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Caterpillar® Product Information

Competitive Bulletin
September 2006

Cat® Mining Trucks

785C, 789C, 793D, 797B

For Dealer Sales Personnel ®

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Table of Contents

Machine Positioning Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Structures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Drive Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Mechanical Versus Electric Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Caterpillar® Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Steering and Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Operator’s Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Monitoring System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Truck Bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

2 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Machine Positioning Strategy

Caterpillar undertakes extensive field research to ensure customer needs are understood. High on the list
of mining customer priorities are:

• Lower cost-per-ton

• Lower risk due to machine performance and operator safety

• Less capital tied up in assets

• Fewer liabilities

Caterpillar has responded with: research and development; continuous product improvement; superior
support, including MARC Contracts and Power-by-the-Hour; and tools such as Mine EIA (Equipment
Investment Analysis).
Today, as miners seek to reduce cost-per-ton, manufacturers are pushed to increase the payload capacity
of haul trucks. New tire, electronic and engine technologies have been developed to deliver a more powerful,
yet fuel efficient and environmentally friendly range of trucks. Caterpillar entered the ultra-truck market
with the introduction of the largest mechanical drive mining truck in the world, the 797.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B   3

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Competitive Situation

Field Population
Highest Hour Unit
Total Units Fleet Hours (As of June 2006)
785 2,300+ 71 million 127,000
789 1,800+ 67 million 106,000
793 1,900+ 70 million 105,400
797 190+ 3.9 million 49,000

Caterpillar clearly leads the Mining Truck market with over 5,780 mining trucks shipped since 1985.
Today, of every ten mining trucks sold worldwide, more than half bear the Cat® brand. The remaining
sales are shared between four major competitors:

• Komatsu

• Liebherr

• Terex-Unit Rig

• Euclid-Hitachi

The Caterpillar global dealership network is comprised of 182 Dealers with 59 in the United States and
123 outside the U.S. Caterpillar® dealers worldwide provide an unsurpassed level of personalized customer
service through more than 3,492 facilities (defined as main stores – 182, branch stores – 1,741 and rental
stores – 1,569) in 182 countries.

There are 135 Caterpillar manufacturing centers worldwide with around 57 located in the U.S. and 78 located
outside the U.S. With 14 remanufacturing centers, 12 technical centers, 4 proving grounds and 16 training
centers, Caterpillar applies more resources than any of its competitors to developing, testing and producing
innovative, high quality products that are supported by the best quality technical and service personnel in
the industry.

The Caterpillar parts distribution network features 22 distribution centers in eleven countries with 11 located
in the United States. No matter where in the world customers are located, a Caterpillar dealer is within reach
and has the most replacement parts in stock. On rare instances when a part is not found at the local level,
the ANTARESSM Parts Order System can locate it in seconds. A dedicated Emergency Floor handles “rush”
requests and is “on call” 24 hours a day, seven days a week. Many “Emergency” orders are routinely shipped
in less than four hours. This level of support differentiates Caterpillar from all the competitors and adds
tangible value to the Cat product.

4 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Competitive Situation – Caterpillar

Target Payload Capacity*

(91-363 Metric Tonne Size Class)
(100-400 Short Ton Size Class)

CATERPILLAR 785C 789C 793D 797B

EH3000 EH3500 EH4500-2 EH5000

EUCLID/HITACHI

HD 1500 730E   830E 930E-3

KOMATSU 830E - AC 930E-3SE

MT3000 MT3300 MT3600B MT3700B MT4400 MT5500B

MT3300AC MT3700AC MT4400AC MT5900AC

TEREX/UNIT RIG

T252 T262   T282B

LIEBHERR

Metric Tons 91 100 109 118 127 136 145 154 163 172 181 191 200 209 218 227 236 245 254 263 272 281 290 299 308 318 327 336 345 354 363 372 381
Short Tons 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420

* Approved weights as of 2005.

Note: Caterpillar models represent recommended target payloads for both standard body and
MSD body configurations.
Competitors may approve higher payloads than indicated by using lighter weight bodies.

Caterpillar offers a range of mining truck models in the 136 to 363 tonne (150 to 400 ton) size class.
Caterpillar’s trucks are all mechanical drive with Caterpillar’s 797B being the largest mechanical drive
truck in the world. The Cat ® mining truck line-up includes:

• 785C: 136+ tonne (150+ ton) mechanical drive

• 789C: 176+ tonne (195+ ton) mechanical drive

• 793D: 218+ tonne (240+ ton) mechanical drive

• 797B: 345+ tonne (380+ ton) mechanical drive

The 793D is available in four different normal altitude configurations and one arrangement for high altitude
operations. All configurations include key components matched to performance requirements in specific
applications and conditions:

• Standard (MA1) – for balanced all-around performance

• Extra Retarding (MA2) – for long, downhill-loaded hauls

• Extra Top Speed (MA3) – for long, flat hauls

• Extended Life Wheel Groups (MA4) – for long, uphill hauls

• High Altitude Arrangement (MA5) – for operations above 2750 m (9,000 ft)

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B   5

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Competitive Situation – Komatsu

General Observations. Due to the strong mining market, Komatsu and other suppliers have reported record
sales and profits driven by the huge increase in demand for mining equipment. Komatsu is the principal
mining machine competitor with a full-line of products.

Model Line-Up and Recent Introductions.

• HD1550-5: 136 to 149 tonne (150- to 164-ton) mechanical drive

• 730E: 184 tonne (230-ton) DC electric drive

• 830E: 223 tonne (246-ton) DC electric drive

• 830E-AC: 221 tonne (244-ton) AC electric drive.

• 930E-3: 290 tonne (320-ton) AC electric drive.

• 930E-3SE: 290 tonne (320-ton) AC electric drive.

In 2004, Komatsu introduced the 930E-3 and 930E-3S in the 290 tonne (320-ton) class, which replaced
the 930E-2. The 930E-3, powered by the Cummins QSK60 engine, is rated at 2013 kW (2,700 hp), and
the 930E-3SE, powered by the Cummins QSK78 engine, is rated at 2610 kW (3,500 hp), which appear
to be offered predominantly for high altitude applications in locations such as Chile.

Komatsu also introduced the 830E-AC in 2004 that among other features, is capable of speeds up to
64 km/h (40 mph), an increase of 13 km/h (8 mph) versus the standard 830E DC that seems likely will
continue in the market.

It appears Komatsu is promoting the 930E over the 830E, as the market in the 290 tonne (320 short-ton)
class appears to offer more opportunities.

6 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Competitive Situation – Komatsu

Product Issues and Known Problems. Feedback gathered indicated Komatsu has encountered the following
issues in the filed:

• Komatsu trucks are bigger and heavier than Caterpillar trucks. With slightly higher GMW, Komatsu
trucks have a significantly higher EMW, which translates into payload disadvantage. For example,
several Cat® 789C versus Komatsu 730E studies have shown at least 10-15 metric tons (11-17 tons)
payload advantage for Cat 789C. A similar situation is found for the Komatsu 830E versus Cat 793C.

• Additional weight represents tires and fuel consumption disadvantage. Mine records estimate that the
average tire life on Komatsu 830E is at least 12 percent shorter compared to tires on Cat 793C. Also, field
study data indicates the Cat 793C is in average 17 percent-20 percent more fuel efficient than
Komatsu 830E on a metric tons per liter basis.

• Significant problems with Komatsu 730E DC wheel motor armatures when working in downhill
hauling applications. Replacements were required with low operating hours.

• Komatsu 730E are experiencing numerous disc brake pad failures due to excessive downhill speeds.

Successes and Selling Points.

• Komatsu 930E is promoted as being a perfect three pass-match with cable shovels swinging 100 tonnes
(110 short tons).

• Selling downhill hauling speed and braking capabilities, leveraging AC drive system that provide
significant performance and safety improvements over the DC drive system.

• Developing commercial alliances with mining companies with a long history of operating electric
drive trucks, such as Rio Tinto and Cleveland Cliffs, Codelco and Grupo Mexico.

• Building a strong alliance with Cummins for the design and development of engines. The joint venture
agreement, effective in 1997, nominates Cummins as preferred engine supplier for Komatsu Mining
Equipment.

• Targeting emerging markets in India and Indonesia, at reduced prices with a global product.

