Komatsu HD785-7 Dump Truck Parts Book FEN00222-01-N1-00 – Serial N10001-N10560 Engine SAA12V140E-3B-02 PDF Catalog

Description

The Komatsu HD785-7 Dump Truck Parts Book FEN00222-01-N1-00 is the illustrated parts catalog for HD785-7 dump trucks built in serial range N10001 through N10560, fitted with the SAA12V140E-3B-02 engine from engine serial number 50013 and up. Every assembly on the machine is broken down into its individual components, with the figure number, index number, part number, description, required quantity and the applicable engine or machine serial printed beside the exploded illustration, so a part can be traced from the drawing straight to the order line. Whether the truck is working in the pit, sitting in the workshop or going through a scheduled component replacement, this is the reference that tells you which piece belongs to which group and which serial number break it applies to.

File Details

• Manual type: Illustrated Parts Book (Parts Catalog)
• Document number: FEN00222-01-N1-00
• Machine: Komatsu HD785-7 Dump Truck
• Machine serial range: N10001 – N10560
• Engine: SAA12V140E-3B-02
• Applicable engine serial: 50013 and up
• Language: English
• Format: PDF
• Page count: 1,112 pages

Chapters Covered

The catalog follows the way the truck is actually built, starting at the engine and working back through the driveline, hydraulics, frame, cab, body and options.

