 1.6 l

Drain plug: 58.8 78.5 Nm {6 8 kgm}
15
SEN01265-00

engine hood assembly
4.
Loosen the clamp and disconnect air conditioner duct hose (5).
5.
Remove 2 mounting bolts (6) on the rear side

of the engine hood.
6.
Lift off engine hood assembly (7).
Removal
k
1.
2.

Remove radiator top cover (1).
Remove mounting bolt (2) on the front side of

the engine hood and remove plate (3).
3.
Engine hood assembly: 155 kg
Open both engine side covers (4).
Installation
q
16

removal.
D85EX, PX-15E0
SEN01265-00

18
SEN01266-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN01266-00
Power train, Part 1

Removal and installation of power
train unit assembly
1
1
7.
Remove work equipment valve cover (2).
8.
Disconnect 2 ripper hoses (3).

a Secure the ripper assembly.
9.
Disconnect 2 blade tilt hoses (4).
Removal
k
1.

Drain the oil.
6
6
2.
3.
4.
Power train case: Approx. 90 l

Hydraulic tank:

assembly.
assembly.
assembly.
5.
Remove the fuel tank assembly. For details,

see Removal and installation of fuel tank
assembly.
6.
Remove power train undercover (1).
10. Disconnect 2 HSS motor hoses (5).

a Disconnect these hoses from the HSS
motor, too.
11. Disconnect main hoses (6) of the HSS and
work equipment pump.
D85EX, PX-15E0
SEN01266-00
12. Disconnect breather hose (7) and oil level detection pipe lower tube (8) from the steering case.
18. Disconnect pump pressure sensor connector

HHP (17).
13. Remove clamp (9) and oil level detection pipe

assembly (10).
19. Remove wiring harness clamp (18) and wiring

harness assembly (19).
14. Remove ripper hose clamp (11) and move the

hose toward the ripper.
20. Disconnect main hoses (6) of HSS and work

equipment pump.
15. Remove blade lift hose clamp (12) and clamp

bracket (13).
21. Remove hose clamp bracket (20) and disconnect 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
SEN01266-00
23. Disconnect torque converter outlet hose (23)

and transmission lubrication inlet hose (24).
26. Remove cover (29).

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]
D85EX, PX-15E0
SEN01266-00
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 following 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 position 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
SEN01266-00
Installation
q

removal.
[*1]
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).
q
Refilling with oil

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
5

Hydraulic tank:
Hydraulic tank drain plug:
58.8 78.5 Nm {6 8 kgm}
D85EX, PX-15E0
SEN01266-00
Disconnection and connection of

power train unit assembly
1
7.
Remove hoses (10), (11), and (12) and suction

tubes (13) and (14).
8.
Remove suction tube (15).
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).
4.
Remove 9 oil pressure pickup hoses (5).
5.
Remove wires (6).

a The wiring connectors are TMV, TVC,
HHP, 453, TMI, and FAC.
6.
Disconnect hoses (7), (8), and (9).
D85EX, PX-15E0
[*2]
SEN01266-00
9.
Lift off HSS motor assembly (16).
12. Lift off HSS and work equipment pump assembly (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).
D85EX, PX-15E0
17. HSS assembly

1) Set the power train assembly on blocks [1]
and [2].
2) Sling HSS assembly (26) temporarily.
3) Remove the mounting bolts and separate
HSS assembly (26) from transmission
assembly (27).
4 HSS assembly: 750 kg
18. PTO assembly

1) Set the power train assembly on block [3]
with PTO assembly (28) up.
2) Remove coupling (29) and retainer (30). [*3]
3)
SEN01266-00
4)
5)
Sling PTO assembly (28) temporarily and

remove the mounting bolts.
Sling PTO assembly (28) to separate it
from transmission assembly (27).
a The torque converter assembly will
be left on the transmission side.
4 PTO assembly: 300 kg
19. Remove 8 mounting bolts. Using eyebolt [4], lift

off torque converter assembly (33).
Remove sleeves (31) and (32).
D85EX, PX-15E0
SEN01266-00
Connection
q
Carry out connection in the reverse order to

disconnection.
[*1] [*2]
a Bend the cotter pin securely.
[*3]
q
10
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)
D85EX, PX-15E0
Disassembly and assembly of

PTO assembly
SEN01266-00
2.
Cover assembly (left)

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)
3)
2)
3)
Remove snap ring (26) and spacer (27).

Drive out gear assembly (9) from cover (10).
4)
Remove snap ring (28) and inner race (29).
Drive out gear assembly (4) from cover (5).

Remove bearing (6) from gear (7).
D85EX, PX-15E0
11
SEN01266-00
5)
Remove snap ring (31) from cover (30),

and then remove bearing (32).
6)
Remove snap ring (34) from PTO case

(33), and then remove bearing (35).
2)
Remove the mounting bolts on the shaft

side. Using forcing screws [3] and [4],
remove shaft (14).
3)
Remove bearing (16) and spacer (17)

from gear (15).
a When reusing bearing, do not change
its combination with the outer race.
Remove outer race (18) from gear (15).
4)
3.
Idle gear
1) Remove the mounting bolts and plate (13).
4.
12
Cover
Remove cover (20) on the opposite side of
cover assembly (right).
D85EX, PX-15E0
5.

1) Remove snap ring (21).
2) Drive out gear (22) from the snap ring side.
SEN01266-00
Assembly
a
a
a
3)
6.
Clean the all parts and check them for dirt or

damage before installing.
Drop engine oil onto the rotating parts of each
bearing and rotate it several turns.
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.
2.

1) Install bearing (23) to the case.
2) Install snap ring (36).
Remove snap ring (36) and bearing (23).
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
SEN01266-00
3)
4)
3.
Install gear (22) to bearing (23).

Install snap ring (21).
Idle gear
1) Install shaft (14).
3 Mounting bolt:
98 122.5 Nm {10 12.5 kgm}
2) Install bearing (16).
3)
4)
14
Install spacer (17).

Install outer race (18) to gear (15).
4.
5)
6)
Install gear (15).

Install bearing (16).
a Press fit the inner race side to the shaft.
7)
Install plate (13) and tighten the mounting

bolts.
3 Mounting bolt:
98 122.5 Nm {10 12.5 kgm}
Cover assembly (left)

1) Install bearing (35) to case (33).
D85EX, PX-15E0
3)
4)
Install bearing inner race (29) to the gear.

5)
6)
Install bearing (32) to cover (30).

SEN01266-00
9)
Install cover assembly (8), meshing it with

the idle gear.
10) Tighten the mounting bolts.
3 Mounting bolt:
98 122.5 Nm {10 12.5 kgm}
5.
7)
8)
Cover assembly (right)

1) Install bearing (6) to gear (7).
2) Install gear assembly (4) to cover (5).
Install gear assembly (9) to cover (10).

Install spacer (27) and snap ring (26).
3)
4)
D85EX, PX-15E0
Install cover assembly (3), meshing it with

the idle gear.
Tighten the mounting bolts.
3 Mounting bolt:
98 122.5 Nm {10 12.5 kgm}
15
SEN01266-00
6.
16
Cover
Install cover (20).
D85EX, PX-15E0

torque converter assembly
SEN01266-00
3.
Case assembly
2) Remove spacer (9).
Disassembly
1.
Case and turbine assembly

Remove 30 bolts (2) from underside. Using eyebolt [1], remove case and turbine assembly (1).
3)
2.
Using puller [3], disconnect case assembly (10) from turbine (11).
Gear and input shaft

1) Remove mounting bolts (3).
2) Using forcing screw [2], remove gear and
input shaft (4).
4.
D85EX, PX-15E0
Stator
1) Remove mounting bolts (12) and stator (15).
17
SEN01266-00
2)
Remove snap ring (14) and race (13).
Assembly
a
a
a
a
1.
5.

Drop engine oil onto the rotating parts of each
bearing and rotate it several turns.
Check that the snap rings are fitted in the
grooves.
Apply grease (G2-LI) thinly to each seal ring.
Pump assembly
1) Press fit bearing (21) to cage (20) and
install snap ring (22).
Pump assembly
1) Remove pump assembly (16) from stator
shaft (17).
2)
2)
18
Install cage assembly (18) to pump (23)

and tighten mounting bolts (19).
3 Mounting bolt:
58.9 73.6 Nm {6 7.5 kgm}
Remove mounting bolts (19), and then pull

case assembly (18) out of pump assembly
(23).
D85EX, PX-15E0
3)
SEN01266-00
3)
Install seal ring (24) to stator shaft (17).

a Apply grease (G2-LI) to the seal ring
and put the openings opposite to
each other.
Install pump assembly (16) to stator shaft
(17).
a Press the inner race side of the bearing 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.
2.
Install stator (15) and tighten bolts (12).

3 Mounting bolt:
58.9 73.6 Nm {6 7.5 kgm}
Case
1) Install bearing (25) and case (26).
Stator
1) Install race (13).
2)
D85EX, PX-15E0
Press the inner race side of the bearing to

install case assembly (10) to the boss of
turbine (11).
19
SEN01266-00
3)
4)
4.
5.
Case and turbine assembly

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}
Gear and input shaft

1) Press fit bearing (6) to input shaft (4).
3)
20
Install spacer (9).

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}
D85EX, PX-15E0
SEN01266-00

TORQFLOW transmission
assembly
3)
4)
Disconnect 10 ECMV connectors (4).

Remove cover (131) and wiring harness
(130) together.
5)
Remove control valve assembly (6).
1 791-415-1300
Puller assembly t 1
2 799-301-1600
Oil leak tester
Sketch
Q'ty
Part name
New/Remodel
Part number
Necessity
Symbol
Special tools
t 1
Disassembly
a
Store the removed discs and plates on a level

place so that they will not be warped.
1.
Relief valve assembly

Remove relief valve assembly (1).
2.
Control valve assembly

3.
2)
Transmission case
1) Remove 9 tie rods (132) tightened together
with the case and 2 case clamp bolts
(marked with a).
Using eyebolt [1], remove sleeve (3).
D85EX, PX-15E0
21
SEN01266-00
2)
4.
Using eyebolt [2], lift off transmission case

(7).
2)
Disassemble the input shaft/front

No. 1 carrier assembly according
i) Remove snap ring (10), No.
gear (11), and snap ring (12).
ii) Remove snap ring (13), No.
gear (14), and collar (15).
plate/
to the
2 sun
1 sun
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

gear (22).
SEN01266-00
8.
No. 2 piston
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).
6.
No. 1 discs, plates, and springs

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
SEN01266-00
3)
Disassemble No. 2 housing and No. 2 carrier assembly according to the following
procedure.
i) Remove snap ring (51) and pull No. 2
carrier assembly (52) out of No. 2
housing (53).
ii)
Remove spacer (54) from No. 2 carrier assembly (52).

iii) Remove No. 2 ring gear (56).
iv) Pull out shaft (57) and remove thrust
and ball (61).
v) Remove seal ring (133).
24
vi) Remove snap ring (49) which was

removed in step 11-1).
vii) Remove snap ring (63) and ring gear
(64).
12. No. 3 discs and plates

Remove springs (140), discs (68), and plates
(69).
13. No. 3 ring gear
Remove No. 3 ring gear (70).
14. No. 3 and No. 4 carriers assembly
1) Remove No. 3 and No. 4 carriers (71).
D85EX, PX-15E0
2)
Disassemble No. 3 and No. 4 carriers

assembly according to the following procedure.
i) Remove seal ring (72).
ii) Drive pin (73) into shaft (74).
iii) Drive out shaft (74) from No. 3 carrier
side.
iv) Remove thrust washer (76), No. 4
planetary gear (77), and bearing (78).
a Pull the pin out of the shaft.
v)
Drive out shaft (79) and remove thrust

washer (80), No. 3 planetary gear
(81), bearing (82), and ball (83).
vi) Remove snap ring (84) and bearing
(85).
D85EX, PX-15E0
SEN01266-00
15. No. 3 housing

1) Remove No. 3 housing (86).
2) Remove No. 3 piston (87).
17. No. 5 carrier and No. 4 ring gear assembly

2) Remove No. 5 carrier and No. 4 ring gear
assembly (92).
25
SEN01266-00
3)
Disassemble No. 5 carrier and No. 4 ring

gear assembly according to the following
procedure.
i) Drive out shaft (93) and remove thrust
and ball (97) from carrier (100).
18. No. 4 housing assembly

1) Remove No. 4 housing assembly (101).
2) Remove No. 4 piston (102).
19. Guide pin
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
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
SEN01266-00
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.
3)
4)
Remove snap ring (136).

Remove bearing (137) from case (116).
D85EX, PX-15E0
27
SEN01266-00
Assembly
q
1.
Using the push tool, install shaft assembly

(117) to case (116).
a Push the outer race side of the bearing with a press to install the shaft
assembly.
3)
Precautions for assembly

a Clean the all parts and check them for dirt
or damage before installing.
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.
Output shaft
1) Press fit the bearing (137) to shaft (117)
and install snap ring (120).
2.
28
2)
Cage (For fixing No. 5 carrier)

1) Using the push tool, press fit bearing (124)
to cage (125).
D85EX, PX-15E0
2)
3)
4)
Install seal rings (138) and (139).

