specalog for 785c mining truck aehq5320-02 · engine @ 1750 rpm engine model cat® 3512b eui gross...

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Engine @ 1750 RPMEngine Model Cat® 3512B EUIGross Power 1082 kW 1,450 hpFlywheel Power 1005 kW 1,348 hp

WeightsGross Machine Operating Weight 249 480 kg 550,000 lb

Operating SpecificationsBody Capacity – SAE (2:1) 78 m3 102 yd3

Nominal Payload Capacity 136 tonnes 150 tons

785CMining Truck

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785C Mining TruckEngineered for performance, designed for comfort, built to last.

Top Performance.Developed specifically for high productionmining and construction applications, the785C Mining Truck keeps material movingat high volume to lower your cost-per-ton.

Reliable, Durable Operation.Rugged construction and easy maintenanceprocedures ensure long life with lowoperating costs.

Truck Body Systems

A variety of Caterpillar designed andbuilt truck bodies ensure optimalperformance and reliability in toughmining applications. Cat dealers canhelp build an optimum hauling systemto maximize truck payloads and extendbody and truck wear life. pg. 14

Monitoring System

Vital Information Management System(VIMS) provides operators, servicetechnicians and managers with vitalmachine health and payload data tokeep the 785C performing at peakefficiency and top production levelswhile lowering cost-per-ton. pg. 12

Engine/Power Train Integration

The Cat Data Link electronicallycombines engine, transmission,brake and operational information tooptimize overall truck performance.Stored diagnostic data can be accessedvia the Electronic Technician (ET) toimprove troubleshooting and reducedowntime. pg. 6

Power Train – Transmission

The Cat six-speed power shifttransmission and mechanical powertrain, matched with the electronic unitinjection 3512B engine, providesconsistent power and efficiency forpeak power train performance. pg. 5

Power Train – Engine

The Cat® 3512B engine delivers thepower and reliability necessary toperform in the most demandingapplications. Designed for efficientoperation, the 3512B offers excellentfuel efficiency, lower emissions,reduced engine noise and loweroperating costs. pg. 4

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Customer Support

Caterpillar dealers provide unmatchedproduct support, anywhere in the world.With industry-best parts availabilityand a wide range of maintenance andservice options, Cat dealers have whatit takes to keep your mining machinesproductive. pg. 17

Serviceability

The 785C is designed for quick andeasy servicing. Simplified service andmaintenance features reduce downtime,allowing the machine to spend less timebeing serviced and more time on thehaul roads. pg. 16

Operator’s Station

The ergonomic cab is designed foroperator comfort and ease of operationto allow the operator to focus onproduction. Controls and gauges arepositioned within easy reach foroptimum efficiency and superiorcontrol all shift long. pg. 11

Structures

Caterpillar truck frames are built toresist twisting in the most severe, highimpact applications. Mild steel providesflexibility, durability and resistance toimpact loads. Castings and forgings inhigh stress areas provide exceptionalstrength and durability for long life.pg. 10

Caterpillar® Brake System

Cat oil-cooled, multiple disc brakesoffer exceptional, fade-resistantbraking and retarding for maximumperformance and productivity in all haulroad conditions. Integrated BrakingControl combines retarding and tractioncontrol into one system for optimumbraking efficiency. pg. 8

Engine. The Cat 3512B EUI twinturbocharged and aftercooled dieselengine delivers high power andreliability in the world’s most demandingmining applications. The 3512B is a16-cylinder, four-stroke design that useslong, effective power strokes for morecomplete fuel combustion and optimumefficiency.

EPA Compliant. The 3512B engine iscompliant with U.S. EnvironmentalProtection Agency Tier I emissionsstandards.

Altitude Compensation. Designed formaximum operating efficiencies ataltitudes under 3048 m (10,000 ft).

High Torque Rise. The 23 percenttorque rise provides unequalled luggingforce during acceleration, on steepgrades and in rough underfoot conditions.Torque rise effectively matchestransmission shift points for maximumefficiency and fast cycle times.

Enhanced Life. High displacement, lowrpm rating and conservative horsepowerratings mean more time on the haulroads and less time in the shop.

Two-Piece Piston Design. Two-piecearticulated pistons with a deep bowl,low volume crevice design enhancescombustion efficiency, improves fuelefficiency and lowers emissions.

Electronic Unit Injection (EUI). Theelectronically controlled unit injectionfuel system senses operating conditionsand regulates fuel delivery for optimumfuel efficiency. The proven high-pressurefuel system provides improved responsetimes and more efficient fuel burn withlower emissions and less smoke.

Electronic Control Module (ECM).ECM utilizes advanced enginemanagement software to monitor,control and protect the engine utilizingself-diagnosing electronic sensors.The computerized system sensesoperating conditions and powerrequirements and adjusts engine forpeak performance and most efficientoperation and at all times.

Separate Circuit Aftercooler. Allows theaftercooler circuit to operate cooler thanjacket water temperature for a denser aircharge and greater combustion.

Oil Renewal System. Optional oilrenewal system extends engine oilchange intervals from 500 hours to4000 hours or more to increase machineavailability.

Engine Protection. Computerizedsystem electronically protects theengine during cold starts, high altitudeoperation, air filter plugging, and highexhaust temperature.

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Power Train – EngineThe Cat 3512B engine is built for power, reliability and efficiency for superior performancein the toughest applications.

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Mechanical Power Train. The Catmechanical drive power train and powershift transmission provides unmatchedoperating efficiency and control onsteep grades, in poor underfootconditions, and on haul roads withhigh rolling resistance.

1) Transmission. The Cat six-speedplanetary power shift transmission ismatched with the direct-injection 3512Bdiesel engine to deliver constant powerover a wide range of operating speeds.

Robust Design. Designed for thehigher horsepower of the 3512B engine,the proven planetary power shifttransmission is built tough for longlife between overhauls.

