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The Best Truck for

PAMA

HD785-7

2006May15

HD

785

1.

Best travel performance with


895KW(1217ps) engine

2.

Air to Air Charge Cooling


System

3.

Better Fuel Economy

4.

Wider Body

5.

Suspension improvement

6.

ARSC (All Wheel Retarder)

7.

And more .

Major features of the HD785-7


Red shaded items show the requested features by PAMA
Engine

Control/Monitoring

Komatsu SAA12V140E-3

Monitoring system

895KW(1217ps) gross power engine


Automatic derate for high altitude operation

HD785-7
Blue letter: similar to the HD465-7

Cab
Low noise CAB

CAB

VHMS (std.)
Electrical hoist control

Built-in 4 post ROPS

Body

Fuel economy

Wider body
Fuel economy engine with VHPC
(Variable Horsepower Control)

Backward exhaust outlet

Hydraulic loss reduction

Hydraulic system
Increased T/C cooling capacity

Brakes
All hydraulic brake control
Built-in 4 wheel park brakes
ARSC (std.)
All wheel retarder
Exhaust retarder (option)

Transmission

Axle, Suspension

ENG-TRANS integrated control

Suspension improvements

Skip-shift function

Flange-type rim

Enhanced reverse operation: F7R2 (w/lockup)

ASR (Auto. Spin Regulator)

Major Specification
Items
Weight
Body

Max. Payload
Empty Weight
SAE (2:1) heaped

Units

Body inner width

ton
ton
m3
mm

Make / Model

Tire
Engine

HD785-7

Gross Power / Rated


Speed

KWPS
/rpm

KOMATSU
HD785-7
91
72.0
60
5,200

HD785-5
91
69.4
60
4,880

HITACHI
EH1700
94.398.4
71.7
60.3
5,440

27R49
SAA12V140E Tier2
895-809-750-698

27R49
SA12V140

31/80R49
Cummins QST30

27R49
CAT 3508B

7831065/2000

8951217/2100

7461014/1750

Komatsu Power shift


transmission (K-Atomics)

Allison MT9600A

CAT Power shift


transmission

F6R2
Caliper disc
Wet disc
Caliper disc
Wet disc, Rear wheels
1,051 (1430)
All HYD.
ELECTRONIC
OP
--

F7R1
Wet disc
Wet disc
Wet disc, All wheels
Wet disc, All wheels
895 (1,216)
Air over hydraulic
ELECTRONIC
OP
OP

(1217-1100-1020-950)/1900
w/VHPC

Komatsu Power shift:


Transmission

Brakes

Make / Model
Speed
Front
Rear
Parking
Retarder
Continuous rating

Control
ARSC
VHMS

HD785-7

Brakes
Body Hoist

K-Atomics w/EngTrans,integrated control, and


skip shift

*
F7R1
F7R2
Wet disc
Caliper disc
Wet disc
Wet disc
Wet disc, All wheels
Caliper disc
Wet disc, All wheels
Wet disc, Rear wheels
1,092 (1,484)
993 (1,350)
All HYD.
Air over hydraulic
ELECTRONIC
MECHANICAL
STD
OP
STD
OP
* RH/RL selectable w/lock-up
HD785-5
EH1700

KWPS

CAT
777D
91
67.9
60.1
5,200

777D

Body Design

HD785-7

HD785-7 std VS EX2500

5500
5400

Body width (mm)

5300

B
A

Good matching with


EX2500

5200
5100

Good matching with


WA800

5000
4900
4800
Good matching with
PC1800

4700

4600
6000 6200 6400 6600 6800 7000 7200 7400 7600

HD785-7(Std)
HD785-7(Op)
HD785-5(Std)
HD785-5(PAMA)
EH1700
777D

Body length (mm)


Criteria
A > Excavator bucket width X 1.6
B > Loader bucket width X 1.3

Body inside width (A)


Body lenth (B)
Loading height (C)

