D85EX-15E0 and Additional Models (JPN) EU SN 11001-UP

SEN00060-06
BULLDOZER D85EX -15E0

D85PX -15E0
D85EX- 11001
SERIAL NUMBERS and up
D85PX- 1201
SEN00069-06
BULLDOZER 1SHOP MANUAL
D85EX-15E0
D85PX-15E0
Machine model Serial number

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

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
D85EX, PX-15E0 1
SEN00069-06 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title ............................................................................................................................Form Number
Shop Manual, contents binder, binder label and tabs ............................................................ SEN00060-06
00 Index and foreword ......................................................................................................... SEN00061-06

Index ............................................................................................................................... SEN00069-06 q
Foreword and general information .................................................................................. SEN00070-02
01 Specification.................................................................................................................... SEN00062-02
Specification and technical data...................................................................................... SEN00071-02
10 Structure, function and maintenance standard ............................................................... SEN00063-02

Engine and cooling system ............................................................................................. SEN00293-00
Power train, Part 1 .......................................................................................................... SEN00295-01
Undercarriage and frame ................................................................................................ SEN00298-01
Hydraulic system, Part 1 ................................................................................................. SEN00299-01
Work equipment.............................................................................................................. SEN00305-00
Cab and its attachments ................................................................................................. SEN00306-00
Electrical system ............................................................................................................. SEN00308-02
20 Standard value table ....................................................................................................... SEN00064-02

Standard service value table........................................................................................... SEN00629-02
30 Testing and adjusting ...................................................................................................... SEN00065-04

Testing and adjusting, Part 1........................................................................................... SEN00630-04 q
Testing and adjusting, Part 2........................................................................................... SEN00631-03 q
Testing and adjusting, Part 3........................................................................................... SEN00632-02
40 Troubleshooting .............................................................................................................. SEN00066-02

General information on troubleshooting.......................................................................... SEN00633-02
Troubleshooting by failure code (Display of code), Part 1 .............................................. SEN00634-01
Troubleshooting of electrical system (E-mode)............................................................... SEN00638-02
2 D85EX, PX-15E0
00 Index and foreword SEN00069-06
Troubleshooting of hydraulic and mechanical system (H-mode) .................................... SEN00639-00

Troubleshooting of engine (S-mode) .............................................................................. SEN00640-01
50 Disassembly and assembly ............................................................................................ SEN00067-02

General information on disassembly and assembly ....................................................... SEN01263-02
Engine and cooling system, Part 1 ................................................................................. SEN01264-01
Undercarriage and frame, Part 1 .................................................................................... SEN01268-01
Hydraulic system ............................................................................................................ SEN01270-01
Electrical system............................................................................................................. SEN01273-01
90 Diagrams and drawings .................................................................................................. SEN00068-03

Hydraulic diagrams and drawings................................................................................... SEN00072-00
Electrical diagrams and drawings ................................................................................... SEN00073-03
D85EX, PX-15E0 3
Table of contents 1
00 Index and foreword
Index ............................................................................................................................... SEN00069-06
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information .................................................................................. SEN00070-02
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code................................................................................................. 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table .............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data...................................................................................... SEN00071-02
Specification dimensions ......................................................................................................... 2
Specifications........................................................................................................................... 3
Weight table ............................................................................................................................. 11
Table of fuel, coolant and lubricants ........................................................................................ 16
10 Structure, function and maintenance standard

Engine and cooling system ............................................................................................. SEN00293-00
Engine mount........................................................................................................................... 2
Cooling system ........................................................................................................................ 4
Cooling fan pump..................................................................................................................... 6
Cooling fan motor .................................................................................................................... 14
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...................................................................................................... 36
Main relief valve and torque converter relief valve .................................................................. 41
Lubrication relief valve ............................................................................................................. 43
Bevel gear shaft, HSS and brake ............................................................................................ 2
Brake valve .............................................................................................................................. 22
Final drive ................................................................................................................................ 28
Undercarriage and frame ................................................................................................ SEN00298-01
Main frame............................................................................................................................... 2
Suspension .............................................................................................................................. 4
Track frame.............................................................................................................................. 8
Idler cushion ............................................................................................................................ 10
Idler.......................................................................................................................................... 12
Track roller ............................................................................................................................... 14
Carrier roller............................................................................................................................. 16
4 D85EX, PX-15E0
Sprocket................................................................................................................................... 18
Track shoe ............................................................................................................................... 20
Hydraulic system, Part 1................................................................................................. SEN00299-01
Work equipment hydraulic piping diagram .............................................................................. 2
PPC control piping diagram..................................................................................................... 5
Work equipment control........................................................................................................... 6
Hydraulic tank and filter ........................................................................................................... 8
Scavenging pump.................................................................................................................... 10
Power train and steering lubrication pump .............................................................................. 11
HSS pump ............................................................................................................................... 12
HSS motor ............................................................................................................................... 30
Control valve............................................................................................................................ 2
Self pressure reducing valve ................................................................................................... 36
Oil cooler bypass valve............................................................................................................ 2
PPC valve................................................................................................................................ 4
Electric lever (steering)............................................................................................................ 20
Quick drop valve...................................................................................................................... 23
PPC lock valve ........................................................................................................................ 24
Accumulator............................................................................................................................. 25
Cylinder stay ............................................................................................................................ 3
Blade ....................................................................................................................................... 4
Cutting edge and end bit ......................................................................................................... 6
Ripper ...................................................................................................................................... 8
Hydraulic cylinder .................................................................................................................... 10
Piston valve ............................................................................................................................. 12
Cab mount ............................................................................................................................... 2
Cab .......................................................................................................................................... 3
Air conditioner.......................................................................................................................... 5
Monitor system ........................................................................................................................ 2
Monitor panel ........................................................................................................................... 4
Engine control.......................................................................................................................... 12
Engine control system ............................................................................................................. 13
System components ................................................................................................................ 14
CRI engine control system ...................................................................................................... 24
Palm command control system ............................................................................................... 26
KOMTRAX system .................................................................................................................. 28
Sensor ..................................................................................................................................... 30
20 Standard value table

Standard service value table........................................................................................... SEN00629-02
Standard service value table for engine .................................................................................. 2
Standard service value table for chassis ................................................................................. 3
30 Testing and adjusting

Testing and adjusting, Part 1 .......................................................................................... SEN00630-04
Tools for testing, adjusting, and troubleshooting ..................................................................... 3
Testing engine speed............................................................................................................... 7
Testing intake air pressure (boost pressure) ........................................................................... 10
Testing exhaust temperature ................................................................................................... 12
Testing exhaust gas color ........................................................................................................ 14
Adjusting valve clearance........................................................................................................ 15
D85EX, PX-15E0 5
Testing compression pressure ................................................................................................. 17

Testing blow-by pressure ......................................................................................................... 19
Testing engine oil pressure ...................................................................................................... 20
Testing EGR valve and bypass valve drive oil pressure .......................................................... 21
Handling of fuel system devices .............................................................................................. 22
Releasing residual pressure from fuel system......................................................................... 22
Testing fuel pressure................................................................................................................ 23
Handling of reduced cylinder mode operation ......................................................................... 24
Handling of no injection cranking operation............................................................................. 24
Testing fuel return and leak amount......................................................................................... 25
Bleeding air from fuel circuit .................................................................................................... 28
Testing fuel circuit for leakage ................................................................................................. 30
Testing and adjusting alternator belt tension ........................................................................... 31
Testing and adjusting air conditioner compressor belt tension ................................................ 32
Adjusting fuel control dial and decelerator pedal ..................................................................... 33
Testing power train oil pressure ............................................................................................... 35
Adjusting transmission speed sensor ...................................................................................... 40
Simple method to test brake performance............................................................................... 41
Adjusting brake pedal .............................................................................................................. 42
Adjusting parking brake lever .................................................................................................. 44
Emergency escape method when power train has trouble...................................................... 45
Adjusting clearance of idler...................................................................................................... 48
Inspecting wear of sprocket ..................................................................................................... 49
Testing and adjusting track shoe tension................................................................................. 49
Testing and adjusting work equipment and HSS oil pressure.................................................. 50
Testing control circuit basic pressure....................................................................................... 54
Testing PPC valve output pressure.......................................................................................... 55
Adjusting work equipment PPC valve play .............................................................................. 57
Checking parts which caused hydraulic drift of blade and ripper............................................. 59
Testing internal leakage of work equipment cylinder ............................................................... 60
Bleeding air from work equipment cylinder.............................................................................. 60
Releasing residual pressure in work equipment cylinder......................................................... 61
Adjusting work equipment lock lever ....................................................................................... 62
Testing fan motor speed .......................................................................................................... 63
Testing fan pump circuit pressure ............................................................................................ 64
Bleeding air from fan pump...................................................................................................... 65
Adjusting blade ........................................................................................................................ 66
Testing and adjusting operator cab.......................................................................................... 68
Special functions of monitor panel (EMMS)............................................................................. 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 ....................................................................................... 22
40 Troubleshooting
General information on troubleshooting.......................................................................... SEN00633-02
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
Connection table for connector pin numbers ........................................................................... 11
T- branch box and T- branch adapter table.............................................................................. 47
6 D85EX, PX-15E0

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
Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected .... 68
Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected ........... 70
Failure code [CA234] Engine over speed: Excessively high speed ................................................ 72
Failure code [CA238] Abnormal power source for Ne speed sensor:
Excessively low voltage detected........................................................................................ 74
Failure code [CA263] Fuel temperature sensor too high: Excessively high voltage detected......... 76
Failure code [CA265] Fuel temperature sensor too low: Excessively low voltage detected............ 78
Failure code [CA271] PCV1 short circuit: Short circuit .................................................................... 79
Failure code [CA272] PCV1 disconnection: Disconnection............................................................. 80
Failure code [CA273] PCV2 short circuit: Short circuit .................................................................... 81
Failure code [CA274] PCV2 disconnection: Disconnection............................................................. 82
Failure code [CA322] Injector No. 1 system disconnection or short circuit:
Disconnection, short circuit................................................................................................. 4
D85EX, PX-15E0 7

Failure code [CA342] Engine controller data matching error: Matching error ................................. 16
Failure code [CA351] Abnormal injector drive circuit: Abnormal circuit .......................................... 18
Failure code [CA352] Sensor power source (1) too low: Excessively low voltage detected ........... 20
Failure code [CA386] Sensor power source (1) too high: Excessively high voltage detected ........ 22
Failure code [CA441] Power source voltage too low: Excessively low voltage detected................ 24
Failure code [CA442] Power source voltage too high: Excessively high voltage detected ............. 24
Failure code [CA449] Common rail pressure too high (2):
Excessively high pressure trouble occurred ............................................................................ 25
Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected 26
Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected ... 28
Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected .... 28
Failure code [CA554] In-range error in common rail pressure sensor: In-range error .................... 29
Failure code [CA559] Loss of pressure feed from supply pump (1):
Loss of pressure feed detected ............................................................................................... 30
Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal .................................. 34
Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase ................... 36
Failure code [CA757] Loss of all engine controller data: Loss of all data ....................................... 37
Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal ..................... 38
Failure code [CA1228] Abnormal EGR valve servo (1): EGR out of control ................................... 40
Failure code [CA1625] Abnormal EGR valve servo (2): EGR out of control ................................... 41
Failure code [CA1633] Abnormal KOMNET: Abnormal communication ......................................... 42
Failure code [CA2185] Decelerator pedal sensor power source too high:
Excessively high voltage detected........................................................................................... 44
Failure code [CA2186] Decelerator pedal sensor power source too low:
Excessively low voltage detected ............................................................................................ 45
Failure code [CA2249] Loss of pressure feed from supply pump (2):
Loss of pressure feed detected ............................................................................................... 46
Failure code [CA2271] EGR valve lift sensor too high: Excessively high voltage detected ............ 48
Failure code [CA2272] EGR valve lift sensor too low: Excessively low voltage detected............... 50
Failure code [CA2351] EGR valve solenoid drive short circuit: Short circuit................................... 52
Failure code [CA2352] EGR valve solenoid drive disconnection: Disconnection ........................... 54
Failure code [CA2555] Intake air heater relay disconnection: Disconnection ................................. 55
Failure code [CA2556] Intake air heater relay short circuit: Short circuit ........................................ 56
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
8 D85EX, PX-15E0
Failure codes [DAQ7KK] and [DB37KK] Steering and transmission controller sensor
5 V power source (2): Power source voltage drop and input ................................................... 36
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 [DB37KK] and [DAQ7KK] Steering and transmission controller sensor
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
Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal ....................... 89
Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection.................................... 90
Failure code [DK56KB] Forward-reverse potentiometer (1): Short circuit ....................................... 92
Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection.................................... 94
Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit ....................................... 96
Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit ...................................... 3
Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection ................................... 4
D85EX, PX-15E0 9
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
Troubleshooting of electrical system (E-mode)............................................................... SEN00638-02
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................................................... 28
E-12 Fuel gauge does not indicate properly.................................................................................... 31
E-13 Gear speed and engine speed are not indicated properly...................................................... 32
E-14 The preset mode and service meter do not indicate properly................................................. 32
E-15 The warning lamp does not flash or does not go out.............................................................. 33
E-16 The alarm buzzer does not sound or does not stop. .............................................................. 34
E-17 Auto shift down does not operate or does not release. .......................................................... 36
E-18 Buzzer cancel switch does not work....................................................................................... 38
E-19 The information switch does not work. ................................................................................... 40
10 D85EX, PX-15E0
E-20 The manual mode does not operate or does not release. ...................................................... 42
E-21 The monitor panel cannot be set in the service mode or
cannot be set out of the service mode. .................................................................................... 44
E-22 The back-up alarm does not sound. ....................................................................................... 46
E-23 The head lamp and rear lamp do not light up. ........................................................................ 48
E-24 The horn does not sound or does not stop. ............................................................................ 51
E-25 Malfunction of wipers .............................................................................................................. 52
E-26 Washer does not spray water ................................................................................................. 68
E-27 The air conditioner does not operate ...................................................................................... 73
E-28 KOMTRAX system does not operate normally. ...................................................................... 78
E-29 Fan does not reverse .............................................................................................................. 80
E-30 Gear cannot be shifted............................................................................................................ 82
Troubleshooting of hydraulic and mechanical system (H-mode) .................................... SEN00639-00
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
Troubleshooting of engine (S-mode) .............................................................................. SEN00640-01
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)................................................. 18
S-9 Oil becomes contaminated quickly ................................................................................... 19
S-10 Fuel consumption is excessive ....................................................................................... 20
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)............................. 21
S-12 Oil pressure drops........................................................................................................... 22
S-13 Oil level rises (water, fuel in oil) ...................................................................................... 23
S-14 Coolant temperature becomes too high (overheating).................................................... 25
S-15 Abnormal noise is made. ................................................................................................ 26
S-16 Vibration is excessive ..................................................................................................... 27
50 Disassembly and assembly