Future Developments. Komatsu announced the development of the new 960E (327-345 tonnes
[360-380 short tons]) and the new 860E (254 tonnes [280 short tons]). August 2006 Komatsu started the
field trial of 2  960E trucks. It has a 222 m3 (290 yd3) wider lower profile body and the truck has a rated
payload of 327 tonnes (360 tons). One is running in the Canadian Oil Sands and the second is running in
Wyoming’s Powder river basin. It is rumored the truck is one year late from the proposed in the dirt date
from Komatsu due to frame problems.

The 960E appears to have two different drive systems; for oil sands or hard rock mines.

The 960E has a 20 cylinder Cummins engine with 12 turbo chargers, and it is rated at 2759 kW (3,700 hp)
but de-rated to 2535 kW (3,400 hp) in the oil sands. It has high torque Siemens AC drives. The truck shares
930E elements and the same front end, but it is built slightly heavier. It has the same tire scuffing on the
outside fronts. The machine has bladder style steering accumulators that are very tall, and bladder change
is considered to be difficult.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B   7

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Competitive Situation – Komatsu

Initial timing studies in the oil sands, de-rated 960E, indicate the 797B is significantly faster (10 percent)
in High RR (> 9 percent).

Speculation is high the company also is developing the 730E-AC.

It also announced the development of a new manufacturing facility in Japan for off-highway trucks
scheduled for January 2007.

Five autonomous Komatsu trucks are being tested in Codelco, Chile.

Komatsu announced the co-development of hybrid drive systems with GE.

8 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Competitive Situation – Liebherr

General Observations. Liebherr has increased its participation rate and is indicating a strong
desire to compete. However, it appears Liebherr it is not willing to entertain high risk deals.

Model Line-Up and Recent Introductions.

• T252: 181 tonne (200-ton) DC electric drive

• T262: 218 tonne (240-ton) DC electric drive

• T282B: 363 tonne (400-ton) AC electric drive

Liebherr
capacity.offers threefocuses
Liebherr miningheavily
truck models,
on the with
T282Bthe and
T282B
doesbeing the largest
not actively size atthe
market 363other
tonne (400 short-ton)
machine models.

Product Issues and Known Problems. Limited manufacturing capacity (80-100 units per year)
The T282B truck was successfully promoted as an ultra lightweight truck. However, it has many product
problems that tremendously affect its availability, and there is a big concern the lighter weight of the truck 
will generate frame issues in the long term.

Unsuccessful introduction of its ultra light truck design concept, TI272, because of safety issues with
rear tire changes.

Successes and Selling Points.

• A special sound attenuation package targeted in sound sensitive areas such as Hunted Valley
in Australia is a strong selling point.

• It offers the best GMW/HP ratio in the industry.

Future Developments. Liebherr developed its own drive system, which will eventually integrate into the T282B.
There are speculations that Liebherr will reintroduce the TI-272 and also a second-generation machine,
the TI-264, that will replace the current T262.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B   9

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Competitive Situation – Terex/Unit Rig

General Observations. After the collapse in failure of the negotiations with Caterpillar, Terex has reorganized
its Unit Rig and created more distance from O&K. Due to Terex’ reporting structure, it is difficult to establish
Unit Rig’s profitability contribution to Terex. It is however generally understood that Unit Rig contribution
is probably under par and O&K sales carried the Mining dealerships.
Model Line-Up and Introductions.
• MT3000: 109 tonne (120-ton) DC electric drive

• MT3300: 136 tonne (150-ton) DC electric drive

• MT3300 AC: 136 tonne (150-ton) AC electric drive

• MT3600B: 154 to 172 tonne (170- to 190-ton) DC electric drive

• MT3700B: 172 to 186 tonne (190- to 205-ton) DC electric drive

• MT3700 AC: 186 tonne (205-ton) AC electric drive

• MT4400: 218 to 236 tonne (240- to 260-ton) DC electric drive

• MT4400: 218 to 236 tonne (240- to 260-ton) DC electric drive

• MT4400 AC: 218 to 236 tonne (240- to 260-ton) AC electric drive

• MT5500B: 326 tonne (360-ton) AC electric drive

Since 2002, Terex has added three new AC drive trucks in its wide range of truck product offering,
the MT3700AC (186 tonnes [205 tons]), the MT4400AC (up to 236 tonnes [260 tons]) and the
MT5900AC (327-354 tonnes [360-390 tons]).
Product Issues and Known Problems. Terex has limited manufacturing capacity.
The company lacks infrastructure for product support and is considered weak in many territories.

The General Atomic AC system on MT5500B has experienced serious problems, particularly wheel motors
overspeed.

Field study data indicates Terex MT4400 AC (793 class) weighs much more than what is documented
in their publications, which affects tire and fuel consumption negatively.

Successes and Selling Points.

• Terex/Unit Rig is successful with Rio Tinto through the HME agreement.

• North Hauler Lt. (NHL) is a joint venture with Terex for the manufacture and distribution in China
of 20-92 metric tons (22-101 tons) mechanic OHT and 154-340 metric tons (170-375 tons) electric
OHT. Recently, the joint venture has been awarded an order for MT4400AC and MT5500B/MT5900
AC trucks by a state-owned Chinese company for coal application.

Future Developments. Persistent rumors indicate Terex will exit the large off-highway truck business.

10 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Competitive Situation – Hitachi

General Observations. Hitachi’s focus appears to be in system selling, matching shovels to trucks.
Hitachi has decided to move large off-highway trucks manufacturing facilities to Japan away from
its traditional truck production facility in the U.S.

Model Line-Up and Introductions.

• EH3000: 154 tonne (170-ton) DC electric drive

• EH3500: 172 to 181 tonne (190- to 200-ton) DC electric drive

• EH4500: 254 tonne (280-ton) AC electric drive

• EH5000: 284 tonne (312-ton) AC electric drive

Hitachi has four mining truck sizes. EH5000 is the largest with a nominal payload of 283 tonnes (312 tons).
It also introduced the new EH4500-2, which provides a higher maximum gross machine weight than its
predecessor EH4500 in response to a nominal rated payload, not maximum.

In 2005, Siemens AC drive system was upgraded with EGBT technology only for EH4500 and EH5000.

Product Issues and Known Problems. Feedback gathered indicated Hitachi encountered the following
issues in the filed:

• Very weak distribution, except for good Euclid dealers (Rudd, Colombia)
• Overheating of AC drive motors and frame cracking on EH4500

• Weight distribution on EH4500 creates serious safety concern related to front tire overloading
and steering system operation.

• In some sites, average availability of EH4500 is 15 percent lower than that of the Cat 793’s.

• Operators note rear axle tire spinning in wet conditions on EH4500.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B   11

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Competitive Situation – Hitachi

Successes and Selling Points.

• In downhill haul applications at high speed. The recent introduction of the Cat 793D MA2
(Extra Retarding) has narrowed or eliminated the AC drive advantage in this application.
• EH5000 and EH4500-2 are relatively strong products.

• Selling shovel/truck system.

Future Developments. There are speculations the company is designing two new trucks, a 191 tonne-truck 
(210 ton-truck) and the largest of its range with a capacity of at least 363 tonnes (400 tons) that could be
the EH5500 or EX6000.

12 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Other Competition: Truck Manufacturers

Belaz.
• Belaz offers a range of rigid dump trucks from 30- to 220-tonnes (33-243 tons) capacity.

• Considering upsizing

• Developing the first 320 tonne (354 short ton) capacity prototype with a 2610 kW (3,500 hp)
Cummins engine and an electromechanical transmission.

• Following is the 2006 line up of Belaz (all are equipped with a Cummins engine).
7514 120 metric tonnes (132 short tons) 895 kW (1,200 hp)
7513 130 metric tonnes (143 short tons) 1193 kW (1,600 hp)
7530 220 metric tonnes (243 short tons) 1790 kW (2,400 hp)

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B   13

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Other Competition: Components

General Electric (GE).

• Co-developed the OHT hybrid drive system with Komatsu.

• Transitioning to IGBT technology in all AC systems in the future.

• Market share of 92 percent, but OEM’s moving away from GE.

Siemens.
• Adding Komatsu to their OEM portfolio, along side Liebherr and Hitachi.