Long Life. A dedicated oil tank andcircuit provides cooler, cleaner oil formaximum performance and longercomponent life.

Transmission Chassis Control (TCC).TCC uses electronically transferredengine rpm data to execute shifts atpreset points for optimum performance,efficiency and clutch life.

2) Lock-Up Torque Converter. Combinesmaximum rimpull and cushioned shiftingof torque converter drive with theefficiency and performance of directdrive. Engages at approximately8 km/hr (5 mph), delivering morepower to the wheels.

Lock-Up Clutch. Quickly releases andre-engages to reduce power train torqueloads for smoother shifting, long lifeand a more comfortable ride.

Smooth Shifting. Individual clutchmodulation provides smooth clutchengagements to optimize performanceand extend clutch life.

3) Final Drives. Cat final drives work asa system with the planetary power shifttransmission to deliver maximum powerto the ground. Built to withstand theforces of high torque and impact loads,double reduction final drives providehigh torque multiplication to furtherreduce drive train stress.

Steering System. Hydraulic steeringcontrol system is designed forexceptional smoothness and precisecontrol. A separate circuit preventscross contamination for long life.

Supplemental Steering. Supplementalsteering system uses pressureaccumulators and allows up to three90 degree turns in case of engine failure.

Wheels and Rims. Cast rear wheels andCat center-mount rims are mountedusing studs and nuts to minimizemaintenance and maximize durability.

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Power Train – TransmissionCat mechanical power train delivers more power to the ground for greater productivity andlower operating costs.

Cat Data Link. Electronically integratesmachine computer systems to optimizeoverall power train performance,increase reliability and componentlife, and reduce operating costs.

Controlled Throttle Shifting. Regulatesengine rpm during shifting to reducepower train stress and clutch wearby controlling engine speed, torqueconverter lock-up and transmissionclutch engagement for smoother shiftsand longer component life.

Directional Shift Management.Regulates engine speed during directionalshifts to prevent damage caused by highspeed directional changes.

Neutral Coast Inhibitor. Preventstransmission from shifting to neutralat speeds above 6.5 km/h (4 mph) toprotect the transmission from operatingwith insufficient lubrication.

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Electronically combines critical power train components to work more intelligently andto optimize overall truck performance.

Engine/Power Train Integration

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1 Gauge Cluster Module 2 Message Center Moduleg

3 ontrol (IBC)Integrated Braking Co4 Control (TCC)Transmission/Chassis 5 Brakes6 Wheel Sensor7 Transmission8 CAT Data Link9 e (ECM)Engine Control Module

10 Sensors11 or (EUI)Electronic Unit Injecto

VIMS

VIMS MainModule

ET

Body-up Reverse Neutralizer.Automatically shifts the transmissionto neutral if the hoist lever is activatedwhile transmission is shifted in reverse.

Body-up Shift Inhibitor. Prevents thetransmission from shifting above apre-programmed gear without thebody fully lowered.

Overspeed Protection. The transmissioncontrol electronically senses engineconditions and automatically up-shiftsone gear to prevent overspeeding.If overspeeding occurs in top gear,the lock-up clutch is disengaged.

Programmable Top Gear. Transmissiontop gear maximum can be set using theET service tool to help the operatormaintain speed limits.

Anti-Hunt Function. Prevents gearhunting when operating near a shiftpoint and minimizes shifts by notallowing an upshift or downshiftimmediately after a shift has occurredfor increased component life.

Downshift Inhibitor. Prevents engineoverspeeding by keeping the transmissionfrom downshifting until engine speedreaches the downshift point.

Electronic Technician (ET). ET servicetool provides service technicians witheasy access to stored diagnostic datathrough the Cat Data Link to simplifyproblem diagnosis and increasemachine availability.

Diagnostic Capability. Critical datafrom the electronic engine andtransmission controls, includingtransmission shifting, engine speedand fuel consumption, provides servicetechnicians with enhanced diagnosticcapability to reduce downtime andoperating costs.

Integrated Braking Control (IBC).IBC integrates Automatic RetarderControl and Traction Control into onesystem for optimum performance andefficiency.

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1 Parking/Secondary Piston2 Service/Retarding Piston3 Friction Discs4 Steel Plates5 Actuating Springs6 Cooling Oil In7 Cooling Oil Out

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Integrated Braking System. The Catoil-cooled braking system deliversreliable performance and control inthe most extreme haul road conditions.The integrated system combines theservice, secondary, parking brake andretarding functions in the same robustsystem for optimum braking efficiency.

Cat Data Link. All control modulescommunicate via the Cat Data Link andwork together as an integrated systemto maximize production efficiency andextend component life.

Oil-Cooled Multiple Disc Brakes.Caterpillar four-wheel, forced oil-cooled,multiple disc service brakes arecontinuously cooled by water-to-oilheat exchangers for exceptional,non-fade braking and retardingperformance.

Brake Design. Cat oil-cooled discbrakes are designed with large discsand plates for reliable, adjustment-freeoperation and performance. Brakes arecompletely enclosed and sealed toprevent contamination and reducemaintenance.

Long Life. An oil film prevents directcontact between the discs. This designabsorbs the braking forces by shearingthe oil molecules and carrying heataway to extend brake life.

Pistons. The Caterpillar two-pistondesign combines the service, secondary,parking brake and retarding functionsin the same system. The primary pistonhydraulically actuates both service andretarding functions. The secondarypiston is spring-applied and held inthe disengaged position by hydraulicpressure. If hydraulic system pressuredrops below a specified level, thespring-applied secondary pistonautomatically applies the brakes.

Parking Brake. Oil-cooled, spring-applied, hydraulically released parkingbrake is applied to all four wheels forsuperior parking capability on all gradesup to 15 percent.

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Reliable braking with superior control gives the operator the confidence to focus onproductivity.

