specalog for 789c mining truck...
TRANSCRIPT
Cat® 3516B Electronic Unit Injection EngineGross power at 1750 rpm 1417 kW 1900 hpFlywheel power at 1750 rpm 1335 kW 1791 hp
Body capacity (SAE 2:1) 105 m3 137 yd3
Max. operating weight 317 520 kg 700,000 lbPayload weight
Standard configuration 154-177 metric tons 170-195 tons
®®
789CMining Truck
2
789C Mining TruckEngineered for performance, designed for comfort, built to last.
Mechanical Power TrainStarting with the high torque rise,Caterpillar® 3516B, Electronic UnitInjection (EUI) diesel engine, through theelectronic, six-speed power shifttransmission, the mechanical power trainis designed and built by Caterpillar,assuring the highest standards forquality, performance, efficiency andreduced operating costs.
pg. 4-5
Oil-cooled Disc BrakesCaterpillar four-wheel forced oil-cooled, multiple disc brakes arecontinuously cooled for exceptional,non-fade braking and retarding. TheIntegrated Braking Control (IBC)system integrates the AutomaticRetarder Control (ARC) on all wheelsand Traction Control System (TCS) ondrive wheels only into one system toenhance truck performance andproductivity and improve operatorconfidence. pg. 8
Engine Power Train IntegrationThe Caterpillar intelligent power traincombines engine, transmission andbrake information over the CAT DataLink to optimize overall truckperformance. The CAT Data Linkallows the engine and transmission toelectronically exchange information sothe components work together as asystem for increased component lifeand improved operator comfort. TheElectronic Technician (ET) softwareprogram can access stored diagnosticdata to significantly reduce downtimeand improve troubleshooting. pg. 6-7
✔
Top performance.The 789C is designed for highproduction and low cost-per-tonhauling in mining applications.
Reliable, durable operation.Rugged construction and easymaintenance guarantee extendedlife with low operating costs.
3
StructuresCaterpillar truck frames are built toresist the most severe twisting, highimpact applications. Mild steel providesflexibility, durability and resistance toimpact loads even in cold climates. Theframe incorporates 21 castings and twoforgings in high stress areas forincreased strength and extended life.pg. 10
Operator’s StationThe 789C operator’s station has beensignificantly improved over previousmodels by ergonomically designing fortotal machine control in a comfortableand productive environment. Allcontrols, levers, switches and gaugesare positioned to maximize productivityand minimize operator fatigue.Electronic hoist control provides ease ofoperation. The integral ROPS structureprovides superior operator protection. pg. 12
✔ New feature
✔
Vital Information Management System(VIMS) VIMS monitors vital machine systemsand functions. It helps coach theoperator in the operation of the machineand alerts him to out of specificationconditions. Down time is reduced byallowing service personnel to accessmachine data for faster, more accuratediagnosis. VIMS provides informationto enhance equipment management,increase productivity and reduce cost-per-ton. pg. 13-14
4
The Caterpillar Electronic Unit Injector(EUI) diesel engine is a four-strokedesign that uses long, effective powerstrokes for more complete fuelcombustion and optimum efficiency.The 3516B is a high displacement andlow operating rpm engine, designed forextended hours of service betweenscheduled overhauls and reducedoperating costs.
The 23 percent torque rise provideshigh lugging force during accelerationand less down shifting on grade or insoft underfooting for faster cycle times.Torque rise effectively matches thetransmission shift points to maximizeefficiency and yield higherperformance.
The 3516B engine provides unmatchedcombustion efficiency:
■ Electronic Unit Injector (EUI) is aproven high-pressure, direct injectionfuel system. New components of thefuel system provide 22 percent higherinjection pressures than the previousgeneration of 3500 engines. Thehigher pressures provide improvedresponse time and more efficient fuelburn with lower emissions and lesssmoke.
■ Electronic Control Module (ECM)utilizes advanced engine managementsoftware to monitor, control andprotect the engine utilizing self-diagnosing electronic sensors. Themodule controls a wide spectrum ofengine functions, providing infinitelyvariable injection timing to maintainpeak performance.
■ Two-piece articulated pistons utilizea deep bowl, low crevice volumedesign that enhances combustionefficiency, improves fuel efficiency,and lowers emissions.
■ Separate circuit aftercooler allowsthe aftercooler coolant to operate atlower temperatures than jacket waterfor a denser air charge in thecombustion chamber.
Results:
■ 3516B EUI has improved fuelefficiency by three percent; NOxlevels are reduced by 20 percent andtransient smoke levels are down by asmuch as 15 percent. No derating up to2290 m (7,500 ft.).
Proven reliability, durability andenhanced serviceability:
■ 500 hour service interval for engineoil, oil and fuel filter changes,increasing mechanical availabilityand production.
■ Additional electronic protection of theengine during cold starts, highaltitude operations, air filter pluggingand high exhaust temperatureconditions.
■ Quick diagnosis of engine conditionsenable effective maintenance andrepairs utilizing the ElectronicTechnician (ET) service tool.
EngineThe field proven 3516B EUI engine delivers the power and reliability necessaryto perform in the world’s most demanding mining applications.
5
Mechanical Power TrainCompletely designed and manufactured by Caterpillar to assure maximum efficiency, high quality, extended service life and low operating costs.
3 Large, differential and double-reduction final drives provide torquemultiplication of 28.8:1 to furtherreduce stress on the drive train.
The hydraulic steering system providesprecise, controllable steering:
■ The steering system is a separatecircuit from the other hydrauliccircuits to prevent crosscontamination and provide easierserviceability.