• Speculations indicate they are working with Belaz on 354T truck.

• Transitioning to IGBT technology in all AC systems in the future.

• Active in less than 200T trolley systems.

• Recently acquired Flender Gear for $1.4 billion.

General Atomics.
• Joint development with Terex on MT5500 and MT5900 models.

Cummins.
• Tier 2 engines: QSK50 (1044-1566 kW [1,400-2,100 hp]) and QSK60 (1342-2237 kW [1,800-3,000 hp]).

• Tier 1 engine: QSK78 (2610 kW [3,500 hp]) is experiencing reliability problems.

Detroit Diesel.
• Tier 2 engines: 12V4000 (1193-1678 kW [1,600-2,250 hp]), 16V4000 (1491-2237 kW [2,000-3,000 hp])
and 20V4000 (2375-2796 kW [3,185-3,750 hp]).

• Routinely demonstrating 24,000-hour life.

14 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Structures

Structures. Caterpillar main frames are the backbone of the mining truck’s durability.

Caterpillar integral ROPS cab frame.

Caterpillar truck frame with castings shown in red.

• Integral ROPS Cab. Frame is designed for an
Caterpillar Truck Frames. Cat frames are built integral ROPS cab and provides increased strength
for strength and durability and incorporate the in the front frame supports. Durable design provides
following key features: added operator protection.

• Finite Element Analysis. Proprietary computer Caterpillar Castings. Caterpillar uses castings
generated method of showing stress concentration because of their proven strength and capacity to
areas under load based on empirical data from actual produce design flexibility. Castings eliminate the
trucks. Castings are used for added strength and need for a lot of high quality welding that is
durability in these high stress locations. expensive and hard to achieve consistently. With
more than 50 percent of the mining truck market,
• Controlled Weld Quality. Weld quality is strictly Caterpillar is the only truck manufacturer that can
controlled. All welders are trained and certified. achieve economies of scale needed to make castings
The use of rollover fixtures ensures all welding is affordable. For competitors, castings are less
done horizontal – not overhead. All critical welds affordable due to lower volumes.
are 100 percent ultrasonically tested to find
subsurface defects. All defective welds are
immediately repaired and then rechecked.

• Mild Steel Construction. The high strength low

alloy (mild) steel used in Caterpillar OHTs offers
superior fatigue resistance and outstanding
weldability characteristics. The weakest link in any

frame is in thethe
has designed welds.
frameFor thatmild
using reason Caterpillar
steel because of 
its ability to produce the strongest welds. In addition
large castings are used to move the welds away from
the high stress areas. Mild steel is easily repaired
in the field with standard welding techniques and
equipment.

• No Horse Collar. Easy in-frame engine access

allows quick repairs with less downtime.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 15

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Structures

• Crack propagation rates are much higher,

rendering in-field service inspection and repair
very difficult. As a result, the structures become
much more prone to catastrophic failures.
Caterpillar Field Testing. Caterpillar and its
customers learned of this trade-off through
extensive field experience and testing.

• The full scale fatigue testing conducted by

Caterpillar was corroborated by laboratory
testing of welded specimens by the British
Caterpillar Integral Four-Post ROPS Cab.
Welding Institute.
Integral Four-Post ROPS Cab. Resiliently mounted • An optimum balance of yield and toughness
to the main frame to reduce vibration and sound, needs to be maintained. Caterpillar’s weld
the integral ROPS is designed as an extension of   joints reflect this balance of yield strength
the truck frame. The structure provides “five-sided and maximized toughness.
protection” for the operator and is ROPS- and
FOPS-certified to ISO standards. Caterpillar has • In field applications, toughness and ability to
chosen to meet the toughest standards and then go locally deform plastically provides a significant
beyond test certification requirements. Caterpillar benefit in case of accidents involving
cabs are designed to offer maximum operator extraordinary strains. Events that can be absorbed
protection in the event of a rollover accident. through plastic deformation rather than crack 
initiation are less likely to result in subsequent
Competitive Designs. Although the competition fractures.
promotes their
parent plate use ofstructures
in their relativelywith
highimplications
yield strength • Rolled section steel in frame rails allows
that this provides lighter weight and longer life, J-groove welds for better penetration.
catastrophic field failures at multiple sites have
• Castings transition weld location to areas
proven otherwise. In fact, their structures
of lower stress.
seriously compromise field supportability.
• While these mechanisms have their limits,
High yield strength provides increased resistance
Caterpillar Mining Trucks are much better
to gross plastic deformation and fatigue strength
configured for tolerance of abnormal events
of the parent material. However, it does not improve
than competitors.
fatigue life of full-scale welded structures, because:

• Increasing yield strength comes at the expense

of toughness and results in increased sensitivity
to inherent notches at the weld joints.

• Localized plastic deformation, which occurs at

these notches, is much more damaging to high
yield strength steels due to reduced toughness.

16 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Structures

• Mild steel provides a balance of medium yield

strength and high toughness for:

– Ease of welding. No pre-heat or post-heat.

– Impact resistance.

– Slow crack propagation.

– Ease of weld repair, if required.

– Long life.

• High quality control during manufacturing.

797B frame. Extensive use of castings and • Critical welds are 100 percent ultrasonically
new weld technology results in longer life.
tested for weld integrity.
Caterpillar Frame Design Versus Competition. • Komatsu Frame Design.
Cat frames are backed by years of design experience • Fabricated horse collar surrounds engine,
using same design philosophy since 1963, resulting increasing repair and service time.
in a superior structure. Caterpillar has control over
quality by manufacturing its own frames. • 930E is an upgraded 830E frame with thicker
main rail plates with an unoptimized modulus.
• Frames are designed using the latest static and
dynamic analysis techniques. • 930E uses 4921 kg/cm2 (70,000 psi) yield
strength plate material and difficult to weld
• Frame design incorporates the loads and repair 6328 kg/cm2 (90,000 psi) casting material.
deflections required by the integral ROPS cab.
• Terex/Unit Rig Frame Design.
• Front superstructure eliminates the need for
a “horse collar”, providing superior engine • All fabricated. No castings used. More vulnerable
access and increased front frame strength. to cracking failures.

• Castings are used in areas of high stress.

• Weld joints are located in areas of lower stress.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 17

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Structures

Euclid/Hitachi truck frame. Liebherr truck frame.

• Euclid/Hitachi Frame Design. • Liebherr Frame Design.

• All fabricated. No castings used. More vulnerable • Fabrication and welding in high stress areas,
to cracking failures. which is more vulnerable for cracking failures.
• No consistent frame design among various • Nickel copper combination steel frame.
models.
• Minimal section high stress dump
• Material yield strength varies among models. body interface.
Euclid/Hitachi EH4500-2 and EH5000 use
3515 kg/cm2 (50,000 psi) yield strength material.
Other models use 7031 kg/cm2 (100,000 psi)
yield strength material, which is not easily
weld repairable.

18 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Engine

Engine. Cat engines are built for power, reliability and maximum operating efficiency.

793D HAA*
789C 789C HAA 797B HAA*
Model 785C 785C HAA 793D 797B
Engine 3512B 3516B 3516B HD 3524B HD**
Configuration V-12 V-16 V-16 V-24
Bore – mm (in) 170 (6.7) 170 (6.7) 170 (6.7) 170 (6.7)
Stroke – mm (in) 190 (7.5) 190 (7.5) 215 (8.5) 215 (8.5)
Displacement – L (in ) 3
51.8 (3158) 69 (4211) 78 (4758) 117 (7146)
*Two Stage Turbo charging
**3524 is a tandem unit with two 3512B HD engines.

Cat 3500B Engine Enhancements. The improvements

to the Caterpillar 3500B engine, as compared to
earlier 3500 Caterpillar engine models, include
higher injection pressure, electronically controlled
fuel injection timing and duration, enhanced
combustion chamber design, improved air system
management, and electronic engine protection and
monitoring. Design enhancements have met specific
objectives for reduced fuel consumption, increased
power capability, transient response, smokeless
operation, and lower emissions.