Caterpillar Brake System

Integrated Braking Control (IBC).Combines Automatic Retarder Control(ARC) and Traction Control System(TCS) into one integrated brake controlsystem for optimum efficiency,performance and reliability.

Automatic Retarder Control (ARC).Electronically controls retarding ongrade to maintain optimum engine rpmand oil cooling. Additional braking maybe applied using the manual retarderor the brake pedal. ARC is deactivatedwhen the operator applies the brakesor throttle.

Four Corner Retarding. Four cornerretarding with 60/40 percent split(rear/front) in braking effort providessuperior control in slippery conditions.Balanced front to rear brake torqueprovides exceptional braking performanceand minimizes wheel lock-up, especiallyduring retarding.

Faster Speeds. ARC allows the operatorto maintain optimum engine speeds forfaster downhill hauls and greaterproductivity.

Superior Control. Automatic brakemodulation offers a smoother ride andbetter control in slippery conditions,allowing the operator to concentrateon driving.

Ease of Operation. ARC increasesoperating ease, resulting in greateroperator confidence with less fatigue.

Engine Overspeed Protection.Automatically activates ARC whenengine speed exceeds factory presetlevels, regardless of operator inputs,to avoid potentially damaging engineoverspeeds.

ARC Operating Efficiency Advantages

Fuel Efficiency. The engine providesadditional retarding by running againstcompression on downhill hauls.During retarding applications the engineECM does not inject fuel into thecylinders for exceptional fuel economy.

Traction Control System (TCS).Electronically monitors and controlsrear wheel slippage for greater tractionand enhanced truck performance in poorunderfoot conditions. If slippage exceedsa set limit, the oil-cooled disc brakesengage to slow the spinning wheel.Torque is then automatically transferredto the wheel with better traction.

Differential Action. Normal differentialaction provides superior maneuveringand control in slippery conditions.

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Automatic Retarder Control(Maintains Engine rpm between 2160-2300)

Manual Retarder Control(Wide Variation in Engine rpm)

* Optimum Engine rpm

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TCSARC 1 Service Brake Sensor2 Engine Sensor3 ARC4 ARC Switch5 Brakes6 Service Brakes7 Axle Speed Sensor8 TCS

Box-Section Design. The 785C frameuses a box-section design, incorporatingtwo forgings and 24 castings in highstress areas with deep penetrating andcontinuous wrap-around welds to resistdamage from twisting loads withoutadding extra weight.

Steel Structures. Mild steel usedthroughout frame provides flexibility,durability and resistance to impactloads, even in cold climates, and allowsfor easy field repairs.

Castings. Castings have large radii withinternal reinforcing ribs to dissipatestress in areas of high stress concentration.Castings move welds to lower stressareas for greater frame life.

Rollover Protective Structure (ROPS).Integral to the cab and frame, ROPS isresiliently mounted to reduce vibrationand noise levels.

Suspension System. Designed todissipate haul road and loading impactsfor longer frame life and a morecomfortable ride.

Cylinders. Four independentself-contained, oil pneumatic,variable-rebound suspension cylindersare designed to absorb shocks in themost severe applications.

• Front. Front cylinders with presetcaster and camber are mounted to theframe and serve as steering kingpinsfor a tight turning radius with excellentmaneuverability and low maintenance.

• Rear. Rear cylinders allow axleoscillation and absorb bending andtwisting stresses caused by unevenand rough haul roads rather thantransmitting them to the main frame.

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StructuresRugged Cat structures are the backbone of the 785C mining truck’s durability.

Ergonomic Layout. The 785C operatorstation is ergonomically designed fortotal machine control in a comfortable,productive and safe environment.All controls, levers switches and gaugesare positioned to maximize productivityand minimize operator fatigue.

Quiet Cab. Integral, sound-suppressedROPS/FOPS cab is resiliently mountedto the mainframe to isolate the operatorfrom sound and vibration for a quiet,secure and comfortable ride.

Viewing Area. Designed for excellentall-around visibility and clear sight linesto the haul road, the large viewing areaenables the operator to maneuver withconfidence for high productivity.

1) Air Suspension Seat. Ergonomicallydesigned, fully adjustable air suspensionseat with adjustable armrests providesoptimal driving comfort. A wide,retractable seat belt provides a secure,comfortable restraint.

2) Hoist Levers. Low effort electronichoist control is mounted next to theoperator’s seat for ease of operation.

3) Secondary Brake Pedal.Conveniently located on thefloor for easy operator control.

4) Monitoring System. VIMS featuresan easy-to-read display and easy-to-useoperator input keypad for precisemachine status information.

5) Steering Column. Offers tilt andtelescoping steering features to providea comfortable driving position.

6) Transmission Console. Designed withbacklit gear indicators and ergonomicshift knob.

7) Storage Compartment. Located underthe trainer seat for a safe, unclutteredworking environment.

8) Trainer Seat. Full-size, fully paddedtrainer seat features a backrest, wide hipand shoulder room, and seat belt forsecure travel.

9) Operator Window. Powered operatorwindow and sliding trainer seat windowoffer simple operation and an excellentunobstructed view.

10) Operator Controls. Easy to reachturn signal, high beam, intermittentwindshield wiper and windshieldwasher controls are designed foroptimum efficiency and comfort.

11) Heating/Air Conditioning. Efficientdesign provides fresh, pressurized,temperature-controlled air circulationfor a comfortable working environmentin any climate.

Radio Ready. Cab is prewired withpower converter, speakers, wiringharness, antenna and provision foradd-on communication systems.

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Operator’s StationErgonomically designed for operator comfort, superior control and high productivity.

