🏷️ Basic Information Identification Make: Komatsu Model: HD785-7 Product Type: Service Repair Manual + Field Assembly Manual + Operation & Maintenance Manual 👋 Introduction Market Position Market Segment: Large capacity rigid frame dump trucks for mining, quarrying, and heavy construction Competitive Analysis Competitors: Caterpillar 777 series, Hitachi EH3500AC series, Liebherr T 264 Key Features Payload Capacity: Approximately 107 tonnes (118 US tons) Dump Body Design: Designed for high payload and efficient dumping in demanding environments Operator Comfort: Ergonomic operator station with advanced control systems 📋 Manual Details Coverage Areas Primary Coverage: Komatsu HD785-7 Dump Truck Additional Coverage: Field Assembly Procedures Page Count Service Repair Manual Estimated Pages: 800+ Operation Maintenance Manual Estimated Pages: 250+ Field Assembly Manual Estimated Pages: 150+ Manual Type Type 1: Service Repair Manual Type 2: Operation & Maintenance Manual Type 3: Field Assembly Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Torque Converter, Final Drives, Differentials Hydraulics: Steering, Hoist, Brake, Cooling Fan Hydraulic Systems Electrical: Starter, Alternator, Battery, Lighting, Gauges, Sensors, Control Systems (ECMS) Chassis And Body: Frame, Suspension, Steering Linkage, Hoist Cylinder, Dump Body, Cab, Operator Station Braking System: Service Brakes (Wet Multi-Disc), Parking/Secondary Brakes, Retardation Systems Cooling System: Radiator, Fan, Water Pump, Thermostat, Coolant Specifications Lubrication System: Engine Oil, Transmission Oil, Hydraulic Oil, Grease Points Steering System: Hydrostatic power steering system, steering cylinder, linkage components Suspension System: Front and rear suspension system (gas-oil suspension cylinders), kingpins, knuckle components Hoist System: Hydraulic hoist cylinder, pump, control valve, oil tank, hydraulic lines Procedures Included Diagnostics: Troubleshooting charts, fault code analysis, diagnostic flowcharts Maintenance: Scheduled maintenance, fluid changes, filter replacement, lubrication Repair: Component disassembly, inspection, repair, reassembly, and adjustment procedures Assembly Disassembly: Detailed steps for major component removal and installation Torque Specifications: Critical fastener torque values for all major assemblies Special Tools: Identification and usage of required special service tools Technical Depth Depth: Comprehensive; covers routine maintenance to major overhaul and system diagnostics 📊 Manual Specifications File Format Searchability: Searchable text within PDF files Resolution: High-resolution images and diagrams for clarity File Size Estimate: Variable, likely exceeding 500MB due to comprehensive nature and detailed diagrams. Print Quality Print Compatibility: Printable pages for on-site reference Binding Type Binding Type Physical: Not Applicable (Digital Format) Paper Type Paper Type Physical: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Manufacturer: Cummins Model: QSK60-C Type: Tier 3 Certified, 4-stroke, turbocharged, aftercooled, V16 diesel engine Performance Gross Horsepower: 540 kW (724 hp) @ 1800 rpm Peak Torque: 3153 Nm (2325 lb-ft) @ 1500 rpm Bore X Stroke: 159 mm x 159 mm (6.26 in x 6.26 in) Displacement: 15.98 L (975 cu. in.) Fuel System Injection System: Cummins PT (Pressure-Time) Fuel System with Electronic Control Fuel Type: Diesel fuel conforming to ASTM D975 Grade No. 2-D 🔧 Transmission Standard Type: Komatsu heavy-duty, electronically controlled, planetary gear type automatic transmission Number Of Gears: 6 forward speeds, 1 reverse speed Features Shift Control: ProShift technology for optimized shift points and fuel efficiency Transmission Oil Type: Komatsu Genuine Transmission Oil (KTO) or approved equivalent 📐 Dimensions Exterior Overall Length: Approx. 9,400 mm (30 ft 10 in) Overall Width: Approx. 4,100 mm (13 ft 5 in) Overall Height: Approx. 4,560 mm (15 ft 0 in) Wheelbase: 4,350 mm (14 ft 3 in) Ground Clearance: Approx. 595 mm (1 ft 11 in) Cargo Body Capacity Heaped: Approx. 47.2 m³ (61.7 cu. yd.) Body Capacity Struck: Approx. 35.7 m³ (46.7 cu. yd.) Weights Operating Weight: Approx. 76,000 kg (167,550 lb) Payload Capacity: Approx. 107,000 kg (235,900 lb) Gross Vehicle Weight: Approx. 183,000 kg (403,450 lb) 🛡️ Safety Features Ratings Nacap Rating: Designed to meet applicable industry safety standards; specific rating not typically provided in manual Active Features Braking System: Full hydraulic braking system with fail-safe parking brake Retardation: Integrated retarder system for controlled downhill speed Visibility: Large cab windows, optimized lighting, optional rearview camera system integration Passive Features Operator Station Protection: ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) compliant cab Seatbelts: Operator seatbelt (3-point) Fire Suppression Readiness: Provisions for optional fire suppression systems 💡 Technology Features Infotainment Operator Interface: Advanced diagnostic displays and controls within the operator cab Driver Assistance Payload Monitoring: Integrated payload meter (PLM) for accurate load management Engine Management: Komatsu Electronic Control System (KECS) for optimized engine and powertrain performance Connectivity Telematics Readiness: Provisions for Komtrax remote monitoring system (data on machine hours, location, fuel consumption, etc.) 🔧 Maintenance Service Intervals Engine Oil And Filter Change: Refer to O&M Manual; typically every 250-500 operating hours depending on application and oil analysis. Transmission Oil Change: Refer to O&M Manual; typically every 1000-2000 operating hours, subject to oil analysis. Hydraulic Oil Change: Refer to O&M Manual; typically every 1000-2000 operating hours, subject to oil analysis. Air Filter Service: Service as indicated by air cleaner restriction...