■ Supplemental steering is provided byaccumulators for emergency use.Designed to provide at least three 90degree turns after engine failure.
Cat center mounted rims and cast rearwheels are mounted using studs andnuts to minimize maintenance andprovide outstanding durability.
The CAT mechanical power train isdesigned for optimum componentmatch. A wide application range isavailable in each gear. A 35 percentstep between each gear allows thetransmission to utilize the full torquerange of the 3516B engine, resulting infewer shifts for extended power trainlife.
■ Overall power train efficiency ofbetween 82 and 85 percent ismaintained up to 15 percent effectivegrade.
■ Electric drive power train trucksproduce their peak efficiency of 76 to79 percent at approximately five toseven percent effective grade.
■ Higher power train efficiencyprovides faster truck speeds with lessfuel consumption.
Transmission/Chassis Control (TCC)module communicates over the CATData Link with the engine ECM tomanage engine speed during shifts forincreased clutch life and operatorcomfort. When the transmission is insixth gear, the engine is allowed to runout to 2000 rpm, so the truck canachieve speeds up to 54 km/h (34 mph).The shifts points are set at the factoryfor optimal performance, efficiency andcomponent life.
■ TCC monitors and records keyoperating conditions and parametersfor later downloading and diagnostictroubleshooting by service personnel.
1 Lock-up Torque Converter combinesthe maximum rimpull and cushionedshifting of torque converter drivewith the efficiency and performanceof direct drive. The lock-up clutchengages at approximately 7.2 km/h(4.5 mph). During shifts the lock-upclutch quickly releases and re-engages to reduce power train torqueloads. This action provides forsmoother shifting, extendedcomponent life, and increasedoperator comfort.
■ Rimpull at stall is 785 kN (176,600 lb) – 26 percentgradeability at maximumoperating weight.
2 Six speed, planetary power shifttransmission is designed for thehigher horsepower of the 3516Bengine. The design makes the newtransmission more robust, with an extended life between overhauls. To accomplish this, the transmissionutilizes an additional clutch disk andplate to transmit the horsepower.
■ The transmission utilizes adedicated oil tank and circuit forcooler, cleaner oil and extendedcomponent life.
1
2
3
6
Engine/Power Train IntegrationCombining the electronic engine control with the Caterpillar electronically programmabletransmission control allows these critical power train components to work more intelligently.
The CAT Data Link electronicallyconnects the engine and transmissioncontrols to optimize overall power trainperformance, reliability and componentlife for reduced power train operatingcosts. To lower operating cost-per-tonthe system incorporates:
■ Controlled throttle shift. Engine rpmis regulated during a shift to reducedriveline torque stress for smoothershifts, extended component life andimproved operator comfort.
■ Directional shift managementregulates engine speed duringdirectional shifts to prevent damagecaused by high speed directionalchanges. This prevents shifts intoreverse when forward ground speedsare in excess of 4.8 km/h (3 mph).This protects the transmission fromhigh shock loads created by abusivedirectional shifts.
■ Neutral coast inhibitor prevents thetransmission from shifting to neutralat speeds above 6.5 km/h (4 mph).This protects the transmission againstoperating with insufficientlubrication.
■ Body-up shift inhibitor prevents thetransmission from shifting above thepre-programmed gear without thebody fully lowered.
■ Reverse neutralized with body-up. If the hoist lever is activated and thetransmission is in reverse, thetransmission will automatically shiftto neutral.
■ Engine overspeed protection. Thetransmission control senses possibleoverspeed conditions and up shiftsone gear. If overspeed conditionsoccur in top gear, the lock-up clutchis disengaged.
■ Programmable top gear. Thetransmission top gear may beelectronically set using ET. Thisfeature helps operators maintainspeed limits. Reprogramming of thetop gear can only be accomplishedwith the ET service tool.
■ Anti-hunt function. The transmissionwill not allow an upshift ordownshift for approximately 2.3seconds after a shift has occurred.This prevents gear hunting whenoperating near a shift point andminimizes transmission shifts toincrease component life.
■ Downshift inhibitor. The transmissionwill not allow a down shift to occuruntil engine speed reaches thedownshift point, preventing an engineoverspeed condition.
1
2
10
9
11
VIMS
VIMS MainModule
7
■ Electronic Technician (ET) allowsfor easy access to service diagnosticdata through the use of a singleservice tool.
■ ET accesses data stored in the engineand transmission controls via theCAT Data Link. Information ontransmission shift data, engine speed,fuel consumption and other data canbe retrieved by ET.
Integrated Braking Control (IBC)combines braking controlenhancements into one system forefficiency and simplification. IBCsystems, Automatic Retarder Control(ARC), and Traction Control System(TCS) both utilize the standard oilcooled disc brakes in their operation.
Improved diagnostics/serviceability.The electronic engine and transmissioncontrols provide enhanced diagnosticcapability. The ability to store bothactive and intermittent indicators willsimplify problem diagnosis and totalrepair time, resulting in improvedmechanical availability and loweroperating cost.
3
48
56
7
ET
1 Gauge Cluster Module
2 Message Center Module
3 Integrated Braking Control (IBC)
4 Transmission/Chassis Control (TCC)
5 Brakes
6 Wheel Sensor
7 Transmission
8 CAT Data Link
9 Engine Control Module (ECM)
10 Sensors
11 Electronic Unit Injector (EUI)
8
Oil-cooled Disc BrakesReliable braking gives operators the confidence to concentrate on truck operation andmaximize productivity.