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1 VIMS Interface Modules2 Transmission/Chassis Control (TCC)3 Integrated Braking Control (IBC)4 Engine Control Module (ECM)5 Sensors6 CAT Data Link7 Diagnostic Connector (ET)8 Gauge Cluster Module9 Message Center Module

10 Data Port (VIMS-PC)11 Action Lamp12 Action Alarm13 Service Lamp14 Payload Lamps15 Radio System

Vital Information Management System(VIMS). Intelligent Caterpillar designedmachine monitoring system providescritical machine health and payloaddata in real-time to keep the 785Cperforming at top production levels.

Integrated System Monitoring. Sensorslocated throughout the machine systemsenable VIMS to quickly exchange andmonitor information from all machinesystems for efficient, high performanceoperation.

Advanced Diagnostics. VIMS simplifiestroubleshooting, reduces downtime andlowers operating costs by identifyingabnormal conditions before they causeextensive damage.

Data Access. Monitoring and diagnosticinformation is stored on-board untilit can be downloaded for analysis.Data can be accessed through themessage center, transmitted viaoptional radio or downloaded ontoa computer for detailed analysis.

Machine Management. Servicetechnicians or mine management candownload data and generate reports forbetter machine management. Data canbe used to improve effectiveness ofscheduled maintenance programs,maximize component life, improvemachine availability, and loweroperating costs.

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Vital machine health and payload data keeps the 785C performing at peak production levels.

Monitoring System

MAIN MODULEVIMS

TRANS./ CHASSISCONTROL

INTEGRATEDBRAKINGCONTROL

ETVIMS

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1 VIMS Interface Modules2 Transmission/Chassis Control (TCC)3 Integrated Braking Control (IBC)4 Engine Control Module (ECM)5 Sensors6 CAT Data Link7 Diagnostic Connector (ET)8 Gauge Cluster Module9 Message Center Module

Gauge Cluster. Conveniently locatedgauge cluster maintains a constantdisplay of vital machine functions,including:

• engine coolant temperature

• brake oil temperature

• air system pressure

• fuel level

Speedometer/Tachometer/GearIndicator. Backlit display offersexcellent operator visibility.

Keypad. Provides operator or servicetechnician immediate access to currentmachine information, gauge valuesand stored data through the messagecenter display.

Message Center. Displays messagesrequested by operator and advisesoperator of abnormal machine conditions.

Alert System. Three-category warningsystem alerts operator of abnormalmachine health conditions.

• Category I. Machine or system needsattention.

• Category II. Requires operator toevaluate and correct situation beforecontinuing work.

• Category III. Immediate shutdownrequired to prevent serious damageto machine or system.

Production Management. True WeightProduction Management providesaccurate production reporting byutilizing suspension strut pressuredifferentials and advanced algorithmto weigh the truck after it moves awayfrom the loading tool and shifts intosecond gear. Production data enhancestruck and loading tool effectivenessand fleet productivity, and minimizesoverloading to reduce downtime andlower operating and maintenance costs.

Data Storage. VIMS stores up to2400 cycles for a complete record ofpayload weight, cycle times, distancesand actual dates/times.

Payload Lights. External lights on bothsides of the truck signals loading tooloperator when to cease loading foroptimum payloads without overloading.

Road Analysis Control (RAC). Optionalsystem monitors haul road conditionsby measuring frame rack and pitch toimprove haul road maintenance, cycletimes, tire life and fuel efficiency.

VIMS-PC. VIMS-PC, the off-boardreporting software program, allowsservice personnel to download acomplete record of machine health andproductivity data to a laptop computerfor diagnosis and analysis. Easy-to-usesoftware enables service techniciansand mine management to generatehealth and payload reports for moreeffective machine management.

VIMS Supervisor. Optional softwareallows mine management to easilymanage and interpret VIMS data foroptimum fleet management andproductivity.

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Payload Weight Distribution

Payload Weight (Tons)

Perc

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Recommended Payload Range

Inefficient Payload Ranges

With Production Management

Without Production Management

Cat Truck Bodies. Caterpillar offersthree specific body styles and custombody options to help customers obtainthe lowest cost-per-ton hauling solution.

• Dual-Slope

• Flat Floor

• Mine Specific Design (MSD)

Body Selection. Selection of the rightbody depends on material and haul roadconditions. The better the match of bodyto application, the greater the efficiency.Your Cat dealer can help you select theright body system for your site specificapplications.

Body/Chassis Integration. Caterpillartruck bodies are designed and matchedwith the integrated chassis system foroptimum structural reliability, durabilityand long life.

Fast Hoist Cycle Times. Two-stagehoist cylinders provide fast dump cycletimes of 15.2 seconds for raise and16.2 seconds for dump.

Body Design. Cat truck bodies aredesigned for optimal strength, capacityand durability. Wear surfaces areequipped to handle even the toughestimpact and abrasion over the long haulwithout diminishing capacity.

• Five-Sided Beams tie in the sidewalland floor junctions add increasedbody rigidity and strength.

• Wide Ribs in body floor provideincreased durability and impactsupport.

• Full-Length Stringers create strengthand rigidity throughout the bed.

• Box Section Beams offer increaseddurability in the floor, sidewall, toprail, corner, and cab canopy areas.

Custom Body Options. Tail extensions,sideboards, tumblebars, rock boxes androck shedders are available to maintainrated payload, reduce spillage, andimprove hauling efficiencies.

• Sideboards are designed to maximizeor attain gross machine weight.

• Tail extensions are used to helpretain the rear portion of the pileand limit load spillage on haul roads,extending tire life.

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Cat designed and built for rugged performance and reliability in the toughest miningapplications.

Truck Body Systems

1) Dual-Slope Body. The advanceddual-slope body design with V-shapedfloor increases load retention, maintainsa low center of gravity, reduces shockloading, and maintains optimum loaddistribution on steep inclines and inchallenging haul road conditions.

• Reinforced, rolled steel top railincreases body strength and protectsthe body from damage caused by theloading tool or falling material.

• 8 degree “V” reduces shock loadingand centers the load.

