Mining Truck
2
Structures Engine/Power Train Integration Caterpillar Brake System
®
Caterpillar truck frames are built to The Cat Data Link electronically Cat oil-cooled, multiple disc brakes
optimize torsional load displacement. combines engine, transmission, brake offer exceptional, fade-resistant braking
Mild steel provides flexibility, and operational information to optimize and retarding for maximum performance
durability and resistance to impact overall truck performance. Stored and productivity in all haul road
loads. Castings and forgings in high diagnostic data can be accessed via the conditions. Integrated Braking Control
stress areas provide exceptional strength Electronic Technician (Cat ET) to combines retarding and traction control
and durability for long life. pg. 7 improve troubleshooting and reduce into one system for optimum braking
downtime. pg. 8 efficiency. pg. 10
3
Power Train – Engine
The Cat 3516B High Displacement engine is built for power, reliability and efficiency
for superior performance in the toughest applications.
4
Power Train – Merchandising Arrangements
Five configurations are performance matched to meet specific applications and conditions.
Merchandising Arrangements.
The 793D is available in four different
normal altitude configurations, and a high
altitude arrangement. All configurations
deliver increased speed on grade and
include key components that are
performance matched to the hauling
application and site conditions.
Standard Arrangement.
The standard arrangement
is designed for exceptional, all-around
performance. Three factors combine
to produce up to 9% more power at
the wheels than the 793C, including:
5% more engine horsepower; a common
rail hydraulic system for greater power
train efficiency; and a hydraulically
driven demand fan that reduces parasitic
load by operating only when needed.
More power at the wheels reduces cycle
times and lowers cost-per-ton.
Extended Life Wheel Groups.
Developed for uphill
hauling applications, this
arrangement is designed to extend
wheel life and hauling performance on
long uphill hauls. Extended life wheel
groups are built with larger, more durable
components, including larger spindles,
wider wheel bearing spacing, a larger
braking surface, and extended life Extra Retarding. Developed for High Altitude Arrangement.
friction disc material for longer brake downhill loaded applications, Developed for high altitude
life and more time between overhauls. this configuration typically applications, the 3516B short
Extra Top Speed. Developed delivers an extra gear of retarding stroke engine delivers enhanced power
for long, flat haul applications, capability of 35% more speed on management at higher altitudes – from
the extra top speed configuration delivers downhill grades. Extra retarding is 2750 to 1600 m (9,000 to 12,000 ft).
a 10% increase in maximum speed to achieved by adding more robust wheel This arrangement also includes
60 km/h (37 mph) via a new input transfer groups, larger brakes, extended life Extra Retarding.
gear group. This arrangement also friction material, and additional
includes Extended Life Wheel Groups. cooling capacity.
5
Power Train – Transmission
Cat mechanical power train delivers more power to the ground for greater productivity
and lower operating costs.
6
Structures
Rugged Cat structures are the backbone of the 793D mining truck’s durability.
7
Engine/Power Train Integration
Electronically combines critical power train components to work more intelligently
and optimize overall truck performance.
2 9
6 8
1 7
Cat Data Link. Electronically integrates Directional Shift Management. Body-up Shift Inhibitor. Prevents the
machine computer systems to optimize Regulates engine speed during directional transmission from shifting above the
overall power train performance, shifts to prevent damage caused by pre-programmed gear without the body
increase reliability and component life, high speed directional changes. fully lowered.
and reduce operating costs.
Neutral Coast Inhibitor. Prevents Overspeed Protection. The transmission
Controlled Throttle Shifting. Regulates transmission from shifting to neutral control electronically senses engine
engine rpm during shifting to reduce at speeds above 6.5 km/h (4 mph) to conditions and automatically up-shifts
power train stress and clutch wear protect the transmission from operating one gear to prevent overspeeding.
by controlling engine speed, torque with insufficient lubrication. If overspeeding occurs in top gear,
converter lock-up and transmission the lock-up clutch is disengaged.
Body-up Reverse Neutralizer.
clutch engagement for smoother shifts
Automatically shifts the transmission
and longer component life.
to neutral if the hoist lever is activated
while transmission is shifted in reverse.
