🏷️ Basic Information Identification Make: Komatsu Model: HD785-5LC Product Type: Factory Service Repair Manual 👋 Introduction Market Position Market Segment: Heavy-duty off-highway mining and construction haul trucks. Competitive Analysis Key Competitors: Caterpillar (e.g., 777 series), Hitachi (e.g., EH3500 series), Liebherr (e.g., T 284), BelAZ. Key Features Vehicle Type: Large capacity rigid frame dump truck designed for high-volume material transport in mining, quarrying, and large construction projects. Payload Capacity: Approximately 41 metric tons (90,400 lbs) payload capacity (specific to LC designation). Operational Focus: Durability, reliability, operator comfort, and efficient payload delivery in demanding environments. 📋 Manual Details Coverage Areas Coverage Description: Comprehensive service and repair information for the Komatsu HD785-5LC Dump Truck. Page Count Estimated Page Count: High volume (typical for heavy equipment service manuals, often 1000+ pages) Manual Type Manual Type: Factory Service Repair Manual Language Language: Likely English (based on common industry practice for this equipment, but confirmation might be needed for specific editions) Format Format: Digital (e.g., PDF, likely with searchable text and high-resolution diagrams) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, overhaul procedures, component testing, cooling system, lubrication system, fuel system, air intake and exhaust system. Transmission: Automatic power shift transmission (e.g., Komatsu proprietary, Allison), troubleshooting, overhaul, torque converter, hydraulic control system, cooler circuits. Powertrain: Driveline components, including differentials, final drives, drive shafts, and propeller shafts. Braking System: Service brakes (wet disk type), parking brake, retarder system, hydraulic brake circuits, component testing, adjustments, and replacement. Steering System: Hydraulic power steering, steering control valve, steering cylinders, hydraulic pump, troubleshooting. Electrical System: Starter motor, alternator, battery system, lighting system, instrument panel, sensors, wiring diagrams, troubleshooting of electrical faults. Chassis And Frame: Frame inspection, structural integrity, suspension components, and mounting points. Operator Station: Cab structure, seating, controls, HVAC system (if applicable), instrumentation. Body And Attachments: Dump body construction, lifting and lowering mechanisms, any factory-fitted accessories. Hydraulic System Hoist System: Hoist cylinders, control valve, hydraulic pump, reservoir, troubleshooting, repair, and bleeding procedures. Auxiliary Hydraulics: Any ancillary hydraulic systems for attachments or functions. Procedures Included Preventive Maintenance: Lubrication charts, filter replacement schedules, fluid level checks, general inspections. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and complex faults. Disassembly And Assembly: Step-by-step instructions for component removal, repair, and reinstallation. Component Testing: Procedures for testing the functionality and performance of individual components (e.g., hydraulic pumps, injectors, solenoids). Adjustments And Calibrations: Procedures for setting clearances, pressures, and calibrating electronic systems. Overhaul And Rebuild: Detailed instructions for complete rebuilding of major components like engines, transmissions, and hydraulic cylinders. Special Tools And Equipment: Identification and usage instructions for specialized tools required for specific repair tasks. Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission overhauls. Includes detailed diagnostic flowcharts and schematics. 📊 Manual Specifications File Format File Format: Likely PDF with optimized resolution for clarity of diagrams and text. Print Quality Diagram Quality: High-resolution, vector-based or high-quality raster images for clear technical diagrams and schematics. Searchability Text Searchability: Searchable text fields allowing for quick location of specific terms, part numbers, or procedures. Navigation Navigation Features: Likely includes a table of contents with hyperlinks for easy navigation between sections and chapters. ⚙️ Engine Specifications Primary Engine Engine Model: Komatsu SAA6D140E-5 (or similar Tier II/III compliant engine) Performance Gross Horsepower: Approx. 517 HP (385 kW) at rated speed (e.g., 1800 RPM). Peak Torque: Significant torque output for hauling heavy loads, specific figures vary by engine tuning. Fuel System Fuel Type: Diesel Injection System: Common rail direct injection or HEUI (Hydraulically Actuated Electronically Controlled Unit Injector) system. Cooling System Cooling Type: Water-cooled, high-capacity radiator with fan. Emissions Emissions Standard: Likely meets EPA Tier II or Tier III emission standards for off-highway engines, depending on manufacturing region and year. 🔧 Transmission Standard Transmission Type: Komatsu heavy-duty automatic power shift transmission (e.g., KTSS series) with electronic shift control. Number Of Speeds: Typically 6 forward and 1 reverse speed. Features Control System: Electronic control unit (ECU) for optimized shift points, torque converter lock-up for efficiency. Fluid Requirements Transmission Fluid Type: Komatsu genuine transmission oil or equivalent approved fluid (e.g., CAT TO-4 or equivalent specification). 📐 Dimensions Exterior Overall Length: Approx. 10.7 meters (35 ft 1 in). Overall Width: Approx. 3.7 meters (12 ft 2 in). Overall Height: Approx. 4.1 meters (13 ft 5 in). Weights Operating Weight: Approx. 75,000 kg (165,350 lbs). Payload Capacity: Approx. 41,000 kg (90,400 lbs). Cargo Body Capacity Heaped: Approx. 24.5 cubic meters (32.1 cubic yards). Body Capacity Struck: Approx. 19.4 cubic meters (25.4 cubic yards). 🛡️ Safety Features Ratings Rol Protection: ROPS (Roll-Over Protective Structure) certified cab. Fops Protection: FOPS (Falling Object Protective Structure) certified cab. Active Features Braking System Type: Full hydraulic, dual-circuit, oil-immersed, multi-disc brakes on all wheels with automatic brake actuation for parking brake. Retarder System: Integrated engine retarder and transmission retarder for downhill speed control. Passive Features...