1 Parking/Secondary Piston
2 Service/Retarding Piston
3 Friction Discs
4 Steel Plates
5 Actuating Springs
6 Cooling Oil In
7 Cooling Oil Out
2
5
4
3
1
6
7
Caterpillar four-wheel forced oil-cooled, multiple disc brakes arecontinuously cooled for exceptional,non-fade braking and retarding. TheIntegrated Braking Control (IBC)combines control of ARC and TCS,utilizing standard oil-cooled brakes toenhance truck performance and increaseproductivity.
Oil-cooled disc brakes are designedwith large discs and plates for reliable,adjustment-free operation, providingsuperior performance and service life incomparison to shoe-type and dry discbrake systems.
An oil film prevents direct contactbetween the discs. The film absorbs thebraking forces by shearing the oilmolecules. The heat generated istransferred to the oil and carried awayto oil coolers, extending brake life.
Caterpillar’s patented, two-pistondesign combines the service, secondary,parking brake and retarding functions inthe same robust system.
■ The primary piston is hydraulicallyactuated and provides both serviceand retarding functions.
■ The secondary piston is spring-applied and is held in the disengagedposition by hydraulic pressure.
■ The brake system is designed so that,in the event hydraulic systempressure drops below a specifiedlevel, the spring-applied secondarypiston automatically applies thebrakes. These brakes are designed tohold a fully loaded truck on a 15percent grade.
No fuel is used during retarding. Theengine provides additional retarding byrunning against compression ondownhill hauls. During retardingapplications the engine ECM does notinject fuel into the cylinders forexceptional fuel economy.
Four corner retarding with 60/40percent split (rear/front) in brakingeffort provides superior control inslippery conditions. Control at all fourcorners increases operator confidencewhen compared to only rear wheeldynamic retarding systems.
9
Integrated Braking Control (IBC)Electronically combines Automatic Retarding Control (ARC) and the Traction ControlSystem (TCS) into one, integrated control system.
ARC Production Advantages2500
2000
1500
1000
500
10Time (Seconds)
20 30 40 50 60
With Automatic Retarder Control(average speed, 1950 rpm)
With Manual Retarder Control(average speed, 1730 rpm)
Engi
ne S
peed
(rpm
)
700
The Automatic Retarder Control (ARC)is an integral part of the intelligentpower train. It electronically controlsretarding on grade to maintain optimumengine rpm and oil cooling. Settings areadjustable from 1850-1950 rpm inincrements of 10 rpm. While ARCmodulates the brakes, the operator mayalso apply additional braking forceusing either the manual retarder or thebrake pedal. When the operator appliesthe throttle, ARC is deactivated. Anauto resume feature reactivates thecontrol without additional operatorinput.
ARC results in:
■ Increased production with fasterdownhill speeds. By maintainingconsistently higher engine speeds,overall truck speed will be higherthan a manually controlled truck.
■ Excellent controllability and reducedoperator effort. Automatic brakemodulation provides a smoother ride,better control in slippery conditionsand allows the operator to focus moreon driving.
■ Faster troubleshooting and diagnosiswith self-diagnostic capability andthe ability to communicate with ETthrough the CAT Data Link.
■ Reduced operator fatigue resultingfrom ease of operation.
■ Engine overspeed protection.ARC will automatically activatewhen engine speed exceeds factorypreset levels, regardless of otheroperator inputs, including when thesystem is turned “off”, to help ensurethat engine overspeed conditions donot occur.
ARC production advantages (versusmanual retarder control) are illustratedin the chart below.
■ ARC can increase vehicle speed byas much as 15 percent over manualretarder control.
■ The system allows trucks to operateat maximum speeds with aconsistently high engine speed.
■ Truck handling is significantlyenhanced through improved retardingmodulation.
Traction Control System (TCS) improvestraction and truck performance in poorunderfoot conditions by electronicallymonitoring and controlling rear wheelslippage.
■ Axle sensors monitor wheel speed. Ifslippage exceeds a set limit, the oilcooled disc brakes engage to slow thespinning wheel. Torque is thenautomatically transferred to the wheelwith better traction.
■ Utilizes normal differential action toprovide superior maneuvering in poorunderfoot conditions. Should thesensors fail, normal differential actionis still available to maintain controland steering.
■ Operators feel more confident withthe anti-slip benefits provided by theTCS.
1 Service Brake Sensor
2 Engine Sensor
3 ARC
4 ARC Switch
5 Brakes
6 Service Brakes
7 Axle Speed Sensor
8 TCS
7
8
1 2
6
3
4
5
6
7
ARC TCS
The 789C frame uses a box-sectiondesign and deep penetrating,continuous wrap around welds to resistdamage from twisting loads withoutadding extra weight. Frame repairs canbe made without preheating in ambienttemperatures above 16° C/60° Favoiding metallurgy destruction.
■ Caterpillar truck frames use mildsteel providing flexibility, durabilityand resistance to impact loads evenin cold climates.
■ The frame incorporates two forgingsand 21 castings in high stress areasproviding increased strength overfabricated structures.
StructuresThe backbone of the Cat truck.
■ Rear cylinders allow axle oscillationand absorb the bending and twistingstresses caused by uneven and roughhaul roads rather than transmit themto the main frame.
■ Front cylinders are mounted to theframe and serve as steering kingpins.This provides for a tight turningradius, good maneuverability andreduced truck maintenance. Frontspindles and wheels are rigidlymounted to the cylinder rod ends,eliminating caster and camberadjustments.