2 Seal ring: Grease (G2-LI)
Install cage (114) to case (116).
a Press fit the inner race side of the
bearing.
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).
5.
No. 5 ring gear

Install No. 5 ring gear (107).
6.
No. 5 piston
Install the seal ring and No. 5 piston (108).
D85EX, PX-15E0
SEN01266-00
7.
Guide pin
Install guide pin (103).
8.
No. 5 discs, plates, and springs

1) Install discs (105) and plates (106).
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.
10. No. 5 carrier and No. 4 ring gear assembly

1) Assemble No. 5 carrier assembly according to the following procedure.
i) Set No. 4 ring gear (99) to carrier
(100) and install snap ring (98).
29
SEN01266-00
ii)
Install bearing (96) to gear (95) and fit

thrust washers (94) to both sides, and
then set them to carrier (100).
iii) Install ball (97) and shaft (93).

Install No. 4 discs (89), plates (90), and springs
(88).
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 assembly 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

gear (77) and fit thrust washers (76)
to both sides, and then set them to
the carrier.
v) Install shaft (74), matching its pin hole
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).
SEN01266-00
17. No. 2 housing and No. 2 carrier assembly

1) Assemble No. 2 housing according to the
i) Press fit bearing (68) to No. 2 housing
(53) and install snap ring (70).
ii)
2)
Set ring gear (64) to No. 2 carrier (55)

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).
1) Install No. 3 discs (68) and plates (69).
2) Install springs (140).
D85EX, PX-15E0
iii)
Install bearing (60) to gear (59) and fit

thrust washers (58) to both sides,
then set them to the carrier.
iv) Install ball (61) and shaft (57).
a After assembling the 2 gear sets,
install snap ring (49).
31
SEN01266-00
v) Install the seal ring.

vi) Install No. 2 ring gear (56).
vii) Install spacer (54).
a Install the spacer with the cut
inside end directed to the carrier.
4)
5)
Install sleeve (67).

a When installing the sleeve, install it to
the bolt hole marked * in the figure
with the slit (d) side down.
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).

Install No. 2 discs (46) and plates (47).
2)
3)
32
Using eyebolts, install No. 2 housing and

No. 2 carrier assembly (50).
Using tool D1, push up No. 3 carrier (48)
19. No. 2 clutch springs

Install springs (45).
20. No. 2 piston
Install the seal ring and No. 2 piston (43),
matching the spring to the spring groove.
D85EX, PX-15E0

1) Fit the seal ring and install No. 1 piston
(42) to housing (41).
2) Using eyebolts, install No. 1 housing assembly (41), matching it to No. 2 piston.
a Press the housing and hit the dowel pin.
SEN01266-00
iii)
Set No. 1 ring gear (22) to No. 1 carrier and install snap ring (21).
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
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)
D85EX, PX-15E0
Install input shaft (20) to No. 1 carrier

assembly (34), and then install snap
ring (19).
33
SEN01266-00
vi)
vii)
viii)
ix)
2)
Install collar (15).

Install No. 1 sun gear (14).
Install snap rings (13) and (12).
Install No. 2 sun gear (11) and snap
ring (10).
24. Front plate

1) Fit seal ring (31) and install collar (32) to
No. 1 carrier (33).
2)
Install the following parts to the front plate.

i) Press fit bearing (28) and install snap
ring (29).
ii) Install seal ring (30).
3)
Using eyebolts [3], install front plate (18),

matching it to the guide pin and spring.
Press fit the inner race side of bearing (28)
to No. 1 carrier (33) and install snap ring
(17).
a Check that the spring is fitted to the
cover.
Sling and install input shaft and No. 1 carrier assembly (34), meshing No. 2 sun
gear with No. 1 planetary gear.

Install discs (36), plates (37), and springs (35).
a Disc: 5 pieces, Plates: 5 pieces
34
4)
D85EX, PX-15E0
SEN01266-00
25. Tie bolts

Install 4 tie bolts (8).
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.
Piston
Standard stroke (mm)
No.1
No.2
No.3
No.4
No.5
D85EX, PX-15E0
27. Transmission case

Fit the O-ring and install transmission case (7),
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}
28. Control valve

1) Place the transmission on its side.
2) Fit the O-ring and install control valve
assembly (6).
3 Mounting bolt:
49 4.9 Nm {5 0.5 kgm}
35
SEN01266-00
3)
4)
Install cover (131) and wiring harness

together.
2 Cover: Gasket sealant (LG-6)
2 1 bolt marked with *:
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

38
SEN01267-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN01267-00
Power train, Part 2

HSS assembly
2)
Remove 5 sleeves (24) and 2 sleeves (25)

from the HSS case.
Hanger
t 1
2 790-302-1500
Wrench set
q 1
3 796-730-2300
Wrench
t 1
Commercially
4 available or
795-630-1810
Torque wrench
q 1
1 791T-422-1320
Sketch
New/Remodel
Part name
Q'ty
Part number
Necessity
Symbol
Special tools
Disassembly
1.
Disassembly of cover assembly

1) Input gear assembly
i) Remove snap ring (12).

Remove brake valve assembly (4).
ii)
2.
Cover assembly
1) Using eyebolts [1], remove cover assembly (5).
Pull out gear assembly (6) and cage

(7) as a unit with puller [2], then
remove gear assembly (6) from cage
(7).
a Take care not to lose ball (8).
D85EX, PX-15E0
iii)
2)
iv) Remove bearing (17) and spacer

(17a) from gear (15).
Remove bearing (10) from gear (9).
Intermediate gear assembly

i) Remove tube (11).
ii)
iii)
SEN01267-00
Remove the bolt and holder (13).

Drive out shaft (14) from the bolt side
and remove gear (15).
D85EX, PX-15E0
3)
Left carrier drive gear

i) Remove bolt (19) and holder (20).
ii) Remove gear (22).
iii)
Using gear puller [3], push out shaft

(21).
SEN01267-00
iv) Remove snap ring (23), then remove

bearing (28) from cover (32).
v) Remove outer race (29) from cover
(32).
3.
Brake and carrier assembly

1) Remove the mounting bolts, and then
remove brake assembly (34) with tool E1.
a Do not remove 4 hexagon socket
head bolts.
Disassembly of brake assembly

1) Remove flange (36).
2) Remove snap ring (37) and spacer (38).
vi) Remove bearing (26) from shaft (21).
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.
D85EX, PX-15E0
4)
Remove bearing (60) from cover (41).
5)
6)
Remove spring (42).

Using eyebolts [5], remove piston (43).
7)
Push up and remove cage (51), taking

care not to damage the disc.
Remove seal rings (53) and (27) from
cage (51).
Using eyebolts [7], remove drum (45),
discs, and plates as a unit.
8)
9)
D85EX, PX-15E0
SEN01267-00
10) Remove discs (46), plates (47), and

springs (48) from drum (45).
11) Remove snap ring (59) and bearing (57).

a Pry up the bearing from the notch of
the hub.
12) Remove 18 mounting bolts, and then

remove hub (39) from hub (54).
SEN01267-00
13) Remove bushing (60) from hub (39).

14) Remove snap ring (58), and then remove
stopper (56) from the hub.
Disassembly of carrier assembly

1) Turn over the hub and carrier assembly
and remove bolts (89), and then remove
carrier assembly (64) from hub (54).
2)
Remove hub (92) from carrier assembly

(64), then remove snap ring (50) and ring
gear (52).
4.
3)
4)
Drive roll pin (65) into the shaft.

Pull out shaft (66) and remove gear (52),
thrust washer (67), and bearing (69).
a Pull roll pin (65) out of the shaft.
5)
Remove bushing (91) from carrier (90).
Sun gear
1) Remove snap ring (70) and collar (73).
2)
Using gear puller [8], remove sun gear

(72) and bearing (98).
D85EX, PX-15E0
3)
4)
5)
Using the bearing race puller, remove

bearing (74).
Remove collar (71).
Remove snap ring (93).
a Perform this work for only right side of
the machine.
SEN01267-00
3)
Disassembly of bevel pinion assembly

i) Remove bolt (97), plate (99), and pin
(100).
ii)
iii)
5.
Bevel pinion assembly

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.
Secure the pinion with a press and

remove nut (101) with tool E2.
Using push tools [11], remove bevel
pinion (102) from cage (103).
iv) Remove bearing (104).

v) Remove outer races (105) and (107)
from cage (103).
D85EX, PX-15E0
SEN01267-00
vi) Remove bearing (106) and spacer

(108) from bevel pinion (102).
6.
Bevel gear shaft and bevel gear assembly

1) Sling bevel gear and shaft assembly (75)
temporarily.
2) Remove cage assemblies (76) and (86).
a Check the thickness, quantity, and
positions of shims (77).
a Since both cages are different from
each other, make marks on them.
4)
Sling bevel gear (79), remove mounting

nut (80), and pull out bevel gear shaft
assembly (81) to the right side of the
machine.
5)
Remove bearing (78) from bevel gear

shaft (82).
Remove bolts (83).
Remove outer race (84) from cage (76).
6)
7)
8)
3)
Remove seal ring (85) from bevel gear

shaft (81).
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.
D85EX, PX-15E0
Assembly
q
Precautions for 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 Coat the sliding parts with engine oil before
installing.
a Apply grease (G2-LI) to each piston seal
ring and install it evenly, with the pressure
receiving side directed to the housing.
2 Rotary seal ring: Fix each seal ring
with grease (G2-LI) and install it
very carefully not to catch it in the
parts.
a Check that the snap rings are fitted in the
grooves.
1.
Suction tube
Install suction tube (55).
SEN01267-00
2.
Bevel gear shaft and bevel gear assembly

1) Install bolt (83) to bevel gear shaft (82)
2) Heat bearing (78) with a bearing heater,
etc. and install it to the right side of the
bevel gear shaft by shrink fit.
a If the bearing temperature is raised
too high, the hardness of the heattreated part lowers. Accordingly, do
not raise the bearing temperature
more than 120C.
a After installing the bearing, drop
engine oil onto its rotating parts and
rotate it several turns.
a Check that the clearance at the bearing end is 0.03 mm or less.
3) Install outer race (84) to cages (76) and
(86).
4)
D85EX, PX-15E0
Install seal ring (85) to bevel gear shaft

(81).
SEN01267-00
5)
Insert bevel gear shaft (81) in bevel gear

(79) slung at the center of the case from
the right side of the machine.
a Tighten mounting nut (80) temporarily.
7)
8)
Install cages (76) and (86) to bevel gear

and shaft assembly (75).
a Since both cages are different from
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}
Tighten the bevel gear mounting nut permanently.
a Place a plastic hammer, etc. between
the bevel gear and case to lock them.
3
6)
10
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 heattreated part lowers. Accordingly, do
not raise the bearing temperature
more than 120C.
a After installing the bearing, drop
engine oil onto its rotating parts and
rotate it several turns.
a Check that the clearance at the bearing end is 0.03 mm or less.
Mounting nut:
245 309 Nm {25 31.5 kgm}
D85EX, PX-15E0
9)
3.
Adjusting pre-load
a Adjust the pre-load with the bevel pinion assembly removed.
i) Rotate the bevel gear and shaft
assembly several turns to fit the bearing.
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.
Bevel pinion assembly

1) Assembly of bevel pinion
i) Using the push tool, press fit bearing
(106) to bevel pinion (102) and install
spacer (108).
D85EX, PX-15E0
SEN01267-00
ii)
iii)
Using the push tool, press fit outer

races (105) and (107) to cage (103).
Place bevel pinion (102) on the press
stand and set cage (103).
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.
a Tighten the nut, while turning the
cage.
a After tightening the nut, check
that the bevel pinion rotates
smoothly.
11
SEN01267-00
vii) Install pin (100) and plate (99), and

then tighten bolt (97).
3 Bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
2)
4.
Adjusting backlash and tooth contact

1) Adjusting backlash
Apply the probe of dial gauge [13] to the
tooth tip at the end of the bevel gear at
right angles. Fix the bevel pinion and
move the bevel gear forward and backward, 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
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
12
Adjust the backlash by increasing or

decreasing the thickness of both
shims. Do not change the total thickness 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.)
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).)
D85EX, PX-15E0
2)
When backlash is too large

Decrease the thickness of the shim
on the left side of the machine body
and increase the thickness on the
right side by the same quantity.
(Move the bevel gear in direction (B).)
Adjusting tooth contact

Testing
i) Apply red lead thinly to the tooth surfaces of the bevel gear and turn the
bevel gear in the forward and reverse
directions, then check the tooth contact pattern on the bevel gear.
ii)
SEN01267-00
Check that there is not a strong contact at the tips (A) or roots (B) of the
teeth of both small end (C) and large
end (D).
If the bevel gear and bevel pinion are
adjusted in this way, their teeth come
in contact with each other correctly
when they are loaded.
Adjusting
If the tooth contact pattern is not proper,
adjust the tooth contact according to the
i) If the bevel pinion is too far from the
center line of the bevel gear, the contact 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.
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
SEN01267-00
ii)
a
iii)
5.
If the bevel pinion is too close to the

center line of the bevel gear, contact
is at the large end of the bevel gear
tooth faces curved outward and the
small end of the bevel gear tooth
faces curved inward.
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.
Do not change the total thickness of
the shims on both sides.
When adjustment is finished, tighten
the mounting bolts of the cage and
bevel pinion assembly to the specified torque.
3 Mounting bolts of cage and bevel
pinion assembly:
98 123 Nm {10 12.5 kgm}
Sun gear
1) Install snap ring (93) to the shaft.
a Perform this work for only right side of
the machine.
2) Install collar (71).
3) Install bearing (74) with the push tool.
6.
q
4)
5)
Install sun gear (72).