Electronic Unit Injection (EUI). The Cat 3500B Series

Engines feature an electronic governor with
Electronic Unit Injection (EUI). The “brain” of 
the EUI system is the Electronic Control Module
(ECM). The ECM performs much like a mechanical
governor, but has no moving parts. The ECM sends
Caterpillar Truck Engines. The Caterpillar 3500B signals to the injectors to regulate the fuel supply
Series EUI engine design focuses on performance, to control engine speed and power.
reliability and durability. Parameters are established Electronic Unit Injection eliminates complex
to maximize engine performance while protecting hydraulic governor linkages resulting in fewer
the engine from damage and undue wear. Success moving parts. That means EUI provides customers
of this philosophy is evidenced by the 3500’s significant improvements in reliability and durability.
dominance of its market segment.
EUI offers the following advantages:
Caterpillar has shipped more than 105,000 units
over the past 25 years. • Reduced Exhaust Smoke. EUI reduces smoke by
electronically adjusting the fuel limits to maintain
High quality manufacturing of the 3500B Series correct air/fuel ratio.
engines is ensured by the Caterpillar Engine Center
in Lafayette, Indiana, an ISO9001 Certified Facility. • Reduced Emissions. EUI reduces gaseous and
particulates emissions. Through electronic injection
timing control, deep crater piston design and
increased injection pressure, fuel burn is optimized.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 19

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Engine

• Improved Fuel Efficiency. The ECM’s ability • Injector Diagnostics. Using an electronic service
to match injection timing and duration with the tool, each injector can be tested to determine which
transmissions demand and a host of other sensed injector requires service without taking exhaust port
parameters allows fuel to be optimized not only temperature readings or picking up a wrench.
during steady state operation but also during transient
acceleration fuel consumption is maximized over Engine Design Limits. Caterpillar performance
the entire engine operating range. engineers impose an exhaust temperature limit,
because exceeding that limit negatively affects fuel
• Fuel Consumption History. The ECM stores burn to overhaul goals. Damage, including warped
information on machine fuel consumption. or burnt exhaust valves and turbocharger damage
This can be used as a management tool to would result if temperatures were allowed to get
ensure maximum life to overhaul. too high.

• Diagnostics and Troubleshooting. EUI offers a Cat engineers also maintain peak cylinder pressure,
new generation of diagnostic and troubleshooting turbo speed, and turbo surge limits to ensure that
features. Advanced, easy-to-use diagnostic systems the engine will not only meet the performance goals
provide easy reference to vital machine information but also meet the expected life to overhaul goals.
and quick solutions if problems arise. With many years of experience in the mining
industry, Caterpillar has been able to establish
• Automatic Altitude Compensation. Power is physical material limitations specifically for
automatically derated as altitude increases to help demanding mining applications to achieve
prevent excessive combustion temperatures and maximum engine life.
subsequent component damage. An on-board
atmospheric pressure sensor derates the engine • Long Engine Life. Caterpillar truck engines are
at the optimal cutoff point for each model. designed to provide the highest customer value over
the life of the machine. The expense of unplanned
• Cold Start Protection. When temperature dictates, downtime has a tremendous impact on cost per ton.
the engine is automatically put into “cold mode” This reality has played an important role in making
to protect it from unequal distribution of load at decisions on how to design and apply the 3500 Series
start-up and to eliminate piston scuffing and seizure. engine. Thermal stress, pressure and vibration
If the parking brake is on and the transmission is stresses caused by high BMEP are major factors
in neutral, low idle speed will rise to 1,600 rpm and in reducing engine life.
timing will be retarded until the engine is warmed
up or until the transmission is put in gear. If the
transmission is put into gear before the engine has
reached operating temperature, the engine reduces
the amount of injection advance upon acceleration,
to provide continuing protection.
• Air Filter Restriction Indicator. By calculating
pressure drop across the filter, restriction can be
detected and the engine automatically derates if 
the allowable limit is exceeded.

20 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Engine

Engine BMEP in Truck and Other Applications

2500
                 G                 8                  0 
2000                  P                  7                 6 
    )                  E
            y     
                 K
                 S
                 K
                 S
                 C
   a                  b
                 d
                 Q                  Q
                 D
                  D
    P            n
                     ta
                 U                    )   
    k
    ( 1500                  S
                 T
                 M                  D
                  H
                  )   
                 D                   )   
                 B                   )                      )                      )   
                  H                 8                   B                  B                  B
                 B         2
    P                 6 
        1
                 B
        4
                0 
                 5         1
                 5
                6 
        1                 8 
                0 
    E 1000                  5
                           (3    
        2
                 5                            (3                               ( 3  
                 5
                          ( 3  
                 5
                          ( 3  
                  )   
                 D
                          ( 3                    D                  C                   H
    M                  D
                3                   B
                 7
                 7
                 7
                 5
                8 
                 C
                9 
                8 
                 R
        1
        1
                 B
                6 
    B                 9 
                 7
                 7
                9 
                 7
                 7                  7                  D         1
                 5
                          (3    
500                  F
        4
                9 
                9 

To calculate Brake Mean Effective Pressure (BMEP): • Caterpillar BMEP Versus Competition.
Recognizing that BMEP is critical in determining
BMEP =
Power  rev/cycle engine life, Caterpillar designs engines to run at
Displacement  Speed a much lower BMEP than the competition.
Although diesel engine technology is the same
BMEP P (kW)  rev/cycle  60,000
= across the industry, Caterpillar consistently
(Metric) D (L3)  N (rpm)
applies engines with a lower BMEP.
BMEP P (Bhp)  rev/cycle  396,000
= BMEP figures for competitive engines are more
(English) D (in3)  N (rpm)
comparable with figures for standby power
number of crank rotations per cycle generators. Due to high early hour failure rates,
Rev/cycle = (2 stroke or 4 stroke) some competitors have abandoned the use of high
BMEP engines in mining trucks. Most of the
• Brake Mean Effective Pressure (BMEP).
available alternatives have substantially higher
Brake Mean Effective Pressure is a measure of 
BMEP than Caterpillar, as clearly indicated on
how hard an engine is being worked for its given
the graphic.
displacement. This calculated parameter, expressed
in units of pressure, could be used to compare
engines of greatly different displacements and
applications.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 21

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Engine

• Cat High Displacement Engine. The physical limits Engine Combustion. The 3500B engine offers
established by Cat performance engineers are not world-class fuel economy. The combustion system
static limits. Caterpillar is always conducting research on the 3500B engine has increased valve lift and
to develop materials, manufacturing techniques and improved combustion efficiency when compared
designs that allow increases in engine capability. to early 3500 series engines. The 3500B fuel system
One example of how this has benefited customers produces high injection pressures over short
is the 3500 HD (High Displacement) program. injection duration resulting in enhanced in-cylinder
Piston technology had improved to the point where combustion and better fuel burn. Internal iron
Caterpillar was confident that piston speed increases changes that provide these results include
could be put into production. An evaluation of the modifications to the camshaft, rocker arms, camshaft
3500B showed an increased stroke was possible. followers, push rods, rear gear train, and pistons.
Applying this change has greatly benefited
customers of the 793D and 797B. With increased As a result of camshaft changes, the 3500B engine
displacement, and superior injection timing control, has increased valve lift for both the intake and
engine temperatures and pressures don’t need to exhaust valve. The new lobe design yields 13%
be as high to produce the same amount of power. more lift, allowing the combustion chamber to fill
The High Displacement 3500 engine optimizes and exhaust with greater efficiency and without
fuel consumption for a more fuel-efficient engine. compromises for engine overspeed.
Customers in the field have experienced higher fuel Design changes to the piston provide significant
efficiencies due to, among others, the machine’s improvements in combustion efficiency of the
ability to hold gears longer with the High air/fuel mixture within the cylinder. The shape has
Displacement engine. a deep bowl crown that reduces crevice volume and
BSFC Comparison increases air compression. This change results in
793D 3516B HD vs 793C 3516B SS improved fuel efficiency and lower emissions.
    )
   t 8%
   n 793D 3516B HD fuel consumption
   e
    l
   e   m advantage in the engine operating range
   u   e
    F    v 6% The piston uses
performance a proven,
design two-piece
with an aluminumhigh
   o
   c   r
    i
    f    p
    i    m
   c    I
   e    ( 4%
skirt and forged steel crown.
   p   n
    S    i
   o
   e   t
    k   p
   a
   r    m 2% Engine Cooling. The Caterpillar cooling system is
    B   u
   s
   n
   o incorporated into the total design of the truck and
    C 0%
1250 1350 1450 1550 1650 1750 consists of two parts, which include the jacket
Engine Speed (RPM) cooling system and the Separate Circuit Aftercooler
(SCAC) system. It is built for efficiency and
• High Displacement Versus Standard Stroke. designed to take up no more space than necessary
A plot of fuel consumption versus engine speed in order not to diminish payload capacity. Use of 
demonstrates one of the benefits of a high separate cooling circuits enables Caterpillar to
displacement versus standard stroke engine. achieve effective cooling without excessive
radiator size or horsepower loss.