• 7.5 degree forward body slope and16 degree ducktail slope helps retainloads on steep grades.

2) Flat Floor Body. The flat floor designwith slight incline delivers excellentpayload capacity, high dump clearancesand smooth, controlled dumping.

• Flat floor design provides consistentwear characteristics on body tail.

• 12 degree forward body slopeprovides good load retentionon better maintained haul roads.

• 400 Brinell steel on surfacesprovides excellent wear.

3) Mine Specific Design (MSD) Body.The MSD body is based on the flat floordesign and is customized to maximizepayload potential and minimize cost-per-ton. Each MSD body design beginswith a detailed mine site profile todevelop a body suitable for a mine’sindividual needs.

Body Liners. A variety of liner optionsare available to save weight and helpextend the body system’s life. Wearsurfaces and liners are equipped tohandle tough impact loads whileresisting abrasion. Wear plates deliverlong life in high wear areas.

Matched Systems. For full truckpayloads with minimum loading time,an efficient loading/hauling systemstarts with a perfect match. The 785Cis matched with specific Cat loadingtools to maximize volume of materialmoved at the lowest cost-per-ton.

• 5130B – 7 pass/match

• 5230B – 5 pass/match

• 994D – 4 pass/match

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Servicing Ease. Easy access to dailyservice points simplifies servicingand reduces time spent on regularmaintenance procedures. Enhancedserviceability and 500-hour serviceintervals are designed to increasemachine availability and productivity.

Maintenance Platform. Provides accessto engine, air filters, steering hydraulictank and battery compartment.

In-Frame Access. Permits easy accessto major components for easy servicingand removal.

Ground-Level Access. Allows convenientservicing to tanks, filters, drains, andengine shutdown. Ground-level VIMSdata port permits easier downloadingof information.

Autolube. Automatic lubricationsystem reduces maintenance time byautomatically lubricating necessarycomponents on a regular basis.

Fast Fill Service Center. Wiggins fastfill service center features high speedfuel and oil exchange.

Oil Renewal System (ORS). Optionalsystem extends oil change intervalsand reduces waste oil handling bycontinuously burning oil from theengine oil pan through normal engineoperation. Make-up oil must becontinually added to compensatefor oil burned.

Scheduled Oil Sampling. S•O•SSM

sampling valves speed sampling andanalysis reliability.

Pressure Test Points. Disconnect valvesare conveniently located throughoutthe hydraulic systems for easypressure testing.

Air Filters. Radial seal air filters areeasy to change, reducing time requiredfor air filter maintenance.

Sealed Electrical Connectors. Electricalconnectors are sealed to lock out dustand moisture. Harnesses are braided forprotection. Wires are color coded foreasy diagnosis and repair.

Cylinder Heads. Individual cylinderheads are interchangeable for easyremoval and visual inspection ofinternal parts.

On-Board Diagnostic Systems. VIMScontinuously checks all critical machinefunctions and components, and helpslocate faults quickly for faster repair.Electronic control system enables quickdiagnosis of engine conditions andeffective maintenance and repairsutilizing the Electronic Technician (ET)service tool.

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ServiceabilityLess time spent on maintenance means more more time on the haul roads.

Machine Selection. Make detailedcomparisons of the machines underconsideration before purchase.Cat dealers can estimate componentlife, preventive maintenance cost,and the true cost of lost production.

Purchase. Look past initial price.Consider the financing options available,as well as day-to-day operating costs.This is also the time to look at dealerservices that can be included in the costof the machine to lower equipmentowning and operating costs over thelong run.

Financing. Your dealer is an expertat arranging affordable financingoptions for all Caterpillar products.

Product Support. You will find nearlyall parts at your dealer parts counter.Cat dealers use a worldwide computernetwork to locate in-stock partsto minimize machine downtime.Save money with Cat Reman parts.Receive the same warranty andreliability as new products at asavings of 40 to 70 percent.

Literature Support. Operation andmaintenance manuals are easy to use,helping you get the full value of yourequipment investment.

Customer Support Agreements.Cat dealers offer a variety of productsupport agreements, and work withcustomers to develop a plan that meetsspecific needs. Plans can cover theentire machine, including attachments,to help protect your investments.

Operation. Improving operatingtechniques can boost your profits.Your Cat dealer has training videotapes,literature and other ideas to help youincrease productivity.

Replacement. Repair, rebuild or replace?Your Cat dealer can help you evaluatethe cost involved so you can make theright choice.

Technology Products. Cat dealers offera range of advanced mining technologyproducts for customers, dealers andoperators designed to improve fleetefficiency, increase productivity andlower costs.

www.CAT.com. For more completeinformation on Cat products, dealerservices, and industry solutions, visit uson the web at www.CAT.com.

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Customer SupportCaterpillar dealers have what it takes to keep mining haul trucks productive.

18 785C Mining Truck specifications

Final Drives

Differential Ratio 2.10:1Planetary Ratio 10.83:1Total Reduction Ratio 22.75:1

• Planetary, full-floating.

Suspension

Effective Cylinder Stroke – Front 306.5 mm 12.1 inEffective Cylinder Stroke – Rear 165 mm 6.5 inRear Axle Oscillation ±5.5°

Brakes

Brake Surface – Front 61 270 cm2 9,497 in2

Brake Surface – Rear 89 729 cm2 13,908 in2

Standards SAE J1473 OCT90 ISO 3450-1985

• Maximum operating weight up to 249 480 kg (550,000 lb).

Body Hoists

Pump Flow – High Idle 750 L/min 198 gal/minRelief Valve Setting – Raise 17 238 kPa 2,500 psiBody Raise Time @ High Idle 15.2 SecondsBody Lower Time Float 16.2 SecondsBody Power Down @ High Idle 15.9 Seconds

• Twin, two-stage hydraulic cylinders mounted inside mainframe; double-acting cylinders in second stage.