Install bearing (98) with the push tool.
a Press fit the inner race and outer race
simultaneously.
6)
Install collar (73) and snap ring (70).
Brake and carrier assembly

Assembly of carrier assembly
1) Install bushing (91) to carrier (90).
2)
3)
4)
14
Install bearing (69) to gear (52). Fit thrust

washers (67) to top and bottom of the
bearing, then set them to the carrier.
Install shaft (66), matching the inside of
the thrust washers and bearing to the
shaft hole of the carrier.
a Match the roll pin hole accurately.
Install roll pin (65).
D85EX, PX-15E0
5)
6)
7)
Set hub (92) to ring gear (52) and install

snap ring (50).
Install hub (92) to carrier assembly (64).
Install hub and carrier assembly (64) to

hub (54) and tighten bolts (89).
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
Assembly of brake assembly

1) Install stopper (56) to the hub, then install
snap ring (58).
2) Install bushing (60) to hub (39).
D85EX, PX-15E0
SEN01267-00
3)
Install hub (39) to hub (54) with 18 mounting bolts.

3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
4)
5)
Install bearing (57) to hub (39).

6)
7)
Set brake drum (45) to hub (39).

Install discs (46), plates (47), and springs
(48).
15
SEN01267-00
8)
Install seal rings (27) and (53) and cage

(51).
a Roughly match the oil holes on the
cage to the 4 oil holes on the drum.
a Press fit the cage to the outer race
side of the bearing.
9) Install the seal ring to piston (43).

10) Install piston (43), aligning counter bore
(b) having assembly match mark (a) with
13.5-drill (c) and opposite side (d) having
the drilled hole of the hydraulic circuit.
11) Install spring (42).

12) Install guide bolt [14] to cage (51).
13) Install bearing (60) to cover (41).
14) Using eyebolts [15] and matching to the

guide bolt, set cover (41).
a Check that the spring is fitted to both
of the piston and case.
15) Compressing the spring with forcing
screws [17] and nuts [16], press fit the
inner race side of the bearing to the hub
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 compress the spring, then install 4 bolts (40).
19) Brake and carrier assembly

i) Equalize the projection of the seal
rings from the shaft on the carrier
side.
ii) Using tool E1, install brake and carrier assembly (34).
7.
q
Cover assembly
Assembly of cover assembly
1) Install valve (31) and spring (30) to the
cover, then install the plug.
D85EX, PX-15E0
SEN01267-00
2)
Left carrier drive gear

i) Press fit bearing (26) to shaft (21).
ii)
iii)
Install outer race (29) to cover (32).

Press fit bearing (28) to cover (32),
then install snap ring (23).
iv) Using puller [18], press fit shaft (21)

to the inner race side of bearing (28).
a Replace the bolt with one having
different length.
17
SEN01267-00
iii)
v) Install gear (22).

vi) Install holder (20) and tighten bolt
(19).
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
Install holder (13) and tighten bolt

(12).
3 Mounting bolt:
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)
ii)
18
Input gear assembly

i) Install bearing (10) to gear (9).
Press fit shaft (14) to the inner race

side of bearing (17). Fit ball (16) halfway and press fit completely.
a Before the shaft enters the cover,
position the ball accurately.
D85EX, PX-15E0
SEN01267-00
2)
ii)
iii)
Install gear assembly (6).

Install cage (7) and ball (8), matching
them to the hole for ball (8).
iv) Install snap ring (12).
Using eyebolts [1], install cover assembly

(5).
2 Mating face of cover:
a Apply gasket sealant to both mating
faces of the case and cover.
a Apply gasket sealant to each mating
face without breakage.
Installation of cover assembly

1) Install 2 sleeves (25) and 5 sleeves (24) to
the HSS case.
8.
D85EX, PX-15E0

Install brake valve assembly (4).
3 Mounting bolt:
44.1 53.9 Nm {4.5 5.5 kgm}
19
SEN01267-00
9.
20
Adjustment and installation of speed sensor

1) Remove the locknut from speed sensor
(109) and apply LG-5 to its threads generously.
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.
D85EX, PX-15E0
SEN01267-00
Removal and installation of final

drive assembly
1
4.
Remove cover (4).
5.
Using forcing screw [2], pull out drive shaft (6).

a If the shaft cannot be pulled out, set a jack
and move the sprocket forward or in
reverse until the shaft can be pulled out.
a Pull out the shaft until it comes in contact
with the sprocket.
6.
Remove the 2 final drive bolts, install tool J1, and

sling the final drive assembly temporarily.
[*1]
Sketch
Q'ty
Lifting tool
t 1
791T-627-2110
Plate
t 1 N Q
01643-32060
Washer
t 6
790-337-1032
J1
Part name
New/Remodel
Part number
Necessity
Symbol
Special tools
Removal
k

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.
3.
Remove guards (2) and (3).
D85EX, PX-15E0
21
SEN01267-00
7.
Remove inside mounting bolts (7) of the final

drive assembly.
[*2]
Installation
q

removal.
[*1]
Tool mounting bolt:

455 565 Nm {46.5 58 kgm}
[*2]
Mounting bolt:
784 980 Nm {80 100 kgm}
[*3]
8.
Remove the mounting bolts and lift off final

drive assembly (8).
[*3]
4
22
Mounting bolt:
784 980 Nm {80 100 kgm}
Final drive assembly: 1,000 kg
D85EX, PX-15E0
SEN01267-00

final drive assembly
J
3
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
791-546-1110
Adapter
t 2
790-201-2690
Plate
t 1
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
790-431-1031
Block
t 1
791-520-4140
Screw
t 1
791-112-1180
Nut
t 2
01643-22460
Washer
t 2
791T-627-2130
Plate
t 1 N Q
791T-627-2120
Push tool
t 1 N Q
790-101-2102
Puller
t 1
790-101-1102
Hydraulic pump
t 1
Installer
t 1
790-101-5201
Push tool kit
t 1
790-101-5281
Plate
t 1
790-101-5221
Grip
t 1
01010-51225
Bolt
t 1
4 791-580-1510
Part name
New/Remodel
Part number
Necessity
Symbol
Special tools
3.
Shaft
Using eyebolts, remove shaft (3).
4.
Sprocket hub assembly

1) Remove the mounting bolts and plate (4).
Disassembly
1.
Draining oil
Remove the drain plug and drain the oil from
the final drive case.
6
2.
Final drive case: Approx. 26 l
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
SEN01267-00
2)
3)
4)
5)
24
Using tool J2, disconnect sprocket hub

assembly (5) and bearing (6).
Using eyebolts (3), remove sprocket hub
assembly (5).
Remove floating seal (7) and 2 bearing

outer races (8).
a Store the floating seal in a safe place
so that it will not be damaged.
Turn over the sprocket hub assembly and

remove sprocket (9).
5.
Cover assembly
1) Remove floating seal (10).
a Store the floating seal in a safe place
so that it will not be damaged.
3)
Using eyebolts, sling cover assembly (12)

temporarily. Using 3 forcing screws [2],
remove the cover assembly.
4)
Using puller [1], pull out bearing (15) and

remove spacer (16).
D85EX, PX-15E0
5)
6)
6.
SEN01267-00
Turn over the cover assembly and remove

6 lock plates (17).
Remove ring (18) and ring gear (19).
Carrier assembly
1) Using 3 eyebolts, remove carrier assembly
(20).
2)
Remove bolts (21) and holder (22).
D85EX, PX-15E0
7.
3)
Pull out planetary gear shaft (23) and

remove planetary gear (24) and bearings
(25A) and (25B).
a Take care of spacer (25D) between
the bearings.
4)
Remove 2 bearing outer races (25C).
Hub and case assembly

1) Remove thrust (26) and sun gear (27).
25
SEN01267-00
2)
Remove gear mounting bolt (28).
3)
Using eyebolts, remove gear (29).
4)
26
5)
Using tool J2, remove hub assembly (31)

and bearing (32A).
6)
Using eyebolts, remove hub assembly (31).
7)
Remove 2 bearing outer races (32C) from

hub (33).
Remove the mounting bolts and plate (30).
D85EX, PX-15E0
8.
8)
Remove collar (35) and bearing (32B)

from case (34).
9)
Remove oil sump plate (36) from case (34).
Cage assembly
1) Remove the mounting bolts of cage assembly (37). Using forcing screw [2], remove the
cage assembly from case (34).
D85EX, PX-15E0
SEN01267-00
2)
Remove shim (39).

a Check the thickness and quantity of
the inserted shims, then store them.
3)
Remove outer race (41) and oil seal (42)

from cage (40).
4)
Remove outer race (43) and oil seal (44)

from case (34).
27
SEN01267-00
9.
Gear assembly
1) Remove gear assembly (45).
2) Using puller [3], remove bearings (47) and
(48) from gear (49).
Assembly
a
a
1.
28

Coat sliding surfaces of each part with engine
oil before installing.
Gear assembly
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:
2)
Using tool J5, press fit bearing outer race

(43) to case (34).
q
Press fitting force for outer race:
1 14 kN {0.1 1.4 tons}
3)
Using push tool [4], press fit bearings (47)

and (48) to gear (49).
q
Press fitting force for bearing:
6 17 kN {0.6 1.7 tons}
Install gear assembly (45).
a Lower and install the gear assembly
slowly so that the oil seal lip will not
be damaged.
4)
D85EX, PX-15E0
2.
Cage assembly
1) Using tool J5, install oil seal (42) to cage
(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:
SEN01267-00
3)
Install the O-ring to cage assembly (37)

and adjust shim (39).
4)
Adjustment of shim
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 clearances (a) and (b) between cage (40)
and case (34) with feeler gauges.
iii) Set shim thickness (c) from the total
of clearances (a) and (b), referring to
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}
q
2)
Using tool J5, press fit bearing outer race

(41) to cage (40).
q
1 14 kN {0.1 1.4 tons}
D85EX, PX-15E0
29
SEN01267-00
Table 1
3.
a + b (mm)
Number of shims to be used
Larger
than
Below
t = 0.15
2.95
3.05
3.05
3.15
3.15
3.25
3.25
3.35
3.35
3.45
3.45
3.55
3.55
3.65
3.65
3.75
3.75
3.85
3.85
3.95
3.95
4.05
4.05
4.15
4.15
4.25
4.25
4.35
4.35
4.45
4.45
4.55
4.55
4.65
4.65
4.75
4.75
4.85
4.85
4.95
t = 0.5
t = 1.0
Total
thickness
of shims
(mm)
1.75
1.80
1.85
1.90
1.95
2.00
2.05
2.10
2.15
2.20
2.25
2.30
2.35
2.40
2.45
1
1
2.50
2.55
2.60
2.65
4.95
2.70
5.05
2.75
5.05
5.15
2.80
5.15
5.25
2.85
5.25
5.35
2.90
5.35
5.45
2.95
5.45
5.55
3.00
5.55
5.65
3.05
5.65
5.75
3.10
5.75
5.85
3.15
5.85
5.95
3.20
5.95
6.05
3.25
6.05
6.15
3.30
6.15
6.25
3.35
6.25
6.35
3.40
6.35
6.45
3.45
6.45
6.55
6.55
6.65
6.65
6.75
6.75
6.85
6.85
6.95
1
1
3.50
3.55
3.60
3.65
6.95
3.70
7.05
3.75
7.05
7.15
3.80
7.15
7.25
3.85
30
Hub and case assembly

1) Install oil sump plate (36) to case (34).
a When installing the plate, press it
against faces (a) and (b) of the case.
2)
3)
Using tool J5, press fit bearing (32B) to

case (34).
q
13 26 kN {1.3 2.6 tons}
Install collar (35).
D85EX, PX-15E0
SEN01267-00
4)
Using tool J5, press fit 2 bearing outer

races (32C) to hub (33).
q
Press fitting force for outer race:
2 15 kN {0.2 1.5 tons}
8)
Install plate (30).

3 Mounting bolt:
230 289 Nm {23.5 29.5 kgm}
5)
Using eyebolts, set hub assembly (31) to

the shaft.
Set bearing (32A) to the shaft.
9)
Using eyebolts, install gear (29).
6)
7)
Using tool J5, press fit bearing (32A) to

case (34).
q
13 26 kN {1.3 2.6 tons}
D85EX, PX-15E0
10) Tighten gear mounting bolts (28).