HD785-7
Std
5200
7060
4285

HD785-5
Std
PAMA
4880
5440
7475
7050
4285
4285

EH1700

777D

5440
6930
4290

5200
6950
4290

Powerful SAA12V140E-3 Engine

HD785-7

Feature
1217ps gross power with VHPC
Meets U.S. EPA Tier2
Enhanced high altitude capability
9

Air to air cooler

Relocate Air Cleaner

Automatic derate

Item
Model
Fuel sys.
Gross power
Rated speed
Max. torque

Air to Air cooler

Power Control

Unit
--ps
kW
rpm
Nm
rpm
--

HD785-7
SAA12V140E
CRI
1217/1100/1020/950
895/809/750/698
1,900
5,080
1,350
VHPC

Air cleaner relocation

HD785-5
SA12V140
KP21
1065/950
783/698
2,000
4,168
1,400
Power/Economy

EH1700
QST30
RP39
1217
895
2,100
4,678
1,400
---

777D
3508B
EUI
1014
746
1,750
4,492
1,300
---

VHPC ( Variable HorsePower Control)

HD785-7

600

Engine torquekgm

500

400

300

200

P-Mode: High production with


895KW(1217ps) engine

VHPC (Variable HorsePower Control)


895KW (loaded)

[Power mode]

809KW (empty)

Automatic power
selection

E-Mode: Equal productivity


with less fuel (vs. HD785-5)

Mode change by manual switch

100

0
1000

750KW (loaded)

[Economy mode]

698KW (empty)

Automatic power
selection

1500
Engine speed rpm

2000

Best Travel Performance in the class


Engine
power

P-mode
E-mode

Power control

Travel speed on 13%


25%

Total resistance (%)

total resistance

H D 785-7
895/809
750/698
Va ria b le
H orse p ow e r

KW
KW
-km/h

20%

12.4

HD785-5
783
698

EH1700
895
--

P/E mode

--

10.8

11.6

HD785-7

HD785-7 (P-mode)

15%
EH1700

10%
5%
HD785-5 (P-mode)

0%
0

10

20

30
40
Speed(km/h)

50

60

Higher Performance with Less Fuel

HD785-7

Engine improvement
1.

Enhanced Engine Technologies

Intelligent Shift Control


1.

Shift schedule control by acceleration

2.

Optimize shift schedule at partial throttle

3.

VHPC

Reduction of power loss


1.

BCV (Brake Cooling Valve)

2.

S/TH/T circuit LS (Load Sensing) System

3.

Variable T/M Main relief pressure

4.

Tandem pumps for T/C-T/M hydraulic circuit

5.

Adjustable T/M lubrication flow

6.

Lower engine rated speed (1900rpm <- 2000rpm)

7.

Rear Brake Disc Gap increase

8.

Hybrid cooling fan

#12 are common system with HD785-5

HD785-7

SAA12V140E-3 Engine
Komatsus engine technology
Engine Transmission integrated control
Heavy Duty HPCR System (High Pressure Common rail injection)

New Combustion System (Optimized combustion chamberFCD pistonTurbocharger and intake )

Tier0 Tier Tier2

Fuel economy
Environmental
Durability

Air to Air Charge Air Cooling System


Air to Air
Charge Air Cooling

Electronically Controlled
High Pressure

High Efficiency
& Wide Range
Tarbocharger
Turbocharger

Dual Intake Port

FCD Piston

Fuel Injection System

Tufftride Liner

Select optimum power setting by load / empty


condition automatically

Engine torque [kgm]

600

HD785-7

Shift schedule control by acceleration (=load)


Select lower shift-up speed in case of light load (=high
acceleration)

Shift-up speed

500
400
Select lower shift-up speed at partial throttle to run
engine at low speed (better BSFC and lower drag loss)

300

BSFC low area


200

BSFC high area


100
0
1000

1200

1400

1600

1800

2000

Engine speed[rpm]

2200

2400

Fuel Economy (simulation examples)


- Heavy duty (14% uphill, 4km round trip)

