🏷️ Basic Information Identification Make: Komatsu Model: HD785-3 / HD985-3 Vehicle Type: Large Mining Dump Truck Product Type: Service Repair Manual Codes Komatsu Model Code Hd785: HD785-3 Komatsu Model Code Hd985: HD985-3 👋 Introduction Market Position Komatsu Market Segment: Heavy-duty mining and construction equipment, specializing in large capacity dump trucks. Competitive Analysis Key Competitors: Caterpillar (e.g., 777 series), Liebherr (e.g., T 264), Hitachi Construction Machinery (e.g., EH3500 series), BelAZ. Key Features Hd785 Hd985 Design Philosophy: Designed for high payload capacity, exceptional durability, reliability in harsh mining environments, and operator comfort/safety. 📋 Manual Details Coverage Areas Applicable Serial Numbers Hd785: 2001 onwards Applicable Serial Numbers Hd985: 1001 onwards Page Count Estimated Pages: Extensive (Typically 1000+ pages for comprehensive service manuals of this type) Manual Type Manual Classification: Service Repair Manual Language Primary Language: English Format Delivery Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, liners, piston rings, lubrication system, cooling system, fuel system, intake and exhaust systems, engine control system (ECU/ECM), troubleshooting, maintenance, overhaul procedures. Powertrain Systems: Transmission (Torque converter, transmission control, planetary gear sets, clutches, brakes), drive shafts, differentials, final drives, hydraulic pumps and motors for propulsion, steering system hydraulics, retarder system. Braking Systems: Service brakes (hydraulic and/or pneumatic), parking brake, retarder brake system, brake actuation, hydraulic circuits, components (calipers, discs, drums), bleeding procedures, troubleshooting. Hydraulic Systems: Hoist system (cylinder, control valve, pump, tank), steering system hydraulics, brake system hydraulics, implement hydraulics, hydraulic pump identification and specifications, hydraulic circuit diagrams, troubleshooting and repair. Electrical Systems: Starting system, charging system, battery, alternator, starter motor, lighting system, indicators, instrumentation, sensors, actuators, wiring diagrams, fuses, relays, diagnostic connector, electrical troubleshooting. Chassis And Suspension: Frame, front and rear axles, suspension components (e.g., trailing arms, shock absorbers, springs or hydropneumatic suspension), wheel bearings, hub assemblies, steering linkage, geometry specifications. Body And Cab: Operator's cab structure, interior components, seats, HVAC system (if applicable), access panels, guards, dump body construction, tailgate (if applicable), lubrication points. Procedures Included Routine Maintenance: Oil change intervals, filter replacement (oil, fuel, hydraulic, air), lubrication schedules, inspection points, component checks. Diagnostic Procedures: Troubleshooting guides based on symptoms, diagnostic codes (DTCs), fault finding charts, pressure testing, electrical diagnostics. Repair And Overhaul: Step-by-step disassembly and reassembly instructions for major components and systems, torque specifications for fasteners, seal replacement, bearing replacement, component testing and adjustment. Special Tool Requirements: Identification of specific tools or equipment required for certain maintenance and repair tasks. Technical Depth Diagnostic Capability: Advanced diagnostics including system checks, sensor data analysis, and component testing. Repair Scope: Comprehensive repair procedures from minor adjustments to major component overhauls. Information Detail Level: Detailed technical specifications, schematics (hydraulic, electrical), diagrams, and procedural steps. 📊 Manual Specifications File Format Document Format: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Image Resolution: High-resolution, suitable for clear viewing of diagrams and text. Binding Type Digital Binding: N/A (Digital document) Paper Type Digital Paper Emulation: N/A (Digital document) ⚙️ Engine Specifications Primary Engine Engine Model Hd785: Komatsu SAA6D140E-5 (or similar Cummins/Komatsu variants depending on exact configuration and market) Engine Type: Diesel, Turbocharged, Intercooled, Direct Injection Performance Engine Displacement Hd785: Approx. 15.24 Liters Net Power Hd785: Approx. 523 HP (385 kW) @ 2000 RPM (Note: Exact spec varies by engine variant) Gross Power Hd785: Approx. 572 HP (420 kW) @ 2000 RPM (Note: Exact spec varies by engine variant) Peak Torque Hd785: Approx. 1600-1800 lb-ft (2170-2440 Nm) (Note: Exact spec varies by engine variant) Fuel System Fuel Injection Type: Common Rail Direct Injection (CRDI) or similar advanced electronic control system. Fuel Type: Diesel 🔧 Transmission Standard Transmission Type: Komatsu Traction System (KTS) - Planetary gear type, electronically controlled automatic transmission. Number Of Gears: Typically 6 forward and 1 reverse, or similar optimized for mining duty cycles. Features Transmission Control: Electronic control unit (ECU) for optimized shifting, load sensing, and grade logic. Retarder System: Integrated engine retarder and/or transmission retarder for downhill speed control. 📐 Dimensions Exterior Overall Length Hd785: Approx. 9.9 meters (32.5 ft) Overall Width Hd785: Approx. 4.5 meters (14.8 ft) Overall Height Hd785: Approx. 4.5 meters (14.8 ft) (to top of cab) Cargo Body Capacity Hd785 Heaped: Approx. 47.5 m³ (62 yd³) Weights Operating Weight Hd785: Approx. 53,000 - 55,000 kg (116,845 - 121,255 lbs) Payload Capacity Hd785: Approx. 73,000 kg (80.5 US tons) 🛡️ Safety Features Ratings Operator Visibility: Designed for good visibility from the cab, with mirrors and optional camera systems. Active Features Braking System Safety: Dual-circuit hydraulic braking system, automatic brake adjustment, emergency/parking brake. Retarder Control: Essential for safe operation on inclines. Passive Features Operator Cab Protection: ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) compliant cab. Fire Suppression Options: Often available with factory-installed or optional automatic fire suppression systems. 💡 Technology Features Infotainment Cab Features: Modern operator cabins with ergonomic controls,...