• Power raise in both stages; power down in second stage.

Approximate Weights – Dual-slope

Gross Vehicle 95 710 kg 211,040 lbChassis 74 450 kg 164,170 lbBody 21 250 kg 46,865 lbFront Axle – Empty 47 %Front Axle – Loaded 33 %Rear Axle – Empty 53 %Rear Axle – Loaded 67 %

Approximate Weights – Flat Floor

Gross Vehicle 102 130 kg 225,200 lbChassis 74 450 kg 164,170 lbBody 25 690 kg 56,630 lbStandard Liner 2000 kg 4,400 lbFront Axle – Empty 47 %Front Axle – Loaded 33 %Rear Axle – Empty 53 %Rear Axle – Loaded 67 %

• Percentages represent weight distribution without liner.

Engine

Engine Model Cat 3512B EUIGross Power 1082 kW 1,450 hpFlywheel Power 1005 kW 1,348 hpNet Power – Cat 1005 kW 1,348 hpNet Power – ISO 9249 1005 kW 1,348 hpNet Power – SAE J1349 (6/95) 1005 kW 1,348 hpNet Power – EEC 80/1269 1005 kW 1,348 hpTorque rise 23%Bore 170 mm 6.7 inStroke 190 mm 7.5 inDisplacement 51.8 L 3,158 in3

• Net power advertised is the power available at rated speedof 1750 rpm, measured at the flywheel when the engine isequipped with fan, air cleaner, muffler and alternator.

• Ratings based on standard air conditions of 25° C (77° F) and99 kPa (29.32 Hg) dry barometer. Power based on fuel havingAPI gravity of 35 at 16° C (60° F) and an LHV of 42 780 kJ/kg(18,390 BTU/lb) when engine used at 30° C (86° F).

• No engine derating required up to 3050 m (10,000 ft) altitude.• Compliant with U.S. Environmental Protection Agency Tier I

emissions standards.

Weights

Gross Machine Operating Weight 249 480 kg 550,000 lbOperating Weight – Empty – 102 130 kg 225,200 lbFlat Floor BodyOperating Weight – Empty – 95 710 kg 211,040 lbDual-Slope BodyOperating Weight – Loaded 249 480 kg 550,000 lb

Operating Specifications

SAE (2:1) Capacity 78 m3 102 yd3

Nominal Payload Capacity 136 tonnes 150 tonsTop Speed – Loaded 56 kph 35 mphMaximum Capacity CustomMaximum Capacity Struck (SAE) CustomCircle Clearance Diameter 30.5 m 99.2 ft

• Refer to the Caterpillar Mining Truck 10-10-20 payload policyfor maximum gross machine weight limitations.

Transmission

Forward 1 12.1 kph 7.5 mphForward 2 16.3 kph 10.2 mphForward 3 22.2 kph 13.8 mphForward 4 29.9 kph 18.6 mphForward 5 40.6 kph 25.2 mphForward 6 54.8 kph 34 mphReverse 11 kph 6.8 mph

• Maximum travel speeds with standard 33.00-R51 tires.

19785C Mining Truck specifications

ROPS

ROPS Standards SAE J1040 APR88ISO 3471:1994

• ROPS (Rollover Protective Structure) for cab offered byCaterpillar meets SAE J1040 APR88 and ISO 3471:1994Level II ROPS criteria.

Sound

Sound Standards ANSI/SAE J1166 MAY90SAE J88 APR95

• The operator sound exposure Leq (equivalent soundpressure level) measured according to work cycleprocedures specified in ANSI/SAE J1166 MAY90 is 80 dB(A)for cab offered by Caterpillar, when properly installed andmaintained and tested with doors and windows closed.

• The exterior sound pressure level for the standard machinemeasured at a distance of 15 m (49 ft) according to the testprocedures specified in SAE J88 APR95, mid-gear movingoperation is 89 dB(A).

• Hearing protection may be needed when operating withan open operator station and cab (when not properlymaintained or doors/windows open) for extended periodsor in a noisy environment.

Steering

Steering Standards SAE J1511 OCT90ISO 5010:1992

• Turning diameter on front wheel track with standard tires:27.5 m (90 ft 2 in).

• Machine clearance turning circle: 30.2 m (99 ft 2 in).• Steering angle, left or right: 36 degrees.• Separate hydraulic system prevents cross contamination.

Tires

Standard Tire 33.00-R51 (E4)33.00-R51 (E3)

• Productive capabilities of the 785C truck are such that,under certain job conditions, TKPH (TMPH) capabilities ofstandard or optional tires could be exceeded and, therefore,limit production.

• Caterpillar recommends the customer evaluate all jobconditions and consult the tire manufacturer for propertire selection.

Capacity – Dual-slope – 100% fill factor

Struck 57 m3 74 yd3

Heaped 2:1 (SAE) 78 m3 102 yd3

Capacity – Flat Floor – 100% fill factor

Struck 74 m3 96 yd3

Heaped 2:1 (SAE) 91 m3 119 yd3

Service Refill Capacities

Fuel Tank 1893 L 500 galCooling System 379 L 100 galCrankcase 204 L 54 galDifferentials and Final Drives 436 L 115 galSteering Tank 90 L 24 galSteering System (Includes Tank) 117 L 31 galBrake/Hoist Hydraulic Tank 337 L 89 galBrake/Hoist System (Includes Tank) 641 L 169 gal

Dimensions

Height to Top of ROPS 5122 mm 202 inOverall Body Length 10 615 mm 418 inInside Body Length 7652 mm 301 inOverall Length 11 022 mm 434 inWheelbase 5180 mm 204 inRear Axle to Tail 3410 mm 134 inGround Clearance 987 mm 39 inDump Clearance 1284 mm 51 inLoading Height – Empty 4968 mm 196 inRear Sidewall Height 906 mm 36 inInside Body Depth – Max 2132 mm 84 inOverall Height – Body Raised 11 207 mm 441 inOperating Width 6640 mm 256 inCenterline Front Tire Width 4850 mm 191 inEngine Guard Clearance 1057 mm 41 inOverall Canopy Width 6200 mm 249 inOutside Body Width 5890 mm 232 inInside Body Width 5510 mm 217 inFront Canopy Height 5769 mm 227 inRear Axle Clearance 1080 mm 43 inCenterline Rear Dual Tire Width 4285 mm 169 inOverall Tire Width 6277 mm 247 in

DimensionsAll dimensions are approximate.