HD785-7 8
- Medium and Light duty

HD785-7 E-mode: Equal production performance with


HD785-5 P-mode

Up to 10% reduction compared to HD785-5 (P-mode) in L/H


at Medium and Light application

Hourly Production
350
274

264

258

250
200

150

100
50
0
HD785-7

-1

244

60

56.1

Heavy duty application:


HD785-7 E-mode vs. HD785-5 P-mode
40
-1.Production T/H equal or better (+2%)
-2.Fuel L/H
equal or better (2%)
20
-3. Fuel/Production L/T approx. less

HD785-5

129

120

120

-2

122

59.1

Fuel consumption
140

63.8

56.1

L/H

300

T/H

Fuel consumption (medium duty: 4km round trip)


80

-1

114

80

HD785-7
HD785-5
Fuel consumption (Light duty: 1.6km round trip)

80

60
40
20
0
HD785-7

HD785-5

60

Medium and Light application;


HD785-7 E-mode vs. HD785-5 P-mode
T/H: equal , L/H: approx. 10% less
-1 Medium duty (L/H)
-2 Light duty (L/H)

L/H

L/H

100

-3

0 .4 7

L/T

0 .3 0
0 .2 0

0 .1 0
0 .0 0

Fuel and Production


figures may vary
depending on
payload, road
conditions, driving
skill and so on.

HD785-5

HD785-5

Hourly Production: t/h is same for medium and light duty application
600

600
500

477

476

477

476

500
400

400
300

200

100

100

328

327

332

332

300

200

0
HD785-7

HD785-7

48.3

HD785-7

0 .4 7

0 .4 0

48.3

T/H

0 .4 5

-2

T/H

0 .4 7

40

41.2

20

Fuel / Production
0 .5 0

41.8

HD785-5

(Medium duty)

HD785-7

(Light duty)

HD785-5

Fuel Economy (simulation examples)


140

HD785-7

UP-hill (14% slope) course *


* : 4km(round trip) course simulation

HD785-5(P)
HD785-5(E)
HD785-7(P)
HD785-7(E)

UP-hill (10% slope) course *

Fuel consumption [L/H]

120

P-Mode (HD785-7)

100
E-Mode (HD785-7)

Down-hill (14% slope) course *

* : 4km(round trip) course simulation

80
Down-hill (10% slope) course *

Flat course
(Medium duty)*

60
PAMA Bontang (05May course)
Flat (light duty) *

3km(round trip) course

1.6km(round trip) course

40

speed limit 35km/h

20
0
10

12

14
16
18
20
Average speed [Km/h] (=Odometer/SMR)

22

Course profile PAMA Bontang site (2005 Mar.)


Haul road profile (seam 0) on 31March & 1 April
pt.1

Distance: 1.5km one way


Max. grade: 12.6% (hauling)
14.6% (return)

dumping area
178m -0.6%

pt.2
107m -1.9%

rough terrain
RR: 5%

pt.3
104m -1.0%
70m 0%

pt.4

pt.5

66.5m -1.5%
86m 1.2%

pt.6

100

80

14m 14.6%

44m 4.5%

pt.8
pt.9
pt.10
pt.11

90

pt.12

33.5m 9.0%
40.5m -12.3%
34m -6.0%
46m -2.2%
29m 3.5%
53m 0%
55m 0%
58m 1.7%

39m 2.6%
45m -6.7%
24m -12.6%

pt.14

pt.13
31m -9.6%
52m -5.8%

70

Elevation [m]

pt.7

EX 3000 (15m3)
x 4 buckets

Rank B-C RR: 2.5%

46m 6.6%
41m 0%

pt.17
pt.15 pt.16

pt.18
pt.19

pt.21 pt.22
pt.20

pt.23

46m -2.2%

33.5m 0%

loading area
RR: 5%

pt.28 pt.29

pt.24 pt.25
pt.26 pt.27

pt.30

11m 0%

38m 2.6%
32m 3.1%

40m -5.0%

60

dumping are a
50

pt.11

pt.1

loding are a

40
pt.30

30
20

pt.22

10
0
-

200

400

600

800
Distance [m]

1,000

1,200

1,400

1,600

Fuel / Production @ PAMA-BONTANG 05Mar COURSE


TEST RESULT
UNIT CODE
BRAND
1 HD785-5 #755 (W/B)
2 HD785-5 #758 (W/B)
3 HD785-5 #680 (STD)
4 CAT777D #451
5 EH1700 #14

(3/31 & 4/1 at Seam 0)