3 Mounting bolt:
230 289 Nm {23.5 29.5 kgm}
31
SEN01267-00
4.
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.
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.
1) Using tool J5, press fit bearing outer race
(25C) to planetary gear (24).
q
10 35 kN {1.0 3.6 tons}
4)
Install bolt (21) and holder (22).

3 Mounting bolt:
230 289 Nm {23.5 29.5 kgm}
5)
Using 3 eyebolts, install carrier assembly

(20).
2)
32
Install bearings (25A) and (25B) and

spacer (25D) to planetary gear (24).
D85EX, PX-15E0
5.
SEN01267-00
Cover assembly
1) Install ring gear (19) and ring (18) and
secure them with 6 lock plates (17).
5)
Tighten mounting bolts (11).

3 Mounting bolt:
455 565 Nm {46.5 58 kgm}
2)
3)
Install spacer (16).

Using tool J3, press fit bearing (15).
q
24 52 kN {2.4 5.3 tons}
6)
Using tool J4, press fit floating seal (10).

a Degrease the O-ring and O-ring fitting
surfaces thoroughly and dry them
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.
a Check that the mating faces of the
case and cover are free from bruise,
rust, oil, grease, dirt, and water.
2 Mounting bolt:
D85EX, PX-15E0
6.
Sprocket hub assembly

1) Using tool J5, press fit bearing outer race
(8).
q
15 35 kN {1.5 3.6 tons}
33
SEN01267-00
2)
Install sprocket (9) to the sprocket hub.

3 Mounting bolt:
931 1,127 Nm {95 115 kgm}
3)
Using tool J4, press fit floating seal (7).

a Degrease the O-ring and O-ring fitting
surfaces thoroughly and dry them
before installing.
a After installing the floating seal, check
that its slant is less than 1 mm.
4)
5)
34
Using eyebolts, install sprocket hub

assembly (5) to the cover assembly.
a Check that the sliding surfaces of the
floating seal are free from dirt and
apply engine oil to them thinly.
Set bearing (6).
7.
6)
Using tool [3], press fit bearing (6).

a Press fit the bearing, turning the
sprocket hub assembly.
q
24 52 kN {2.4 5.3 tons}
7)
Install plate (4) and secure it with the

mounting bolts.
3 Mounting bolt:
230 289 Nm {23.5 29.5 kgm}
Shaft
Install the O-ring to the sprocket hub assembly
side. Using eyebolts, install shaft (3).
3 Mounting bolt:
824 1,030 Nm {84 105 kgm}
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}
Refilling with oil

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
3
3
SEN01267-00
Final drive case: Approx. 26 l

Oil filler plug and drain plug:
127 176 Nm {13 18 kgm}
Oil level gauge plug:
58.8 76.4 Nm {6 8 kgm}
D85EX, PX-15E0
35
SEN01267-00

36
SEN01268-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

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
SEN01268-00

Removal and installation of track
frame assembly
1
1
5.
Remove guards (3) and (4).
6.
Remove cover (5) of the equalizer bar.
7.
Temporarily sling the track frame assembly to

be removed.
Removal
k

1.
Remove the blade assembly. For details, see

Removal and installation of blade assembly.
2.

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.
4.
Set a hydraulic jack under the center of the

equalizer bar to raise the front part of the chassis and set stand [2] under the frame to float
the front part.
a After floating the chassis, set the hydraulic
jack and ripper again as auxiliary supports.
D85EX, PX-15E0
8.
SEN01268-00
Remove pin lock plate (6) and pull out pin (7).
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.
k If the track frame assembly on the
opposite side is floated before the pin
is pulled out, support it on a block, etc.
1)
2)
Right track frame assembly

Remove cover (10).
Remove spacer (11).

[*4]
a Receive the oil flowing out of the pivot
case with an oil pan, etc.
6
3)
9.
Removal of track frame assembly

q
Left track frame assembly
[*3]
Pivot case: Approx. 8 l
Remove washer (12).

a Remove seal (13) and washer (12)
together.
[*1]
10. Lift off track frame assembly (13).

2)
Remove spacer (9).

[*2]
a Receive the oil flowing out of the pivot
case with an oil pan, etc.
6 Pivot case: Approx. 8 l
D85EX, PX-15E0
Track frame assembly:

D85EX-15E0; 2,160 kg
D85PX-15E0; 2,270 kg
SEN01268-00
Installation
q

removal.
[*1] [*2] [*3] [*4]

3 Mounting bolt: 54 123 Nm {5.5 12.5 kgm}
q
Refilling with oil

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
3
Pivot shaft case: Approx. 8 l

Oil filler plug:
127 176 Nm {13 18 kgm}
D85EX, PX-15E0
Removal and installation of idler

assembly
1
SEN01268-00
6.
Remove spring (6) and seat (7).
7.
Remove yoke (8).
8.
Lift off idler assembly (4).
Removal
k
k

Never stand in front of the idler assembly to
prevent danger.
1.

2.

3.
Loosen mounting bolts (2) of support (1) and

spring seat clamping bolts and remove plate (3).
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.
4
5.
Idler assembly: 300 kg
Remove guide plate (5).
D85EX, PX-15E0
SEN01268-00
Installation
q

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.
D85EX, PX-15E0
SEN01268-00

idler assembly
Installer
t 1
2 791-601-1000
Oil pump
t 1
7.
Remove floating seal (9) from support (8).
8.
Sling idler (7) and pull it out of shaft and support assembly (10).
a When hanging the idler with sling rope [2],
prevent sling rope [2] from opening with
wires or ropes [3].
9.
Remove floating seals (11) and (12) from idler

(7).
Sketch
Q'ty
1 791-530-1510
New/Remodel
Necessity
Symbol
L
Part name
Using push puller [1], pull support (8) out of

idler (7).
Special tools
Part No.
6.
Disassembly
1.
Remove the oil filler plug and drain the oil.

6
Idler: 0.33 0.37 l
2.
Set idler (1) to a block.
3.
Remove the spring seat mounting bolts and

plate (2).
a Record the number of the removed shims.
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
SEN01268-00
10. Remove floating seal (13) from shaft and support assembly (10).
Assembly
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}
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}
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).
13. Remove 2 bushings (18) from idler (7).
D85EX, PX-15E0
4.
Using tool L1, install floating seal (13) to shaft

and support assembly (10), and then install the
O-ring to shaft (17).
a Degrease the O-ring and O-ring fitting surfaces 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.
D85EX, PX-15E0
SEN01268-00
6.
Sling idler (7) and install it to shaft support

assembly (10).
7.
Using tool L1, install floating seal (11) to idler

(7).
installing.
SEN01268-00
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
3
9.
Idler: Approx. 0.33 0.37 l

Oil filler plug:
157 255 Nm {16 26 kgm}
Using tool L1, install floating seal (9) to support

(8).
installing.
14. Refilling with oil

Ordinary method of refilling with oil
Remove plug (20) from shaft (17), add oil
through the oil filler, and tighten plug (20).

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}
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).
5

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

spring assembly
1
SEN01268-00
6.
Remove spring (6) and seat (7).
7.
Slide idler assembly (4) further and install

wires on spring case (8) side, and then slide
the assembly forward to remove.
Removal
k
Never stand in front of the idler assembly to

prevent danger.
1.

2.

3.
Loosen mounting bolts (2) of support (1) and

spring seat clamping bolts and remove plate (3).
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).

Take measures to prevent the idler assembly from leaning for safety.
4
D85EX, PX-15E0
Idler and recoil spring assembly: 640 kg
Idler assembly: 300 kg
11
SEN01268-00
9.
Remove the mounting bolts and yoke (10).

4
Recoil spring assembly: 350 kg
Installation
q
12

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.
D85EX, PX-15E0
SEN01268-00

recoil spring assembly
If cylinder (18) is not broken and shaft end nut

(21) is not lost, disassemble the yoke and piston
3.
Remove holder (14) from recoil spring case

(13).
Never stand in front or in the rear of the
recoil spring assembly to prevent danger.
Sketch
Q'ty
Compressor
t 1
791-635-3160
Extension
t 1
791T-630-2610
Spacer
t 1 N Q
790-101-1300
Cylinder
t 1
790-101-1102
Hydraulic pump
t 1
791-685-8006
M1
Part name
New/Remodel
Part No.
Necessity
Symbol
Special tools
Disassembly
1.
Remove yoke and piston assembly (2) from

recoil spring assembly (1).
2.
Disassembly of yoke and piston assembly

1) Remove snap ring (3), ring (4), packing
(5), and ring (6).
2) Remove bolt (7), plate (8), and washer (9).
3) Using push tool (12) and a press, pull piston (11) out of yoke (10).
D85EX, PX-15E0
4.
Disassembly of holder
1) Remove cover (15) from holder (14).
2) Remove seal (16) and bushing (17) from
holder (14).
13
SEN01268-00
5.
Remove lock plate (19) form cylinder (18), and

then remove lubricator (20).
9.
Take recoil spring (23) and cylinder (18) out of

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
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
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 following procedure in this case.
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.
D85EX, PX-15E0
1)
2)
3)
4)
Set recoil spring assembly (1) to tool M1.

a Installed load of spring:
23.2 kN {23,200 kg}
Apply hydraulic pressure slowly to secure
recoil spring assembly (1).
SEN01268-00
3.
Install recoil spring (23) and cylinder (18) to

recoil spring case (13) temporarily and set tool
M1.
a Installed load of spring:
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
4.
Install nut (21) and spacer (22).
5.
Reduce the hydraulic pressure slowly to eliminate the spring tension, and then remove recoil
spring assembly (1) from tool M1.
Remove mounting bolt (26) of holder (14)

under the condition in step 2).
Reduce the hydraulic pressure slowly to
release the spring.
Assembly
1.
Using the push tool, press fit bushing (24) to

recoil spring case (13) and install seal (25).
q
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).
q
19.6 29.4 kN {2.0 3.0 tons}
2 Bushing: Grease (G2-LI)
D85EX, PX-15E0
15
SEN01268-00
6.
Install lubricator (20) to cylinder (18), and then

install lock plate (19).
7.
Assembly of holder
1) Press fit bushing (17) to holder (14) and
install seal (16).
q
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).
9.
Assembly of yoke and piston assembly

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)
10. Install yoke and piston assembly (2) to recoil

spring assembly (1).
8.
16
Install holder (14) to recoil spring case (13).
D85EX, PX-15E0
Removal and installation of track

roller assembly
1
SEN01268-00
8.
Remove the mounting bolts of track roller

assembly (8).
9.
Start the engine and raise the chassis by operating 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.
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]
10. Pull out and remove controller assembly (8).

a Take care of the key on the inside.
4
5.
Remove guard tension bolt (2).

a Take care of the guide spacer on the inside.
6.
Remove 2 retainers (5) on the outside of the

track frame, and then remove the 5 mounting
bolts and track roller guard (6).
[*4]
7.
Track roller assembly:

Single flange; 72 kg
Double flange; 80 kg
Installation
q
Remove the mounting bolts and rear roller

guard (7).
[*5]

removal.
a Install the track roller assembly with the oil
filler plug on the outside of the chassis.
[*1] [*2] [*3] [*4] [*5]

3 Mounting bolt:
750 829 Nm {76.5 84.5 kgm}
q
D85EX, PX-15E0
Adjust the track shoe assembly tension. For

details, see Adjusting track shoe assembly
tension.
17
SEN01268-00

track roller assembly
1 791-651-1510
Installer
t 1
2 791-601-1000
Oil pump
t 1
6.
Remove mounting bolt (8) of bushing (7).
7.
Set track roller assembly (1) on a block and

push the end of shaft (9) to pull out bushing (7)
and remove the O-ring.
8.
Turn over track roller assembly (1) and set it on

the block and push the end of shaft (9) to pull
out bushing (7) and remove the O-ring on the
opposite side.
Sketch
New/Remodel
Q'ty
Necessity
Symbol
N
Part name
Remove collar (3), floating seal (5), (6) and Oring on the opposite side, similarly to steps 2)
4).
Special tools
Part No.
5.
Disassembly
1.

6
2.
Idler: 0.26 0.29 l
Set track roller assembly (1) on the block [1].

Using push puller [2], push in collar (3) and
then remove ring (4) and collar (3).
3.
Remove floating seal (5) from collar (3).
4.
Remove floating seal (6) and O-ring from track

roller assembly (1).
18
D85EX, PX-15E0
Assembly
a

1.
Set track roller (10) on a block.
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)
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)
D85EX, PX-15E0
SEN01268-00
5.
Install mounting bolt (8) of bushing (7).