General information on disassembly and assembly ....................................................... SEN01263-02
How to read this manual.......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7
Sketch of special tool............................................................................................................... 12
D85EX, PX-15E0 11

Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of cylinder head assembly ............................................................... 6
Removal and installation of fuel injector assembly .................................................................. 18
Removal and installation of engine front seal .......................................................................... 23
Removal and installation of engine rear seal........................................................................... 26
Removal and installation of engine oil pan .............................................................................. 30
Removal and installation of engine assembly.......................................................................... 2
Removal and installation of radiator assembly ........................................................................ 6
Removal and installation of fan drive assembly....................................................................... 10
Removal and installation of fan motor assembly ..................................................................... 12
Removal and installation of fuel tank assembly ....................................................................... 13
Removal and installation of damper assembly ........................................................................ 15
Disassembly and assembly of damper assembly.................................................................... 17
Removal and installation of engine hood assembly................................................................. 22
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
Disassembly and assembly of HSS assembly......................................................................... 2
Removal and installation of final drive assembly ..................................................................... 21
Disassembly and assembly of final drive assembly................................................................. 23
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
Expansion and installation of track shoe assembly ................................................................. 2
Whole disassembly and whole assembly of track shoe assembly .......................................... 6
Field disassembly and assembly of one link............................................................................ 19
Disassembly and assembly of master link............................................................................... 26
Removal and installation of pivot shaft assembly .................................................................... 29
Removal and installation of equalizer bar assembly................................................................ 30
Disassembly and assembly of equalizer bar assembly ........................................................... 32
Hydraulic system............................................................................................................. SEN01270-01
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
Removal and installation of blade assembly............................................................................ 2
Disassembly and assembly of ripper assembly....................................................................... 4
12 D85EX, PX-15E0

Removal and installation of ROPS guard assembly ................................................................ 2
Removal and installation of operator’s cab assembly ............................................................. 3
Removal and installation of operator’s cab glass (Stuck glass)............................................... 9
Removal and installation of floor frame assembly ................................................................... 18
Removal and installation of engine controller .......................................................................... 2
Removal and installation of steering and transmission controller............................................ 4
Removal and installation of KOMTRAX terminal ..................................................................... 5
90 Diagrams and drawings

Hydraulic diagrams and drawings................................................................................... SEN00072-00
Power train hydraulic circuit diagram....................................................................................... 2
Hydraulic circuit diagram ......................................................................................................... 3
Electrical diagrams and drawings ................................................................................... SEN00073-03
Electrical circuit diagram.......................................................................................................... 3
Cab electrical circuit diagram .................................................................................................. 19
Air conditioner electrical circuit diagram .................................................................................. 21
Connector list and stereogram ................................................................................................ 23
D85EX, PX-15E0 13
SEN00069-06
D85EX, PX-15E0 Bulldozer

Form No. SEN00069-06
© 2010 KOMATSU
All Rights Reserved
Printed in Japan 06-10
14
SEN00630-04
D85EX-15E0
D85PX-15E0

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

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Testing engine speed ...................................................................................................................................... 7
Testing intake air pressure (boost pressure) ................................................................................................. 10
Testing exhaust temperature......................................................................................................................... 12
Testing exhaust gas color ............................................................................................................................. 14
Adjusting valve clearance ............................................................................................................................. 15
Testing compression pressure ...................................................................................................................... 17
Testing blow-by pressure .............................................................................................................................. 19
Testing engine oil pressure ........................................................................................................................... 20
Testing EGR valve and bypass valve drive oil pressure ............................................................................... 21
Handling of fuel system devices ................................................................................................................... 22
Releasing residual pressure from fuel system .............................................................................................. 22
Testing fuel pressure..................................................................................................................................... 23
Handling of reduced cylinder mode operation .............................................................................................. 24
Handling of no injection cranking operation .................................................................................................. 24
Testing fuel return and leak amount.............................................................................................................. 25
D85EX, PX-15E0 1
SEN00630-04 30 Testing and adjusting
Bleeding air from fuel circuit.......................................................................................................................... 28

Testing fuel circuit for leakage....................................................................................................................... 30
Testing and adjusting alternator belt tension................................................................................................. 31
Testing and adjusting air conditioner compressor belt tension...................................................................... 32
Adjusting fuel control dial and decelerator pedal .......................................................................................... 33
Testing power train oil pressure .................................................................................................................... 35
Adjusting transmission speed sensor............................................................................................................ 40
Simple method to test brake performance .................................................................................................... 41
Adjusting brake pedal.................................................................................................................................... 42
Adjusting parking brake lever........................................................................................................................ 44
Emergency escape method when power train has trouble ........................................................................... 45
Adjusting clearance of idler ........................................................................................................................... 48
Inspecting wear of sprocket .......................................................................................................................... 49
Testing and adjusting track shoe tension ...................................................................................................... 49
Testing and adjusting work equipment and HSS oil pressure ....................................................................... 50
Testing control circuit basic pressure ............................................................................................................ 54
Testing PPC valve output pressure ............................................................................................................... 55
Adjusting work equipment PPC valve play.................................................................................................... 57
Checking parts which caused hydraulic drift of blade and ripper .................................................................. 59
Testing internal leakage of work equipment cylinder..................................................................................... 60
Bleeding air from work equipment cylinder ................................................................................................... 60
Releasing residual pressure in work equipment cylinder .............................................................................. 61
Adjusting work equipment lock lever............................................................................................................. 62
Testing fan motor speed................................................................................................................................ 63
Testing fan pump circuit pressure ................................................................................................................. 64
Bleeding air from fan pump ........................................................................................................................... 65
Adjusting blade.............................................................................................................................................. 66
Testing and adjusting operator cab ............................................................................................................... 68
2 D85EX, PX-15E0
30 Testing and adjusting SEN00630-04
Tools for testing, adjusting, and troubleshooting 1
Quantity
Symbol
Testing or adjusting
Part No. Part name Remarks
item
Air boost pressure

A 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
(boost pressure)
Water temperature, oil
temperature and B 799-101-1502 Digital temperature gauge 1 –99.9 – 1,299°C
exhaust temperature
1 799-201-9001 Handy smoke checker 1
Exhaust gas color C Commercial Bosch index: 0 – 9
2 Smoke meter 1
item
Commercial
Valve clearance D Clearance gauge 1
item
0 – 7 MPa {0 – 70 kg/cm2}
1 795-502-1590 Compression gauge 1
KIT Part No.: 795-502-1205
Compression pressure E
2 795-471-1420 Adapter 1 For 125E-5
3 6217-71-6112 Gasket 1
Blow-by pressure F 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge:
799-101-5002 Hydraulic tester 1 2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Engine oil pressure G
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Gauge 1 Pressure gauge: 1.0 MPa {10 kg/cm2}
799-101-5002 Hydraulic tester 1
1 *As common as G1
Testing fuel pressure H 790-261-1204 Digital hydraulic tester 1
2 799-401-2320 Gauge 1 *As common as G2
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
Commercial
3 Hose 1
item
Testing fuel return and Commercial
J 4 Hose 1
leak amount item
Commercial
5 Measuring cylinder 1
item
Commercial
6 Stopwatch 1
item
1 *As common as G1
Power train oil pressure K 790-261-1204 Digital hydraulic tester 1
2 799-401-2320 Gauge 1 *As common as G2
19M-06-32820 Switch assembly 1
1
Emergency escape 17M-06-41530 Wiring harness 1
method when power L 799-101-5220 Nipple (10 x 1.25 mm) 1
train has trouble 2
07002-11023 O-ring 1
3 790-190-1601 Pump assembly 1
Testing and adjusting 1 *As common as G1
790-261-1204 Digital hydraulic tester 1
work equipment and M
HSS oil pressure 799-101-5220 Nipple (10 x 1.25 mm) 2
2 *As common as L2
07002-11023 O-ring 2
D85EX, PX-15E0 3
Quantity
Symbol
item

Testing control circuit 1 *As common as G1
N 790-261-1204 Digital hydraulic tester 1
basic pressure
2 799-401-3200 Adapter (size 03) 1
1 *As common as G1
Testing PPC valve out- 790-261-1204 Digital hydraulic tester 1
P
put pressure 2 799-401-3100 Adapter (size 02) 1
3 799-401-3200 Adapter (size 03) 1
Testing internal leakage
Commercial
of work equipment Q Measuring cylinder 1
item
cylinder
Testing fan motor
R 799-205-1100 Tachometer KIT 1
speed
1 *As common as G1
Testing fan pump
S 2 799-401-3400 Adapter (size 05) 1
circuit pressure
799-101-5220 Nipple (10 x 1.25 mm) 1
3 *As common as L2
07002-11023 O-ring 1
79A-264-0021 0 – 294 N {0 – 30 kg} 1
Operating effort T
79A-264-0091 0 – 490 N {0 – 50 kg} 1
Stroke and hydraulic Commercial
U Scale 1
drift item
Commercial
Work equipment speed V Stopwatch 1
item
Commercial
Voltage and resistance W Tester 1
item
Testing EGR valve and 1 *As common as G1
bypass valve drive X
pressure 2 790-301-1190 • Nipple 1 R1/4 o R1/8
3 799-101-5160 • Nipple 1
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP070 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 Connector
799-601-9300 T-adapter assembly 1 DRC26-24, 40 (pin)
799-601-7360 Adapter 1 Relay (5 pins)
799-601-4101 T-adapter assembly 1 Engine related connector
795-799-5530 • Socket 1 Engine coolant
Diagnosis for controller, 799-601-4250 • Socket 1 Boost pressure sensor
—
sensor and actuator 799-601-4130 • T-adapter 1 Ne sensor
799-601-4150 • T-adapter 1 Hydraulic pressure sensor
799-601-4211 • T-adapter 1 Controller (50 poles)
799-601-4240 • T-adapter 1 Ambient pressure sensor
799-601-9430 • Socket 1 PCV
799-601-9420 • T-adapter 1 Common rail pressure sensor
4 D85EX, PX-15E0
Quantity
Symbol
item
795-799-5540 • Socket 1 Boost temperature sensor

Diagnosis for controller, 799-601-4330 • Socket 1 G sensor
—
sensor and actuator 799-601-9020 • T-adapter 1 Injector
799-601-9040 • T-adapter 1 EGR stroke sensor
Commercial 21 mm (width across flats) deep socket
Removal and installa- — Socket 1
item (*1)
tion of engine coolant
temperature sensor 19 mm (width across flats) deep socket
— 795T-981-1010 Socket 1
(*2)
(*1) Engine serial No.: 560001 – 564999