11

3

1

7

5

4

6

8

9

10

12 14

15

13

16

17

18

19

20

21

22

2

1 Height to Top of ROPS 5122 mm 202 in2 Overall Body Length 10 615 mm 418 in3 Inside Body Length 7652 mm 301 in4 Overall Length 11 022 mm 434 in5 Wheelbase 5180 mm 204 in6 Rear Axle to Tail 3410 mm 134 in7 Ground Clearance 987 mm 39 in8 Dump Clearance 1284 mm 51 in9 Loading Height – Empty 4968 mm 196 in10 Rear Sidewall Height 906 mm 36 in11 Inside Body Depth – Max 2132 mm 84 in

12 Overall Height – Body Raised 11 207 mm 441 in13 Operating Width 6640 mm 256 in14 Centerline Front Tire Width 4850 mm 191 in15 Engine Guard Clearance 1057 mm 41 in16 Overall Canopy Width 6200 mm 249 in17 Outside Body Width 5890 mm 232 in18 Inside Body Width 5510 mm 217 in19 Front Canopy Height 5769 mm 227 in20 Rear Axle Clearance 1080 mm 43 in21 Centerline Rear Dual Tire Width 4285 mm 169 in22 Overall Tire Width 6277 mm 247 in


0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

mph

kg x 1000

5th Gear

2nd Gear

6th Gear

1st Gear

4th Gear

3rd Gear

LE

E

FFEC

TIVE

GRA

DE

(Fav

orab

le)

Gross Weight

lb x 1000

25%

5%

10%

15%

20%30%

SPEEDContinuous Grade Length

0 50 100 150 200 250 300

Gross Machine Operating Weight249 500 kg/550,000 lb

Typical Field Empty Weight

0 100 200 300 400 500 600

0 5 10 15 20 25 30 35 40 45 50

To determine retarding performance: Add lengths of alldownhill segments and, using this total, refer to properretarding chart. Read from gross weight down to the percenteffective grade. Effective grade equals actual % grade minus1% for each 10 kg/t (20 lb/ton) of rolling resistance. From thisweight-effective grade point, read horizontally to the curvewith the highest obtainable gear, then down to maximumdescent speed brakes can properly handle without exceeding

cooling capacity. The following charts are based on theseconditions: 32° C (90° F) ambient temperature, at sea level,with 33.00-R51 tires.

NOTE: Select the proper gear to maintain engine rpm at the highestpossible level, without overspeeding the engine. If cooling oiloverheats, reduce ground speed to allow transmission to shift tothe next lower speed range.

Retarding Performance


0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

mph

kg x 1000

5th Gear

2nd Gear

6th Gear

1st Gear

4th Gear

3rd Gear

LE

EFFE

CTIV

E G

RAD

E (F

avor

able

)

Gross Weightlb x 1000

25%

5%

10%

15%

20%30%

SPEEDGrade Distance — 450 m (1500 ft.)

0 50 100 150 200 250 300



0 100 200 300 400 500 600

0 5 10 15 20 25 30 35 40 45 50

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

mph

kg x 1000

5th Gear

2nd Gear

6th Gear

1st Gear

4th Gear

3rd Gear

LE

EFFE

CTIV

E G

RAD

E (F

avor

able

)Gross Weight

lb x 1000

25%

5%

10%

15%

20%30%


0 50 100 150 200 250 300



0 100 200 300 400 500 600

0 5 10 15 20 25 30 35 40 45 50



0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

mph

kg x 1000

5th Gear

2nd Gear

6th Gear

1st Gear

4th Gear

3rd Gear

LE

EFFE

CTIV

E G

RADE

(Fav

orab

le)


25%

5%

10%

15%

20%30%

SPEED Grade Distance — 900 m (3000 ft.)

0 50 100 150 200 250 300


Typical Field Weight

0 100 200 300 400 500 600

0 5 10 15 20 25 30 35 40 45 50

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 km/h

mph

kg x 1000

5th Gear

2nd Gear

6th Gear

1st Gear

4th Gear

3rd Gear

LE

EFFE

CTIV

E G

RADE

(Fav

orab

le)


25%

5%

10%

15%

20%30%


0 50 100 150 200 250 300



0 100 200 300 400 500 600

0 5 10 15 20 25 30 35 40 45 50



mph

km/h

33.00-R51 TiresGross Weight

70 100 150 200 300 400 600 lb x 1000

90

70

50

40

30

20

15

10

5

3

2

1

200

100

50

20

10

5

2

0 5 10 15 20 25 30 35 40 45 50

0 10 20 30 40 50 60 70 80

SPEED

RIM

PULL

TOTA

L RE

SIST

AN

CE(G

rade

plu

s Ro

lling

)

5 15 25 35 45 55 65 75

20 30 40 50 70 100 150 200 300 kg x 1000

1st Gear

1st Gear

2nd Gear

3rd Gear

4th Gear

5th Gear

6th Gear

4%

6%

8%

10%

15%

LE

20%

25%30%

2%

kg x1000

lb x1000

Torque Converter Drive

Direct Drive

To determine gradeability performance: Read from grossweight down to the percent of total resistance. Total resistanceequals actual percent grade plus 1% for each 10 kg/t (20 lb/ton)of rolling resistance. From this weight-resistance point, read

horizontally to the curve with the highest obtainable gear, thendown to maximum speed. Usable rimpull will depend upontraction available and weight on drive wheels.