■ Front wheel caster and camber areset at the factory, no longer requiringfield adjustments.
10
2
1 Castings have large radii and areused in areas of high stressconcentration to dissipate the stressesthat can cause fatigue and cracking.
■ Castings allow welds to berelocated to areas of lower stress,enhancing frame life.
2 Rollover Protection Structure (ROPS)is integral to the cab and integral tothe frame. The cab is resilientlymounted to the frame to reducevibration and noise levels.
The suspension system is designed todissipate haul road and loadingimpacts:
■ Four, independent variable reboundsuspension cylinders absorb shocksbefore forces get to the mainframe.This extends frame life and providesthe operator a more comfortable ride.
1
1
1
11
Truck BodyCaterpillar builds a variety of rugged, durable bodies to perform in the toughest miningapplications.
1 Standard dual-slope body designprovides excellent load retention, alow center of gravity and cleandumping characteristics.
■ Reinforced, rolled steel top railincreases body strength andprotects the body from damagecaused by the loading tool orfalling material.
■ Eight degree “V” reduces shockloading and centers the load.
■ 7.5 degree forward body slope and16 degree ducktail slope helpsretain loads on steep grades.
■ Box-beams in floor, sidewalls, toprail, corner and cab canopy areasprovide added impact resistance.
2 Flat floor body design providessmooth, metered dumping and higherdump clearances.
■ Flat floor design improves wearcharacteristics of body tail.
■ 12 degree forward slope.
■ 400 Brinell steel.
Custom truck body options are availableto match individual mine applications.These products are specificallydesigned to match material hauled andprovide extended service life. YourCaterpillar Dealer, through CustomProducts, can provide a body systemthat will help you obtain the lowestcost-per-ton hauling solution.
■ Lightweight bodies to maximizepayloads in lighter, less abrasivematerial.
■ Bodies to allow easy unloading ofsticky materials with high contactadherence qualities.
■ Bodies that provide a larger targetarea for the loading tool.
■ Miscellaneous products availableinclude: ducktail extensions, sideboards, tumblebars, rock boxes androck shedders.
Liner options are available to helpextend the body system’s life. A variety of steel grades provideoptions to absorb impacts whileresisting abrasion. Numerous optionscan be configured to save weight andextend the life:
■ A variety of steel grades: 260, 400and 500 Brinell hardness as well asoverlay coatings.
■ Wear plates in high wear areas.
■ Attachment options, huck bolting andwelding.
1
2
12
The operating station on the 789C isergonomically designed for excellentmachine control in a comfortable,productive, and safe environment.
Exceptional all-around visibilityreduces strain and fatigue allowingconfident maneuvering and increasedproductivity.
Integral, sound-suppressedROPS/FOPS Cab is standard. The cab isresiliently mounted to the mainframeand isolates the operator from soundand vibration. (Sound levels are lessthan 80 dB(A) in the operatorcompartment as per SAE J1166 workcycle rating.)
1 Ergonomically designed, airsuspension seat is fully adjustablefor operator comfort.
■ Retractable 75 mm (3") wideseat belt provides positive,comfortable restraint.
■ Integral adjustable armrest.
2 Electric hoist control is mountednext to the operator’s seat for easeof operation. This is a low effortcontrol to minimize operator input.
3 Secondary brake pedal is locatedon the floor to provide easyoperator control.
4 VIMS displays and operator keypad for precise machine statusinformation.
5 Tilt and telescoping steering wheelimproves operator access andcomfort.
6 Transmission console has beenredesigned with backlit gearindicators and ergonomic shiftknob.
7 Large storage compartment islocated under the trainer seat.
8 Trainer seat has wide hip andshoulder room. A back rest and seatbelt are standard. An optional airsuspended seat is available.
9 Powered operator window isstandard. Sliding trainer seatwindow is standard.
10 Operator controls for turn signal,high beam, intermittent windshieldwiper, windshield washer and hornhave been redesigned for operatorefficiency and comfort.
11 Standard heater and air conditionerhave a more efficient design,permitting increased flow,modulation, and serviceability.These systems provide fresh,pressurized, temperature-controlledair circulation.
Radio ready cab prewired with powerconverter, speakers, wiring harness,and antenna. Provision for add-oncommunication systems.
Operator’s StationControl ease and comfort maximizes productivity.
3
1
2
45
6
7
8
910 11
2
13
VIMS is an integrated Caterpillar-designed system that monitors machineperformance to provide criticalinformation on a real-time basis. VIMSmonitors many of the machine’ssystems through a single simple systemthat allows quick exchange ofinformation for smooth, efficientoperations. This helps keep the 789Cperforming at top production levels.
Gauge cluster in the cab maintains aconstant display of several, machinefunctions:
■ Engine coolant temperature.
■ Brake oil temperature.
■ Air system pressure.
■ Fuel level.
Speedometer/Tachometer/GearIndicator.
VIMS keypad allows the operator orservice technician to access through themessage center, gauge values (real-time) and stored information. Thekeypad can also be used by servicepersonnel to access diagnosticinformation.
Message center displays operatorrequested information and utilizes a three-category warning system to alertthe operator to an abnormal machinecondition.
The three-category alert systemprovides advisory information on anexception basis to the operator via themessage center on abnormal machineconditions. The information isdisplayed when conditions in amonitored system fall outside aprescribed setting for ordinaryoperations.