(*2) Engine serial No.: 565000 and up
D85EX, PX-15E0 5
Sketche of special tool

Note: Komatsu will not be held responsible for special tools manufactured according to these sketches.
Socket
6 D85EX, PX-15E0
Testing engine speed 1

a Testing the engine speed under the following 3. Measuring high idle speed
condition. 1) Start the engine and set the fuel control
q Coolant temperature: dial in the high idle position.
Within operating range 2) Set the PCCS lever and work equipment
q Hydraulic oil temperature: control lever in neutral and measure the
Within operating range engine speed.
q Power train oil temperature: a The high idle speed measured in the
Within operating range “Monitoring mode” or in the “Pm Clinic
auxiliary mode” is the auto-deceleration
1. Preparatory work speed.
Turn the starting switch ON and set the monitor a When measuring the high idle speed of
panel in the “Monitoring mode” to prepare for the engine, use the “Adjustment mode”.
measurement of the engine speed. Adjustment code:
a For the operating method, see “Special 0007 (Engine decelerator cut mode)
functions of monitor panel (EMMS)”.
D85EX Serial No.: 11001 – 11473
q Monitoring code: 01000 (Engine speed)
D85PX Serial No.: 1201 – 11473
D85EX Serial No.: 11001 – 11473
D85PX Serial No.: 1201 – 11473
D85EX, PX Serial No.: 11474 and up
4. Measuring decelerator pedal speed

1) Start the engine and set the fuel control
2. Measuring low idle speed dial in the high idle position.
1) Start the engine and set the fuel control 2) Set the PCCS lever and work equipment
dial in the low idle position. control lever in neutral, and measure the
2) Set the PCCS lever and work equipment engine speed with the decelerator pedal
control lever in neutral and measure the depressed.
engine speed.
D85EX, PX-15E0 7
5. Measuring torque converter stall speed D85EX Serial No.: 11001 – 11473
q Adjustment mode: D85PX Serial No.: 1201 – 11473
0530 (Stall speed check mode)
k This machine is equipped with the
cooling fan speed control function to
protect the radiator when the engine is
not fully warmed up. Since that func-
tion does not work while this mode is
used, warm up the engine fully before
using this mode.
dial in the low idle position.
2) With the brake pedal depressed securely
and the parking brake lever in the “free”
position, set the PCCS lever in the “for-
ward” and 3rd gear speed position. D85EX, PX Serial No.: 11474 and up
a Before going to the next step, check
that the upper display unit of the mon-
itor panel is set in the normal display
state and it displays [F3].
a Keep the steering unit in neutral.
3) Press the decelerator pedal and set the
fuel control dial in the high idle position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at
high idle.
k Keep pressing the brake pedal
securely and keep your right foot
on the decelerator pedal for safety
until the work is finished. 6) Repeat above steps 2) – 5) 3 times.
5) Just after the power train oil temperature 7) Perform steps 2) – 4) again and measure
gauge upper section (a) of the green the engine speed about 5 seconds after
range, return the direction of the PCCS the power train oil temperature gauge
lever into neutral. reads the top line of the green range.
a After finishing measurement, return
the direction of the PCCS lever into
neutral and lower the power train oil
temperature with the engine at high
idle.
6. Measuring torque converter stall + work

equipment relief speed (full stall speed)
q Adjustment mode:
0530 (Stall speed check mode)
k This machine is equipped with the
cooling fan speed control function to
protect the radiator when the engine is
not fully warmed up. Since that func-
tion does not work while this mode is
used, warm up the engine fully before
using this mode.
dial in the low idle position. Operate the
ripper lever and raise up the ripper lift cyl-
inder to the stroke end.
8 D85EX, PX-15E0
2) With the brake pedal depressed securely 8) Perform steps 2) – 4) and also operate
and the parking brake lever in the “free” blade RAISE relief and measure the
position, set the PCCS lever in the “for- engine speed when the power train oil
ward” and 3rd gear speed position. temperature gauge upper section (a) of
a Before going to the next step, check the green range.
that the upper display unit of the mon- a After finishing measurement, return
itor panel is set in the normal display the direction of the PCCS lever into
state and it displays [F3]. neutral and lower the power train oil
a Keep the steering unit in neutral. temperature with the engine at high
3) Press the decelerator pedal and set the idle.
fuel control dial in the high idle position. a The engine speed can be measured
4) Return the decelerator pedal slowly to stall by the following operation:
the torque converter with the engine at q “Pm clinic auxiliary mode” of the
high idle. monitor panel
k Keep pressing the brake pedal q Each time the information switch
securely and keep your right foot is set to the right or left when the
on the decelerator pedal for safety monitor panel is in the normal
until the work is finished. display state, the display in the
5) Operate the blade lever to raise the blade multi information section turns to
lift cylinder to the stroke end. the display of service meter or
6) Just after the power train oil temperature engine speed. (However, mea-
gauge upper section (a) of the green sure the high idle speed of the
range, return the direction of the PCCS engine in the “Adjustment
lever into neutral. mode“).
D85EX Serial No.: 11001 – 11473 D85EX Serial No.: 11001 – 11473
D85PX Serial No.: 1201 – 11473 D85PX Serial No.: 1201 – 11473
D85EX, PX Serial No.: 11474 and up D85EX, PX Serial No.: 11474 and up
7) Repeat above steps 2) – 6) 3 times.
D85EX, PX-15E0 9
Testing intake air pressure 4. Run the engine at medium or higher speed and
(boost pressure) 1 drain the oil from the hose.
a Insert the joint of the gauge and hose half-
a Testing instruments for intake air pressure way and open the self-seal on the hose
(boost pressure) side repeatedly, and the oil is drained.
a If Pm kit (A) is available, the air bleeding
Symbol Part No. Part name
coupling (790-261-1130) in it may be
A 799-201-2202 Boost gauge kit used.
a If any oil is left in the hose, the gauge does
k When installing and removing the measur- not move. Accordingly, be sure to drain
ing instrument, take care not to touch a hot the oil.
part of the engine.
a Measure the intake air pressure (boost pres- 5. Measure the intake air pressure (boost pres-
sure) under the following condition. sure) while the engine is running at high idle
q Coolant temperature: and the torque converter is stalling.
Within operating range a For the procedure for stalling the torque
q Hydraulic oil temperature: converter, see “Measuring engine speed”.
Within operating range a Normally, the intake air pressure (boost
q Power train oil temperature: pressure) should be measured while the
Within operating range engine is running at the rated output. In
the field, however, an approximate value
1. Open the left side cover of the engine. can be obtained by stalling the torque con-
verter.
2. Remove air intake connector boost pressure
pickup plug (1) (R1/8).
6. After finishing measurement, remove the mea-

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

“Pm Clinic auxiliary mode” of the monitor
panel.
D85EX Serial No.: 11001 – 11473
D85PX Serial No.: 1201 – 11473
D85EX, PX-15E0 11
Testing exhaust temperature 1 4. Procedure for measuring the maximum value

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

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

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

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

parts.
D85EX, PX-15E0 13
Testing exhaust gas color 1

a Testing instrument for exhaust gas color

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

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

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

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

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

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

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

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

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

forward by 120° at one time and adjusting the
va lve clearan ce of e ach cylinde r 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}
16 D85EX, PX-15E0
Testing compression pressure 1 4. Set cylinder to be tested at compression top

dead center and remove rocker arm assembly
a Testing instruments for compression pressure (4).
a Refer to “Adjusting valve clearance”.
1 795-502-1590 Compression gauge 5. Disconnect the fuel high-pressure tube (5) and
E 2 795-471-1420 Adapter injector harness (6), and remove injector (7).
3 6217-71-6112 Gasket a Before disconnecting the fuel high-pres-
sure tube, loosen all the intermediate
k When measuring the compression pres- clamps on the tube.
sure, take care not to burn yourself on the a To remove injector harness from injector,
exhaust manifold, muffler, etc. or get disconnect the terminal in the injector side
caught in a rotating part. and the bracket in the rocker housing side
a Measure the compression pressure after the and pull them out of the rocker arm hous-
engine is warmed up. ing. (Loosen 2 terminal nuts alternately.)
(Engine oil temperature: 40 – 60°C) a Lead a wire under the fuel pipe which
comes out sideways from the injector and
1. Open the left upper side cover of the engine. pull up the wire to remove injector (do not
ply the upper part of the injector to remove
2. Remove air cleaner (1) and bracket (2). it).
3. Remove cylinder head cover (3).
D85EX, PX-15E0 17
6. Install gasket E3 and install adapter E2 to the 9. Crank the engine with the starting motor and
mounting hole of the injector and connect com- check the compression pressure.
pression gauge E1. a Measure the pressure when the pointer of
a Fix the adapter with the holder for injector. the gauge is stabilized.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm} 10. When the checking is completed, remove the
a Leakage can be prevented by applying a instruments and reinstall the removed parts.
little amount of engine oil to the fitting a Install the injector, injector harness and
faces of the adapter and gauge. fuel high-pressure tube according to fol-
lowing procedure.
7. Install rocker arm assembly (4) and adjust 1) Install O-ring and gasket to injector (7).
valve clearance. 2) Set holder (8) to injector (7) and install it
3 Rocker arm assembly mounting bolts: temporarily to the cylinder head integrally.
58.8 – 73.5 Nm {6.0 – 7.5 kgm} 3) Tighten mounting bolt (9) with spherical
a Refer to “Adjusting valve clearance”. washer (10) to install injector to cylinder
head.
2 Spherical surface section of spheri-
cal washer: Engine oil (SAE30DH)
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
4) Insert harness (6) into rocker arm housing
and fix with mounting bolt (11).
5) Insert harness (6) into holder (12).
6) Tighten 2 nuts at the end of harness (6)
onto injector (7) alternately.
3 Nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
7) Tighten tube (5) to injector (7).
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
8) Tighten the clamping bolt of the fuel pip-
8. Disconnect connector EGC3 of engine control-
ing.
3 Clamping bolt:
ler.
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
k Be sure to disconnect the connector.

Otherwise, engine may start during the 3 Rocker arm assembly mounting
measurement and this may create a bolts:
dangerous condition. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
k Since connector (EGC3) includes the a Adjust valve clearance referring to
power source circuit of engine control- “Adjusting valve clearance”.
ler, cover the connector on the harness 3 Cylinder head cover mounting bolt:
side with a vinyl sheet, etc. to prevent 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
electric leakage and ground fault.
18 D85EX, PX-15E0
Testing blow-by pressure 1 4. Measure the blow-by pressure while the

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

and disconnect hose (1) and install
another hose (KES07287-01914 or equiv-
alent). 5. After completing the measurement, remove
the measuring instrument and set to the origi-
3. Install nozzle [1] of blow-by checker F to blow- nal condition.
by hose (1) and connect to gauge [2].
D85EX, PX-15E0 19
Testing engine oil pressure 1 4. Start the engine and measure the engine oil
pressure when the engine is running at low idle
a Testing instruments for engine oil pressure and at high idle.
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Gauge
a Measure the engine oil pressure under the fol-

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

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

plug installation portion and connect to gauge
G2.
20 D85EX, PX-15E0
Testing EGR valve and bypass 4. Start the engine and measure the oil pressure
valve drive oil pressure 1 at low idle and high idle.
a Testing tools for EGR valve and bypass valve

drive oil pressure
1
799-261-1204 Digital hydraulic tester
X
2 799-301-1190 • Nipple
3 799-101-5160 • Nipple
1. Remove air conditioner compressor assembly

(1) and bracket (2) referring to Disassembly
and assembly, "Removal and installation of
fuel supply pump assembly".
suring instruments and return the removed
parts.
a Remove the gasket sealant sticking to the
threaded part of the removed plug with a
wire brush, apply adhesive or gasket seal-
ant to it, and install it.
2 Plug: LT-2 or LG-5
3 Plug:
16.7 – 37.2 Nm {1.7 – 3.8 kgm}
2. Remove one of oil pressure pickup plug (3)

(R1/4) on the side of the timing gear cover.
3. Install nipples [2] and [3] of hydraulic tester X

and connect hydraulic gauge [1] (2.5 MPa
{25 kg/cm2}).
D85EX, PX-15E0 21
Handling of fuel system devices 1 Releasing residual pressure from

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

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

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

tester H1, and connect to gauge H2.
D85EX, PX-15E0 23
Handling of reduced cylinder Handling of no injection cranking

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

fuel flowing out during the test.
2) Insert spacer J1 to return block (2) side
and retighten it with the currently removed
joint bolt.
a Be sure to fit the gaskets to both ends
of the spacer.
D85EX, PX-15E0 25
3) Insert joint J2 to common rail (1) side and a If the leakage from the pressure lim-
retighten it with the currently removed joint iter is in the following range, it is nor-
bolt. mal.
a Be sure to fit the gaskets to both ends Engine speed Leaking amount
of the joint. (rpm) (cc/min)
4) Connect inspection hose J3 to the tip of
Equivalent to rated
joint J2. Max. 10
operation
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
3. Testing return rate from injector