3 Initial torque: 49 10 Nm {5 1 kgm}
a After tightening, retighten by 90 5
2 Mounting bolt:
Molybdenum disulfide (LM-P)
6.
Using tool N1, install floating seal (5) to bushing (7) and collar (3).
a Clean and degrease the O-ring and O-ring
fitting surfaces thoroughly and dry them
before installing.
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)
19
SEN01268-00
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
3
20
Track roller: Approx. 0.26 0.29 l

Oil filler plug:
157 255 Nm {16 26 kgm}
D85EX, PX-15E0

carrier roller assembly
SEN01268-00
Installation

removal.
Adjust the track shoe assembly tension. For

details, see Adjusting track shoe assembly
tension.
Removal
1.
Loosen the track shoe assembly. For details,

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
SEN01268-00

carrier roller assembly
5.
Using tool [2], remove nut (4).
6.
Using puller [3], remove the fitted part of the

bearing. Then, using eyebolts, remove bearing
(5) and carrier roller (6) together.
7.
Remove outer race (7) of the bearing from carrier roller (6).
8.
Using puller [4], remove collar (8) and bearing

inner race (9) together from shaft (11).
9.
Remove floating seal (10) from collar (8).
1 791-651-1510
Installer
t 1
2 791-601-1000
Oil pump
t 1
Sketch
New/Remodel
Part name
Q'ty
Part No.
Necessity
Symbol
Special tools
Disassembly
1.

6
Idler: 0.47 0.53 l
2.
Set carrier roller assembly (1) on a block [1].
3.
Remove the mounting bolts, cover (2), and Oring.
4.
Remove ring (3).
22
D85EX, PX-15E0
SEN01268-00
10. Using push tool [5], remove ring (12) from shaft
(11).
3.
Set carrier roller (6) and bearing inner race (9)

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).

3 Nut: 98 Nm {10 kgm}
a After nut (4) is tightened, if its hole is not
matched to the hole on the shaft side,
loosen it until the holes are aligned.
6.
Install ring (3).

a Check that the end play (clearance between
the bearing and nut) is 0 0.22 mm.
7.
Install the O-ring and cover (2).

1.
Using push tool [6], press fit bearing inner race

(9) to shaft (11).
2.
Using push tool [7], press fit bearing outer race

(7) to carrier roller (6).
D85EX, PX-15E0
23
SEN01268-00
8.
Using tool N1, install floating seal (10) to collar

(8).
before installing.
9.
Fit the O-ring to collar (8) and install them to carrier roller (6), matching them to the dowel pin.
a Take care not to damage the O-ring.
11. Using push tool [9], press fit ring (12) to carrier
roller assembly (1).
q
Press fitting force for ring:
40 73 kN {4.1 7.4 tons}
a Press fit the ring so that distance (b)
between the shaft end and ring top will be
120 0.2 mm.
a After press fitting the ring, check that its
slant from the shaft is less than 0.4 mm.
12. Using tool N2, add oil through the oil filler and
tighten the oil filler plug.
10. Using tool N1, install floating seal (13) to ring
(12).
before installing.
24
5
3
Carrier roller: Approx. 0.47 0.53 l

Oil filler plug:
157 255 Nm {16 26 kgm}
D85EX, PX-15E0
SEN01268-00

26
SEN01269-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

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
SEN01269-00

Expansion and installation of
track shoe assembly
Check before expanding track shoe

assembly
k
Since it may be very dangerous to expand

the track shoe assembly, check the following items in advance.
Do not loosen the lubricator more than 1
turn. If the grease is not discharged well,
move the machine forward and in reverse.
1.
Remove cover (1) and loosen lubricator (2) of

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 assembly (When track frame has internal trouble).
a The track frame may have an internal trouble (damage of the recoil spring or recoil
spring set bolt, fall of the shaft end nut, etc.)
1
Expansion of track shoe assembly
(Ordinary)
a
If any abnormality is not detected by Check

before expanding track shoe assembly, perform the following procedure.
1.
Set master link (3) in position.

a Set the master link above the idler (a little
after the center of the idler).
a Set blocks [1] and [2] between the front
side of the idler and carrier roller so that
the mating part of the master link will not
open until the master bolt is pulled out.
D85EX, PX-15E0
2.
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.
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
SEN01269-00
4.
Sling the front end of the master link and move

the machine slowly forward and in reverse to
expand track shoe assembly (7).
a Length of track shoe: Approx. 10.5 m
SEN01269-00
Expansion of track shoe assembly

(When track frame has internal trouble)
a
k
1.
2.
3.
Remove idler guide (10).

a Be sure to remove the idler guide at this
time. If the track shoe is expanded without
removing the idler guide, the idler guide
moves forward and is pressed against the
track frame. If the idler guide is removed
at this time, the idler yoke assembly will
jump forward.
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).
If any abnormality is detected by Check

before expanding track shoe assembly, perform the following procedure.
If the track shoe is removed while the track
frame has an internal trouble, it may spring
back. Even if the track shoe is removed, the
idler may jump out, and that can cause a serious result. Accordingly, expand the track
shoe according to the following procedure.
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 discharged.
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.
D85EX, PX-15E0
SEN01269-00
Installation
q

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 molybdenum 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
SEN01269-00

a
Whole disassembly and assembly

of track shoe
1
Remover and
installer
t 1
Cylinder
assembly
t 1
Jack assembly
t 1
790-101-1102
Hydraulic pump
t 1
791-650-3500
Remover and
installer
t 1
791-675-5542
Adapter
t 1
791-675-5571
Adapter
t 1
790-101-1300
Cylinder
assembly
t 1
790-105-2300
Jack assembly
t 1
1 790-101-1300
790-105-2300
Hydraulic pump
t 1
3 791-646-7531
Push tool
t 1
4 791-660-7460
Pin puller
t 1
Plug push tool
t 1
790-101-1102
791-646-7900
790-434-1210 Bar
5 790-434-1220 Guide
791-646-7523
Bar
t 1
791-646-7590
Guide
t 1
6 791-632-1060
Installer
t 1
7 790-701-3000
Seal checker
t 1
8 791-646-8002
Lubricator
t 1
Sketch
New/Remodel
Part name
Q'ty
Part No.
791-650-3000
a
Necessity
Symbol
Special tools
For the whole disassembly of the track shoe,

see Guidance for reusable parts, Undercarriage, Lubricated track and Guidance for
reusable parts, Undercarriage, Reversing procedure for lubricated track.
2.
If a shoe bolt is turned forcibly while its

torque is not 0, it and link will adhere to
each other and they will need to be
repaired.
When moving the shoe assembly, take
care not to damage the master link.
If it is obliged to cut a shoe nut with gas,
keep the seal temperature below 80C to
prevent thermal deterioration of the seal
and take measures to prevent the spatters
from entering through the clearances
among the links.
Disassembly of link
1) Set the link assembly on a link press and
hit it with a hammer so that the bushing
will be fitted to the jaw [1].
a If the link tread, outside of the bushing, etc. are worn, adjust the height of
jaw [1] or guide plate to align both disassembling jigs [2] and [3] with the
pin and bushing so that the link hole
will not be damaged when the link is
assembled.
a If the pin and bushing are not aligned
well, the link hole may be damaged
and the pin and bushing may be broken during disassembly work.
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.
D85EX, PX-15E0

a
2)
SEN01269-00
4)
Using tool R1, drive the small plug of

the pin inward after the disassembly
work so that the workplace will not
become dirty.
Operate the left cylinder to pull out the pin

and bushing from the left link simultaneously.
a Check the pulling out force of the pin
and bushing to see if press fitting
force for them necessary for reversed
reassembly is obtained.
3.
Inspection
Check the parts for the following items to see if
they can be used for a lubricated track or a
grease-filled track, then examine them generally 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, Undercarriage, Lubricated track.
1)
3)
Return the right cylinder and take out the

links, pins, bushings, and spacers on both
sides and feed the next 1 set of the link
assembly to the jaw.
a If the bushing ends and sealing surfaces are damaged, oil will leak.
Accordingly, handle them carefully.
Check the parts visually for damage. If a

part seems to be damaged, check it by
dye penetrant test or magnaflux inspection. If it has any crack, it cannot be used
again. Discard it.
Return the left cylinder and operate the

right cylinder to pull out the pin and bushing from the right link simultaneously.
D85EX, PX-15E0
SEN01269-00
2)
Measure the outside diameter of the press

fitting parts of the pin and bushing and the
inside diameter of the pin and bushing fitting parts of the link with a micrometer and
a cylinder gauge to see if the allowable fitting allowance is obtained. When using
the pin, bushing, and link for a lubricated
track, however, secure the standard fitting
allowance between the pin and link.
a If the allowable fitting allowance is not
obtained, replace the parts with new
ones.
a For the dimensional criteria, see Maintenance standard.
Precautions for storage

1) Store the seal without removing it from the
link so that the counterbore portion will not
be rusted and take care not to damage the
seal lip.
2) Apply rust-preventive oil to the pin and
bushing fitting parts, shoe mating surface,
and master link mating surface of the link.
3) When storing, apply rust-preventive oil to
the all surfaces of the pin, bushing, and
spacer. Take care not to damage the ends
of the bushing in particular.
Whole assembly
a
For the whole assembly of the track shoe, see

Guidance for reusable parts, Undercarriage,
Reversing procedure for pin bushing.
When recycling for lubricated track

1. Preparation work
1) Cleaning seal assembly
Remove the seal assembly from the link
and divide it into the seal ring and load
ring, then clean them.
a Since the seal ring (1) and load ring
(2) are deteriorated easily by the
cleaning liquid, clean them quickly.
After cleaning them, wipe off the
cleaning agent from them.
2)
When reusing the pin, chamfer its end corners smoothly with a grinder. Remove the
nodules sticking to the press fitting parts
with the grinder, too.
a If the ends are worn and sharpened,
they may scuff the press fitting parts
and cause oil leakage.
D85EX, PX-15E0
3)
4)
If the link, pin, bushing, and spacer are dirty,

clean them. Remove the nodules sticking to
the link and bushing with the grinder.
a Since these parts rust easily, clean
them just before assembling them.
a Do not polish the bushing ends. If
they are polished, oil may leak.
If the large plug was pulled out, drive it in
by using tool R5.
a In this case, clean the pin hole in
advance by using tool R4.
Insert the plug (3) through the plug

insertion window into the guide hole.
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 (4).
iv) Drive in the bar with a hammer.
a Driving distance (a) from pin end: 6
2 mm
a If the chamfered part of the pin hole
has been worn, chamfer it with a
small-sized grinder (grindstone tip
angle: 45 60) so that the plug will
not be damaged.
a Coat the plug with GO90 and drive it
with the small diameter end ahead.
SEN01269-00
5)
Installation of seal assembly

Clean the counterbore portion (d) of the
link carefully and push in the seal to the
bottom by using tool R6.
a If oil is sticking to the counterbore
portion of the link or seal assembly,
the seal will turn and its sealing performance will lower. Accordingly, do
not apply any oil. When inserting the
seal in the counterbore portion, take
care that oil does not stick to the seal
and counterbore portion.
6)
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 dimensions so that the projections of the
pins and bushings on both sides will
be even.
i)
D85EX, PX-15E0
SEN01269-00
7)
2.
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.)
Assembly of link
1) Apply oil (GO90) to the mating surfaces of
the pin and bushing with a clean brush
and assemble them, then set them before
the jaw of the link press.
a When reusing (reversing) the bushing, set the worn outside surface of
the bushing on the shoe fitting side of
the link (set the bushing with the worn
outside surface up on the link press).
3)
4)
5)
2)
10
Press fit the master links on both bushing

sides to the bushing with the shoe fitting
faces up.
a At this time, use the master links on
the pin side as supports.
a Press fitting force for bushing:
68 108 kN {7 8 tons}
Using the shoe bolt hole pitch gauge,

press fit the master links until the distance
between the shoe bolt holes of both links
is the standard value.
a Remove the all steel chips caused by
press fitting of the bushing with compressed air.
Turn over the master links and check that
they are press fitted in parallel.
Measure the projections of the bushing on

both sides with a depth gauge.
a Adjust the press fitting jig of the link
press so that the projections on both
sides will be even.
D85EX, PX-15E0
6)
SEN01269-00
a
Send the master links and set the next pin

and bushing.
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)
7)
Press fitting force for pin and bushing:

274 363 kN {28 37 tons}
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.
Set the right link and install the spacer to

the pin.
a Check that the seal surface and bushing 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
SEN01269-00
11) Set the left jig on the receiving side and

the right one on the pushing side and
press fit the left link.
a When press fitting, take care that both
seals and spacers will not come off.
a Press fitting force for link:
274 363 kN {28 37 tons}
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. Accordingly, 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
Preparation work.
a Check that adjacent 2 links can turn
around each other.
12
13) Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt
holes and check that the result is within
the standard range.
a If the distance between the shoe bolt
holes is longer than the standard
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.
14) After each link is assembled, bleed air

from the pin by using tool R7 and check
the sealing performance.
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.
D85EX, PX-15E0
SEN01269-00
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 lowtemperature 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.
Supply oil (d) to oil level (a) so that

depth (L) of the hole of pin (c) will be
in the following range when the link
assembly is left with small plug side
(b) up (with the link assembly on its
side) for 30 minutes.
Dimension L: 35 60 mm
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.
2 Shoe bolt: Lubricant containing
molybdenum disulfide (LM-P)
3 Shoe bolt (Regular link):
q
Single shoe:
Initial torque:
343 39 Nm {35 4 kgm}
q
Swamp shoe:
Initial torque:
539 49 Nm {55 5 kgm}
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
SEN01269-00
2)
3)
4)
5)
14
When installing a 2-piece shoe, place the

assembled 2-piece shoes on a level place
in 1 line with the shoe side up.
Pull pin-side master link (1) and bushingside master link (2) together and set them
to each other by the mating faces.
Place and fit shoe (3) to mating surface of
the links.
Check that master bolt (4) can be tightened easily with the fingers, then connect
the links with the master bolts.
2 Master bolt: Lubricant containing
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
When recycling for grease-filled track