• AA – Engine: cylinder head and head cover, air intake manifold and intake connection with sensor, pre-heater switch, exhaust manifold with exhaust temperature sensor, turbocharger and lubricating oil piping, turbocharger water piping, turbocharger KTR110L-F85PW inner parts, heat shield, exhaust brake and mounting with inner parts, thermostat and thermostat housing, cylinder block and cylinder block accessories including blind covers and sensors, front cover, gear case and front cover accessory, flywheel housing, crankshaft, piston and connecting rod, camshaft, cam follower, oil pump, common rail inner parts, fuel supply pump bracket and rail return piping, fuel injection piping sections 1/4 through 4/4, fuel supply pump lubricator, fuel injection pump drive, fuel piping R.H. and L.H. bank, fuel connection, fuel filter, fuel air vent, fuel priming pump, fuel injection nozzle and spill pipe, fuel return, fuel controller, water pump and bypass piping, air vent piping and water outlet, cooling fan, fan pulley and drive belt, fan drive, tension pulley, corrosion resistor, alternator 90A and mounting with inner parts, alternator drive, starting motor mounting 7.5KW and 11KW, starting motor inner parts, electrical wiring and injector harness group, cylinder head gasket kit, cylinder block gasket kit, water pump gasket kit, name plate and caution, PM-clinic accessory, fuel filter and pre-filter for poor fuel arrangement spec, water separator and sensor.
• BO – Engine Related Parts: engine mounting, engine assembly references, exhaust bracket, engine damper, engine cooling tube, damper, fuel line block to engine and filter to engine, air intake, engine control engine harness, engine control heater relay harness, engine earth, vehicle health monitoring system harness.
• CO – Cooling System: radiator sections 1/2 and 2/2, radiator for oil cooler strainer and caution, radiator with air conditioner, radiator fan net, radiator mounting bracket, radiator baffle, coolant line sections, coolant line air intake piping, coolant line for quick charge water, coolant level sensor, brake cooler piping, air conditioner related parts.
• EO – Electrical, Rear Hood and Brake: battery box battery, stay, box, relay and circuit breaker variants including additional filter, rear hood and rear hood for exhaust brake, rear hood related parts, brake line valve box, breather including sand protection, brake line under hood and cab hood, exhaust brake valve, electrical system main harness and bracket clamps, starter cable, horn and bracket, clip R.H., rear lamp bracket and lamp with buzzer including additional lamp and LED variants, rear lamp mounting parts, side lamp including payload meter variants and side lamp cover, fog lamp, payload meter lamp R.H. and L.H.
• FO – Torque Converter and Transmission: front propeller shaft unit, rear propeller shaft unit, torque converter 1/7 through 7/7 covering bare unit, input shaft, drive case, rear housing, power take off, valve mount and charge pump, torque converter valve, transmission 1/10 through 10/10 covering first, second, third and reverse clutch, high clutch, low and fourth clutch, carriers, case, docking unit, input and output, transmission control valve 1/4 through 4/4, transmission lubrication valve, transmission oil pan, transmission sensor, rear axle differential, final drive L.H. and R.H., final brake L.H. and R.H., rear axle housing, rear axle brake piping, rear axle axle sensor, blind parts and support, front axle R.H. and L.H. hub, brake, front suspension assembly, valve, cover, sensor, lubrication, lever, final brake line, brake cooling line, hose and transport, transmission mounting parts.
• GO – Auto Suspension Piping: auto suspension piping runs, valve, clip and block groups.
• HO – Hydraulic System: hydraulic tank sections with strainer, element, breather, valve, filter and petrol piping, brake control valve, brake cooling valve inner parts, hydraulic main pump, transmission piping sections, steering and hoist piping including steering cylinder, cross over valve, piping runs, pump to filter, hoist valve to hoist cylinder, pump suction, dump control line, exhaust brake and demand valve to steering valve, crossover relief valve, brake cooling oil line pump to rear brake and transmission to front brake, brake cooling oil line brake to oil cooler and oil cooler to filter, brake piping filter line, frame L.H. and R.H. side, parking brake valve line, proportional valve line, rear brake piping, front brake piping R.H. and L.H., accumulator box R.H. and L.H., accumulator mounting parts, accumulator charge valve inner parts, emergency steering flow switch.
• JO – Main Frame and Related Parts: main frame variants for standard, auto suspension, exhaust brake, tire stopper, ASR, side cover, inclination ladder, additional filter and muffler configurations, main frame brackets, axle support, rear support and rear support with muffler, front support L.H. and R.H. with support, bracket, step, steering valve and steering piping, vehicle health monitoring system sensor, stairway with step, ladder, inclined type guard, power ladder, handrail, hydraulic oil valve, hydraulic oil piping, wiring harness, step mounting, power ladder cylinder, angle sensor, drain piping and pressure release piping, engine fuel filter and related parts L.H. and R.H. with additional filter, positioner, air intake, exhaust piping, exhaust piping for exhaust box and muffler, exhaust box, muffler, engine control harness, engine earth, steering link with lever and rod and related parts, exhaust brake cylinder R.H. and L.H. with mounting bracket and related parts, exhaust brake hose, auto suspension piping, exhaust brake bracket, transmission control, emergency steering control with motor and related parts, lubrication piping, tire stopper.
• KO – Operator’s Cab: operator’s cab and cab body, L.H. door sections 1/3 through 3/3, R.H. door sections 1/3 through 3/3 with sash window variant, door related parts, glass and defroster glass, antenna cable, wiper, cab interior sheet, cab accessory with and without speaker and sun visor variants, roof pad and cover, mark and plate, window washer tank, air conditioner filter, floor related parts, accelerator pedal, brake control sections, air conditioner piping, dashboard sections, air duct, radio less and radio with cassette variants, monitor decal variants, rear view TV monitor, defroster glass switch, monitor panel, steering column, column switch and steering wheel with sensor, operator’s seat KAB/Seating and Isringhausen with inner parts, dump control, console box, rear cover, auxiliary seat, fuse box and relay, side lamp relay, roll over angle sensor, floor wiring, emergency starting timer, VHMS, connector plug, cab under parts, air conditioner unit inner parts, floor mat, cab guard front step, side step, toe guard, side mirror L.H., bolt line, radio antenna, cap, mud guard, cab under cover.
• LO – Platform: platform sub assembly L.H. and R.H., platform related parts, mud guard, handrail, toe guard, air cleaner inner parts, coolant reserve tank with vandalism protection variant, under mirror, side mirror with additional side mirror variant.
• MO – Radiator Guard, Hood and Fire Protection: radiator guard for standard, sandy and dusty terrain arrangement, cold area specification, extreme hot area specification, hood, engine side cover R.H. and L.H., fire protection engine rear cover, fire protection with muffler and with exhaust box, exhaust cover, steering piping protection, brake line protection, fender L.H. and R.H. with muffler variant, fuel tank ladder, engine under guard, transmission under guard.
• SO – Rim and Tire: rim front wheel and front wheel large valve, rim extreme cold area specification mounting parts, rim rear wheel and rear wheel large valve, tire 2700R49 E4 CR, E4 GP, E4 and E4 HR, tire 31/90R49 E4, rear suspension, rear suspension pressure sensor.
• TO – Body: body, body with platform guard, body with body liner, body with 300mm spill guard, body with muffler, body with platform guard and spill guard and muffler and rock, body accessory, body related parts without muffler and with muffler and for quarry, hoist cylinder and hoist cylinder L.H. and R.H., platform guard, exhaust box and exhaust box with muffler.
• UO – Marks and Plates: name plate unit sections, English name plate unit, Indonesian name plate unit, caution plates, VHMS and ORBCOMM caution plates.
• VO – Tool: spare parts unit, spare parts unit large bore valve, spare parts fuel filter, general tool unit with hose, tool box unit, jack unit 30 ton and 50 ton, payload meter soft and payload meter.
• WO – Air Conditioner and Options: air conditioner related parts sections, cap lock, fire extinguisher English and Indonesian, front propeller shaft guard, rear propeller shaft guard, ABS/ASR chassis steering sensor, ABS/ASR chassis valve, wiring harness, axle sensor, common wiring harness, ASR valve inner parts, rear monitor, vehicle health monitoring system with and without ORBCOMM, VHMS less parts, antenna.
• YO – Service Kits and Major Components: transmission and torque converter service kits, hydraulic pump steering and hoist, hydraulic pump assemblies, hoist cylinder inner parts, steering cylinder L.H. and R.H. inner parts, accumulator brake control inner parts, hoist valve sections, demand valve sections, check valve, electric lever.