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

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

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

set up the condition necessary for check-
ing the engine speed.
5) Start the engine and operate at the equiv-
alent to rated operation (torque converter
stall load).
6) After making sure that the engine speed is
stabilized, measure return rate per minute
by use of measuring cylinder J5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
D85EX, PX-15E0 27
Bleeding air from fuel circuit 1
a Bleed the air as follows if the engine has run 2. Remove air bleeding plug (3) of fuel main filter
out of fuel or the fuel circuit equipment has (2) and operate priming pump (4).
been removed and installed. a Operate until fuel flows through plug hole
and when fuel is confirmed, install the
1. Remove fuel pre-filter (1), fill up fuel inside and plug.
reinstall. 3 Air bleeding plug:
a When filling, use clean fuel and be careful 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
not to let dirt get in.
a Add fuel through inlet port (a) areas (8 3. There can be following two cases concerning
places) of the filter. Area (b) is the outlet the reason why the engine does not start up
port after the fuel has been filtered (clean easily after bleeding air from the common rail
side), so never add fuel from here. fuel injection system (CRI) even after carrying
a If clean fuel is not available, do not out the items 1 and 2 above.
remove the filter. Operate the priming a If the air has not been bled completely and
pump to fill the filter with fuel. remained in the circuit, cranking the
engine with the starting motor cannot
bleed air in a short period of time. Thus
the engine start-up becomes difficult.
1) In the cases that the fuel has run out, that
the fuel filter has been replaced or that
some fuel device has been removed and
installed.
q Most of the fuel is left in the fuel cir-
cuit, so the engine may be started
after bleeding air with the air bleeding
procedure introduced in the item 1
and 2 above.
28 D85EX, PX-15E0
2) In the case that a number of fuel devices q Still continue to operate the prim-
have been removed and installed in ing pump until it becomes harder
course of engine overhauling. to operate and a relief noise (a
q Since little fuel is left in the fuel circuit, high pitch noise) of overflow
so air cannot be eliminated com- valve (7) in the supply pump is
pletely by the air bleeding methods heard. It requires approx. 50
introduced in the item 1 and 2 above times of operation to reach that
(ordinary method). In that case, stage.
bleed air in the following procedure. 4] Tighten bolt of priming pump (4) to fix.
5] Crank the engine with the starting
motor and start the engine.
a Do not operate the starting motor
continuously for more than 20
seconds. Moreover try to start up
the engine only after 2 minutes
pause.
a If the engine does not start up
even after repeating to crank for
20 seconds 4 times, insufficient
air bleeding is suspected. In that
case, start the air bleeding steps
once again from step 1].
4. Loosen air bleeder (6) of the fuel supply pump

1] Remove air bleeding plug (3) of fuel
and operate priming pump (4) 90 to 100 times.
main filter (2) and operate priming
a Operate priming pump until fuel flows
pump (4).
through air bleeder and when fuel is con-
q Bleed air
firmed, tighten air bleeder and operate
Operate the priming pump until
several times more until priming pump
fuel flows through plug hole and
becomes stiff.
3 Air bleeder:
when fuel is confirmed, tighten
the plug.
3 Air bleeding plug:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
5. Crank the engine with the starting motor and
2] Remove fuel pressure measuring
start the engine.
plug (5) for the fuel filter and operate
a The air in the high-pressure circuit is bled
priming pump (4).
automatically if the engine is cranked.
q Operate the priming pump until
a If the engine does not start, there still may
fuel flows through plug hole and
be air in the low-pressure circuit. In this
when fuel is confirmed, tighten
case, repeat the above procedure from
the plug.
3 Fuel measuring plug:
step 2.
3.9 – 6.9 Nm {0.4 – 0.7 kgm}
3] Loosen air bleeder (6) of fuel supply
pump (after loosening locknut) and
operate priming pump (4) from 90 to
100 times.
q Operate the priming pump until
fuel flows through air bleeder (6)
and when fuel is confirmed,
tighten the plug.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
D85EX, PX-15E0 29
Testing fuel circuit for leakage 1 9. Inspect the fuel piping and the devices for fuel
leakage.
k Very high pressure is generated in the high- a Inspect the high-pressure circuit parts
pressure circuit of the fuel system. If fuel concentration on the areas coated with the
leaks while the engine is running, it is dan- color checker, for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
and installing its components, check for a If any fuel leakage is not detected, inspec-
fuel leakage according to the following pro- tion is completed.
cedure.
a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel

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

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

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

leakage.
6. Run the engine at high idle.

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

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

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

(3).
D85EX, PX-15E0 31
Testing and adjusting air

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

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

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

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

decelerator pedal 1 1) Start the engine, set the monitor panel in
the “Adjustment mode”, and prepare to
1. Outline of fuel control system measure the engine speed.
q The following signals are inputted as rota- a For the operation method, see “Spe-
tion command signals to the engine con- cial functions of monitor panel
troller. (EMMS)”.
q Decelerator pedal potentiometer signal q Adjustment code: 0007
q 3rd throttle signal (Engine deceleration cut mode)
The engine controller controls the fuel a The engine speed is displayed by 1 rpm.
control system of the engine (CRI system)
according to the lowest engine speed sig- D85EX Serial No.: 11001 – 11473
nal among those input signals. D85PX Serial No.: 1201 – 11473
q Adjust the deceleration slow speed by
adjusting the decelerator pedal linkage.
[1] Fuel control dial

[2] Engine controller
[3] Steering and transmission controller
[4] Decelerator pedal
[5] Decelerator potentiometer
[6] Engine (CRI system)
[7] 3rd throttle signal
[8] Rod
D85EX, PX-15E0 33
3. Adjusting decelerator pedal engine speed

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

Set the fuel control dial in the high idle position
and check that the engine speed at high idle is
normal.
q Engine speed at high idle: 2,050 – 2,150
rpm
q Standard installation dimension (b) of
stopper bolt: 6 mm
q Monitoring mode 31701 decelerator open-
ing 100%
(Exit from the engine deceleration cut
mode and carry out in real time monitoring
mode.)
a If the engine speed is out of range, per-
form the following.
q When the engine speed is 2,050 rpm or
less:
Adjust the engine speed to the high idle
speed with stopper bolt (3).
q When the decelerator opening is less than
100%:
Adjust the decelerator opening to 100%
with stopper bolt (3).
34 D85EX, PX-15E0
Testing power train oil pressure 1

a Testing tools for power train oil pressure

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

the work equipment to the ground, and set
the parking brake lever and work equip-
ment lock lever in the lock position.
a Measure the power train oil pressure under the
following condition.
q Power train oil temperature: 1. Measuring torque converter outlet pressure
Within operating range (OUT)
a The centralized power train oil pressure pickup 1) Connect gauge K2 to oil pressure mea-
ports are installed inside the inspection cover surement nipple (1).
on the left outside of the operator cab. a Use an oil pressure gauge of 1.0 MPa
a A nipple for measuring oil pressure is not {10 kg/cm2}.
installed as standard.
a List of oil pressure measuring points and

gauges to be used.
Gauge
No. Mark Oil pressure reading
(MPa {kg/cm2})
Torque converter outlet
1 OUT 1.0 {10}
pressure
Torque converter main
2 TM 6 {60}
relief pressure
Torque converter inlet
3 IN 2.5 {25}
pressure
Transmission forward
4 FWD 6 {60}
clutch pressure 2) Run the engine and set the PCCS lever in
Transmission reverse the full neutral position.
5 R 6 {60} 3) Measure the oil pressure while the engine
clutch pressure
is running at low idle and high idle.
Transmission 1st clutch
6 1ST 6 {60}
pressure
Transmission 2nd clutch
7 2ND 6 {60}
pressure
Transmission 3rd clutch
8 3RD 6 {60}
pressure
9 BR Steering brake pressure 6 {60}
4) After finishing measurement, remove the

measuring instrument and reinstall the
removed parts.
D85EX, PX-15E0 35
2. Measuring transmission main relief pressure 3. Measuring torque converter inlet pressure
(TM) (IN)
1) Connect oil pressure gauge [1] of hydrau- 1) Connect oil pressure gauge [1] of hydrau-
lic tester K1 to oil pressure measurement lic tester K1 to oil pressure measurement
nipple (2). nipple (3).
a Use an oil pressure gauge of 6 MPa a Use an oil pressure gauge of 2.5 MPa
{60 kg/cm2}. {25 kg/cm2}.
2) Run the engine and set the PCCS lever in 2) Run the engine and set the PCCS lever in
the full neutral position. the full neutral position.
3) Measure the oil pressure while the engine 3) Measure the oil pressure while the engine
is running at low idle and high idle. is running at low idle and high idle.
removed parts.
a For the oil pressure gauge, see
BPD11546.

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

pressure (FWD) pressure (R)
a Use an oil pressure gauge of 6 MPa a Use an oil pressure gauge of 6 MPa
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the parking brake 2) Start the engine and set the parking brake
lever in free position. lever in the free position.
3) With the brake pedal depressed, set the 3) With the brake pedal depressed, set the
PCCS lever in the “forward” and 3rd gear PCCS lever in the “reverse” and 3rd gear
speed position. speed position.
is running at high idle. is running at high idle.
k Since the torque converter is k Since the torque converter is
stalled, press the brake pedal stalled, press the brake pedal
securely and keep your right foot securely and keep your right foot
on the decelerator pedal for safety on the decelerator pedal for safety
until the work is finished. until the work is finished.
a For the oil pressure gauge, see a For the oil pressure gauge, see
BPD11546. BPD11546.
5) After completing the measurement, 5) After completing the measurement,
remove the measuring instrument and set remove the measuring instrument and set
to the original condition. to the original condition.
D85EX, PX-15E0 37
6. Measuring transmission 1st clutch pres- 7. Measuring transmission 2nd clutch pres-
sure (1ST) sure (2ND)
a Use an oil pressure gauge of 6 MPa a Use an oil pressure gauge of 6 MPa
{60 kg/cm2}. {60 kg/cm2}.
2) Run the engine and set the parking brake 2) Run the engine and set the parking brake
lever in free position. lever in free position.
3) With the brake pedal depressed, set the 3) With the brake pedal depressed, set the
PCCS lever in the “forward” and 1st gear PCCS lever in the “forward” and 2nd gear
speed position. speed position.
is running at low idle. is running at low idle.
k Since the torque converter is k Since the torque converter is
stalled, keep pressing the brake stalled, keep pressing the brake
pedal securely. pedal securely.
k Do not run the engine at high idle k Do not run the engine at high idle
while measuring. while measuring.
a For the oil pressure gauge, see a For the oil pressure gauge, see
BPD11546. BPD11546.
5) After completing the measurement, 5) After completing the measurement,
remove the measuring instrument and set remove the measuring instrument and set
to the original condition. to the original condition.
38 D85EX, PX-15E0
8. Measuring transmission 3rd clutch pres- 9. Measuring steering brake pressure (BR)
sure (3RD) 1) Connect oil pressure gauge [1] of hydrau-
1) Connect oil pressure gauge [1] of hydraulic tester K1 to oil pressure measurement
lic tester K1 to oil pressure measurement nipple (9).
nipple (8). a Use an oil pressure gauge of 6 MPa
a Use an oil pressure gauge of 6 MPa {60 kg/cm2}.
{60 kg/cm2}.
2) Run the engine and set the parking brake

2) Run the engine and set the parking brake lever in free position.
lever in free position. 3) Measure the oil pressure while the engine
3) With the brake pedal depressed, set the is running at low idle and high idle.
PCCS lever in the “forward” and 3rd gear a Check that the oil pressure lowers to
speed position. 0 when the brake pedal is depressed
4) Measure the oil pressure while the engine or the parking brake lever is set in the
is running at low idle. lock position.
k Since the torque converter is a For the oil pressure gauge, see
stalled, keep pressing the brake BPD11546.
pedal securely. 4) After completing the measurement,
k Do not run the engine at high idle remove the measuring instrument and set
while measuring. to the original condition.
a For the oil pressure gauge, see
BPD11546.
5) After completing the measurement,
remove the measuring instrument and set
to the original condition.
D85EX, PX-15E0 39
Adjusting transmission speed 6. Taking care of the mounting direction of cover

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

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

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

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

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

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

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

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

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

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

that the machine does not start when the
engine speed reaches the high idle level.
k Since the torque converter is stalled,
press the brake pedal securely and
keep your right foot on the decelerator
pedal for safety until the work is fin-
ished.
D85EX, PX-15E0 41
Adjusting brake pedal 1
k Tighten the locknuts of the rods and cables

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

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

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

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

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

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

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

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

of the brake potentiometer (Adjustment mode:
0005).
a For the operating method, see “Special
D85EX, PX-15E0 43
Adjusting parking brake lever 1
1. Assembling and installing lever assembly 3. Checking brake oil pressure

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

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

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

connect wiring harness [2] to PL1 connec-
tor (1) and PL2 connector (2).
q PL1 connector (1): Connect to male
side and female side.
q PL2 connector (2): Connect to female 4) Run the engine and set the parking brake
side. lever in free position.
a PL2 connector on the male side is
kept disconnected, mask it with a
vinyl sheet, etc.
D85EX, PX-15E0 45
5) Operate switch assembly [1] and move 2. Emergency escape method with brake
the machine to a safe place. releasing device (Use L3)
a The electrical circuit of the gear a If the engine cannot be started and the
speed switches is configured so that parking brake cannot be released, carry
the switch on the lower gear speed is out the emergency escape according to
operated first. the following procedure.
k Take care that the L.H. and R.H. 1) Assemble pump assembly L3.
steering directions are opposite
when reverse.
2) Install volume pump [1] of pump assembly

