Komatsu D85ESS-3 Bulldozer Operation and Maintenance Manual (PEN00706-04)

On a D85ESS-3 that spends its life pushing fill, ripping hard ground, or building haul roads, this Operation and Maintenance Manual is what I use to keep the machine predictable and available. It lays out a sensible rhythm for daily and scheduled checks so you can spot loose hardware, track wear, or cooling issues before they park the dozer in the cut. If an operator reports the blade won’t hold grade or the machine is running hotter than usual, I lean on this book to trace the problem step by step and verify the basics are right before we start swapping parts.

Applications & Use Cases

Set up a daily walkaround so operators inspect undercarriage, blade gear, and leaks the same way every shift.
Plan service intervals to align with your job schedule, minimizing downtime and surprise stoppages.
Trace early wear signs in tracks, rollers, and cutting edges and decide when to rotate or replace.
Verify adjustment points on controls and linkages after repairs or hard impacts.
Train new operators on proper warm-up, shutdown, and load limits to avoid abuse-related failures.

FAQ

Q: Can I keep a digital copy on a tablet in the field?

A: Yes, it’s practical to use a digital copy for quick searching; just keep a clean printed copy in the shop for greasy hands.

Q: Is this manual enough for major overhauls?

A: It’s mainly for operation and routine service; for deep rebuilds you’d pair it with a dedicated service or shop manual.

Safety Note

Always follow the manual’s lockout, support, and engine shutdown steps before you inspect, test, or adjust anything on the dozer.

📘 Show Index

Komatsu D85ESS-3 Bulldozer Index:

CONTENTS
FOREWORD 1- 1
READ THIS MANUAL 1- 2
IMPORTANT SAFETY INFORMATION 1- 4
INTENDED USE 1- 5
USE OF MACHINE 1- 5
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE 1- 5
VISIBILITY FROM OPERATOR’S SEAT 1- 6
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 7
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE 1- 7
ENGINE SERIAL NO. PLATE POSITION 1- 7
SERVICE METER POSITION 1- 8
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR 1- 8
SAFETY 2- 1
SAFETY 2- 2
SAFETY LABELS 2- 5
POSITIONS OF SAFETY PICTOGRAMS 2- 5
SAFETY LABELS 2- 6
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE 2- 10
PRECAUTIONS BEFORE STARTING OPERATION 2- 10
PREPARATIONS FOR SAFE OPERATION 2- 10
FIRE PREVENTION 2- 12
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE 2- 13
DO NOT GET CAUGHT IN WORK EQUIPMENT 2- 15
UNAUTHORIZED MODIFICATION 2- 15
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS 2- 15
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING 2- 15
PRECAUTIONS FOR OPERATION 2- 16
PRECAUTIONS FOR JOBSITE 2- 16
STARTING ENGINE 2- 19
OPERATION 2- 22
TRANSPORTATION 2- 26
TOWING 2- 27
PRECAUTIONS FOR MAINTENANCE 2- 28
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE 2- 28
PRECAUTIONS FOR INSPECTION AND MAINTENANCE 2- 32
OPERATION 3- 1
GENERAL VIEW 3- 2
GENERAL VIEW OF MACHINE 3- 2
GENERAL VIEW OF CONTROLS AND GAUGES 3- 3
EXPLANATION OF COMPONENTS 3- 5
FRONT PANEL 3- 5
SWITCHES 3- 32
CONTROL LEVERS AND PEDALS 3- 33
FUSE 3- 39
FUSIBLE LINK 3- 40
ELECTRIC POWER TAKE-OUT ADAPTER 3- 40
OIL FILLER CAP 3- 41
TOOL BOX 3- 42
KOMTRAX 3-

OPERATION 3- 44
CHECK BEFORE STARTING ENGINE, ADJUST 3- 44
STARTING ENGINE 3- 61
OPERATIONS AND CHECKS AFTER STARTING ENGINE 3- 67
STOPPING ENGINE 3- 71
MACHINE OPERATION 3- 72
SHIFTING GEARS 3- 75
SHIFTING BETWEEN FORWARD AND REVERSE 3- 76
STEERING MACHINE 3- 78
PRECAUTIONS FOR OPERATION 3- 82
WORK POSSIBLE USING BULLDOZER 3- 84
RECOMMENDED MODE FOR EACH TYPE OF OPERATION 3- 86
ADJUSTING POSTURE OF WORK EQUIPMENT 3- 87
PARKING MACHINE 3- 94
CHECK AFTER FINISHING WORK 3- 95
LOCKING 3- 96
TIPS FOR LONGER UNDERCARRIAGE LIFE 3- 97
TRANSPORTATION 3-100
TRANSPORTATION MEANS 3-100
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT 3-100
LOADING, UNLOADING WORK 3-101
LIFTING MACHINE 3-105
TRAVELING ON ROADS 3-106
COLD WEATHER OPERATION 3-107
PRECAUTIONS FOR LOW TEMPERATURE 3-107
AFTER COMPLETION OF WORK 3-108
AFTER COLD WEATHER 3-108
LONG-TERM STORAGE 3-109
BEFORE STORAGE 3-109
DURING STORAGE 3-109
AFTER STORAGE 3-109
STARTING MACHINE AFTER LONG-TERM STORAGE 3-109
TROUBLESHOOTING 3-110
AFTER RUNNING OUT OF FUEL 3-110
METHOD OF TOWING MACHINE 3-111
IF BATTERY IS DISCHARGED 3-112
OTHER TROUBLE 3-116
MAINTENANCE 4- 1
GUIDE TO MAINTENANCE 4- 2
OUTLINE OF SERVICE 4- 5
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC 4- 5
BATTERY TERMINAL 4- 10
RELATING TO ELECTRIC SYSTEM 4- 10
HANDLING HYDRAULIC SYSTEM 4- 11
WEAR PARTS LIST 4- 12
WEAR PARTS LIST 4- 12
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 4- 13
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 4- 14
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN
KOMATSU GENUINE OIL 4- 16

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS 4- 17
TORQUE LIST 4- 17
DEFINED LIFE PARTS 4- 18
DEFINED LIFE PARTS LIST 4- 18
MAINTENANCE SCHEDULE CHART 4- 20
MAINTENANCE SCHEDULE CHART 4- 20
SERVICE PROCEDURE 4- 22
WHEN REQUIRED 4- 22
CHECK BEFORE STARTING 4- 50
EVERY 50 HOURS SERVICE 4- 51
EVERY 250 HOURS SERVICE 4- 52
EVERY 500 HOURS SERVICE 4- 61
EVERY 1000 HOURS SERVICE 4- 66
EVERY 2000 HOURS SERVICE 4- 75
EVERY 4000 HOURS SERVICE 4- 83
EVERY 8000 HOURS SERVICE 4- 87
SPECIFICATIONS 5- 1
SPECIFICATIONS 5- 2
ATTACHMENTS, OPTIONS 6- 1
GENERAL PRECAUTIONS 6- 2
PRECAUTIONS RELATED TO SAFETY 6- 2
HANDLING TOWING WINCH 6- 3
EXPLANATION OF COMPONENTS 6- 3
OPERATION 6- 4
SERVICE PROCEDURE 6- 9
SPECIFICATIONS 6- 10
INDEX 7- 1