8
Programmable Top Gear. Transmission
top gear maximum can be set using
the Cat ET service tool to help the Steering
Control
operator maintain speed limits. Main
Oil Cooler
Engine
Anti-Hunt Function. Minimizes shifting Fan
by not allowing the transmission to up
or down shift immediately after a shift
has occurred. This prevents gear Steering
Fan
hunting when operating near a shift Cylinders
Pump
point and minimizes transmission
shifting for increased component life. Rear Axle Valve
Cooler
Downshift Inhibitor. Prevents engine Fan
9
Caterpillar Brake System
Reliable braking with superior control gives the operator the confidence to focus
on productivity.
10
HARC 1 Service Brake Sensor TCS
1 2 2 Engine Sensor
3 HARC
4 HARC Switch
5 Brakes
6 Service Brakes 6
7 Axle Speed Sensor
8 TCS 7
8
3
7
5 6
HARC vs. ARC. Faster Speeds. HARC allows the Traction Control System (TCS).
operator to maintain optimum engine Electronically monitors and controls
• Less chance for engine overspeed
speeds for faster downhill hauls and rear wheel slippage for greater traction
• Smoother engagement greater productivity. and enhanced truck performance in
poor underfoot conditions. If slippage
• No loping Superior Control. Automatic brake
exceeds a set limit, the oil-cooled disc
modulation offers a smoother ride and
• Less air system demand brakes engage to slow the spinning wheel.
better control in slippery conditions,
Torque is then automatically transferred
• Reduces operating costs allowing the operator to concentrate
to the wheel with better traction.
on driving.
HARC Production Advantages.
Differential Action. Normal differential
2500
Ease of Operation. HARC increases
action provides superior maneuvering
operating ease, resulting in greater
and control in slippery conditions.
2000 operator confidence with less fatigue.
Integrated Braking Control (IBC).
Engine Speed (rpm)
11
Operator’s Station
Ergonomically designed for operator comfort, superior control and high productivity.
12
Serviceability
Less time spent on maintenance means more time on the haul roads.
13
Monitoring System
Vital machine health and payload data keeps the 793D performing at peak production levels.
1 Gauge Cluster
2 Message Center and Keypad
3 ADEM III Engine Control Module
11 4 CAT Data Link
5 Action Alarm
6 Action Lamp
1 2 7 Payload Lamps
8 Payload Display (optional)
10 12 9 Radio System (optional)
10 Data Port (VIMS-PC)
11 Service Lamp
13 12 Diagnostic Connector (ET)
13 Integrated Brake Control (IBC)
9 and Cooling Fan Control Module
14 14 Transmission/Chassis Control (TCC) Module
15 Road Analysis Control (RAC) Module (optional)
7 6
5
8 15
4
14
Payload Management. Max Payload to identify potential problems before
Speed Manager is a feature that aids in they occur, utilizing the efficiency
managing the Caterpillar 10/10/20 of Preventative Maintenance.
Overload Policy. Based on target payload
External Payload Indicators. External
weight and overload settings, the
lights on both sides of the truck signals
VIMS system logs and warns the
loading tool operator when to cease
operator when the truck reaches overload
loading for optimum payloads without
after 2nd gear reweigh. The truck will
overloading. Optional external payload
be limited to 2nd gear at 1,750 rpm,
display with digital numeric monitor are
and the automatic retarder speed setting
available to replace the standard
is reduced to 1,750 rpm until the load
red/green indicator lamps.
is dumped.
Road Analysis Control (RAC). Optional
Payload management enables the
system monitors haul road conditions
manager to enhance truck/loading tool
by measuring frame rack and pitch to
effectiveness and productivity levels
improve haul road maintenance, cycle
by preventing overloads that can cause
times, tire life and fuel efficiency.
damage to component life and affect
operator safety. VIMS-PC. VIMS-PC, the off-board
reporting software program, allows
The Payload Weight Distribution chart
service personnel to download a
Keypad. Provides operator or service illustrates the benefit of managing
complete record of machine health and
technician immediate access to current payloads with VIMS production
productivity data to a laptop computer
machine information, gauge values management tools.
for diagnosis and analysis. Easy-to-use
and stored data through the message Data Storage. The VIMS system stores software enables service technicians
center display. payload information, which is used to and mine personnel to generate health
Message Center. Displays messages manage production. The system stores and payload reports for more effective
requested by operator and advises up to 2,400 production cycles for a machine management.
operator of abnormal machine conditions. complete record of payload weight,
VIMS Supervisor. Optional software
cycle times, distances and actual
Alert System. Three-category warning allows mine personnel to easily manage
dates/times. It also allows storage of
system alerts operator of abnormal and interpret VIMS data for optimum
maintenance data such as Events, Trends,
machine health conditions. fleet management and productivity.