1. Preparation work
1) Cleaning seal assembly
Remove the seal assembly from the link
and divide it into the seal ring and load
ring, then clean them.
a Since the seal ring and load ring are
deteriorated easily by the cleaning liquid, clean them quickly. After cleaning
them, wipe off the cleaning agent
from them.
2)
When reusing the pin, chamfer its end corners carefully with a grinder so that it will
be press fitted smoothly.
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.
Tighten the bolts in the order of 1 4.
D85EX, PX-15E0
SEN01269-00
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 disassembled, reuse them as they are.
7)
4)
5)
6)
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 dimensions so that the projections of the
pins and bushings on both sides will
be even.
If the outside of the pin, surfaces of the

spacer, and ends and inside of the bushing are dirty, clean them.
Apply grease to the outside of the pin and
surfaces of the spacer.
Installation of seal assembly
Clean the counterbore portion of the link
carefully and push in the seal to the bottom by using tool R6.
a If grease is sticking to the counterbore portion of the link or seal assembly, the seal will turn and its sealing
performance will lower. Accordingly,
do not apply any oil.
D85EX, PX-15E0
15
SEN01269-00
2.
Assembly of link
1) Apply lithium grease (G2-LI) to the mating
surfaces of the pin and bushing and
assemble them, then set them before the
jaw of the link press.
3)
4)
5)
2)
16
Press fit the master links on both bushing

sides to the bushing with the shoe fitting
faces up.
a At this time, use the master links on
the pin side as supports.
68 108 kN {7 8 tons}
Using the shoe bolt hole pitch gauge,

press fit the master links until the distance
between the shoe bolt holes of both links
is the standard value.
a Remove the all steel chips caused by
press fitting of the bushing with compressed air.
Turn over the master links and check that
they are press fitted in parallel.
Measure the projections of the bushing on

both sides with a depth gauge.
a Adjust the press fitting jig of the link
press so that the projections on both
sides will be even.
D85EX, PX-15E0
6)
7)
Send the master links and set the next pin

and bushing.
a When reusing a pin, install it so that
its side hole 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 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.
SEN01269-00
8)
Using a shoe bolt hole pitch gauge, measure the distance between the shoe bolt
holes. When the distance is in the standard range, stop press fitting.
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.
Set both links and operate both pushing

jigs to 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.
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
SEN01269-00
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.
2 Shoe bolt: Lubricant containing
3 Shoe bolt (Regular link):
q
Single shoe:
Initial torque:
343 39 Nm {35 4 kgm}
q
Swamp shoe:
Initial torque:
539 49 Nm {55 5 kgm}
2)
3)
4)
5)
18
When installing the assembled 2-piece

track shoes, place them on a level place in
1 line with the shoe side up.
Pull pin-side master link (1) and bushingside master link (2) together and set them
to each other by the mating faces.
Place and fit shoes (3) to the mating surface of the links.
Check that master bolt (4) can be tightened easily with the fingers, then connect
the links with the master bolt.
q
Single shoe:
Initial torque:
343 39 Nm {35 4 kgm}
00
q
Swamp shoe:
Initial torque:
343 39 Nm {35 4 kgm}
00
Tighten the bolts in the order of 1 4.
D85EX, PX-15E0
SEN01269-00
Dimensions table of fitting jig of link press
Adjusting
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 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 dimensions so that the projections of
the pins and bushings on both sides will be
even.
Precaution
1. The link receiving faces of jaw (5) must be vertical.
2.
Replaceable wear plate (6) shown below is

desirable.
Unit: mm
Dimensions of jig
a
2.0
47.9
D85EX, PX-15E0
19
SEN01269-00
Disassembly of 1 link in the field

k
6.
Only how to use the tools is explained

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 cylinder to pull out the 2 pins.
Assembly of 1 link in the field

1.
5.
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}
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
20
Apply high pressure to jack R2-7 gradually to

disconnect the link.
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}
D85EX, PX-15E0
2.
Set the link (3) to which link sub-assembly will

be connected.
3.
Set link (4) on the opposite side and support it

with tool R2-10.
SEN01269-00
5.
Connection of link
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.
4)
4.
After connecting the link with guide R2-11,

remove jack R2-7.
Set tool R2 as in the procedure for removing

the pin. Using tool R2-1, press fit the pin to link
sub-assembly (5).
206 255 kN {21 26 tons}
D85EX, PX-15E0
21
SEN01269-00
6.
Press fitting of pin

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 press fit pin (6).
a Set the pin with its side hole directed
toward the tread of the link.
412 510 kN {42 52 tons}
4)
5)
6)
Disassembly of master link

1.
Removal of track shoe assembly

Remove the track shoe assembly from the
chassis.
2.
Removal of master link

1) Cutting and removal of master link on
bushing side with gas
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
Remove adapter R2-5 and set adapter

R2-11 in the large hole.
Set pusher R2-12 to extension R2-2.
Apply the specified final pressing force to
the 2 link connecting parts to install.
2)
22
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
D85EX, PX-15E0
SEN01269-00
Assembly of master link

1.
2)
Set spacer (3) and seal assembly (4) to

the counterbore of the link at the connecting section.
3)
Align the holes of the pin and bushing (7)

and connect with guide pin R2-11.
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.
Assembly of link on bushing side

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
2.
146
L2
182.8
D1
25 drill
D2
22 2.0
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
D85EX, PX-15E0
23
SEN01269-00
5)
6)
2)
Install the shoe to the link at the connecting section.

Drive in large plug (6) with tool R5, add oil
with tool R8, and drive in small plug (7)
with R5.
a Press fit both master links in parallel
(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 section (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.
3)
4.
3.
24
Installation of link on pin side

1) Set spacer (3) and seal assembly (4) to
the counterbore of the master link.
Pass bushing (8) and pin (9), set master

links (10) on the pin side from both sides,
and press fit them with tool R2.
Drive in large plug (11) with tool R5, add
oil with tool R8, and drive in small plug
(12) with R5.
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 bushingside master link (14) together and set
them to each other by the mating faces.
3) Place and fit the shoes to the mating surface of the links.
4) Check that master bolt (15) can be tightened easily with the fingers, then connect
the links with the master bolt (15).
q
Single shoe:
Initial torque:
343 39 Nm {35 4 kgm}
00
q
Swamp shoe:
Initial torque:
343 39 Nm {35 4 kgm}
00
D85EX, PX-15E0
Removal and installation of pivot

shaft assembly
1
Removal
1.
Remove the track frame assembly. For details,

see Removal and installation of track frame
assembly.
2.
Remove the mounting bolts of pivot shaft assembly (1) (Leave 2 3 of them, however).
[*1]
3.
Sling pivot shaft assembly (1) temporarily and

pull it out, using forcing screw [1].
4
4.
Pivot shaft assembly: 100 kg
Remove seal (2) from pivot shaft assembly (1).

[*2]
SEN01269-00
Installation
q
[*1]
2
3
Mounting bolt: Adhesive (LT-2)

Mounting bolt:
823 1,029 Nm {84 105 kgm}
[*2]
a Install the seal according to the following procedure.
1) Reverse the seal (2) so that the relief letters (a) will be on the inside.
2) Install the reversed seal (2) to the shaft
(1).
2 Seal: Oil (EO-30)
a
a
D85EX, PX-15E0

removal.
Use tool [2] to press fit ring (4).

q
Press fitting of force:
23.2 42.7 kN {2.37 4.35 tons}
Check that press fitting dimension (a) of the
seal from the shaft end is proper.
q
Press fitting dimension (a): 412 1mm
25
SEN01269-00

equalizer bar assembly
Removal
k
1.
2.

Remove engine undercover (1) and power
train undercover (2).
Remove grease hose (8).
6.
Remove lock plate (9).
7.
Set jack [2] at the center of equalizer bar center pin (10).
[*3]
Set a hydraulic jack under the center of the

equalizer bar to raise the front part of the chassis and set stand [1] under the frame to float
the front part.
3.
Remove 2 bolts (4) and cover (5).
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
5.
[*1]
D85EX, PX-15E0
SEN01269-00
8.
Using tool [3], pull out center pin (10).
9.
Lower and remove equalizer bar (13) by operating jack [2].

4
[*4]
Equalizer bar assembly:

D85EX-15E0; 158 kg
D85PX-15E0; 204 kg
Installation
q

removal.
[*1]
Mounting bolt:
319 608 Nm {32.5 62 kgm}
[*2]
k
When aligning the pin holes, never insert

your fingers in them.
Before installing the side pin, adjust the hanging height on the track frame to align the hole
of the equalizer bar with the hole on the track
frame side.
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]
Mounting bolt:
147 309 Nm {15 31.5 kgm}
[*4]
When 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
SEN01269-00

equalizer bar assembly
3.
Center bushing
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)
28
Using tool [1], remove spherical bushing

(3) from equalizer bar (4).
D85EX, PX-15E0
Assembly
1.
Center bushing
Using a press, press fit center bushing (5) to
equalizer bar (4).
a Press fitting force for center bushing:
57.8 161.7 kN {5.9 16.5 tons}
2 Periphery of spherical bushing:
Lubricant containing molybdenum
disulfide (LM-P)
2.
Side bushing
1) Install ring (2) to one side of equalizer bar
(4).
2) Using the press, press fit spherical bushing (3) to equalizer bar (4).
a Press fitting force for spherical bushing:
49 118 kN {5 12 tons}
Lubricant containing molybdenum
disulfide (LM-P)
D85EX, PX-15E0
SEN01269-00
3)
4)
Install ring (2) on the opposite side.

Using the press, press fit seal (1).
a Press fitting force for seal:
57.8 161.7 kN {5.9 16.5 tons}
Lubricant containing molybdenum disulfide (LM-P)
2 Between spherical bushing and seal:
Grease (G2-LI)
29
SEN01269-00

30
SEN01270-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN01270-00
Hydraulic system
Removal and installation of work
equipment control valve assembly1
1
5.
Removal
k
k
a
a
1.
2.

Lower the work equipment to the ground.
Referring to Testing and adjusting, Releasing
residual pressure in work equipment cylinder, release the residual pressure in the piping and lock the work equipment lock lever.
Plug the disconnected pipes and hoses to prevent foreign matter from entering them.
Put tags to the disconnected pipes and hoses
to prevent a mistake in re-connecting them.
6.
Remove hose clamp plate (9).
Drain the oil.

6
Hydraulic tank:
Remove covers (1) and (2) from the right side

of the chassis.
7.
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).
Disconnect the right PPC hoses.

[*1]
(11): Ripper lift cylinder RAISE hose coupler (Port PA4) Color band: Black
q
(12): Blade lift cylinder LOWER hose coupler (Port PA3) Color band: Black
q
(13): Blade tilt cylinder LEFT tilt hose coupler (Port PA2) Color band: Yellow
q
8.
Disconnect the following hoses.

(6): Hydraulic tank return hose
q
(7): Fan motor drain hose
q
(8): Cooler return hose
q
Disconnect hose (14) for the right of the HSS

(Port PA1).
D85EX, PX-15E0
9.
Disconnect the left PPC hoses.

[*2]
q
(15): Ripper lift cylinder LOWER hose
coupler (Port B4) Color band: None
q
(16): Blade lift cylinder RAISE hose coupler (Port B3) Color band: None
q
(17): Blade tilt cylinder RIGHT tilt hose
coupler (Port B2) Color band:
Green
SEN01270-00
11. Disconnect the following 8 work equipment

hoses.
q
(19): Ripper lift RAISE hose (Port A4)
q
(20): Ripper lift LOWER hose (Port B4)
q
(21): Blade lift RAISE hose (Port A3)
q
(22): Blade lift LOWER hose (Port B3)
q
(23): Blade tilt RIGHT hose (Port A2)
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
SEN01270-00
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
Refilling with oil

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
Installation
q

removal.
[*1] [*2]
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 control 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)
Hydraulic tank:
Bleeding air
Bleed air from the piping. For details, see Testing and adjusting, Bleeding air from work
equipment cylinders.
D85EX, PX-15E0

work equipment control valve
assembly
a
a
SEN01270-00
Only the precautions for assembling the work

equipment control valve assembly are
described in this section.
For the tightening torque of each part, see Structure, function and maintenance standard.
Assembly
a
a
a

damage. Coat their sliding surfaces with
engine oil before installing.
When assembling the suction valve, check that
the spring is installed normally in the sleeve.
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 periphery of the backup ring.
After installing the main relief valve assembly,
adjust it, referring to Testing and adjusting,
Testing and adjusting work equipment hydraulic pressure.
D85EX, PX-15E0
SEN01270-00
Removal and installation of HSS

and work equipment pump
assembly
1
7.
Disconnect oil pressure sensor connector HHP

(4) and disconnect wiring harness clamp (5).
8.
Disconnect TVC valve solenoid connector TVC

(6).
9.
Remove hose clamp bracket (7).
Removal
k
1.