DATE
START FINISH
31-Mar-05
4,131
4,136
1-Apr-05
4,142
4,146
31-Mar-05
3,918
3,923
1-Apr-05
3,929
3,933
31-Mar-05
1-Apr-05
16,701 16,704
31-Mar-05
16,197 16,202
1-Apr-05
16,210 16,215
31-Mar-05

Hrs
5.2
4.2
5.2
4.3
3.5
5.3
4.3

Km
START
FINISH
39,589.1
39660.9
39,738.9
39787.6
37,226.4
37299.8
37,371.3
37418.8
213,347.9
143,805
143,950

213387.6
143876
143995

Cycle

71.8
48.7
73.4
47.5

25
15
25
15

FUEL
Ltr
311
273
370
238

39.7
71.0
45.0

13
25
14

237
305
285

FUEL
Ltr/Hrs
59.81
65.00
71.84
55.57
67.71
57.55
66.28

HD785-7

Reliable Brakes, Axles

HD785-7

[Safety & Reliability]

[More Stability & Maneuverability]

9All Hydraulic Brake control

9All wheel retarder

9Wet disc brakes, all wheels

9ARSC (standard)

9Inboard parking brakes, all wheels

[Serviceability]

9Brake disc improvement (disc surface area,


disc gear reinforcement)

9Flange-type rim

9Bevel gear improvements


Inboard park brakes

Flange-type rim

Bevel gear width &


module increase
Wet disc brakes, all wheels
Disc surface area : 37% increase

Front axle

Disc gear module increase

Rear axle

Transmission

F7R2 Komatsu transmission (New)


- K-ATOMiCS; Reduce the shifting shock and improves the durability of the
power train
- Higher versatility with two reverse gear selection (w/Lock-up)

Engine- Transmission integrated control (similar to HD465-7)


- Synchronize the transmission input/output speeds
- Improve the durability of the power train

Skip Shifting Function ( similar to HD465-7)


- Prevent a spillage of load when frequent gear down-shifting
F3
F4

F2

F3
F2

F4
F4
F4

F2

F2

Spacious and comfortable CAB

HD785-7

*same concept as HD465-7

Superior riding comfort


- Viscous mounted CAB; Less noise and vibration
- Large capacity air conditioner
w/ Pressurized and defrost function
- Hydro-pneumatic suspension
- Large capacity CAB

Easy Operation
- Electronic hoist control lever
- Telescopic and tiltable steering wheel
- Superb visual instrument panel

>Comfort cab interior equipment (Standard equipment)


Sun visor
Tiltable and telescopic steering
window (LH)
Power windows
Suspension operator seat

Cup holder
Ash tray and cigar lighter
Assistant seat

HD785-7


9Rod size increase
9Durable Bushing material: DD DU

9Heat resistant material for Packing & Buffer ring


9Oil brand change : HO-MVK EO10

Item
Rod dia.
Cylinder dia.
Bushing
Bushing
Packing
Buffer ring
Oil

HD785-5

HD785-7

Unit
mm
mm
mm
-----

Front suspension
HD785-7
HD785-5
210
180
250
220
210 x 120 180 x 120
DD
DU -> DD
UH05
U801
UH05
NA ->U641
HO-MVK
EO10

Rear suspension
HD785-7
HD785-5
210
200
250
250
210 x 75
200 x 70
DD
DU -> DD
UH05
U801
UH05
NA ->U641
HO-MVK
EO10

Easier Tire exchange

HD785-7

Front : Wedge type rim

Rear : Wedge type rim

Front : Flange type rim

Rear : Flange type rim

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