Histograms, Cumulatives, Snapshot and
• Category I. Machine or system Dataloggers. This data allows the user
needs attention.
• Category II. Requires operator to Payload Weight Distribution
evaluate and correct situation before
continuing work.
Percentage of Total Loads
15
Truck Body Systems
Cat designed and built for rugged performance and reliability in the toughest mining
applications.
16
1 2 3
1) Dual-Slope Body. The dual-slope 2) Flat Floor Body. The flat floor design 3) Mine Specific Design (MSD II) Body.
body design with V-shaped floor with slight incline delivers excellent The lightweight MSD II body is based on
provides excellent load retention, payload capacity, high dump clearances the flat floor design and is customized
maintains a low center of gravity, and smooth, controlled dumping. to maximize payload potential and
reduces shock loading, and maintains minimize cost-per-ton. Each MSD II
• Flat floor design provides consistent
optimum load distribution on steep body design begins with a detailed mine
wear characteristics on body tail.
inclines and in challenging haul road site profile to develop a body suitable
conditions. • 12 degree forward body slope for a mine’s individual needs.
provides good load retention
• Reinforced, rolled steel top rail
on better maintained haul roads.
increases body strength and protects
the body from damage caused by • 400 Brinell steel on surfaces
the loading tool or falling material provides excellent wear.
• 8 degree “V” reduces shock loading
and centers the load.
• 7.5 degree forward body slope and
16 degree ducktail slope helps retain
loads on steep grades.
Target Payload Strategy. Your Caterpillar
Dealer can help you manage to target
payload to maximize equipment
utilization, ensure safe operation, increase
productivity and lower cost-per-ton.
• Underloading increases costs due to
lost payloads, underutilizes equipment,
and drives cost-per-ton.
• Overloading or surpassing
maximum gross machine weight,
causes excessive wear on vehicle
components such as brakes, tires and
drivetrain, reducing component life
and increasing maintenance costs
and repairs.
17
Customer Support
Caterpillar dealers have what it takes to keep mining haul trucks productive.
18
Safety
Caterpillar mining machines and systems are designed with safety as the first priority.
19
Engine Transmission
Engine Model Cat 3516B HD EUI Forward 1 11.8 km/h 7.3 mph
Rated Power 1,750 rpm Forward 2 15.9 km/h 9.9 mph
Gross Power – SAE J1995 1801 kW 2,415 hp Forward 3 21.5 km/h 13.4 mph
Net Power – SAE J1349 1743 kW 2,337 hp Forward 4 29 km/h 18.1 mph
Net Power – ISO 9249 1743 kW 2,337 hp Forward 5 39.4 km/h 24.5 mph
Net Power – 80/1269/EEC 1743 kW 2,337 hp Forward 6 54.3 km/h 33.7 mph
Torque Rise 23% Reverse 10.9 km/h 6.8 mph
Bore 170 mm 6.7 in • Maximum travel speeds with standard 40.00-R57 tires.
Stroke 215 mm 8.5 in
Displacement 78 L 4,760 in3
• Power ratings apply at 1,750 rpm when tested under the Final Drives
specified condition for the specified standard.
Differential Ratio 1:8:1
• Ratings based on SAE J1995 standard air conditions of 25° C
(77° F) and 99 kPa (29.61 Hg) dry barometer. Power based Planetary Ratio 16:1
on fuel having API gravity of 35 at 16° C (60° F) and an LHV of Total Reduction Ratio 28.8:1
42 780 kJ/kg (18,390 Btu/lb) when engine used at 30° C (86° F). • Planetary, full-floating.
• No engine derating required up to 2750 m (9,000 ft) altitude.