The 797B and 793D cooling system employs

hydraulics rather than belt drive, allowing the use
of a demand fan. The demand fan reduces parasitic
losses when cooling requirements are less than
maximum.

22 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Engine

For most efficient combustion, highest density

charge air (coolest air) is required in the
combustion chamber. The lower the aftercooler
water temperature needs to be, the bigger the
radiator required.

Competitors tend to need more cooling to achieve

the same emissions as Caterpillar. Because they
need cooler water, they’re not nearly as well
positioned to meet emissions requirements.
Some competitors already face difficulty meeting
emissions requirements and customers need to
ascertain how these companies plan to deal with
new emissions standards.

Caterpillar has a single aftercooler, or a double

cooler, depending on the model.

Cat Electronics. Cat 3500B engine performance is

optimized by an integrated electronic control system.
The electronics optimize the fuel injection timing
to improve power characteristics and fuel economy.
Overall, the 3500B and 3500B HD series engines
offer 6 percent to 20 percent lower fuel consumption
than competitors’ mechanical engines, and in most • Electronic Control Module (ECM). The ECM uses
cases identical to or better than competitors’ industry leading control algorithms (software) and
electronic engines. It is important to note that often hardware to ensure peak engine performance over
competitors use a fuel consumption tolerance of  the entire operating range. The 3500B engine
±5 percent tolerance compared with ±3 percent controls consist of an engine-mounted Advanced
on Caterpillar engines. Diesel Engine Management (ADEM™) ECM.

With the exception of the 797B, which has a master

control and two slave units, the 3500 engines use
only one ECM. The ADEM control facilitates
integration of the engine with other Caterpillar
controls on board the truck. Electronic unit injectors,
sensors and the ECM regulate and monitor the
operation and health of the engine.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 23

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Engine

The ECM consists of two components: the control Second, the 3500B engine ECM has the ability to
computer and the control software. The control diagnose itself, its electronic sensors, and wiring.
software contains the operating maps defining Diagnostic codes are generated and stored in
horsepower, torque curves, air/fuel ratio, injection memory, as active or non-active, to reflect current
timing and transmission shift information. The ECM and intermittent or repaired problems. The codes
controls the injectors using feedback from various provide event description, number of occurrences,
engine sensors. Based on this input, the ECM hour of first and last occurrence and total hours.
determines fuel injection timing and duration In the 3524B, the codes also indicate which engine
to use for optimum performance. has a fault. Logged diagnostic codes are helpful in
troubleshooting and are accessed via the Caterpillar
Fuel injection timing depends on engine speed, load, Electronic Technician (ET) service tool. To further
throttle and other sensor inputs. The speed/timing enhance serviceability of the system, sensors used
calibration sensor signals the location of top dead to monitor the engine are consolidated with the
center of each cylinder, enabling ECM to control Vital Information Management Systems (VIMS)
timing and length of injection to maximize sensors to reduce redundancy and complexity.
performance. The ECM will deliver only enough
fuel to reach Caterpillar’s limit on exhaust
temperature, turbo speed, peak cylinder pressure and
other key factors in maintaining a healthy engine,
which will reach its expected life and beyond.

The ECM controls the variable horsepower settings

on the Cat 797B (3524B) engine, to improve
production. By exchanging information over the
Cat Data Link, the ECM allows the engine to

accelerate up to
is in 7th gear, 1,950 rpm
achieving topwhen
speedthe
of transmission
64 km/h
(40 mph). When in torque converter drive, the
ECM allows the engine to limit its speed and the
torque to the drive train to extend component life.
These features yield an increase in production and Caterpillar Electronic Technician (ET) Service tool
is used to diagnose the Cat 3500B engine.
a decrease in cost per ton.

• Monitoring and Diagnosis. The ECM performs • Cat Data Link. The ECM is a critical component of 
two engine health related tasks. First, it monitors the Caterpillar Integrated Power Train Management
engine parameters such as oil pressure, engine System. Information is shared between smart
speed, filter differential, and boost, and determines components over the Cat Data Link, allowing
if these parameters are consistent with acceptable onboard microprocessors to communicate with
engine limitations. If not, the ECM records an each other and access stored information for
engine event and initiates an alarm, a derate or a troubleshooting. Most competitive machines lack 
shutdown depending on the severity of the problem. such an integrated control and monitoring system.
Recorded events, including the nature of the event,
the number of occurrences and service hour of 
first and last occurrences, can be reviewed and
investigated via the Electronic Technician (ET)
service tool.

24 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Engine

Electronics Integration Features. The Cat integrated • Air Filter Restriction. An air filter restriction
control and monitoring system offers the following indicator monitors the air intake system. When the
electronic control features: air inlet restriction is too high, the system will
activate a warning and record the event in system
• Engine Overspeed Protection. If the engine memory. The system will automatically derate as air
reaches 2,100 rpm, a warning horn and check  intake restriction increases. When restrictions reach
engine message will activate in the message center 660 mm (26 in) of water, fuel is limited 1 percent.
of the VIMS. At 2,300 rpm the transmission will For higher restriction, fuel is limited 2 percent per
automatically upshift one gear regardless of cane 102 mm (4 in) of water up to a maximum of 
position. If the transmission is in top gear, the 20 percent.
torque converter lock up will disengage.
An overspeed upshift event will be logged in • Altitude Compensation. When operating at high
memory. The Automatic Retarder Control (ARC) altitudes, the system automatically derates power
computer will automatically activate in an overspeed by limiting fuel to prevent excessive exhaust gas
condition to control engine speed to 2,180 rpm. temperatures and related damage. The ECM uses
atmospheric pressure to determine the engines
• Acceleration Delay on Start Up. To reduce wear altitude. High Altitude Arrangements (HAA)
on lubricated components, engine acceleration is are available and they use either additional
disabled for two seconds after low idle has been displacement or two stage turbocharging to get
attained, on start-up only. This allows time for all full truck performance even at the highest mine
machine lubrication and cooling systems to achieve sites in the world.
pressure and flow before operating at higher speeds.
An engine pre-lubrication attachment is available • Diagnostics. The ECM is compatible with the
to pre-pressurize oil galleries within the engine Electronic Technician (ET) service tool, and
prior to cranking the engine during start-up. interfaces with Electronic Programmable

• Elevated Low Idle. In cold weather conditions, Transmission Control

the Cat Data Link. ETIIplugs
(EPTC)
intoand ARC viaport
a connector
low idle is elevated to allow the engine to achieve located on the fuse panel behind the operator’s
operating temperature quicker and maintain seat. ET can retrieve and display boost pressure,
temperature. Certain conditions must be met for fuel flow rate, engine rpm, logged diagnostics,
elevated low idle to be enabled: transmission must logged engine events, overspeed events, air filter
be in neutral, parking brake set and engine coolant restriction, oil pressure, overheating and other sensor
temperature below 75° C (167° F). Standard low input. ET provides numerous service features
idle is 700 rpm. including individual cylinder cut out, crank without
• Cold Mode Start Capability. The ability to start injection, and injector solenoid test. ET is the
and to perform is improved in cold weather by primary troubleshooting tool for the 3500B engine.

retarding timing when the engine is below operating

temperature. Retarded timing reduces peak cylinder
pressure and cylinder pressure rate. The engine
operates in “cold mode” when engine coolant
temperature is below 70° C (158° F). The ECM
also modifies the amount of advance on acceleration
when in cold mode to further protect the engine.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 25

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Engine

• Fuel Use Record. The ECM provides a cumulative

3500
record of fuel consumed. This record is accessible Engine Fuel
System Engine Oil
via ET and VIMS. (Injectors) Supply