■ Category I activates the alertindicator lamp when a systemcondition has been identified. (Noaction is required at this time.)Usually all that is required is toinform service personnel on thealerted condition as soon aspossible.
■ Category II, a warning lamp(located above the gauge cluster)flashes in addition to the Category Ialert indicator lamp in the displaypanel. Instructions are displayed onhow machine operation should bemodified or which service shouldbe performed.
■ Category III, the highest alert,sounds an audio action alert inaddition to the Category II alarms.The action lamp and alert remainon until the system readings returnto normal or the machine is shutdown.
Vital Information Management System (VIMS)Provides operators, service technicians and managers with vital machine and productiondata.
14
VIMS simplifies trouble shooting,reduces down time and lowers operatingcosts by allowing minor problems to becorrected before they cause extensivedamage. Many sensors are incorporatedinto machine systems to monitorconditions.
Production management, a featurecomponent of VIMS, enhances truckand loading tool effectiveness forimproved fleet productivity and reducedoperation and maintenance cost.
■ Utilizes Cat-developed technology tosense strut pressure to determinepayload weight accurately.
■ Maximizes truck production whileavoiding future costs and downtimerelated to overloading.
■ External lights on both sides of thetruck signal loading tool operatorwhen to cease loading.
■ Stores 2400 cycles for a record ofpayload weight, cycle segment times,cycle segment distances and actualclock time and date of each cycle.
■ Data can be accessed through themessage center, transmitted viaoptional radio or downloaded fordetailed analysis.
■ Accurate to within ±5 percent of theactual weight over a normal operatingshift.
Vital Information Management System (VIMS)Enhances truck and loader effectiveness for improved fleet productivity and reducedoperating and maintenance costs.
Well-managed mining operations focuson maximizing production and reducingcosts, which should result in lower cost-per-ton. When used properly, VIMS canbe used to increase productivity andreduce costs.
Payload Weight Distribution
Perc
enta
ge o
f Tot
al L
oads
Payload Weight (Tons)
212
2
1 Recommended Payload Ranges
Inefficient Payload Ranges
3
4
Loads using the Payload Measurement System
Loads with no Payload Measurement System4
3
The VIMS off-truck software program(VIMS-PC) allows service personnel todownload a complete record ofproduction information, machine dataevents and system diagnostics to alaptop computer.
The VIMS-PC program uses thisinformation to generate usable reportsfor better machine management. Theinformation can also be used toestablish a baseline for machineperformance in specific applications,and to:
■ Improve the effectiveness ofscheduled maintenance programs.
■ Maximize component lives.
■ Improve machine availability.
■ Lower cost-per-ton.
15
Parts availability. Most Cat parts areimmediately available off the shelf. CatDealers rely on our worldwidecomputer network to find parts instantlyand minimize your machine downtime.
Flexible financing. Your dealer canarrange attractive financing on theentire line of Cat equipment.
Machine management service. CatDealers help manage your equipmentinvestments with:
■ Vehicle systems analysis to match theright machine to your job conditions.
■ Effective preventive maintenanceprograms.
■ Diagnostic programs like ScheduledOil Sampling Analysis and TechnicalAnalysis.
■ Exchange components for quickrepairs.
■ Remanufactured products or rebuiltcomponents for maximumavailability and lower costs.
■ Information to make the most cost-effective repair option decisions.
■ Training for operators and mechanics.
Literature support. Operation andmaintenance manuals are easy to usehelping you get the full value of yourequipment investment.
Remanufactured components areeconomically available for manyCaterpillar components.
Ground-level access providesconvenient servicing to tanks, filtersand compartment drains, as well asengine shutdown capability. VIMS hasa ground-level access port for easierdownloading of information.
Caterpillar Electronic Technician (ET)accesses machine data easily. It quicklyruns tests, makes calibrations andretrieves system data to help find andcorrect problems before they becomecostly failures.
Caterpillar Electronic Technician (ET)accesses machine data easily. It quicklyruns tests, makes calibrations andretrieves system data to help find andcorrect problems before they becomecostly failures.
The maintenance platform providesaccess to engine, air filters, steeringhydraulic tank and batterycompartment.
Automatic lubrication system providesgrease to necessary components on aregular basis to reduce maintenance andimprove machine availability.
Fast fill service center (Wiggins)features high speed fuel and oilexchange.
Scheduled Oil Sampling (S•O•S) valvesspeed sampling and analysis reliability.
Oil Renewal System (ORS) is an optionavailable which extends oil changeintervals and reduces waste oil handlingby continuously burning oil from thesump through normal engine operation.Make-up oil must be added tocompensate for oil burned.
Individual, interchangeable enginecylinder heads can be removed easilyfor visual inspection of internal parts.
In-frame access allows maintenanceand minor repairs without majorcomponent removal. It also facilitatesmajor component removal andreplacement, if necessary.
Quick coupler pressure taps are locatedin most hydraulic systems providingclear, quick pressure checks anddiagnostics.
Radial seal air filters are easy tochange, reducing time required for airfilter maintenance.
Sealed electrical connectors lockoutdust and moisture. Wires are colorcoded for easy diagnosis and repair.Wiring harnesses are braided and have aprotective sheath to prevent damage.
Total Customer Support and ServiceabilityCaterpillar machines are designed to spend less time down for maintenance, allowing more time on the job.
16 789C Mining Truck specifications
TransmissionCaterpillar six-speed, electronicallycontrolled, automatic power shifttransmission.