Gradeability/Speed/Rimpull


136 080 kg (300,000 lb) Load


Standard EquipmentStandard and optional equipment may vary. Consult your Caterpillar dealer for specifics.

Crankcase ProtectionDriveline Operator Safety GuardDumping, Auxiliary Quick Connect for “Buddy Dumping”Electrical System, 24-volt to 12-voltEngine – Caterpillar 3512B with Electronic Injection and

Multi Point Oil Pressure SensingFast-fill Fuel System, WigginsGround Level

Battery DisconnectEngine ShutdownVIMS Dataport

Lighting SystemBack-up Lights, HalogenDirection Signals and Hazard Warning (Rear Halogen)Headlights, Halogen, With DimmerLH Ladder Light and Service Deck LightsStop and Tail Lights (LED)Under-hood Light

Oil Change System, Quick ServiceReservoirs (Separate)

Brake/Converter/HoistSteeringTransmission

Rims, Center Mounted for 33.00-R51 TiresRock EjectorsStarting Aid, Ether, AutomaticSteering, Auxiliary Quick Connect for TowingTie Down EyesTow Hooks, FrontTow Pin, RearTraction Control SystemTransmission, Six-speed, Automatic Power Shift, ElectronicControl and Downshift Inhibitor, Reverse Neutralizer duringDumping, and Neutral Start Switch, Reverse Shift Inhibitor,Controlled Throttle Shifting, Directional Shift Management,Neutral Coast Inhibitor, Body-up Shift InhibitorVandalism Protection LocksVital Information Management System with True WeightProduction Manager

Air Cleaner with Precleaner (2)Air ConditionerAir Line Dryer (2)Air Starter, Vane-typeAlarm, Back-upAlternator (105-amp)Automatic Retarder ControlBatteries, 93-amp-hour, Low-maintenance, 12-volt (2)Body Mounting GroupBody Prop CableBrake Release Motor for TowingBrake System

Oil-cooled, Multiple-disc, Front and RearParkingSecondary, Emergency

Cab, ROPSAshtrayCigarette LighterCoat HookDiagnostic ConnectorElectric Window (Operator Only)Entertainment Radio ReadyGlass, TintedHeater/defroster: 11 070 kCal (43,930 Btu)HornInsulated and Sound SuppressedLight, Dome/courtesyMirrors, Right and LeftQuad-Gauge Panel

Air PressureBrake Oil TemperatureCoolant TemperatureFuel Level

Seat, Air SuspensionSeat, Passenger, Non-suspensionSeat Belts, 75 mm (3") wide retractableSpeedometerSteering, Automatic SupplementalSteering Wheel, Tilt, Padded, TelescopicStorage CompartmentSun VisorTachometerTransmission Gear IndicatorVIMS Dataports (2)VIMS KeypadVIMS Message Center with Universal GaugeWindshield Wiper and Washer


Optional EquipmentWith approximate changes in operating weights.Optional equipment may vary. Consult your Caterpillar Dealer for specifics.

kg lb

Bodies see chart below

Body extensions:

Tail 665 1465

Sideboards1 798 1760

Body heat (exhaust) 36 80

Body and tail extension liners2

Full-length liner 7633 16,828

Tail extension liner3 338 745

Grid liner4 1145 2525

Fuel tank 2500 L (660 gal.) 209 460

Heater, fuelrecirculation type, non-electric 2 5

kg lb

Heater, engine coolant and oil120-volt external power source 2 5

Heater, engine coolant and oil240-volt external power source 10 22

Oil Renewal System 11 25

Prelube system 24 53

Rim, spare for 33.00-R51 tire 889 1960

Shutter group, inside mounted 265 585

Starting system

Air (TDI Turbine) –5 –10

Air (IR Turbine) –17 –37

Variable pitch fan, Flexxaire 273 600

Variable speed fan, Rockford 182 4001 Increases capacity to 91 m3/119 yd3

2 Minimum yield strength 900 mPa/9000 Bar/130,500 psi; 400 Brinell steel3 Use with full liners when tail extension used4 Covers rear third of body only

Flat Floor Dual Slopekg lb kg lb

Empty Chassis Weight 55 421 122,180 55 421 122,180

Fuel Tank and Fuel 1892 L (500 gal.) 2232 4920 2232 4920

Tires (33.00-R51) 10 492 23,130 10 492 23,130Rims 610 mm (24 in.) 6323 13,940 6323 13,940

Chassis Weight 74 468 164,170 74 468 164,170

Debris Allowance (4% of chassis) 2979 6567 2979 6567

Body Weight 25 687 56,630 21 258 46,865

Body Attachments Weight 1996 4400 0 0

Additional Attachments Weight +0000 +0000 +0000 +0000

Total Empty Operating Weight 105 129 231,767 98 704 217,602

Target Payload 144 351 318,233 150 776 332,398

Gross Machine Operating Weight 249 480 550,000 249 480 550,000

*Note: Refer to Caterpillar’s 10/10/20 Payload Policy for calculating maximum gross machine weight allowable.

Weight/Payload Calculation*(Example)

785C Mining Truck specifications 27

Notes

R

For more complete information on Cat products, dealer services, and industry solutions, visit us on the web at www.CAT.com

© 2002 CaterpillarPrinted in U.S.A.

Materials and specifications are subject to change without notice.Featured machines in photos may include additional equipment.

See your Caterpillar dealer for available options.

AEHQ5320-02 (4-02)

Replaces AEHQ5320-01

785C Mining Truck

specalog for 785c mining truck aehq5320-02 · engine @ 1750 rpm engine model cat® 3512b eui gross...

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