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

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

parking brake lever in free position.
6) Operate the volume pump to raise the
brake releasing oil pressure to the initial
pressure.
q Initial pressure: Approx. 2.74 MPa
{Approx. 28 kg/cm2}
a Since an accumulator is installed in
the circuit, the handle must be oper-
ated 30 – 50 times to raise the oil
pressure.
a If the oil pressure does not rise above
a certain level, the relief valve may be
set to low pressure. In this case,
adjust the set pressure of the relief
valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure low-
ers gradually because of internal
leakage and the brake is applied
again about 1 minute after. Therefore,
work immediately.
a If the brake releasing pressure lowers
to about 1.57 MPa {16 kg/cm 2 }, the
brake is applied. In this case, operate
the volume pump again to raise the
brake releasing pressure to the initial
pressure.
8) When disconnecting the hose after finish-
ing the work, loosen the screw slowly and
do not stand in the spouting direction of
the oil.
D85EX, PX-15E0 47
Adjusting clearance of idler 1
a If the lateral guide and vertical guide plates of 4) Pull up vertical guide (4) with a bar, etc.
the idler have worn excessively and the idler and pull out shim (5) by the quantity of
ran out slants, adjust the clearance of the idler adjustment obtained in 1).
according to the following procedure. 5) Add shim (5) pulled out onto shim (6).
(8 places in total on both sides, inside, and
1. Lateral adjustment outside)
1) Drive the machine 1 – 2 m on flat ground, a The total number of shims (5) and (6)
then measure clearance (a) between the before adjustment must be the same
track frame and guide plate (4 places; left, as that after adjustment.
right, inner and outer sides). q Sorts of shim thickness: 1 mm, 2 mm
2) If clearance (a) is larger than 4 mm,
loosen bolt (1) and reduce shim (2).
q Standard clearance (a) on each side:
0.5 – 1.0 mm
q Shim thickness: 0.5 mm, 1.0 mm
2. Vertical adjustment
1) Measure clearance (b), subtract 2 mm
from it, and record the result (quantity of
adjustment).
Example: When clearance (b) = 5 mm
The quantity of adjustment is
5 – 2 = 3 mm.
2) Loosen bolts (3) (4 pieces on inside and
outside) until the reaction force of the
spring is lost.
3) Loosen bolt (1). However, do not loosen it
more than 3 turns.
48 D85EX, PX-15E0
Inspecting wear of sprocket 1 Testing and adjusting track shoe

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

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

Add grease through grease fitting (4).
a If the track shoe is not tensed well, move
the machine forward and in reverse slowly.
D85EX, PX-15E0 49
Testing and adjusting work 3) Install nipple M2 and connect it to oil pres-
equipment and HSS oil pressure 1 sure gauge [1] of hydraulic tester M1.
a Use an oil pressure gauge of 40 MPa
a Equipments for testing and adjusting work {400 kg/cm2}.
equipment and HSS oil pressure

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

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

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

1] Start the engine, set the parking brake
lever in the free position, and depress the
brake pedal.
k Since the steering circuit will be
relieved, keep pressing the brake
pedal securely and keep your right
foot on the decelerator pedal for
safety until the work is finished.
2] Run the engine at high idle and steer to
3) Install nipples M2 and connect it to oil the right or left with the PCCS lever. When
pressure gauge [1] of hydraulic tester M1. the steering circuit is relieved, measure
a Use the following oil pressure gauges the oil pressure.
Work equipment oil pressure: 3] After finishing measurement, remove the
40 MPa {400 kg/cm2} measuring instrument and set to the origi-
HSS oil pressure: nal condition.
60 MPa {600 kg/cm2}
D85EX, PX-15E0 51
a The unload pressure and relief pressure

also can be measured in the “Pm clinic
auxiliary mode” of the monitor panel.
D85EX Serial No.: 11001 – 11473
D85PX Serial No.: 1201 – 11473
52 D85EX, PX-15E0
3. Adjusting
1) LS pressure (Load sensing pressure) of 2) LS pressure (Load sensing pressure) of
work equipment HSS
Loosen locknut (4) of work equipment LS Loosen locknut (7) of HSS LS valve (6)
valve (3) and rotate adjustment screw (5) and rotate adjustment screw (8) to adjust
to adjust the LS pressure. the LS pressure.
a If the adjustment screw is a If the adjustment screw is
q rotated to the right, the oil pres- q rotated to the right, the oil pres-
sure is heightened. sure is heightened.
q rotated to the left, the oil pres- q rotated to the left, the oil pres-
sure is lowered. sure is lowered.
a If the adjustment screw is rotated 1 a If the adjustment screw is rotated 1
turn, the pressure is heightened or turn, the pressure is heightened or
lowered by 17.6 MPa {179 kg/cm2}. lowered by 15.1 MPa {154 kg/cm2}.
3 Locknut: 3 Locknut:
29.4 – 39.2 Nm {3 – 4 kgm} 68.6 – 78.5 Nm {7 – 8 kgm}
q After adjusting, check the relief pres- q After adjusting, check the relief pres-
sure and LS pressure of work equip- sure and LS pressure of work equip-
ment again. ment again.
D85EX, PX-15E0 53
Testing control circuit basic 3. Install oil pressure pickup adapter N2 and con-
pressure 1 nect the disconnected hose again.
a Instruments for testing and adjusting control 4. Install nipple [1] of hydraulic tester N1 and con-
circuit basic pressure nect oil pressure gauge [2].
a Use an oil pressure gauge of 6 MPa
{60 kg/cm 2}.
1
N 790-261-1204 Digital type hydraulic tester
2 799-401-3200 Adapter (size 03)
a The control circuit main pressure is the pres-

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

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

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

a Before measuring the PPC valve output pres-

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

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

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

lock lever in the free position.
D85EX, PX-15E0 55
1. Main valve A. Blade LEFT TILT

2. Self pressure reducing valve B. Blade LOWER
3. PPC lock valve C. Ripper RAISE
4. Blade PPC valve D. Ripper LOWER
5. Ripper PPC valve E. Blade RAISE
F. Blade RIGHT TILT
56 D85EX, PX-15E0
Adjusting work equipment PPC valve play 1

2-axis PPC valve
(Part R in hatched area must not be disassembled)
k Stop the machine on level ground, lower 1. Measuring play in directions of ports P3
the work equipment to the ground, stop the and P4
engine, and set the parking brake lever and Measure play (x) in the neutral position of the
work equipment lock lever in the lock posi- lever at 240 mm from the turn center of the
tions. lever.
a If the blade lever end play is large, adjust the (x): Max. 24 mm
PPC valve according to the following proce- a If the play is out of the above range, joint
dure. (1) may be worn. In this case, replace joint
a The ripper valve cannot be adjusted. (1).
D85EX, PX-15E0 57
Replacement procedure for joint (1) 3. Applying grease

1) Remove boot (2), nut (3) and disc (4). 1) Apply grease to the sliding part of joint (1)
2) Replace joint (1). and contact parts of disc (4) and piston
a Install joint (1) to valve body (6) (5).
according to the following procedure. 2 Grease (G2-LI)
1] Thoroughly degrease and dry the 2) Quantity of grease to be applied

threaded portion and body of the 1] Sliding part of joint (1): 7 – 10 ml/
joint. periphery
2] Apply a drop (about 0.02 g) of 2] Contact parts of disc (4) and piston
LOCTITE (No. 262) each to 2 (5) (4 places): 0.3 – 0.8 ml/place
places at dimension (a) from the
threaded portion of the body end. 4. Install boot (2).
3 Joint (1): 39 – 49 Nm {4 – 5 kgm}

3) Install disc (4).
4) Install nut (3).
2. Adjusting lever end play

1) Remove boot (2) and nut (3).
2) Tighten disc (4) and tighten nut (3) tempo-
rarily.
3) Measure the lever end play.
q Measuring play in directions of
ports P3 and P4
Measure play (x) in the neutral posi-
tion of the lever at 240 mm from the
turn center of the lever.
(x): 0.6 – 3.6 mm
q Measuring play in direction of port
P1 (Full stroke)
(y): 0.03 – 0.1 mm
4) Tighten nut (3).
a Fix disc (4) and tighten nut (3).
3 Nut (3):
98 – 127 Nm {10 – 13 kgm}
58 D85EX, PX-15E0
Checking parts which caused 3) Ripper lift cylinder

hydraulic drift of blade and ripper1 Te nse rippe r to push u p the rea r of
machine.
a When a hydraulic drift of blade or ripper
occurred, check if the parts causing the drift is
located in cylinder packing side or in control
valve side according to the following proce-
dure.
1. Stop the engine with the cylinder at the follow-

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

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

by defective cylinder packing, the rea-
son why the drift speed becomes
2) Blade tilt cylinder faster by above mentioned operation
Retract the tilt cylinder to the stroke end is as follows:
and tense blade further to push up the 1) When work equipment is set in the above
right side of the machine. mentioned position, where the holding
pressure is applied to the bottom side, the
oil leaks from bottom side to head side.
Since the volume of head side is smaller
than that of bottom side by the volume of
the rod, the inner pressure of head side
rises by the oil leak from bottom side.
2) If the inner pressure of head side rises,
cylinder is balanced at certain pressure
(depending on the amount of leakage)
which is in proportion to the inner pres-
sure. Therefore, the drifting speed
becomes slower.
3) At this time, if the circuit in the head side is
opened (bottom side is closed by check
valve) to drain circuit by above mentioned
lever operation, the oil in the head side
flows into the drain circuit causing the lost
of the pressure balance. Then the drift
speed becomes faster.
D85EX, PX-15E0 59
Testing internal leakage of work Bleeding air from work equipment

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

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

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

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

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

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

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

and then stop it.
4. Repeat above steps 2 and 3 by 2 – 3 times.
D85EX, PX-15E0 61
Adjusting work equipment lock lever 1
1. Adjust dimension (a) between pins of rod (1).

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

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

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

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

set the monitor panel in the adjustment mode.
a For the operation method of the adjust-
ment mode, see “Special functions of
monitor panel (EMMS)”.
a Adjustment code:
1005 (Fan 100% speed mode)
D85EX, PX-15E0 63
Testing fan pump circuit pressure1 5. Run the engine, and turn the monitor panel to
the adjustment mode.
a Testing instruments for fan pump circuit pres- a For the operation method of the adjust-
sure ment mode, see “Special functions of
monitor panel (EMMS)”.
a Adjustment code:
799-101-5002 Hydraulic tester 1005 (Fan 100% speed mode)
1
S 2 799-401-3400 Adapter (size 05) 6. Measure the oil pressure of fan circuit while the
engine is running at high idle.
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
1. Open radiator mask (1).
2. Remove fan guard (2).

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

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

Install nipple S3 and connect oil pressure
gauge [1].
a Use an oil pressure gauge of 40 MPa {400
kg/cm2}.
64 D85EX, PX-15E0
Bleeding air from fan pump 1

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

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

bleeder (1).
D85EX, PX-15E0 65
Adjusting blade 1
a If the blade was removed and installed or dis- 2) Adjust the shim of lift (2). (2 pieces)
assembled and assembled, adjust it according Adjusted Adjusted Standard Standard thickness
to the following procedure. point clearance clearance of shim
2 b Max. 1 mm 4 mm
1. Adjusting shims for assembly
1) Adjust the shim of center (1). (6 pieces)
Adjusted Adjusted Standard Standard thickness
point clearance clearance of shim
Refer to the
1 a 4 mm
note.
Note: Adjust the shim so that the play of

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

1) Adjust dimension (c) of brace (3) with the
handle.
q Brace installation dimension (c):
1,287 mm
2) Measure right and left tilting distances (e1)
and (e2).
q Right tilting distance (e1):
Approx. 400 mm
q Left tilting distance (e2):
Approx. 400 mm
3) If the tilting distances are different remark-
ably, adjust installation dimension (c) of
brace (3) according to the following proce-
dure.
q (e1) > (e2): Increase installation di-
mension (c) finely.
q (e1) < (e2): Decrease installation di-
mension (c) finely.
D85EX, PX-15E0 67
Testing and adjusting operator