• Multi-Point Pressure Sensing. The engine oil Transfer

Engine
Pump
pressure alarm will be activated if pressure falls out ECM

of spec. Oil pressure is monitored as a function of  Engine

2u Fuel
engine speed and the information is passed on Filter Mixed Return
to VIMS. If a condition falls outside of normal
Fuel Tank ORS
operating parameters, the operator will be alerted Electronic
Metering
to decrease the risk of piston scuffing and engine Valve
damage.
Diesel Fuel
• Ether Starting Aid. The ECM automatically
controls ether injection by determining if ether
starting aid is necessary based on engine coolant Oil Renewal System

temperature. Automatic ether injection control

prevents the possibility of the operator damaging • Oil Renewal System (ORS). ORS is an optional
the engine by using too much ether during engine system, which increases machine availability and
start-up. productivity by extending oil change intervals and
reducing oil disposal and labor costs. ORS meters
• Starter Protection. The starter is protected from and injects used engine oil from the crankcase
damage in two ways. First, the control feature will into the engine’s return fuel line, within carefully
not allow starter engagement if the engine speed is controlled parameters. The ECM performs control
above 0 rpm. Second, the starter is disengaged by of the ORS. No additional electronic modules
a solenoid after the engine speed reaches 300 rpm. are required.
This prevents the starter from remaining engaged
if an operator continues to hold the key in the start Oil Degradation versus Tim e
position after the engine has started.
  n
  o
   i
   t
  a
   d
  a
  r
  g
  e
   D
   l
   i
   O

0 1000 2000 3000 4000 5000

Hours

• Oil Degradation Versus Time.

26 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Engine

• Electrical Connections. To improve reliability At Komatsu, for example, integration of three

and serviceability, over 80 percent of the electrical different systems is required. Engine control
connections used are Deutsch connectors. VIMS systems from Cummins and GE must be integrated
and ECM sensors were combined to reduce with operating systems from Komatsu. All are
redundant sensors on the engine. Additionally, the developed separately and with different performance
wiring harness and clipping of the harness on the parameters. While GE might want the operating
engine and within the engine compartment is system to protect the engine, Komatsu may want
designed to facilitate easier and faster engine the system to operate differently to meet customer
removal and installation. demands.

Caterpillar Engine Design Versus Competition.

Caterpillar has a very real advantage in being able 1

to design and develop a fully integrated engine and

power train control system.
2

• The Lafayette engine group employs engine

software specialists to develop a system that
will control specific parameters for optimal 17
engine efficiency, reliability and durability.

• Based on extensive experience using the control

16 5
system on engines in different applications, 3
4
Caterpillar has the expertise to integrate engine
and power train specifically for the requirements
of mining. 1. 12 Holset Turbos
2. Belt drive alternator
5. Centrifugal oil filtration system
6. 3 electric starters
3. Jacket water pump 7. Auto prelube

• Through the Mining Truck Engineering Group 4. Coolant filters

in Decatur, IL, Caterpillar ensures system design Cummins QSK78 Engine.
and manufacturing suppliers work together to
offer a fully integrated system. • Komatsu-Cummins Engine Design. In a joint
venture with Komatsu, Cummins has formed a new
• Competitive Engine Design. Competitors are
company (Industrial Power Alliance (IPA), and
challenged when it comes to system integration
added the 2610 kW (3,500 hp) QSK78 (alternatively
because they join together with up to three different
named the Komatsu SSDA18V170), to its range of 
companies, each with their own performance
engines for mining trucks, which also includes the
criteria. Cat doesn’t face these difficulties with
QSK45 and QSK60. The joint venture agreement
integration.
nominates Cummins as exclusive engine supplier
Typically the engine manufacturer develops software for Komatsu Mining Equipment.
to control and protect the engine, but the truck 
manufacturer and the customer may have different
operating parameters in mind. To reach agreement
is a compromise, not likely to be ideal for any of 
the three parties.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 27

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Engine

Reducing product development and manufacturing

time, while minimizing development capital, IPA
sourced off-the-shelf components for the QSK78.
1
In an unprecedented union, the design team had
to accommodate ideas from both Cummins and
Komatsu engineers. On-going development, specific 2
4
manufacturing and operational requirements were
to be achieved in the shortest possible time.

• Komatsu-Cummins Engine Performance.

Although the negative impact of increasing 5
peak cylinder pressures and specific power was
3
acknowledged, the BMEP of the QSK78 is more 6
than a third higher than the Cat 3524B. QSK60
and QSK78 ratings exceed MTU/DDC 4000, and
are similar to ratings for Cat Standby GenSets.
Based on information available, the predicted life 1. 2 Intercoolers 4. Balance tubes
2. Belt fan drive 5. 6 Aftercoolers (3 per side)
of the QSK78 would be significantly less than the 3. Inter/Aftercooler pump 6. Fuel/water separators

published 20,000 hours. To date, there appears to Cummins Quantum Engine was
be no site where a QSK78 engine can be found the basis of the QSK78 design.
operating and reaching expected parameters.
• Komatsu-Cummins QSK Family. Cummins opted
The QSK78 has a peak torque of 13,770 N•m
for a mono-block construction with added “stiffness”
(10,156 lb-ft) at 1,500 rpm while the Cat 3524B
and chose the power cylinder components (head,
peaks at 17,220 N•m (12,701 lb-ft) at 1,300 rpm.
piston, ring pack and liner) from the Komatsu
At 1,900
13,100 N•mrpm(9,662
rated speed, the QSK78
lb-ft) versus 14,444produces
N•m inline SAA6D170 family, which fit, with some
adjustments. QSK78 uses a one-piece nitride
(10,653 lb-ft) at 1,750 rpm for the Cat 3524B,
hardened iron piston design.
a torque rise of 5% versus 19% for the 3524B.
Components for the QSK60 were derived from
Performance curves show 2610 ekW (3,500 BHP) at
the Komatsu SAA6D170 family, but the extended
rated 1,900 rpm and BSFC of less than 201 g/kW/h,
crank length and additional crank throws required
looks good versus Cat BSFC of 211 g/kW/h, but
modification to the piston crank. Concerns about
there is no indication of tolerances.
reliability of the front gear train resulted in design
changes to accommodate wider, high-contact
ratio gears.

Accommodating new performance criteria and the

engineering philosophies of both Cummins and
Komatsu required a “clean sheet” approach in many
areas, but longevity of the QSK78 is yet to be tested
in field applications.

28 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Engine

The QSK60 is a 60 L (16 gal) (2 m3 [3,672 in3]), In tests conducted by Caterpillar, at mid-load and
159 mm bore and 190 mm stroke (6.26 x 7.48 in) at high speed, the MTU had better fuel consumption,
2013 kW (2,700 hp) engine. The engine can be but throughout the entire load range produced
configured with one or two stage aftercooling much more smoke than the Cat 3500 engines.
and with serial or parallel turbochargers. The MTU had higher NOx limits and particulates
Approximately 25% of QSK60 production emission than the Cat engine. The Cat 3500 engine
is placed in mining applications. also has a better NOx/BSFC trade-off than the
MTU/DDC 4000.
Terex/Unit Rig also uses the Cummins QSK60
engine in its larger mining trucks while Hitachi The MTU/DDC 4000 engine was found to have
uses Cummins engines in some of its smaller some advantages over Cat 3500 series engines:
mining trucks.
• Slightly better Brake Specific Fuel Consumption
• MTU/DDC Engine Design. In a joint effort by DDC (BSFC) than the Cat 3500 engines.
and MTU, Series 4000 MTU/DDC engines were
developed to provide fuel economy, reduced service • More efficient two-pass aftercooler.
time and promise of a 20,000 hour life to overhaul • Low and high idle engine noise.
(in most applications). Since their introduction in
1999, attention has been required to address issues Caterpillar offers the following advantages over
with injector seals, high-pressure pump failures, the MTU/DDC engine:
cooling system performance, charge air intake
• Lower installation costs. MTU requires
system and, most recently, main bearings.
26 percent more SCAC flow. More stringent
MTU/DDC engines are used in Liebherr,
inlet and exhaust restriction requirements.
Terex/Unit Rig and some Euclid models.
• Better tested emissions capability.
• MTU/DDC Versus Cat. The MTU/DCC engine
requires a much colder SCAC temperature and still Higher injection pressure.
has higher cycle emissions than the Cat 3500 engine. • Slightly less engine noise at rated point.
The MTU pushes the turbochargers harder to get
its performance and it requires a higher BMEP • Lower cost rebuild as cylinder head has better
to get to its rating. reman potential and flush bottom deck is
cheaper to refinish.
Durability of MTU/DDC 4000 in the 830E and
930E has been reported to be less than expected. • Less expensive pistons.
There is evidence that some MTU/DDC 4000
• Longer engine life.
engines were stripped out due to disappointment
with performance and serviceability in mining
applications. By comparison, with the very
serviceable Cat 3500 series engine, the
MTU engine presents some challenges:

• Very high levels of liquid nitrogen are involved.