• Compliant with U.S. Environmental Protection Agency Tier I
emissions standards. Suspension
8 10
11
7
1
12
13
6
5
3 4
14
15
16
17
To determine retarding performance: Add lengths of all cooling capacity. The following charts are based on these
downhill segments and, using this total, refer to proper conditions: 32° C (90° F) ambient temperature, at sea level,
retarding chart. Read from gross weight down to the percent with 40.00R57 tires.
effective grade. Effective grade equals actual % grade minus NOTE: Select the proper gear to maintain engine rpm at the highest
1% for each 10 kg/t (20 lb/ton) of rolling resistance. From this possible level, without overspeeding the engine. If cooling oil
weight-effective grade point, read horizontally to the curve overheats, reduce ground speed to allow transmission to shift to
with the highest obtainable gear, then down to maximum the next lower speed range.
descent speed brakes can properly handle without exceeding
Standard Retarding*
Gross Weight
0 100 200 300 400 500 600 700 800 900 lb x 1000
30% 25%
20%
Effective Grade
15%
2nd Gear
10%
3rd Gear
4th Gear
5th Gear 5%
6th Gear
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
Speed
*at sea level Continuous Grade Length
Effective Grade
2nd Gear
15%
3rd Gear
4th Gear
10%
5th Gear
6th Gear
5%
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 450 m (1,475 ft.)*
*at sea level
3rd Gear
4th Gear 10%
5th Gear
6th Gear
5%
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 600 m (1,975 ft.)*
*at sea level
Effective Grade
2nd Gear 15%
3rd Gear
10%
4th Gear
5th Gear
6th Gear
5%
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 900 m (2,950 ft.)*
*at sea level
20%
1st Gear
Effective Grade
15%
2nd Gear
3rd Gear
10%
4th Gear
5th Gear 6th Gear
5%
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 1500 m (4,900 ft.)*
*at sea level
To determine retarding performance: Add lengths of all cooling capacity. The following charts are based on these
downhill segments and, using this total, refer to proper conditions: 32° C (90° F) ambient temperature, at sea level,
retarding chart. Read from gross weight down to the percent with 40.00R57 tires.
effective grade. Effective grade equals actual % grade minus NOTE: Select the proper gear to maintain engine rpm at the highest
1% for each 10 kg/t (20 lb/ton) of rolling resistance. From this possible level, without overspeeding the engine. If cooling oil
weight-effective grade point, read horizontally to the curve overheats, reduce ground speed to allow transmission to shift to
with the highest obtainable gear, then down to maximum the next lower speed range.
descent speed brakes can properly handle without exceeding
Additional Retarding*
Gross Weight
0 100 200 300 400 500 600 700 800 900 lb x 1000
30% 25%
20%
Effective Grade
15%
2nd Gear
3rd Gear
10%
4th Gear
5th Gear
5%
6th Gear
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
Speed
*at sea level Continuous Grade Length
2nd Gear
Effective Grade
15%
3rd Gear
4th Gear
10%
5th Gear
6th Gear
5%
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 450 m (1,475 ft.)*
*at sea level
1st Gear
20%
2nd Gear
Effective Grade
15%
3rd Gear
4th Gear
10%
5th Gear
6th Gear
5%
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 600 m (1,975 ft.)*
*at sea level
Effective Grade
2nd Gear
15%
3rd Gear
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 900 m (2,950 ft.)*
*at sea level
2nd Gear
15%
3rd Gear
5th Gear
6th Gear
5%
0 10 20 30 40 50 60 70 80 km/h
0 5 10 15 20 25 30 35 40 45 50 mph
Speed
Grade Distance — 1500 m (4,900 ft.)*
*at sea level
To determine gradeability performance: Read from gross horizontally to the curve with the highest obtainable gear, then
weight down to the percent of total resistance. Total resistance down to maximum speed. Usable rimpull will depend upon
equals actual percent grade plus 1% for each 10 kg/t (20 lb/ton) traction available and weight on drive wheels.
of rolling resistance. From this weight-resistance point, read
E L
100
30% 25% 20%
200
1st Gear
80
15%
60
1st Gear
10%
100 2nd Gear
40
3rd Gear
4th Gear
50 5%
20 5th Gear
6th Gear
Torque Converter Drive
Direct Drive
0 0
0 5 10 15 20 25 30 35 40 mph
0 10 20 30 40 50 60 70 km/h
*at sea level Speed
Weight/Payload Calculation*
kg lb
Chassis** 64 061 141,230
Body Mounting Group 735 1,620
Tires (6) 40.00R57 21 364 47,100
Wheel Arrangement – Standard with 29" Rims 30 547 67,344
TOTAL EMPTY CHASSIS WEIGHT (CLEAN) 116 707 257,294
© 2007 Caterpillar
All Rights Reserved
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Replaces AEHQ5600 used herein, are trademarks of Caterpillar and may not be used without permission.