Laid end to end, those groups add up to a full walk-around of the HD785-7. The engine side alone runs from the cylinder head casting down through the block, crank, pistons and camshaft, out through the turbocharger, exhaust brake, common rail and injector piping, and on into the cooling fan drive and 90A alternator. The chassis side carries the same depth: torque converter and transmission broken into clutch packs and carriers, rear axle differential and final drives split L.H. and R.H., front axle hub and brake split the same way, and the hydraulic tank, main pump, brake control valve and steering and hoist piping each given their own figure. Frame sections cover the many build combinations Komatsu offered on this truck, from auto suspension and tire stopper through to exhaust brake, ASR, inclination ladder, side cover, additional filter and muffler variants, so the serial number break printed next to each part tells you whether it fits the truck in front of you. Cab, platform, radiator guard, hood, fire protection, fenders, rim and tire, body and hoist cylinder groups complete the picture, and the option sections at the back cover air conditioning, cap lock, fire extinguisher, propeller shaft guards, ABS/ASR chassis hardware, rear monitor and the vehicle health monitoring system with its antenna. Service kits for the transmission, torque converter, steering cylinders, hoist cylinder and hydraulic pumps sit in the YO group at the end, useful when a repair is being planned rather than a single fastener replaced.

How the Parts Book Is Put Together

Each spare part group gets an illustration on the left-hand page with every component given an index number, and a parts list on the right-hand page in index number order. The FIG. No. identifies the illustration, not the part, and the numbers are not always continuous, so the illustration and the list have to be read together. The PART No. column carries the number used when ordering, and it is worth reading it carefully – the foreword specifically warns about mistakes in that code number. The DESCRIPTION column gives the part name, with a single dot placed in front of a part name that belongs to an assembly and the item entered below it, and a double dot where that assembly is itself a sub-assembly. Examples in the book include ELEMENT ASSEMBLY, AIR CLEANER with .ELEMENT ASSEMBLY, OUTER and .ELEMENT, OUTER below it, and .NUT, WING and .WASHER following. The Qty column gives the number of pieces used for one machine, or the quantity per assembly where a part sits inside a larger group.

Symbols and Serial Number Breaks

The part number and description columns use symbols to flag interchangeability and supply rules, and the book explains each one: a part on the line above can be used instead of the listed part, a part can be used instead of the part immediately above, two parts are interchangeable, a described part can be used instead of a listed part when supplied as a set, a discontinued part is replaced by the part on the line above or by the description below as a set, a part cannot be supplied individually and comes only as an assembly or as an assembly through an authorised distributor, a part marked as a group is not itself a supply part, and the parts surrounded by a line are the components of the group specified above. There are also codes for kit parts, semi-finished parts needing extra work before installation, parts shipped painted with under coat, parts supplied in colours different from the machine’s original colour, cold weather A specification parts for -30 degrees C machines, and cold weather B specification parts for -50 degrees C machines. Alongside all of this, the SERIAL No. column states the applicable engine serial number for engine items and the machine serial number for chassis items, which is how the catalog separates the earlier and later builds inside the N10001 to N10560 range and inside the engine range from 50013 upward. Getting that break right is the difference between ordering the part that fits the truck in your yard and ordering one that fits a different build.

Why This Catalog Earns Its Place in the Toolbox

A parts book is not a repair manual, and it does not pretend to be one. What it does is remove the guesswork from everything that surrounds a repair: identifying the correct component from an exploded drawing, confirming that the part number matches the serial number of the machine, checking how many pieces the job consumes, and knowing whether an item can be bought on its own or only as part of an assembly. On a truck like the HD785-7, where the same model was built across a long production run with suspension, brake, filter, ladder and body variations layered on top, that last point matters more than it sounds. Assemblies that look identical between two trucks can carry different internal part numbers, and the SERIAL No. column is the only reliable way to tell them apart without a trip to the dealer counter. The kit codes and the discontinued part symbols are equally practical: they tell you when a simple order will turn into a set, or when the number you have been quoting for years has been superseded and something on the line above should be supplied instead.

Ordering and Delivery

IMAGES PREVIEW

Delivered as an instant PDF download, the Komatsu HD785-7 Dump Truck Parts Book FEN00222-01-N1-00 opens on any device – workshop laptop, tablet on the service truck or a phone in the pit – and any page can be printed and taken to the machine, which is still the fastest way to work an exploded view against a real assembly. There is no shipping, no waiting on a disc and no courier. For anyone maintaining, rebuilding or simply keeping a HD785-7 in serial range N10001 to N10560 running, this is the document that turns a vague description of a broken part into a number you can order.