• Flangeless couplings are more complicated

and time consuming to deal with.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 29

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Drive Train

Drive Train. Cat mechanical drive train delivers more power to the ground.

• Precise planet gear tooth profiles are achieved

by CBN grinding after heat treat. This reduces
sound and provides exceptional bending
fatigue life.
• Planet gear teeth also are designed and
manufactured with crown to ensure correct
load distribution across the tooth face.

• Cat planet shafts are stone polished.

This provides superior resistance to frosting
and pitting compared to more common
centerless-grind finished shafts. They also
Caterpillar Planetary Powershift Transmission. are more likely to be reusable at rebuild.

• Proven Cat technology uses durable large • Routine maintenance and most control repairs
diameter clutch packs. Clutches and controls can be made in-chassis. Modular design allows
are designed to provide smooth, automatic quick transmission removal. Electronic controls
shifting while limiting clutch energy input eliminate linkage adjustments and lessen the
to give long clutch life. chance of mechanical failures.
• The Cat patented design for rotating clutch • At rebuild, bearings, seals, gaskets, seal rings
pressure seals minimize drag losses and make and thrust discs are expected to be replaced
rotating clutches as reliable as stationary clutches. regardless of condition; other components,
including clutch discs and gears, may be
• Gears are made from bearing-quality steel to
inspected and reused.
avoid inclusions that can cause tooth breakage.
High Contact Ratio Helical transfer gears • Modular design allows quick transmission
designed by Cat to control sound and give removal. When the transmission must be
long life. exchanged, it can be done by two mechanics
in a half-shift or less.
• On the new 793D, the extra top speed
arrangement provides an input transfer
gear with lower gear ratio.

30 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Drive Train

• Controlled throttle shifting reduces torque

created by the engine during shifts for smooth
clutch engagement and improved component
life. Ability to select any gear with cane.
• Programmable top gear limit with any gear
from 4 to 7 as top limit.

• Directional shift management automatically

reduces engine throttle before shifting from
neutral, reverse to forward and forward to
reverse to protect driveline components.
No operator input change required.

• Neutral coast prevention will not allow the

transmission to shift to neutral if the ground
speed is above 6.4 km/h (4.0 mph). It only
down-shifts to the proper gear for that
ground speed.
Caterpillar Transmission Design. Electronically • On-board alphanumeric diagnostic display
controlled planetary transmission features: records intermittent and active faults.
• Smart shifting with no gear hunting. • On-board memory records shift histograms
• Downshift inhibitor prevents engine overspeed. and lock-up clutch engagements.

• Optimum performance with minimum wear.

• 6 and 7 speeds forward, 1 speed reverse.

• Top speeds: 785C in F6 = 54.8 km/h (34.0 mph);

789C in F6 = 52.6 km/h (32.7 mph); 793D in
F6 = 54.3 km/h (33.7 mph); 797B in F7 =
67.6 km/h (42.0 mph)

• 35 percent ratio steps in all ranges.

• Torque converter lockup in first gear with

torque converter drive in reverse and first
gear below 7.2 km/h (4.5 mph).
• Low torque design with most reduction in
final drives.

• Transmission mounted directly to differential

housing.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 31

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Drive Train

• A new hydraulically driven filtration system on

793D and 797B provides cooler, cleaner oil and
parasitic power loss management via a constant
oil flow to the final drives for longer
component life.

• The VIMS™ Monitoring System monitors the

rear axle system to notify the operator of low
lubrication levels, high temperatures and low
lubrication flow caused by plugged filters.

Extended Power Train Life. Cat final drives, wheels,

Caterpillar Final Drives. Transmission and final and differential are designed and built for long
drive parts work together to put more power on power train life.

the ground. Cat final drives are designed to work 

as a system to withstand the forces of high torque
• Final Drive Features.
and impact loads. They are manufactured and tested • Flat deck carrier – improves the ability to cast
for precise fit and heat-treated to ensure durability and assemble; planet loads are equalized.
and long life. They deliver superior performance
and are of such high quality that they can be • Higher capacity planet bearings for improved
remanufactured for a second life. reliability.

• Spindle bearing journals are laser-hardened. • Improved heat treatment with an exclusive
finish and higher precision.
• The differential bearings utilize newly developed
steel for increased resistance to fatigue failures. • Wheel Features.

• Forged and ground crowned gear teeth prevent • Optimized structure. High casting quality, high
excessive stress on mating teeth and ensure yield strength steel, can be re-manufactured
correct load distribution across the face. and repaired.
Pitting, scoring and breakage is reduced • Front wheel spindle is forged or cast with laser
to extend component life. hardened journals.
• Cat mining trucks are equipped with a one-piece • Rear wheel splined brake to spindle connection;
cast rear wheel to accommodate high-capacity improved stress distribution.
wheel bearings.
• Increased capacity wheel bearings for better
• Cat Duo-Cone™ seal mountings within the load distribution.
wheel station prevent brake hub wear and
increase service life. • Sealing designed to minimize debris
accumulation.
• Direct lubrication of differential bearings is
provided through use of ground driven gear
pump on 785C and 789C or continuous,
hydraulically driven gear pump on 793D
and 797B. The lubrication is filtered prior
to being directed to the components.

32 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Drive Train

• Differential Features. Caterpillar Rim to Wheel Mountings. To mount rims

to wheels, Caterpillar uses a flange type mounting
• Structure designed to maintain optimum gear with sufficient quantity of torqued bolts to
and bearing alignment. accommodate both vertical loads and tractive loads.
• Optimized effective bearing spread. A single torquing of the bolts is sufficient to prevent
slip or loosening of the joint. If, in the unlikely
• Spider bearing sleeves eliminated; new spider event the rim were to slip, the multiple bolts act as
bearings eliminate cage wear. dowels to stop any further slippage. For more than
30 years, Caterpillar has successfully used the
• Pressure lubrication.
flange-type mounting system in off-highway trucks.
• Rear Axle Lube System.
Cat Duo-Cone™ Seals. Since the introduction of 
• Continuous driven lubrication pump on 793D oil-cooled disc brakes on Caterpillar mining trucks,
and 797B. Ground driven lubrication pump Cat Duo-Cone seals have been an integral part of 
on 785C and 789C. the design. Duo-Cone seals were developed in the
late 1950’s to provide a new type of seal to improve
• Parasitic power loss management. lubricant retention in hostile, abrasive and corrosive
environments where elastomeric shaft seals wore
out quickly.

The design of a Caterpillar metal-faced seal

compensates for many manufacturing and operating
variables. Two metal sealing rings float in position;
two elastomeric toric rings exert uniform pressure
to accurately position the metal rings and serve as

the
Thestatic seal between
load rings the housing
also transmit and the
the turning sealfrom
torque ring.
the driven housing to the seal ring. Positive sealing
contact is provided, regardless of assembly tolerance
Caterpillar wheel station with laser hardened journals. build up, deflections or end play.