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

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

5] Fill the hose with water up to about
the half level and bend the hose in the
shape of letter U.
6] Set the water level in the vinyl hose
out of the cab to that in the cab.
7] Run the engine at high idle and mea-
sure water level difference (c). [Value
(c): Pa {mmH2O}]
a [a] side: Inside of cab
(Pressurized)
[b] side: Out of cab
(Atmospheric pressure)
68 D85EX, PX-15E0
3. Testing and adjusting door lock 2] Check the relationship between the
Close the door and check the relationship door latch and striker (on both sides).
between the operator cab and door. If there is q Close door (2) and check the
any fault, repair it. engaging condition of latch (3)
1) Check of current condition and striker (4).
1] Check the installed height to damper Normal: Error of (a) must be 0.5
rubber (1). mm or less.
(Check both sides, 2 pieces on each.) a Check deviation (a) of latch center
q Stick adhesive tape [1], etc. to (y) and striker center (x) from each
the contact surface of damper other from the direction of (A).
rubber (1) and open and close
the door 2 – 3 times. Then, check
the contact surface of adhesive
tape [1] against the operator cab.
Normal:
When the door is closed, the
damper rubber comes in con-
tact lightly.
Abnormal:
When the door is closed, the
damper rubber does not come
in contact or comes in contact
so strongly that adhesive tape
is removed.
D85EX, PX-15E0 69
2) Adjusting 4. Testing and adjusting open lock

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

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

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

per rubber
1. Loosen locknuts (10), (11) of the
stopper rubber upper side (8),
lower side (9).
D85EX, PX-15E0 71
SEN00630-04

© 2010 KOMATSU
All Rights Reserved
72
SEN00631-03
D85EX-15E0
D85PX-15E0

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

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

1. Upper display section operation)
(Gear speed display section) 3. Service switch
2. Lower display section
(Multi-information section) Operation section 2 of special functions
(Changeover operation)
4. Buzzer cancel switch
5. Information switch
6. Shift-up switch
7. Shift-down switch
a EMMS: Equipment Management Monitoring

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

The monitor panel (EMMS) has the normal and special functions, and displays information of various types
at the gear speed display section at the center of the monitor panel and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others
are displayed according to the operation of the switches.
1. Normal function: Operator mode
With this function, an operator can view and change the items displayed normally or displayed by the
operation of the switches.
2. Special function: Service mode
With this function, a serviceman can display and change the displayed items by the specified switching
operation for testing, adjusting and troubleshooting.
Flow of each mode and function
D85EX, PX-15E0 3
Operation and display of operator mode 1. Maintenance mode

(Outline) (1-OIL, FILTER MAINTENANCE MODE)
In this mode, the time up to the next replace-
a In this section, only the outline of operator
ment of oils and filters is displayed on multi-
mode is explained. information section (2). Reset after completion
See Operation and Maintenance Manual for of the replacement is done in this mode.
details of each function and mode as well as a Gear speed display section (1) remains
the operating method. the normal display.
Normal display (Default) D85EX Serial No.: 11001 – 11473

The following information is normally displayed on D85PX Serial No.: 1201 – 11473
the monitor panel.
Gear speed display section (1):
q Left side: Travel direction (P, N, F, R)
q Right side: Gear speed (1, 2, 3)
q Graphics: Engine speed
Multi-information section (2):
q Information is displayed in 2 lines of 16 charac-
ters each.
q Left side: Gear shift mode (F1-R1, F1-R2,
F2-R1, F2-R2, F2-R3) (Displayed
when preset mode is set.)
q Right 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 D85EX, PX Serial No.: 11474 and up
speed are displayed alternately.
D85EX Serial No.: 11001 – 11473
D85PX Serial No.: 1201 – 11473
4 D85EX, PX-15E0
a The items marked with a are displayed 2. Pm clinic auxiliary mode (2-PM CLINIC MODE)
but not used for this machine. In this mode, the condition of the machine is
Replacement interval displayed on multi-information section (2) as
2nd time
an auxiliary function of the periodic diagnoses
Code Display Maintenance item 1st time such as the Pm clinic, even if any measuring
and after
(Can not be
(Can be instrument is not connected.
changed)
changed)
a Gear speed display section (1) remains
01 ENG OIL Engine oil 500 500 the normal display.
02 ENG FILT Engine oil filter 500 500
D85EX Serial No.: 11001 – 11473
FUEL
03
FILT
Fuel main filter 1000 1000 D85PX Serial No.: 1201 – 11473
04 HYD FILT Hydraulic oil filter 250 2000
CORR
06 Corrosion resistor 1000 1000
RES
DAMP
07 Damper oil 2000 2000
OIL
08 FNL OIL Final drive oil 250 1000
10 HYD OIL Hydraulic oil 250 2000
12 HSS FILT aHSS charge filter — —
POWL
19 Power train oil 250 1000
OIL
POWL
20 Power train oil filter 250 500
FILT
F.PRE-
41 Fuel pre-filter 500 500 D85EX, PX Serial No.: 11474 and up
FILT
No. Pm clinic auxiliary item

01 Engine speed
02 Coolant temperature
03 Engine oil pressure
05 Boost pressure
06 Boost temperature
07 Power train oil temperature
08 Work equipment oil temperature
09 Work equipment oil pressure
13 Battery voltage
a Boost pressure is indicated in absolute

pressure.
D85EX, PX-15E0 5
3. Failure code display mode 4. Adjustment mode (4-USER ADJUST MODE)

(3-FAULT CODE DISPLAY MODE) In this mode, the display condition of the moni-
In this mode, the contents of each problem in tor panel can be adjusted on multi-information
the machine are displayed by a 6-character section (2).
failure code on multi-information section (2). a Gear speed display section (1) remains
When a user or an operator needs to be noti- the normal display.
fied of the failure code of each problem, this
D85EX Serial No.: 11001 – 11473
mode is applied.
D85PX Serial No.: 1201 – 11473
a Gear speed display section (1) remains
the normal display.
D85EX Serial No.: 11001 – 11473
D85PX Serial No.: 1201 – 11473
No. Adjustment item

01 Brightness of LCD
02 Brightness of display
a When a serviceman needs to check the 03 Contrast of display
failure codes for troubleshooting, “Electri- 04 Fan 100% mode
cal system failure code display mode” and
05 No injection cranking mode
“Mechanical system failure code display
mode” is recommended to use for more
detailed information.
a 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 cur-
rently are displayed at the interval of about
2 seconds. (To finish displaying, turn the
buzzer cancel switch to the [t] position.)
6 D85EX, PX-15E0
1) Brightness of LCD 5) No injection cranking mode

This mode is to adjust brightness of the This mode is to circulate the engine oil
backup lamp at the liquid crystal gauge while applying no injection conditions to all
section. (See Operation and Maintenance engine cylinders before staring engine
Manual.) after an extended machine storage.
1] This mode is selected by operating
2) Brightness of display the information switch.
This mode is to adjust brightness of the 2] The mode is selected by turning the
backup lamp at the multi-information sec- buzzer cancel switch to the [U] position.
tion. (See Operation and Maintenance 3] In this condition, turn the starting
Manual.) switch to START position to apply no
injection cranking.
3) Contrast of display 4] The mode is released by moving the
This mode is to adjust contrast of the liquid starting switch to ON position and
crystal at the multi-information section. turning the buzzer cancel switch to
(See Operation and Maintenance Manual.) the [t] position.
k Do not continue no injection
4) Fan 100% mode cracking for more than 20 sec-
This function is to control rotation speed of onds in order to protect the
the cooling fan forcedly at approximately starting motor.
k For safety, this mode cannot be
100% of the maximum speed.
operated while the engine is
1] This mode is selected by operating the
running.
information switch.
a Exiting from this mode disables
2] The mode is selected by turning the this function.
buzzer cancel switch to the [U] position.
3] The function is effective under this con-
dition and the rotation speed of the
cooling fan is controlled to approxi-
mately 100% of the maximum speed.
a Exiting this mode disables the
function.
D85EX, PX-15E0 7
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 impor-
tant action codes. The display shown below is
an example. (The form of the displayed phone
number depends on the form of the input num-
ber.)
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 inci-
dent, be sure to check for a failure code in “Electri-
c al syst em f ai l u r e c o d e d i s p l a y mo de ” a n d
“Mechanical system failure code display mode”.
D85EX Serial No.: 11001 – 11473

D85PX Serial No.: 1201 – 11473
8 D85EX, PX-15E0
Action code table

Action Remedy requested for an
Display method of trouble Examples of abnormality
code operator
• Automatic function stops or nor-
• Backup alarm does not turn on. mal function stops partially, but
E01 • Only action code is displayed. • Fan speed is kept at maximum machine can work.
level. • Contact your Komatsu distribu-
tor for repair.
• Stop engine and start it again,
• Gear is not shifted up or down.
and you can operate machine
• The action code is displayed. • Exhaust gas color is bad when
without limiting function. You
E02 • Warning lamp flashes temperature is low.
must take care, however.
• Alarm buzzer sounds. • Abnormal engine oil pressure
• Contact your Komatsu distribu-
sensor
tor for repair.
• Engine boost pressure is abnor-
mal.
• The action code is displayed. • Move machine to safe place.
• Usable gear speeds are limited.
CALL E03 • Warning lamp flashes • Contact your Komatsu distribu-
• Engine speed does not rise fully.
• Alarm buzzer sounds. tor for repair.
• Gear shift shocks become large.
• Steering performance lowers.
• The action code is displayed. • Engine cannot be controlled. • Immediately stop machine.
CALL E04 • Warning lamp flashes • Machine cannot travel. • Contact your Komatsu distribu-
• Alarm buzzer sounds. • Machine stops. tor for repair.
D85EX, PX-15E0 9
Operation and display in service mode

Gear speed
Method of changing to service mode No. Adjustment item
display section
a When using the service mode, change the
Maintenance interval change
screen by the following special operation. 5 1C
mode
Electrical system failure code
1) Special operation of switches 6 EE
display mode
Set the monitor panel in the service mode by
operating service switch (3) and buzzer cancel Mechanical system failure code
7 bE
switch (4). display mode
a Keeping the service switch in ON position, 8 Cb Adjustment mode
hold the buzzer cancel switch in the [U] 9 Ld Load saving display mode
position for more than 2.5 seconds.
10 5R Real-time monitoring mode
a If the monitor panel is set in the service
mode, [1C] is displayed on gear speed 11 dR Dual display monitoring mode
display section (1).
a Each time the monitor panel is set in the 2) Selecting and executing mode to be used
service mode, “Maintenance interval Select the mode to be used with information
change mode” is displayed first. switch (5) and execute it with buzzer cancel
switch (4).
D85EX Serial No.: 11001 – 11473 q [>] : Next mode No.
D85PX Serial No.: 1201 – 11473 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).
D85EX, PX Serial No.: 11474 and up q [t]: Screen returns.
2] When finishing all operations:
Turn off the starting switch.
10 D85EX, PX-15E0
5. Maintenance interval change mode 2) Selecting and displaying maintenance item

(5-EXCHG. INTVAL. SET MODE) 1] Operate information switch (5) on the
In this mode, you can check and set the main- maintenance item selection screen to
tenance interval times of various filters and oils select a maintenance item.
which are the bases of the maintenance dis- q [>]: Next code
play function in the operator mode. q [<]: Previous code
2] Display the maintenance item selec-
1) Selecting and implementing a mode tion screen by operating buzzer can-
1] Select “Maintenance interval change cel switch (4).
mode” on the mode selection screen. q [U]: Execute item.
a If the mode is selected, code [1C]
is displayed on gear speed dis-
play section (1) and the title is
displayed on multi-information
section (2).
2] Display the maintenance item selec-
tion screen by operating buzzer can-
cel switch (4).
q [U]: Execute mode
D85EX Serial No.: 11001 – 11473
D85PX Serial No.: 1201 – 11473
3) Contents of information screen

The following items are displayed on the
information section.
1: Code
2: Maintenance item
3: Replacement interval (Set time)
a Below figure shows an example.
a If the replacement interval does not
need to be changed, finish the opera-
tion on this screen.
a If the replacement interval needs to
D85EX, PX Serial No.: 11474 and up be changed, go to step 4).
D85EX, PX-15E0 11
4) Updating replacement interval 2] If the input time is correct, enter the

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

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

Replacement interval (H)
Code Display Maintenance item 1st time 2nd time and after
(Can not be changed) (Can be changed)
01 ENG OIL Engine oil 500 500
02 ENG FILT Engine oil filter 500 500
03 FUEL FILT Fuel filter 1000 1000
04 HYD FILT Hydraulic oil filter 250 2000
06 CORR RES Corrosion resistor 1000 1000
07 DAMP OIL Damper oil 2000 2000
08 FNL OIL Final drive oil 250 1000
10 HYD OIL Hydraulic oil 250 2000
12 HSS FILT HSS charge filter — —
19 POWL OIL Power train oil 250 1000
20 POWL FILT Power train oil filter 250 500
41 F.PRE-FILT Fuel pre-filter 500 500
a The first interval time cannot be changed. If it needs to be changed for a particular reason, assume that
the first maintenance has been finished in the maintenance mode of the operator mode, then change
the 2nd and after interval times.
D85EX, PX-15E0 13
6. Electrical system failure code display mode 2) Display in case where no codes are
(6-ELEC. FAULT CODE MODE) recorded
In this mode, you can check the electrical sys- If the failure codes which occurred in the
tem failure codes among the information of the past, and the current active failure codes
troubles that occurred on the machine. do not exist, the below display will be
a Refer to the item of “Troubleshooting” for shown.
the failure code list.
1) Selecting and implementing a mode