Drain the oil.
6
Hydraulic tank:
2.

assembly.
3.
Remove the operator's cab assembly. For

details, see Removal and installation of operator's cab assembly.
4.

assembly.
5.
10. Disconnect pump hoses.

q
(8): Discharge hose
q
(9): LS pressure hose
q
(10): Drain hose
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).
D85EX, PX-15E0
13. Sling the pump assembly temporarily and

remove mounting bolts (13).
SEN01270-00
Installation
q

removal.
Refilling with oil

again.
5
14. Lift off pump assembly (14).

4
Pump assembly: 113 kg
D85EX, PX-15E0
Hydraulic tank:
Bleeding air
Bleed air from the HSS and work equipment
pump. For details, see Testing and adjusting,
Bleeding air from HSS and work equipment
pump.
SEN01270-00
Removal and installation of power

train and lubricating oil pump
assembly
1
Installation
q

removal.
Removal
k

1.

assembly.
2.
Remove the operator's cab assembly. For

details, see Removal and installation of operator's cab assembly.
3.

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).
4
D85EX, PX-15E0

pump assembly
1
SEN01270-00
8.
Disconnect EPC valve connector FAC (4).
9.
Disconnect pump hoses.

q
(5): Discharge hose
q
(6): EPC valve basic pressure input hose
q
(7): Drain hose
Removal
k
1.

Drain the oil.
6
Hydraulic tank:
2.

assembly.
3.

assembly.
4.

assembly.
5.
6.
Remove tube clamp U-bolt (2).
7.
Remove 4 suction tube mounting bolts (3).
10. Sling the pump assembly temporarily and

remove mounting bolts (8).
11. Lift off pump assembly (9).
4
Installation
q

removal.
Refilling with oil

5
D85EX, PX-15E0
Hydraulic tank:
Bleeding air
Bleed air from the fan pump. For details, see
Testing and adjusting, Bleeding air from fan
pump.
SEN01270-00

scavenging pump assembly
5.
Remove 2 mounting bolts (4) and scavenging

pump assembly (5).
Removal
k
1.

Installation
2.
Drain the power train oil.

6
3.
Disconnect suction tube (2).
4.
Disconnect discharge hose (3).
10

removal.
Refilling with oil

again.
5
D85EX, PX-15E0
Removal and installation of HSS

motor assembly
1
SEN01270-00
Installation
q

removal.
Removal
k

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
SEN01270-00

hydraulic cylinder assembly
Disassembly
Part No.
790-502-1003
790-101-1102
2 790-102-3802
Part name
Hydraulic pump
t 1
Wrench
t 1
790-302-1310
Socket
Blade lift
t 1
Socket
Blade tilt
t 1
Ripper lift t 1
790-302-1340
Socket
790-201-1702
Push tool KIT
790-101-5021
Grip
01010-50816
Bolt
4 790-201-1791
Blade lift
Push
tool
790-201-1811
U
01010-50816
Bolt
6 790-720-1000
12
Ripper tilt
Push tool KIT
Ring
Clamp
796-720-1680
Ring
07281-01589
Clamp
796-720-1670
Ring
07281-01279
Clamp

Remove 2 U-bolt clamps (3).
Remove 2 cylinder tubes (4) and (5).
Remove bracket (6).
t 1
Blade tilt
Ripper lift
Ripper tilt
07281-01159
1)
2)
3)
1
t 1
Expander
796-720-1660
1
Blade lift
790-201-1620
Ripper lift
Grip
Plate
1
1
790-201-1500
5 790-201-1610
t 1
Blade tilt
790-101-5021
790-201-1630
Cylinder tube
Blade lift cylinder
1) Remove 2 clamps (1).
2) Remove cylinder tube (2).
Cylinder head repair

t 1
stand
3 790-302-1350
790-201-1821
1.
Necessity
Q'ty
New/Remodel
Sketch
Symbol
Special tools
Blade lift
Blade tilt
Ripper lift
t 1
t 1
t 1
t 1
t 1
t 1
D85EX, PX-15E0
2.
Piston rod assembly

q
Blade lift and ripper lift cylinders
1) Set the cylinder assembly to tool U1.
2) Using a hydraulic pump or a power wrench,
disconnect head assembly (7) from the cylinder 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.
SEN01270-00
3.
Piston assembly
q
Blade lift cylinder
1) Set piston rod assembly (11) to tool U1.
2)
3)
4)
q
1)
2)
Using tool U3, remove nut (12) from the

cylinder.
Remove collar (13) and sleeve (14), and
then remove piston assembly (15) from
piston rod (16).
Remove retainer (17) and sleeve (18).
Blade tilt cylinder

Remove the mounting bolts and disconnect
head assembly (10).
Pull piston rod assembly (11) out of cylinder
(12).
a Put an oil pan, etc. under the cylinder
to receive oil.
5)
D85EX, PX-15E0
Disassemble the piston assembly according 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 piston valves (22).
13
SEN01270-00
1)
2)
3)
4)
4.
14
Blade tilt and ripper lift cylinders

Set piston rod assembly (23) to tool U1.
Using tool U3, remove nut (24) from the
cylinder.
Remove piston assembly (25) from piston
rod (23).
2)
Disassemble the head assembly according to the following procedure.

i) Remove O-ring (29) and backup ring
(30).
ii) Remove snap ring (31) and dust seal
(32).
iii) Remove packing (33) and bushing (34).
Remove wear ring (26) and piston ring

(27) form the piston assembly.
Head assembly
1) Remove head assembly (7) or (10) from
piston rod (8) or (11).
D85EX, PX-15E0
SEN01270-00
Assembly
a
a
1.
2)
Take care not to damage the packings, dust

seals, O-rings, etc.
Clean the all parts. After installing them, cover
the piping ports and pin holes to prevent dirt
from entering.
Head assembly
1) Assemble head assembly (7) according to
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 60C.
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)
D85EX, PX-15E0
Fit the O-ring and install head assembly

(7) or (10) to piston rod (8) or (11).
Install wear ring (26).
15
SEN01270-00
3.
Piston assembly
Set piston rod (11) to tool U1.
1)
2)
3)
1)
2)
3)
Blade lift cylinder

Install retainer (17) and sleeve (18).
Install piston assembly (15) to piston rod
(16), and then install sleeve (14) and collar (13).
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.
16
Blade tilt and ripper lift cylinders

Set piston rod assembly (23) to tool U1.
Install piston assembly (25) to piston rod
(23).
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}
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}
D85EX, PX-15E0
1)
2)
3)
SEN01270-00
Blade tilt cylinder

Set cylinder (12) to tool U1.
Insert piston rod assembly (11) in cylinder
(12).
a Push in the piston rod to the stroke end.
2 Sealing part: Grease (G2-LI)
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

18
SEN01271-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Removal and installation of blade assembly ........................................................................................ 2
Disassembly and assembly of ripper assembly ................................................................................... 4
D85EX, PX-15E0
SEN01271-00
Work equipment
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.
k
1.
Remove cap (1) of the lift cylinder assembly. [*1]

a Check the quantity and thickness of the
shims.
2.
Sling lift cylinder assembly (2) temporarily.

Run the engine and retract the piston fully.
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.
Similarly, disconnect the lift cylinder assembly

on the opposite side from the blade.
Release the residual pressure in the work
equipment cylinders. For details, see Testing and adjusting, Releasing residual
pressure in work equipment cylinders.
5.
Remove left and right covers (4).
6.
Disconnect 2 tilt hoses (5) from the right straight

frame.
a Make distinction marks to the hoses and plug
them so that dirt will not enter the piping.
D85EX, PX-15E0
7.
Remove left and right trunnion caps (6).
8.
Remove blade assembly (7).

[*2]
a Run the engine and move the machine
slowly in reverse to disconnect the blade
assembly from the trunnion.
4
SEN01271-00
[*2]
a Adjust height (b) and width (c) of both straight
frames to the following values with blocks [1],
etc.
q
Height (b) of trunnion: 535 mm
q
Width of frame (c): 2,762 mm
Blade assembly:
Straight tiltdozer; D85EX-15E0: 3,305 kg

D85PX-15E0: 3,343 kg
Semi-tiltdozer; D85EX-15E0: 3,575 kg
Installation
q

removal.
[*1]
a Adjust clearance (a) at the cap mating surfaces to the following value with the shim and
check that the trunnion turns smoothly.
q
Standard clearance (a): 0.2 0.5 mm
q
Standard shim thickness: 4 mm
a After installing the blade, adjust the blade tilting
distance. For details, see Testing and adjusting, Adjusting blade.
1)
Refilling with oil (Hydraulic tank)

Bleeding air
Bleed air from the work equipment cylinders.
For details, see Testing and adjusting, Bleeding air from work equipment cylinders.
Remove cover (10).
D85EX, PX-15E0
SEN01271-00

ripper assembly
For D85EX-15E0
Disassembly
1.
k
Set jacks [2] under the respective centers stand

[1] of the arm and beam of the ripper assembly.
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
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.
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 similarly.
Beam (with 3 shanks): 1,580 kg
Remove stands [1] and set them under left and

right sides of the arm.
D85EX, PX-15E0
9.
Sling lift cylinder assembly (3) temporarily and

remove the lock bolt of pin (8).
10. Pull out pin (8) and remove lift cylinder assembly
(3).
a Pull out pin (8) to a position at which you
can remove the lift cylinder assembly.
a Remove the lift cylinder assembly on the
opposite side.
4
SEN01271-00
11. Sling arm (9) and remove stand [1].
12. Pull out pin (8) and remove arm (9).

a Pull out pin (8) to a position at which you
can remove arm (9).
4
Arm: 345 kg
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
D85EX, PX-15E0
Bracket: 107 kg
SEN01271-00
Assembly
1.
2.
3.
4.
Sling lift cylinder assembly (3) and install it to

arm (9).
a Lower the lift cylinder assembly onto the
arm, inserting a block between them.
5.
Insert pin (8) and tighten the lock bolt.
6.
Remove stands [1] and set them under the

center of arm (9).
Sling and install bracket (10) and secure it with

4 bolts (11) and 2 nuts (12).
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}
Sling arm (9) and install pin (8) to bracket (10).

k When aligning the pin holes, never insert
a Insert pin (8) to a position to install arm (9).
a Install the arm on the opposite side similarly.
Set stands [1] under both sides of arm (9).
D85EX, PX-15E0
SEN01271-00
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.

k When aligning the pin holes, never
insert your fingers in them.
a Install the beam on the opposite side similarly.
11. Sling lift cylinder assembly (3) temporarily.

12. Run the engine and extract the piston rod to
align the pin holes.
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 similarly.
D85EX, PX-15E0
SEN01271-00
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.
Bleeding air
a Bleed air from the work equipment cylinders. For details, see Testing and adjusting, Bleeding air from work equipment
cylinders.
a Supply grease (G2-LI) to each connecting
pin.
D85EX, PX-15E0
SEN01271-00

10
SEN01272-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

Cab and its attachments ................................................................................................................................. 2
Removal and installation of ROPS guard assembly ............................................................................ 2
Removal and installation of operators cab assembly .......................................................................... 3
Removal and installation of operators cab glass (Stuck glass) ........................................................... 9
Removal and installation of floor frame assembly.............................................................................. 18
D85EX, PX-15E0
SEN01272-00
Removal and installation of ROPS

guard assembly
1
Removal
Sling ROPS guard (1) temporarily.
2.
Remove mounting bolts (2).
3.
Lift off ROPS guard (1).

removal.
[*1]
1.
Installation
Mounting bolt:
824 1,030 Nm {84 105 kgm}
[*1]
ROPS guard: 371 kg
D85EX, PX-15E0

operators cab assembly
SEN01272-00
5.
6.
Remove right cover (6).
7.
Remove both foot rests (7) and cover (8).
Removal
k

1.
Remove the ROPS guard. For details, see

Removal and installation of ROPS guard.
2.
Remove floor mat (1).
3.
4.
Remove the mounting bolts of left cover (2).
Turn over cover (2), disconnect cigarette lighter

connector CIG (3) and accessory socket connector ACC (4), and remove cover (1).
[*1]
D85EX, PX-15E0
SEN01272-00
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 operators
cab.
10. Disconnect antenna connectors KOM2 and

KOM3 (12) from KOMTRAX controller (11).
D85EX, PX-15E0
14. Remove mounting bolts (19) in the operators

cab.
a Remove 5 bolts in the rear and 4 respective bolts on both sides.
SEN01272-00
Installation
q

removal.
[*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 operators cab.
16. Lift off operator's cab assembly (21).

a When lifting off the operators cab assembly,
check that all the wire are disconnected.
4
Operators cab assembly: 410 kg

q
D85EX, PX-15E0
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 sealant, 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 gasket sealant applied in 2).
a Fill the clearance between seal (30)
and floor frame with adhesive (LT-1A).
SEN01272-00
4)
Apply grease (G2-LI) to the outside of seal