Maximum travel speeds (37.00-R57 tires)
km/h mph
Forward 1 12.0 7.5
2 16.3 10.1
3 22.0 13.7
4 29.8 18.5
5 40.4 25.0
6 54.4 33.8
Reverse 10.9 6.8
Features
■ six speeds forward and one reverse■ reverse and first gear are both torque
converter driven with lock-up in firstthrough sixth gears
■ single-lever shift control providesautomatic shifting in all gears up tothe one selected by the control lever
■ each shift is individually modulatedfor maximum smoothness
■ separate hydraulic circuit with cooler■ controlled throttle shift and directional
shift management maximize shiftsmoothness and minimize shiftdriveline stress
■ electric control has built-indiagnostics and facility code memory,event memory and programmablefeatures
BrakesMeets the SAE J1473 OCT90, ISO 3450-1985 standards up to 317 520 kg (700,000 lb) maximum operating weight.
Features
■ service- forced-oil-cooled- air-over-oil actuated- front and rear disc brakes- sealed from dirt and water- individually serviceable as units
■ retarding system- hand operated friction lever provides
modulated engagement of servicebrakes for retarding
- Automatic Retarder Control standard
■ secondary braking- spring-engaged, hydraulically
released- use disc brakes in service system
■ parking brakes- spring-engaged, hydraulically
released- use disc brakes in service system- toggle switch activated
■ traction system- minimize wheel slip by transferring
torque to wheel with traction- Traction Control System (TCS)
standard
Braking surface 198 338 cm2 30,742 in2
EngineFour-stroke cycle, 3516B quad turbocharged and aftercooled diesel engine.
*Power rating conditions
■ based on standard conditions of 25° C (77° F) and (29.32 in Hg) dry barometer
■ used 35° API gravity fuel having anLHV of 42,780 kJ/kg (18,390 Btu/lb)when used at 30°C (86°F) [ref. a fueldensity of 838.9 g/L (7.001 lb/U.S. gal)]
■ net power advertised is the poweravailable at the flywheel when theengine is equipped with fan, aircleaner, muffler and alternator
■ no derating required up to 2300 m(7,500 ft) altitude
■ automatic derate is included in theelectronic controls
Features
■ full electronic control■ high pressure Electronic Unit
Injection■ two hard faced intake and two exhaust
valves per cylinder with valve rotatorsand hard, alloy-steel seats
■ self-aligning roller followers on camshaft
■ two-piece pistons have steel crowns,thermally isolated aluminum skirts,three rings each and are cooled bydual oil spray
■ steel backed, copper-bondedcrankshaft bearings
■ hardened crankshaft journals■ dry-type air cleaners with primary and
secondary elements and precleaner ■ 24-volt electric system with 105-amp
alternator and two 93-amp-hour, low-maintenance, high-output, 12-voltbatteries
■ vane type air starter, quick connect forsupplemental air supply which is standard
Net power kW hp
Caterpillar 1335 1791
ISO 9249 1335 1791
SAE J1349 1335 1791
EEC 80/1269 1335 1791
DimensionsBore 170 mm 6.7 in
Stroke 190 mm 7.5 in
Displacement 69 liters 4211 in3
Ratings at 1750 rpm* kW hp
Gross power 1417 1900
Net power 1335 1791
The following ratings apply at 1750 rpmwhen tested under the specified standardconditions for the specified standard:
Final DrivesDouble-reduction, planetary, with full-floating axles.
Ratios:
Bevel Gear 2.35:1
Planetary 10.83:1
Total reduction 25.46:1
17789C Mining Truck specifications
FrameFull box-section with torque tubecrossmember.
Features
■ integral front bumper■ front box beams for suspension
cylinder and ROPS support■ box-section rear crossmember for
body and ROPS support withattachment points for maintenanceplatform and rear engine hood hingesupport
■ castings are used to provide additionalstrength in critical stress areas
■ mild-steel plates (310 mPa/42,000 psiminimum yield strength) and castings(241 mPa/35,000 psi minimum yieldstrength) provide:- flexibility- durability- good resistance to impact loads
BodyStandard dual-slope main floor with “V”bottom.
Features
■ high-tensile, heat-treated steel sidewall, front wall and floor plates with900 mPa/9000 bar/130,500 psiminimum yield strength
■ exhaust heating is optional■ “V” bottom centers load and
maintains low center of gravity■ rear floor “ducktail” helps retain load
and reduce spillage■ body options to meet specific mine
application needs are availablethrough your Cat Dealer from CustomProducts
SuspensionIndependent, self-contained, oil-pneumatic suspension cylinder on eachwheel.
Features
■ variable rebound rate reduces impactand smooths ride
■ front suspension cylinders are boltedto upper and lower frame members formaximum support
■ rear sway bar attaches to frame anddifferential housing, minimizes lateralsway, improves machine handling andoperator comfort
Body HoistsTwin, two-stage hydraulic cylindersmounted outside the main frame, doubleacting in second stage.
Features
■ power raise in both stages and powerdown in first stage
■ pump capacity is 731 L/min/193 gpm■ relief valve setting is 172 bar/17 238
kPa/2,500 psi■ body raise time (1750 engine rpm) is
18.86 sec.■ body lower time
- float 17.31 sec.- power down at high idle 15.58 sec.
■ electronic body control■ automatic body-lower modulation to
reduce impact on frameCanopy plate thickness:
Front (40%) 6 mm 0.25"
Rear (60%) 10 mm 0.39"
TiresStandard: 37.00-R57 (E4)
Features
■ productive capabilities of the 789CTruck are such that, under certain jobconditions, T•km/h/Ton-mph limits ofthe tires could be exceeded and,therefore, affect production
■ Caterpillar recommends the userevaluate all job conditions and consultthe tire manufacturer to make propertire selection
ROPSIntegral ROPS cab is standard.