1] Select “Electrical system failure code
display mode” on the mode selection
screen.
a If the mode is selected, code
[EE] is displayed on gear speed
display section (1) and the title is
section (2).
2] Display the failure code display
screen by operating buzzer cancel
switch (4).
q [U]: Execute mode 3) Display in case where 1 or more codes
are recorded
D85EX Serial No.: 11001 – 11473 If any failure codes which happened in the
D85PX Serial No.: 1201 – 11473 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 on service meter after
first occurrence
5] : Elapsed time on service meter after
last occurrence
a The below figure shows an example
of the display.
a Flashing and lighting of failure code

Flashing: Code of the failure which is
currently detected.
Lighting: Code of the failure which is
not currently detected.
14 D85EX, PX-15E0
a Conditions for detecting and keeping 7. Mechanical system failure code display mode
failure code (7-MACHINE FAULT CODE MODE)
When a failure is detected, the failure In this mode, you can check the mechanical
code other than comm un ication system failure codes among the information of
related or engine-related keeps flash- the troubles that occurred on the machine.
ing until the starting switch is turned a Refer to the item of “Troubleshooting” for
off. After turning the starting switch the failure code list.
OFF temporarily, if the starting switch
is turn on or the engine is started 1) Selecting and implementing a mode
again, the failure code keeps lighting 1] Select “Mechanical system failure
until the same trouble is detected. code display mode” on the mode
Communication related or engine selection screen.
related failure code is switched to the a If the mode is selected, code [bE]
lighting when the problem is solved, is displayed on gear speed dis-
even if the starting switch is not play section (1) and the title is
turned off. displayed on multi-information
section (2).
4) Operations in case that multiple codes are 2] Display the failure code display
recorded screen by operating buzzer cancel
When multiple codes are recorded, they switch (4).
can be displayed one by one by operating q [U]: Executes mode.
information switch (5).
D85EX Serial No.: 11001 – 11473
q [>]: Go to next failure code
D85PX Serial No.: 1201 – 11473
q [<]: Return to previous code
a The failure codes are displayed in the
order of their first occurrence times.
5) Method of deleting failure code

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

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

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

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

In this mode, you can adjust the control system 1] On the adjustment code input screen,
and various devices of the machine. input the 4-digit code of the item to be
adjusted by operating information
1) Selecting and implementing a mode switch (5), shift up switch (6) and shift
1] Select “Adjustment mode” on the down switch (7).
mode selection screen. q [>]: Moves cursor rightward.
a If the mode is selected, code [Cb] q [<]: Moves cursor leftward.
is displayed on gear speed dis- q [UP]: Increases number.
play section (1) and the title is q [DOWN]: Decreases number.
displayed on multi-information 2] After inputting the code, operate
section (2). buzzer cancel switch (4) to display
2] Display the adjustment code input the monitoring screen.
screen by operating buzzer cancel q [U]: Enters input mode.
switch (4).
q [U]: Executes mode.
D85EX Serial No.: 11001 – 11473
D85PX Serial No.: 1201 – 11473
a If an incorrect code is input, the

adjustment code input screen
appears again after showing the
below screen. In this case, execute
D85EX, PX Serial No.: 11474 and up the above operation again.
D85EX, PX-15E0 17
3) Contents of display on adjustment screen D85EX Serial No.: 11001 – 11473

1] : Code D85PX Serial No.: 1201 – 11473
2] : Adjustment item
3] : Related information
a For the detailed information and
adjustment procedure, see “Adjust-
ment mode table and adjustment pro-
cedure”.
4) In case of operating the machine in adjust-

ment mode, if the parking brake lever is
set in the “free” position, gear speed dis-
play section (1) returns to the normal dis-
play and the machine can be operated
normally.
a At this time, even if the shift up or shift
down switch is pressed with the
PCCS lever in the neutral position, 5) Scrolling adjustment items in order (lim-
the shift cannot be changed. ited function)
(The displayed number is the code of For some adjustment items once the
adjustment mode selection.) adjustment item is selected, they can be
To change the shift, shift the PCCS scrolled in order by the information switch
lever to the “forward” or “reverse” operation without inputting the codes
position and press the shift up or shift again.
down switch while the machine is q [>]: Next code
traveling. q [<]: Previous code
a To select another screen, return the a This function is applied only for the
parking brake lever to the “lock” posi- items which are distinguished by
tion temporarily and perform the nec- numeric character described in the
essary operation. scroll column of “Adjustment mode
table and adjustment procedure”, and
scrolled in the order of numeric char-
acter.
a Note that this operation is not
accepted while the parking brake
lever is in the released position.
a An adjustment item also can be
selected by returning to the input
screen temporarily and inputting the
code for that item.
18 D85EX, PX-15E0
Adjustment mode table and adjustment procedure

Related Disassembly Sending
No. Code Adjustment item
information and assembly in order
[1] 0001 INP TEL NO. Phone No. input mode Figure/Symbol —
Steering and transmission controller specification
[2] 0002 S/T S.CODE Code q 1
set
[3] 0004 BODY TYPE Machine specification set Code q 2
[4] 0005 BRAKE BASE Brake potentiometer zero point adjustment Voltage q 3
[5] 0007 ENG.FULL CH Engine deceleration-cut mode Speed 4
Speed
[6] 0008 INJ -> 123456 Common rail reduced cylinder mode Fuel injection —
rate
[7] 0009 PITCH SENS. Pitch angle sensor initial set Voltage q 5
FAN 70% Adjustment
[8] 0010 Fan 70% speed mode 7
MODE data
[9] 0021 KMTRX INST KOMTRAX specification set Symbol q 6
[10] 0530 STALL CHECK Stall speed check mode Speed —
FAN 100% Adjustment
[11] 1005 Fan 100% speed mode 8
MODE data
[12] 1012 S/T N-SET Steering control lever neutral set Voltage —
[13] 1013 S/T L-SET Steering control lever left set Voltage —
[14] 1014 S/T R-SET Steering control lever right set Voltage —
[15] 2222 HSS ADJUST HSS lever initial current set Current —
[16] 9997 HI IDLE SET High idle limit mode Speed —
[17] 9998 SFT INHIBIT Gear speed limit mode Symbol —
a After assembling the machine or replacing each controller, be sure to adjust the items marked with q in
the “Disassembly and assembly” column of the above table. (For the adjustment procedure, see
“Adjustment procedure after replacement of controller”.)
a The numbers in “Sending in order” column can be displayed in order by setting the information switch in
[>] or [<] position.
D85EX, PX-15E0 19
[1] 0001: Phone No. input mode 2) Check that the displayed specification
q This code inputs or changes a phone number code has changed from [4*4] to [444].
to be displayed simultaneously with when the a If specification code [444] is not displayed,
user code is displayed. the controller wiring harness or the con-
q The lower part displays a phone number and troller unit may be defective.
symbols. a Even if this code is turned off, the setting
q Available characters: 0 1 2 3 4 5 6 7 8 9 : ; < > ? is effective.
q How to use:
1) By operating information switch (5), shift
up switch (6), and shift down switch (7),
input a phone number and symbols.
q [>]: Moves cursor rightward.
q [<]: Moves cursor leftward.
q [UP]: Advance the numeric character or
character (in the order of available charac-
ters).
q [DOWN]: Reverse the numeric character
or character. (in the order of available
characters)
2) Set buzzer cancel switch (4) in the [U]
position and check that the alarm buzzer
sounds. [3] 0004: Machine specification code setting
a 16 digits of numeric characters are pro- q This code is used to have the machine specifi-
vided. To avoid confusion, input symbols cation recognized by the controllers which
other than numeric characters at digits compose the system.
you will not use. q The machine specification code is displayed
a 0 (zero) is input at all places of the lower on the lower line.
part before shipment from our factory. (No q Adjustment method:
phone number is displayed under this con- a Since this code is reset when “Steering
dition.) and transmission controller specification
a Even if this code is turned off, the setting set” is executed, adjust it after that.
is effective. 1) Select the code of the machine specifica-
tion by setting shift up switch (6).
sounds.
k If the machine specification is different
from the setting in the controller, the
machine may move abnormally or an
error may take place. Accordingly, be
sure to match the setting to the
machine specification.
a For this machine, only 000: standard speci-
fication, is set.
a Even if this code is turned off, the setting
is effective.
[2] 0002: Steering and transmission controller
model code setting
q This code is used to initialize the specification
codes recognized by the steering and trans-
mission controller and the set values of the
memory in the controller.
q The specification code is displayed on the
lower line.
q Adjustment method:
sounds.
20 D85EX, PX-15E0
No. Specification
00 Standard specification
08 (Not used)
80 Standard cold region specification
88 (Not used)
[4] 0005: Brake pedal standard value setting

q This code is used to adjust the zero point of the
potentiometer of the brake pedal.
q The deviation from the standard is displayed
by voltage on the lower line (Display range:
–2500 to 2500 mV).
With the brake pedal released, set buzzer can- [6] 0008: Common rail reduced cylinder mode
cel switch (4) in the [U] position and check a When the engine common rail system seems
that the alarm buzzer sounds. to be defective, this code is used to stop inject-
a Even if the adjustment is carried out, the ing fuel into 1 or more cylinders (reduce the
display of the lower line does not change. number of effective cylinders) while the engine
a Even if this code is turned off, the setting is running and find out a defective cylinder
is effective. from the change of the engine speed and the
a This code is not for the adjustment of the fuel injection rate.
braking performance, etc.. a Since this function diagnoses a failure based
on the differences of the engine speed and the
fuel injection rate in the reduced cylinder mode
operation from that in the normal mode opera-
tion, use this function while the engine is run-
ning.
q Engine speed (A) and fuel injection rate (B) are
displayed on the lower line.
q How to use:
Select the cylinders to be turned off for the
reduced cylinder mode operation by operating
information switch (5) and buzzer cancel
switch (4).
Use this method to turn on the selected cylin-
ders again, too.
[5] 0007: Engine deceleration-cut mode q [>]: Moves cursor rightward.
q This code is used to stop the auto-deceleration q [<]: Moves cursor leftward.
function of the engine and check the high idle q [U]: Executes or stops reduced cylinder
speed of the engine unit. mode operation.
q The engine speed is displayed on the lower
line (Display range: 0 – 3000).
q How to use:
While this code is displayed, its function is
enabled and the auto-deceleration function is
stopped.
a If this code is turned off, its function is dis-
abled.
D85EX, PX-15E0 21
a The below figure is an example that No. 2 cyl- [7] 0009: Pitch angle sensor standard value setting
inder is turned off for reduced cylinder mode q This code is used to correct the installation
operation and turned on again (The cylinder error of the pitch angle sensor by adjusting its
No. lamp is turned OFF in the reduced cylinder zero point.
mode operation and ON in the normal mode q The deviation from the standard neutral posi-
operation). tion is displayed by voltage on the lower line
(Display range: –2500 to 2500 mV).
Stop the machine on level ground, then set
buzzer cancel switch (4) in the [U] position
and check that the alarm buzzer sounds.
a Even if the adjustment is carried out, the
display of the lower line does not change.
is effective.
[8] 0010: Fan 70% mode

q This code forcedly sets the speed of cooling
fan at approximately 70% of the maximum
speed.
q The adjustment data is displayed on the lower
a Only one or more cylinders can be turned off line.
for the reduced cylinder mode operation. q How to use:
a If this code is turned off, its function is disabled. The function is effective with this code dis-
played to control the speed of cooling fan to
approximately 70% of the maximum speed.
a If this code is turned off, its function is dis-
abled.
22 D85EX, PX-15E0
[9] 0021: KOMTRAX specification set a If this code is turned off, its function is disabled.
q This code is used to select the installation set-
ting of KOMTRAX terminal.
a Conduct this setting before the starting
operation of KOMTRAX.
q The terminal installation condition is displayed
on the lower line.
q ACTIVE: KOMTRAX is installed.
q DEACTIVE: KOMTRAX is not installed.
q Setting method:
1) By operating shift up switch (6) and shift
down switch (7), select the installation
condition of KOMTRAX terminal.
2) After correctly selecting the installation
condition of the terminal, set buzzer can-
cel switch (4) in the [U] position and
[11] 1005: Fan 100% mode
check that the alarm buzzer sounds.
q This code forcedly sets the speed of cooling fan
at approximately 100% of the maximum speed.
is effective.
Also by this code, the adjustment value for the
a If the controller is changed, be sure to
maximum speed can be set.
conduct (check) this setting, too.
q The adjustment data is displayed on the lower line.
q How to use:
a The function is effective with this code dis-
played to control the speed of cooling fan
to approximately 100% of the maximum
speed.
i) When changing the adjustment value,
operate shift up switch (6) and shift down
switch (7) to set the adjustment value for
the maximum speed.
q [UP]: Adjustment value increases.
q [DOWN]: Adjustment value decreases.
ii) For confirming the adjustment value, set
buzzer cancel switch (4) in the [U] posi-
[10] 0530: Stall speed check mode tion and check that the alarm buzzer
q This code is the function to make the cooling sounds.
fan speed maximum to check the torque con- a If this code is turned off, its function is dis-
verter stall speed. abled. However, the adjustment value
k In this machine the cooling fan speed con- once set is still effective.
trol function is installed in order to protect
the radiator when the engine is not yet
warmed up enough. However, in case that
this mode is in use, the protecting function
does not work. So use the machine after
carrying out enough warming up.
q The engine speed is displayed on the lower line.
(Display range: 0 – 3000)
q How to use
While this code is displayed, its function is
enabled and the cooling fan speed becomes
maximum.
D85EX, PX-15E0 23
[12] 1012: Swing lever neutral value setting