(30) (sealing face against the cab).
a Apply grease so that the cab will slip
well and the seal will not be moved or
deformed when the cab is installed.
8)
9)
Cut seal (22) flush with seal (23). (See figure

P.)
q
Fit part (k) (the joint) to eliminate
clearance.
Seal (31) to the groove first, and then stick
seal (23). (See section A A.)
Installation of seals of operator's cab mating

faces
1) Sling the operators cab assembly.
2) Remove dirt, oil, and grease from the seal
fitting surfaces.
k Do not stand under the operators
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 conditioner 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
D85EX, PX-15E0
SEN01272-00
When installing the operators cab, obey the

following points.
1) Lower the operators 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 contact 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 operator's cab assembly carefully.
2) Tighten the mounting bolts temporarily.
3) Check that the seal between air conditioner 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)
6)
7)
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 dashboard-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 conditioner to the right or left, if necessary.
Tighten the mounting bolts of the dashboard mounting bracket.
Measure the internal pressure. For details,
see Testing and adjusting operator s
cab.
D85EX, PX-15E0
SEN01272-00
Parts to be installed before operators cab is

mounted
1) Install open lock stopper mounting grip (29).
2)
Install cab mounting L-plate (10) to the cab

temporarily.
D85EX, PX-15E0
SEN01272-00
Removal and installation of operators cab glass (Stuck glass)
Among the panes of window glass of the operators cab, the 3 panes of (1) and (2) on both
sides are stuck. In this section, the procedure
for replacing the stuck glass is explained.
D85EX, PX-15E0
(1) : Front window glass

(2) : Left door window glass
: Right door window glass
(3) : Both-sided adhesive tape
(4) : Trim seal
(5) : Door handle
SEN01272-00
1 793-498-1210
Lifter
(Suction cup)
(The following figure shows the operators cab of a

wheel loader.)
Sketch
New/Remodel
Part name
Q'ty
Part No.
Necessity
Symbol
Special tools
t 2
Removal
a
Remove the window glass to be replaced

1.
Using seal cutter [1], cut the adhesive between

broken window glass (6) and operators cab
(metal sheet) (7).
a
a
If the window glass is broken finely, it may

be removed with knife [4] and a screwdriver.
Widening the cut with a screwdriver, cut
the adhesive and both-sided adhesive
tape with knife [4].

wheel loader.)
10
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
may be broken by the frictional heat, apply
lubricant to it.
2.
Remove the window glass.
D85EX, PX-15E0
Installation
1.
Using a knife and scraper [5], remove the

remaining adhesive and both-sided adhesive
tape from the metal sheets (glass sticking surfaces) of the operators cab.
a Remove the adhesive and both-sided adhesive tape to a degree that they will not affect
adhesion of the new adhesive. Take care
not to scratch the painted surfaces.
(If the painted surfaces are scratched, adhesion will be lowered.)

wheel loader.)
2.
SEN01272-00
3.
Stick both-sided adhesive tape (3) along the

inside edges of the front window glass sticking
section and both door window glass sticking
sections.
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
a When sticking the both-sided adhesive
tape, do not touch the cleaned surface as
long as possible.
a Take care that the both-sided adhesive
tape will not float at each corner of the
window frame.
a Do not lap the finishing end of both-sided
adhesive tape (3) over the starting end but
make clearance (a) of about 5 mm
between them.
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
SEN01272-00
4.
Install trim seals (4) to both door window

glasses (2).
Install each trim seal (4) so that its finishing end and starting end will be jointed at
position (c) and dimension (b) between
the corner and position (c) will be 90 mm.
5.
Position the new window glass.

1) Using tool X1, set the window glass to the
sticking position. Check the clearance
between the window glass and the operators cab on the right, left, upper, and lower
sides, and then adjust it evenly.
a Position front window glass (1) from
inside of operators cab (7). Adjust it
so that the difference between black
coated part and the metal sheet of
operators 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
positional relationship between it and
door metal sheet will be even all
around the window.
2)
3)
12
After positioning the glasses, stick tapes

[6] between front window glass (1) and
operators cab (7) and the right, left, and
lower parts of each door window glass (2)
and each door (9), and then draw positioning line (e).
Cut the tapes between window glasses (1)
and (2) and operators cab (7) with a knife,
and then remove the window glasses.
a Do not remove the tapes left on the
window glasses and operators cab
before installing the window glasses.
D85EX, PX-15E0
6.
Apply adhesive.
2 Adhesive: Sikaflex 256HV manufactured
by Sika Japan
a Do not use primer.
a The using limit of the adhesive is 6 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25C.
a Never heat the adhesive higher than 30C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
D85EX, PX-15E0
SEN01272-00
1)
Break aluminum seal (11) of the outlet of

adhesive cartridge (10) and install the
nozzle.
2)
Cut the tip of the adhesive nozzle (12) so

that dimensions (f) and (g) will be as follows.
q
Dimension (f) : 10 mm
q
Dimension (g): 15 mm
3)
Set adhesive cartridge (10) to caulking

gun [7].
a An electric caulking gun is more efficient.
13
SEN01272-00
4)

a
Remove release tape of the both-sided

adhesive tape (3a) on the glass side.
a
a
5)
Apply adhesive (13) to the outside of bothsided adhesive tape (3) of the operators
cab.
7.
14
Apply adhesive (13) to dimensions (h) and

(j) of both-sided adhesive tape (3) of operators cab (7).
q
Dimension (h): 10 mm
q
Dimension (j) : 15 mm
Apply adhesive (13) higher than bothsided adhesive tape (3).
Apply the adhesive evenly.
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 operators
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.
D85EX, PX-15E0
3)
4)
SEN01272-00
Mask front window glass (1) and operators cab (7) with masking tapes [8].
Fill the clearance between front window
glass (1) and operators cab (7) with caulking 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.
5)
After applying caulking material (14) to

front window glass (1), form it with the fingers as shown in the following figure.
a Use rubber spatula [9] to form the
caulking material around the handrail,
etc. where it is difficult to form with the
fingers.
D85EX, PX-15E0
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
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of each window
glass firmly.
15
SEN01272-00
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.
3)
16
Fill the clearance between each door window glass and trim in the range of dimension (k).
i) Mask the range of dimension (k) of
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
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
front window glass.
(The figure shows the operator's cab of a hydraulic

excavator.)
D85EX, PX-15E0
2)
SEN01272-00
Immediately after sticking both door window 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 operators 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 20C and humidity of 60%).
2) After applying the adhesive, wait for at
least 24 hours, before operating the
machine actually.
D85EX, PX-15E0
17
SEN01272-00
Removal and installation of floor

frame assembly
1
4.
Disconnect turnbuckle (2) of the brake linkage.

[*1]
a Before disconnecting turnbuckle (2), check
the pressing stroke of the brake.
5.
6.
Disconnect fuel level sensor wiring connector

423 (4).
X2
799-703-1200
Service tool kit
t 1
799-703-1100
Vacuum pump
(100 V)
t 1
799-703-1110
Vacuum pump
(220 V)
t 1
799-703-1120
Vacuum pump
(240 V)
t 1
799-703-1401
Gas leak
detector
t 1
Sketch
New/Remodel
Part name
Q'ty
Part No.
Necessity
Symbol
Special tools
Removal
k
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.
1.

assembly.
2.

see Removal and installation of operators cab
assembly.
3.
Remove cover (1).
18
D85EX, PX-15E0
7.
Disconnect accumulator hose (5).
8.
Disconnect 6 PPC hoses from the work equipment control valve.

[*2]
q
Right-hand PPC hoses:
(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).
SEN01272-00
10. Disconnect 2 drain hoses from the drain merge

block.
(13): Ripper control valve drain hose
(14): Blade control valve hose
11. Disconnect centralized connectors (15), (16),

(17), (18) and (19).
12. Remove cover (20) on the dashboard side.
D85EX, PX-15E0
19
SEN01272-00
17. Remove bracket (26) for tool.
13. Disconnect air conditioner hoses (21) and (22).

[*3]
a Before disconnecting the air conditioner
hose, collect the refrigerant (R134a).
18. Disconnect battery relay terminals (27), (28),

(29) and (30).
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).
16. Open battery case cover (23).
20
22. Remove intermediate connector mounting

bracket (38).
D85EX, PX-15E0
23. Remove parking brake lock lever cable assembly

(39).
[*4]
SEN01272-00
27. Lift off floor frame assembly (43).

a When lifting off the floor frame assembly,
check that all the wires have been disconnected.
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
SEN01272-00
Installation
q

removal.
Charging air conditioner circuit refrigerant gas

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 connecting 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.
22
Thread size
Tightening torque
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}
D85EX, PX-15E0
SEN01272-00

24
SEN01273-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 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
SEN01273-00
Electrical system
engine controller
1.
2.
Disconnect air conditioner piping clamps (3)

and (4).
4.
Remove cover (5).
5.
Remove bracket (6).
6.
Disconnect wiring harness connectors (7), (8),

and (9).
Removal
k
3.

Open the engine left side cover (1).
Remove cover (2).
D85EX, PX-15E0
7.
Remove controller (10).

a Ground wire (11) is installed together with
the controller.
SEN01273-00
Installation
q

removal.
[*1]
a Check that there is no dust in connectors (7),
(8) and (9) before connecting.
D85EX, PX-15E0
SEN01273-00

steering and transmission
controller
1.
Remove the 4 mounting bolts and take out

steering and transmission controller assembly
(3).
4.
Disconnect wiring connectors PTC1 (4), PTC2

(5), and PTC3 (6) and remove steering and
transmission controller assembly (3).
[*1]
a Disconnect each connector by loosening
one screw of the center of wiring harness.
Removal
k
3.

Remove operators seat assembly (1).
4
Operators seat assembly: 70 kg
Installation
2.
Remove left side cover (2).

removal.
[*1]
Mounting screw: 2.82 Nm {0.288 kgm}
D85EX, PX-15E0

KOMTRAX terminal
SEN01273-00
3.
Remove the 4 mounting bolts and KOMTRAX

terminal assembly (5).
Removal
k
1.

Remove operators seat assembly (1).
4
Operators seat assembly: 70 kg
Installation
q

removal.
[*1]
2.
Mounting screw: 2.82 Nm {0.288 kgm}
Disconnect wiring connectors KOM1 (2), KOM2

(3), KOM3 (4).
[*1]
a To disconnect wiring connector KOM1 (2),
loosen the central screw of the wiring harness.
D85EX, PX-15E0
SEN01273-00

SEN00072-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

Hydraulic diagrams and drawings................................................................................................................... 2
Power train hydraulic circuit diagram ................................................................................................... 2
Hydraulic circuit diagram...................................................................................................................... 3
D85EX, PX-15E0
SEN00072-00
Power train hydraulic circuit diagram
D85EX, PX-15E0
Hydraulic circuit diagram

(1/2)
D85EX, PX-15E0
Hydraulic circuit diagram (1/2)

D85EX, PX-15E0
SEN00072-00
Hydraulic circuit diagram

(2/2)
D85EX, PX-15E0
SEN00072-00
Hydraulic circuit diagram (2/2)

1
D85EX, PX-15E0
SEN00072-00

SEN00073-00
BULLDOZER
1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model
Serial number
D85EX-15E0
D85PX-15E0
11001 and up
1201 and up

Electrical diagrams and drawings ................................................................................................................... 3
Electrical circuit diagram ...................................................................................................................... 3
D85EX, PX-15E0
D85EX, PX-15E0
SEN00073-00
Electrical circuit diagram
1
1
SEN00073-00


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D85EX-15E0 11001 and up

Copyright 2007 Komatsu

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00 Index and foreword

00 Index and foreword

Composition of shop manual

Shop Manual, contents binder, binder label and tabs

00 Index and foreword

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

00 Index and foreword

Troubleshooting of hydraulic and mechanical system (H-mode)

50 Disassembly and assembly

90 Diagrams and drawings

00 Index and foreword

00 Index and foreword

00 Index and foreword

00 Index and foreword

20 Standard value table

00 Index and foreword

Testing and adjusting, Part 3

00 Index and foreword

00 Index and foreword

Troubleshooting by failure code (Display of code), Part 3

00 Index and foreword

Failure code [DK10KA] Fuel dial: Disconnection ............................................................................ 72

00 Index and foreword

Troubleshooting of electrical system (E-mode)

00 Index and foreword

Troubleshooting of engine (S-mode)

00 Index and foreword

Undercarriage and frame, Part 1

D85EX, PX-15E0 Bulldozer

00 Index and foreword

Foreword and general information

00 Index and foreword

Foreword and general information

Important safety notice

If welding repairs are needed, always

Preparations for work

00 Index and foreword

When disassembling or assembling, support the machine with blocks, jacks, or

Precautions during work

When removing piping, stop the fuel or oil

Precautions for sling work and making

00 Index and foreword

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

00 Index and foreword

If the load is unstable or the wire rope

Precautions for using mobile crane

Selecting wire ropes

The allowable load is one-sixth of the

How to read the shop manual

00 Index and foreword

Revision and distribution

00 Index and foreword

Revised edition mark

00 Index and foreword

Explanation of terms for maintenance standard

Standard size and tolerance