Features■ ROPS (Rollover Protection Structure)
offered by Caterpillar for the machinemeets ROPS criteria SAE J1040APR88, SAE J231 JAN81, ISO 3471-1994, ISO 3449-1992 LEVEL II
■ when correctly installed andmaintained, the cab offered byCaterpillar when tested with doors andwindows closed as per work cycleprocedures specified in ANSI/SAEJ1166 MAY90, results in an operatorsound exposure Leq (equivalent soundlevel) of less than 80 dB(A)
■ this operator weighted sound exposuremeets OSHA and MSHAoccupational noise exposure criteria
SteeringSeparate hydraulic system.
Features■ the steering hydraulic system is
separate from the main hydraulicsystem to prevent cross-contamination
■ secondary steering is provided bybladder-type accumulators
■ normal and secondary steeringsystems meet SAE J1511 OCT90 andISO 5010-1984 standards up tomaximum operating weight317 520 kg (700,000 lb)
■ twin, double-acting cylinders■ front suspension cylinders serve as
kingpins■ turning diameter on front wheel track
(standard tires) 27.5 m/90' 2"■ machine clearance turning circle
30.2 m/99' 2"■ steering angle (left or right) 36°
Effective cylinder stroke:
Front 318 mm 12.5"
Rear 165 mm 6.5"
Rear axle oscillation ±5.3°
Exterior Sound Rating
■ The machine in a standardconfiguration, when measured andoperated as per the prescribed modesin ANSI/SAE J88 JUN86, has a 15 msound pressure level of 89 dB(A) forthe mode that gives the highest level
18 789C Mining Truck specifications
Standard Machine kg lbChassis with hoistand body mountinggroup and tires 95 224 209,929
Option 1 body, empty26 282 57,940
Total empty weight 121 506 267,869
Max. operatingweight 317 520 700,000
Weight distribution (standard machine with body option 1):
Empty Loaded
Front Axle 46.9% 33.6%
Rear Axle 53.1% 66.4%
DimensionsAll dimensions are approximate
Service Refill CapacitiesU.S.
L Gallons
Fuel tank 3222 851
Cooling system 663 175
Crankcase 291 77
Differentials 583 154
Front wheels, each 21 5.5
Final drives, each 83 22
Steering tank 130 34
Steering system(includes tank) 189 50
Brakes, converter,Hoist tank 531 140
Brakes, converter,Hoist hydraulic tank 909 240
Transmission Hydraulic tank 76 20
Transmission system(includes tank) 224 59
Weights(approximate)
NOTE: Standard dual-slope body shown.
19789C Mining Truck specifications
Gradeability/Speed/Rimpull
To determine gradeability performance:Read from gross weight down to thepercent of total resistance. Totalresistance equals actual percent gradeplus 1% for each 10 kg/t/20 lb/ton ofrolling resistance. From this weight-resistance point, read horizontally to thecurve with the highest obtainable gear,then down to maximum speed. Usablerimpull will depend upon tractionavailable and weight on drive wheels.
mph
km/h
Gross Weight
50 70 100 150 200 300 600 700 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 Res
ista
nce
(Gra
de p
lus
Rolli
ng)
5 15 25 35 45 55 65 75
20 30 40 50 60 80 100 150 200 300 kg x 1000500
1st Gear
1st Gear
Torque Converter Drive
Direct Drive
37.00-R57 Tires
2nd Gear
3rd Gear
4%
6%
8%
10%
15%
LE20%
25%30%
2%
kg x1000
lb x1000
1000
4th Gear
5th Gear
6th Gear
Typical Field Empty Weight390,000 lb/176 900 kg-Load
20 789C Mining Truck specifications
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 maximum
descent speed brakes can properly handle without exceedingcooling capacity. The following charts are based on theseconditions: 90° F (32° C) ambient temperature, at sea level,with 37R57 tires.
NOTE: Select the proper gear to maintain engine rpm at the highestpossible level, without overspeeding the engine. If cooling oil overheats,reduce ground speed to allow transmission to shift to the next lowerspeed range.
Retarding Performance
0 10 20 30 40 50 60 70 80
0 5 10 15 20 25 30 35 40 45 50
0 100 200 300 lb x 1000400
mph
km/h
20%
15%
SpeedContinuous Grade Length
Effe
ctiv
e G
rade
(Fav
orab
le)
0 50 100 150 200 250 300 350 kg x 1000
Gross Weight
1st Gear
5%
10%
500 600 700
4th Gear
5th Gear6th Gear
30%
2nd Gear
3rd Gear
25%
Typical Field Empty Weight340,000 lb/154 244 kg-Load390,000 lb/176 900 kg-Load
21789C Mining Truck specifications
0 10 20 30 40 50 60 70 80
0 5 10 15 20 25 30 35 40 45 50
0 100 200 300 lb x 1000400
mph
km/h
SpeedGrade Distance — 450 m (1475 ft.)
Effe
ctiv
e G
rade
(Fav
orab
le)
0 50 100 150 200 250 300 350 kg x 1000
Gross Weight
1st Gear
500 600 700
2nd Gear
3rd Gear
4th Gear
5th Gear6th Gear
30%
5%
10%
15%
25%
20%
0 10 20 30 40 50 60 70 80
0 5 10 15 20 25 30 35 40 45 50
0 100 200 300 lb x 1000400
mph
km/h
SpeedGrade Distance — 600 m (1975 ft.)