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

tive or negative direction, the turning
radius at the start of steering is decreased
(the machine turns more quickly).
a The below figure is an example that the
set current for steering to the left is
reduced to increase the turning radius.
is effective.
D85EX, PX-15E0 25
[17] 9998: 3rd gear speed cut setting 9. Load saving display mode
q This code is used to restrict the shift to the 3rd (9-LOAD MEMORY DISPLAY MODE)
gear. In this mode, the load on the machine, forward
q The usable gear speeds are displayed by bits odometer, and reverse odometer can be
on the lower line (in the order of the 3rd, 2nd checked.
and 1st from the left).
q How to use: 1) Selecting and implementing a mode
Restrict or allow the use of the highest gear 1] Select “Load saving display mode” on
speed by operating information switch (5) and the mode selection screen.
buzzer cancel switch (4). a If the mode is selected, code [Ld]
q [>]: Restricts a shift to 3rd gear speed. is displayed on gear speed dis-
q [<]: Does not restrict shift to 3rd gear play section (1) and the title is
speed. displayed on multi-information
q [U]: Determine the setting. section (2).
q Display on lower line [o]: Gear speed is 2] Display the information screen by
effective. operating buzzer cancel switch (4).
q Display on lower line [ ]: Gear speed is q [U]: Execute mode
ineffective.
D85EX Serial No.: 11001 – 11473
a If the use of a gear speed is restricted, the
D85PX Serial No.: 1201 – 11473
transmission is not shifted to that gear
speed even if the gear shift up switch is
operated.
is effective.
2) Changing information screen

Change the information screen by operat-
ing information switch (5).
q [>]: Next screen
q [<]: Previous screen
No. Displayed information
01 1000 rpm service meter
02 Forward odometer
03 Reverse odometer
26 D85EX, PX-15E0
3) Displayed information of 1,000 rpm ser- 6) When operating machine in the load sav-
vice meter (01) ing display mode
This code is used to display the service If the parking brake lever is set in the
meter which integrates the operation “free” position, gear speed display section
hours only while the engine speed is (1) returns to the normal display and the
higher than 1,000 rpm. machine can be operated normally.
a The data cannot be reset. a At this time, even if the shift up or shift
PCCS lever in the neutral position,
the shift cannot be changed.
(The displayed number is the code of
load saving display mode.)
To change the shift, shift the PCCS
lever to the “forward” or “reverse”
position and press the shift up or shift
down switch while the machine is
traveling.
a To select another screen, return the
parking brake lever to the “lock” posi-
tion temporarily and perform the nec-
4) Displayed information of forward odome- essary operation.
ter (02) D85EX Serial No.: 11001 – 11473
On this screen, the integrated forward D85PX Serial No.: 1201 – 11473
travel distance of the machine is dis-
played.
a The data cannot be reset.
5) Displayed information of reverse odome-

ter (03)
On this screen, the integrated reverse
travel distance of the machine is dis-
played.
a The data cannot be reset.
D85EX, PX-15E0 27
10. Real-time monitoring mode 2) Selecting and entering monitored items

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

1] Select the “Real-time monitoring
mode” on the mode selection screen.
a If the mode is selected, code [5R]
section (2).
2] Display the monitoring code input
switch (4).
q [U]: Select and decide mode.
2] After inputting the code, operate
D85EX Serial No.: 11001 – 11473 buzzer cancel switch (4) to display
D85PX Serial No.: 1201 – 11473 the monitoring screen.
q [U]: Determine input.
a If the input code is correct, the
monitoring screen shown below
appears.
28 D85EX, PX-15E0
a If the input code is not correct, the code input 4) Function of holding monitoring information
screen appears again after the screen shown If a displayed information such as the
below. engine speed is not stabilized and cannot
be read easily in the monitoring mode, it
can be held and released by operating
buzzer cancel switch (4).
q [U]: Hold and release.
a While the monitored item is held, the
letter “H” is displayed at the left end of
the lower line.
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”.
D85EX, PX-15E0 29
5) When operating machine with monitoring 6) Scrolling monitoring item in order (limited
display function)
If the parking brake lever is set in the Once the monitoring screen is selected in
“free” position, gear speed display section step 2), the monitored item can be
(1) returns to the normal display and the scrolled in order by operating only infor-
machine can be operated normally. mation switch (5) without inputting the
a At this time, even if the shift up or shift code again.
down switch is pressed with the q [>]: Next code
PCCS lever in the neutral position, q [<]: Previous code
the shift cannot be changed. a This function is applied only for the
(The displayed number is the code of items which are distinguished by
monitoring mode.) numeric character described in the
To change the shift, shift the PCCS scroll column of “Monitoring mode
lever to the “forward” or “reverse” table”, and scrolled in the order of
position and press the shift up or shift numeric character.
down switch while the machine is a Note that this operation is not
traveling. accepted while the parking brake
a To select another screen, return the lever is in the “free” position.
essary operation.
D85EX Serial No.: 11001 – 11473
D85PX Serial No.: 1201 – 11473
30 D85EX, PX-15E0
Monitoring mode table

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

1: Forward clutch fill switch: ON
18300: Idle validation switch 1 of engine controller 2: Reverse clutch fill switch: ON
1: Idle validation switch: When detecting 3: 1st clutch fill switch: ON
2: (Unused) 4: 2nd clutch fill switch: ON
3: (Unused) 5: 3rd clutch fill switch: ON
4: (Unused) 6: (Unused)
7: (Unused)
8: (Unused)
D85EX, PX-15E0 35
40905: 40909:
Controller switch input 1 related to transmission Controller on/off output 2 related to transmission
1: Shift up switch: OFF 1: (Unused)
2: Shift up switch: ON 2: (Unused)
3: Shift down switch: OFF 3: (Unused)
4: Shift down switch: ON 4: Backup alarm relay: ON
5: (Unused) 5: Neutral safety relay: ON
40906: 40910: Controller switch input 1 related to steering

Controller switch input 2 related to transmission 1: (Unused)
1: Automatic shift down switch: ON 2: (Unused)
2: Fan speed reversal switch: ON 3: (Unused)
3. Fan speed selecting switch: CLN 4: (Unused)
4: (Unused) 5: Parking brake lever switch: FREE
5: (Unused) 6: Parking brake lever switch: LOCK
8: (Unused)
36 D85EX, PX-15E0
40911: Controller switch input 2 related to steering 40914: Controller on/off output 1 related to steering
1: Buzzer cancel switch: At t 1: (Unused)
2: Buzzer cancel switch: At U 2: (Unused)
3: Information switch: At > 3: Fan reverse solenoid: ON
4: Information switch: At < 4: (Unused)
5: Service switch: ON 5: Battery relay drive: ON
40913: Controller switch input 5 related to steering 40915: Controller on/off output 2 related to steering
1: ACC signal: ON 1: (Unused)
2: (Unused) 2: Engine ACC cut relay drive: ON (*)
3: R signal: ON 3: (Unused)
5: Fan speed selecting switch: COLD position (*) 5: (Unused)
6: Fan speed selecting switch: CLN position 6: (Unused)
*: 5 is only in case that OPT is equipped. *: 2 is only in case that OPT is equipped.
D85EX, PX-15E0 37
43502: Cancel flag of warming up 11. Dual display monitoring mode

1: Cancel flag of warming up: ON (11-DUAL DISPLAY MONITORING MODE)
2: (Unused) In this mode, 2 monitored items can be dis-
3: (Unused) played simultaneously.
4: (Unused) a Note that only codes and monitoring infor-
5: (Unused) mation are displayed in this mode since
6: (Unused) the available display columns are limited.
7: (Unused) (Check item names and units cannot be
8: (Unused) displayed.)

1] Select the “Dual display monitoring
mode” on the mode selection screen.
a If the mode is selected, code [dR]
section (2).
2] Display the monitoring code input
switch (4).
q [U]: Execute mode
D85EX Serial No.: 11001 – 11473
60400: Controller switch input 6 related to steering D85PX Serial No.: 1201 – 11473
1: (Unused)
2: (Unused)
3: (Unused)
4: Engine ACC cut signal: ON (*)
5: (Unused)
6: (Unused)
7: (Unused)
8: (Unused)
*: 4 is only in case that OPT is equipped.
38 D85EX, PX-15E0
2) Selecting and entering monitored items a If the input codes are not correct, the code
1] On the code input screen, input the 5- input screen appears again after the screen
digits codes of the items to be moni- shown below.
tored by operating information switch
(5), shift up switch (6), and shift down
switch (7).
q [>]: Cursor moves rightward.
q [<]: Cursor moves leftward.
q [UP]: Number increases.
q [DOWN]: Number decreases.
2] After inputting the code, operate
buzzer cancel switch (4) to display
the monitoring screen.
q [U]: Determine input.
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”.
a If the input codes are correct, the

monitoring screen shown below
appears.
D85EX, PX-15E0 39
4) In case of operating the machine in moni-

toring mode, if the parking brake lever is
set in the “free” position, gear speed dis-
play section (1) returns to the normal dis-
play and the machine can be operated
normally.
a At this time, even if the shift up or shift
PCCS lever in the neutral position,
the shift cannot be changed.
(The displayed number is the code of
monitoring mode.)
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
essary operation.
D85EX Serial No.: 11001 – 11473
D85PX Serial No.: 1201 – 11473
40 D85EX, PX-15E0
D85EX, PX-15E0 41
SEN00631-03

© 2010 KOMATSU
All Rights Reserved
42

D85EX-15E0 and Additional Models (JPN) EU SN 11001-UP

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D85EX-15E0 and Additional Models (JPN) EU SN 11001-UP

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SEN00060-06

BULLDOZER D85EX -15E0

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title ............................................................................................................................Form Number

00 Index and foreword ......................................................................................................... SEN00061-06

10 Structure, function and maintenance standard ............................................................... SEN00063-02

20 Standard value table ....................................................................................................... SEN00064-02

30 Testing and adjusting ...................................................................................................... SEN00065-04

40 Troubleshooting .............................................................................................................. SEN00066-02

Troubleshooting of hydraulic and mechanical system (H-mode) .................................... SEN00639-00

50 Disassembly and assembly ............................................................................................ SEN00067-02

90 Diagrams and drawings .................................................................................................. SEN00068-03

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

Testing compression pressure ................................................................................................. 17

Troubleshooting by failure code (Display of code), Part 1 .............................................. SEN00634-01

Failure code [CA331] Injector No. 2 system disconnection or short circuit:

Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor:

50 Disassembly and assembly

Engine and cooling system, Part 1 ................................................................................. SEN01264-01

Cab and its attachments ................................................................................................. SEN01272-01

90 Diagrams and drawings

D85EX, PX-15E0 Bulldozer

BULLDOZER 1SHOP MANUAL

Machine model Serial number

30 Testing and adjusting 1

Bleeding air from fuel circuit.......................................................................................................................... 28

Tools for testing, adjusting, and troubleshooting 1

Air boost pressure

799-101-5002 Hydraulic tester 1

795-799-5540 • Socket 1 Boost temperature sensor

(*1) Engine serial No.: 560001 – 564999

Sketche of special tool

Testing engine speed 1

D85EX, PX Serial No.: 11474 and up

D85EX, PX Serial No.: 11474 and up

4. Measuring decelerator pedal speed

6. Measuring torque converter stall + work

7) Repeat above steps 2) – 6) 3 times.

6. After finishing measurement, remove the mea-

a The boost pressure can be measured in the

D85EX, PX Serial No.: 11474 and up

Testing exhaust temperature 1 4. Procedure for measuring the maximum value

1. Open the right inspection cover of the engine

5. Procedure for measuring periodically for pre-

2) Stop only relieving the blade tilt and lower

6. After finishing measurement, remove the mea-

Testing exhaust gas color 1

Symbol Part No. Part name

k When installing and removing the measur-

5) Remove the filter paper and compare it 6) Start the engine.

Adjusting valve clearance 1 4. Rotate the crankshaft forward, align of damper

3. Remove all cylinder head cover (3).

5. While the No.1 cylinder is at the compression

6. To adjust the valve clearance, insert clearance

7. While holding adjustment screw (6), tighten

q After finishing the adjustment of all the

8. While the No. 6 cylinder is at the compression

9. It also can be done by rotating the crankshaft

10. After finishing adjustment, set to the original