🏷️ Basic Information Identification Make: Komatsu Model: HD785-5LC Vehicle Type: Heavy-Duty Mining Dump Truck Codes Chassis Model Code: HD785-5LC 👋 Introduction Market Position Segment: Large capacity rigid frame mining dump truck Application: Open-pit mining, large-scale construction, quarrying Competitive Analysis Competitors: Caterpillar 777 series, Liebherr T 264, Volvo A35G/A40G (though smaller capacity) Key Features Payload Capacity: Approximately 42-45 metric tons (93,000 - 100,000 lbs) Body Design: High-tensile strength steel construction, optimized payload distribution Operator Comfort: Ergonomic cab, advanced climate control, suspension seat 📋 Manual Details Coverage Areas Primary Coverage: Workshop service and repair for the Komatsu HD785-5LC Dump Truck Secondary Coverage: Maintenance, diagnostics, troubleshooting, and component overhauls Page Count Estimated Page Count: Refer to actual manual; typically 1000+ pages for this class of vehicle Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English (Primary, based on product description) Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, torque converter, driveline, differentials, final drives Hydraulics: Hoisting system, steering system, braking system, cooling system, lubrication system Electrical Electronics: Starting and charging system, engine control unit (ECU), transmission control unit (TCU), instrument panel, lighting, sensors, wiring diagrams Chassis Frame: Frame construction, front and rear suspension, steering linkage, braking system (service and parking), wheels and tires Bodywork Operator Station: Cab structure, operator controls, seating, HVAC, payload meter Procedures Included Maintenance: Scheduled maintenance, fluid checks and changes, filter replacements, lubrication points, component inspections Troubleshooting: Diagnostic flowcharts, fault code interpretation, symptom-based troubleshooting for all major systems Repair Overhaul: Step-by-step disassembly, assembly, and overhaul procedures for major components (engine, transmission, hydraulic pumps, cylinders, etc.) Diagnostics: Diagnostic testing procedures, use of diagnostic tools, parameter checks, sensor calibration Technical Depth Depth: Comprehensive from basic maintenance to full component rebuilds and advanced diagnostics 📊 Manual Specifications File Format PDF Quality: High-resolution, searchable text, printable pages Print Quality Print Readability: Designed for clear reproduction when printed Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Model: Komatsu SAA6D140E-5 (Turbocharged and aftercooled) Engine Type: Diesel, 4-stroke, direct injection, water-cooled Displacement: 15.24 liters (930 cubic inches) Performance Net Horsepower: Approx. 517 HP (385 kW) @ 2000 RPM (Subject to specific configuration) Peak Torque: Approx. 1,464 lb-ft (1,985 Nm) @ 1400 RPM (Subject to specific configuration) Fuel System Fuel System Type: Common Rail Electronic Fuel Injection Fuel Type: API CJ-4 or ACEA E9 compliant Diesel Fuel 🔧 Transmission Standard Transmission Type: Komatsu Heavy-Duty Automatic Transmission Gear Selection: Electronically controlled, 6 speeds forward, 1 reverse (typical for this class) Features Torque Converter: Lock-up type, with automatic retarder control Cooling: External transmission oil cooler integrated with chassis cooling system 📐 Dimensions Exterior Length Overall: Approx. 9.5 - 10.0 meters (31.2 - 32.8 ft) Width Overall: Approx. 3.7 - 4.0 meters (12.1 - 13.1 ft) Height Overall Ground To Cab: Approx. 3.8 - 4.0 meters (12.5 - 13.1 ft) Height Overall Dumped: Approx. 7.5 - 8.0 meters (24.6 - 26.2 ft) Cargo Body Capacity Struck: Approx. 24 - 26 cubic meters (31 - 34 cubic yards) Body Capacity Heaped: Approx. 32 - 35 cubic meters (42 - 46 cubic yards) Weights Operating Weight: Approx. 60 - 65 metric tons (132,000 - 143,000 lbs) Payload Capacity: Approx. 42 - 45 metric tons (93,000 - 100,000 lbs) Gross Vehicle Weight: Approx. 102 - 110 metric tons (225,000 - 243,000 lbs) 🛡️ Safety Features Ratings Rollover Protection: ROPS (Roll-Over Protective Structure) certified cab Falling Object Protection: FOPS (Falling Object Protective Structure) certified cab Active Features Braking System: Full hydraulic, oil-immersed, multiple-disc brakes (front and rear axle); fail-safe parking brake Retarder System: Automatic transmission retarder and auxiliary hydraulic retarder for downhill control Visibility: Large tinted windows, optional rearview camera system Passive Features Cab Design: Reinforced safety cab structure Seatbelts: Operator seatbelt 💡 Technology Features Infotainment System: Not applicable in the traditional automotive sense; functionality focuses on operational data and diagnostics. Driver Assistance Features: Payload meter, automatic transmission control, advanced braking and retarder systems. Connectivity Telematics: May include Komatsu's KOMTRAX system for remote monitoring of machine health, location, and operating data (depending on factory installation). 🔧 Maintenance Service Intervals Engine Oil Change: Typically every 500 operating hours (refer to manual for exact specification) Hydraulic Oil Change: Typically every 2000 operating hours or as indicated by oil analysis Transmission Oil Change: Typically every 1000 operating hours or as indicated by oil analysis Fluid Specifications Engine Oil Type: Komatsu’s recommended engine oil, typically SAE 15W-40 API CK-4/CJ-4, or equivalent Hydraulic Oil Type: Komatsu Hydraulic Oil (or equivalent ISO VG 46 or 32, depending on application and temperature) Transmission Oil Type: Komatsu Transmission Oil (or equivalent DEXRON III/Allison C-4 equivalent) Coolant Type: Komatsu Super Long Life Coolant (SLLC) or equivalent ethylene glycol based coolant with necessary additives Known Issues Common Wear Items: Brake disc wear, hydraulic cylinder seals, articulation pin...