Effe
ctiv
e G
rade
(Fav
orab
le)
0 50 100 150 200 250 300 350 kg x 1000
Gross Weight
1st Gear
500 600 700
2nd Gear
3rd Gear
4th Gear
5th Gear6th Gear
30%
15%
10%
5%
25%
20%
0 10 20 30 40 50 60 70 80
0 5 10 15 20 25 30 35 40 45 50
0 100 200 300 lb x 1000400
mph
km/h
SpeedGrade Distance — 900 m (2950 ft.)
Effe
ctiv
e G
rade
(Fav
orab
le)
0 50 100 150 200 250 300 350 kg x 1000
Gross Weight
1st Gear
500 600 700
2nd Gear
3rd Gear
4th Gear
5th Gear6th Gear
30%
15%
10%
5%
25%
20%
0 10 20 30 40 50 60 70 80
0 5 10 15 20 25 30 35 40 45 50
0 100 200 300 lb x 1000400
mph
km/h
SpeedGrade Distance — 1500 m (4900 ft.)
Effe
ctiv
e G
rade
(Fav
orab
le)
0 50 100 150 200 250 300 350 kg x 1000
Gross Weight
1st Gear
500 600 700
2nd Gear
3rd Gear
4th Gear
5th Gear6th Gear
30%
15%
10%
5%
25%
20%
22 789C Mining Truck specifications
Standard EquipmentStandard equipment may vary. Consult your Caterpillar Dealer for specifics.
Air cleaner (2)Air conditionerAir line dryerAir 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 towingBrakes system:
Oil-cooled, multiple-disc, frontand rear
ParkingSecondary, emergency
Cab, ROPS:AshtrayCigarette lighterCoat hookDiagnostic connectorElectric window (operator only)Glass, 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, with storage areaSeat 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
Crankcase protectionDriveline operator safety guardDumping, auxiliary quick connect for
“buddy dumping”Electrical system, 24-volt to 12-volt Engine – Caterpillar 3516B with
Electronic Injection and Multi PointOil Pressure Sensing
Fast-fill fuel system, WigginsGround level:
Battery disconnectEngine shutdownVIMS Dataport
Lighting system:Back 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 for37.00-R57 tires
Rock ejectorsStarting aid, ether, automaticSteering, auxiliary quick connect
for towingTie down eyesTow hooks, frontTow pin, rearTraction Control SystemTransmission, six-speed, automatic
power shift, electronic control anddownshift inhibitor, reverseneutralizer during dumping, andneutral start switch, reverse shiftinhibitor, controlled throttle shifting,directional shift management, neutralcoast inhibitor, body-up shiftinhibitor
Vandalism protection locksVital Information Management System
with Production Manager
23789C Mining Truck specifications
Optional EquipmentWith approximate changes in operating weights.Standard equipment may vary. Consult your Caterpillar Dealer for specifics.
kg lbBodies see chart below
Body extensions:
Tail (Option 1) 1005 2,214
Tail (Option 2) 787 1,734
Sideboards (Option 1 - increases capacity to 121 m3 / 158 yd3) 1300 2,860
Body heat (exhaust) 36 80
Body and tail extension liners (900 mPa/9000 Bar / 130,500 psiminimum yield strength; 400 Brinell steel)
Full-length liner (Option 1) 9430 20,790
Tail extension liner (Option 1 - use withfull liners when tail extension used) 488 1,075
Grid liner (Option 2 - covers rearthird of body only) 1650 3,638
Tail extension liner grid (Option 2 - use 535 1,180with grid liner when tail extension used)
kg lbHeater, fuel recirculation type,
non-electric 2 5
Heater, engine coolant and oil240-volt external power source 10 22
Oil Renewal System 11.4 25
Prelube system 24 53
Rim, spare for 37.00 - 57 tire 1406 3,100
36.00 - 51 tire 916 2,020
Shutter group, inside mounted 299 660
Starting system,
Air (TDI Turbine) -22 -49
Air (IR Turbine) -14 -31
Tires, 36.00-R51 (E4) -2280 -5,020
Variable pitch fan, Flexxaire 273 600
Variable speed fan, Rockford 182 400
Truck Body
CapacityStruck 73m3 96 yd3 92 m3 120 yd3
Heaped 2:1 (SAE) 105 m3 137 yd3 121 m3 158 yd3
Empty Loading Height 5663 mm 18' 7" 5680 mm 18' 8"
Plate ThicknessSidewall 12 mm .47" 12 mm .47"Front wall 14 mm .55" 14 mm .55"Floor 20 mm .79" 20 mm .79"
Weight* 26 282 kg 57,940 lb 29 600 kg 65,200 lb
Specification and Standard Dual-Slope Flat FloorDimensions Option 1 Option 2
* - Standard dual-slope body has no sideboards, tail extension, or liners.* - Flat floor body has 20” sideboards included, no tail extension or liners.
400 Brinell steel is standard.Other options are available through Custom Products. Consult your Caterpillar Dealer for more information.
789C Mining Truck
AEHQ5321-01 (2-99)(Replaces AEHQ5062)
Featured machines may include additional equipment only for special applications.
See your authorized Caterpillar Dealer for available options.
Materials and specifications are subject to change without notice.
www.CAT.com© 1998 Caterpillar
Printed in U.S.A.