Power Train Reliability. Caterpillar builds the best

drive train parts on the market and achieves the
highest availability in the industry. Backed by
excellent maintenance and repair options, the result
is maximum productivity and lower costs. Cat offers
effective drive train maintenance, including
Preventive Maintenance (PM) programs, Oil
Analysis, Inspections, Training, Scheduling, and
Recordkeeping, which result in fewer failures and
less unexpected downtime. Operating costs decrease,
as machine life and availability increase.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 33

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Drive Train

Metal-faced seals feature: Service Support. Cat dealers can restore system
performance and get machines back to work – fast,
• Corrosion resistant seal rings. helping to evaluate repair indicators and determine
• Precision lapped, self-renewing seal surface. the lowest cost repair option. Dealer service is
guaranteed, with professional service people who
• Minimum face load variations. have the training and technology to handle all levels
of repairs. Even in remote areas, Caterpillar dealers
• Long life.
have access to the worldwide expertise and support
• Good performance across a wide range of Caterpillar. Cat dealers also offer an unmatched
of face loads. Exchange or Cat Remanufactured parts service
providing parts that carry a “same as new” parts
warranty but cost far less than new.

34 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Mechanical Versus Electric Drive

Mechanical Versus Electric Drive. Cat mechanical drive trucks are built for superior control in the most 
severe applications.

Caterpillar trucks are used in relatively more

severe applications than competitive DC drive
trucks, but withranges
the application the advent of newer
are now more AC trucks,
comparable.
Caterpillar mechanical drive systems offer the
following benefits:

• Efficiency... more power getting to the ground

and thus more useful work done.

• Reduced fuel cost per ton... less fuel burned

per ton of material moved.

Power Train Efficiency. Power train efficiency

quantifies how much of the engine power generated
gets to the ground to do the work... moving material
efficiently from point A to point B. Engine power
that doesn’t get to the ground is wasted.

Caterpillar Mechanical Drive. Caterpillar entered the

mining market with the introduction of the 77 tonnes
(85-ton) 777 in 1975. Prior to the introduction of 
the 777, all trucks in the 77 tonnes (85-ton) class
were electric drive. No competitor had attempted
a mechanical drive with a power shift transmission
in larger trucks. The mechanical drive 777 with
power shift transmission soon became the dominant
leader in the 77-91 tonnes (85- to 100-ton) class
construction/mining trucks. Because of the greater
efficiency, rimpull, gradeability and durability,
mechanical drive quickly replaced the electric
drive in the 77-91 tonnes (85- to 100-ton) class.
Today, no competitor offers an electric drive
in the size classes below 91 tonnes (100 tons).

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 35

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Mechanical Versus Electric Drive

Gross Power Train Efficiency

100% Peak 12%
95%

90%
797B 88 86.7
   y
   c 85% 793D 88 85.4
   n
   e 80%
    i AC 83 79
   c
    i
    f
    f 75%
    E DC 81.5 72.2
   n 70%
    i
   a
   r
    T 65%
   r
   e 60%
   w
   o 55%
    P 793D 797B
   s 50%
   s
   o
   r
AC Drive DC Dr ive
45%
    G
40%

35%

30%
0% 5% 10% 15% 20% 25% 30%

Effective Grade

Mechanical drive systems are the most efficient over a broad operating range

• Mechanical Drive. The mechanical drive system As effective adverse grades increase, the electric
is more efficient than both the DC or AC electric drive becomes less efficient while the mechanical
drive system. A comparison of efficiencies on a drive has a relatively constant efficiency as adverse
typical mine haul grade of 10 percent shows the grades change. For example, the efficiency of the
793 to be about 8 percent more efficient than an 830E truck drops from 81 percent on a 5 percent
830E. Under the same conditions, the 797 is about effective grade to 66 percent on a 15 percent grade.
6 percent more efficient than a 930E. The efficiency of the 793 truck actually increases
slightly from 81 percent on the 5 percent grade to
83 percent on a 15 percent grade.

Higher efficiency of the drive train system results

in less fuel burned per ton of material moved, which
translates into lower cost per ton operating costs.

36 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Mechanical Versus Electric Drive

Gross Power Train Efficiency Peak 12%

797B 88 86.7
100% 793D 88 85.4
95%
AC 83 79
90%
   y DC 81.5 72.2
   c
   n 85%
   e
    i 80%
   c
    i
    f
    f 75%
    E
   n
    i 70%
   a
   r
    T 65%
   r
   e 60%
793D 797B
   w
   o 55%
A C D riv e D C D ri ve
    P
   s 50%
   s
   o
   r 45%
    G
40%

35%

30%

0 10 20 30 40 50

Ground Speed-mph

Mechanical drive systems are the most efficient over a broad operating range

• Electric Drive. The efficiency losses in an Because electric drive systems are less efficient,
electric drive system are caused by losses in competitors with electric drives must increase
power conversion. gross engine power to have grade power equivalent
to mechanical drive. For example, the 830E has
For DC systems: 1864 kW (2,500 gross horsepower) compared to
• Engine power to alternating current. the 793D at 1801 kW (2,415 gross horsepower).

• Alternating current to direct current. • Mechanical Drive Advantages.

Miners acknowledges that mechanical drive trucks
• Direct current to mechanical motion at the offer the following advantages:
wheel motor.
• Broader application range, steeper grades,
• Additional accessory losses to support the good performance in poor underfoot conditions
electric drive system. and superior performance in high rolling
resistance in tar sands.
For AC systems:
• Few thermal limitations on grade. The insulation
• Engine power to alternating current. in the Electric Drive wheel motor breaks down
• Alternating current to direct current. under high heat and load conditions experienced
over long periods of time.
• Direct current back to multiphase alternating
current. • No high voltage electric support required.

• Alternating current to mechanical motion • High voltage safety.

at the wheel motor. • Potential to use mechanical drive in more
• Additional accessory losses to support the severe conditions.
electric drive system. • Better controllability – retarding and driving.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 37

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Mechanical Versus Electric Drive

• High stall rimpull. • Conclusion. Caterpillar’s field research concluded

Cat mechanical drive trucks have functional
• Environmental tolerance – mechanical drive capabilities that promote their use in a broader range
is less affected by wet conditions. of applications than the DC and AC drive trucks.
• Lower fuel costs per ton. • Competitive DC trucks perform well in light
• Fewer electrical parts. duty applications.

• Electric Drive Advantages. • Competitive AC trucks have a wider range

of applications than the DC drive trucks.
• Less maintenance time is required to change
oil and filters. • The 218 tonnes (240-ton) AC drive trucks were
preferred in severe downhill hauling until the
• Trolley compatibility. recent introduction of the Cat 793D MA2 (Extra
Retarding), which has narrowed or eliminated
• Less oil volume. the AC drive advantage in this application.
• Fewer gears and mechanical parts, although
• The responsiveness of power electronic
mechanical drive has no high voltage lines
traction control software in electric trucks is
or control cabinets.
slightly inefficient when compared to the Cat
• Faster downhill hauling speeds. mechanical drive Traction Control System.

• No wearing of brake parts during retarding, • Some competitors market machines with
but mechanical systems have no blowers lower prices for repair and maintenance
or heat rejection grids. contracts falsely, creating the perception that
electric drive is a lower cost-per-ton option.
• Electric Drive Disadvantages. Maintenance costs and conditions need
to be compared carefully.
• Efficiency.

• Support multiple suppliers.

• System integration – multiple software systems.

• Complex to trouble shoot.

• Stall torque capability.

• Thermal capacity.

• High voltage lines and control cabinets.

• Traction control.

38 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Mechanical Versus Electric Drive

Operating Cost Comparison. Miners acknowledge Product Support. Every element of Caterpillar’s
cost per hour (or ton) varies widely between mine mechanical drive train is performance-matched
sites depending on a number of variables, and and built to take the abuse of haul truck applications.
Caterpillar’s studies confirmed this variation is far
greater than the variation between mechanical and From the heavy-duty design of the 3500 series engine
electric drive systems. For mature systems operating to the six/seven speed transmission, through double
under similar conditions, there is no significant reduction planetary final drives and the all-wheel,
difference in operating costs for the electric vs. oil-cooled disc brakes, each component in every
mechanical power transmission system in mining system is designed for maximum durability.
trucks. The difference in drive type impacts on The result is a mining truck that performs better,
only 16.5 percent of the total cost-per-ton. breaks down less and lasts longer. And just as
Cost-per-hour of the total propulsion system important is an unmatched product support team –
averaged: Repair Before Failure programs, remanufactured
components and reusable parts, Scheduled Oil
• Engine: 46 percent Sampling, regular maintenance options,
worldwide parts inventories and an extensive
• Power Transmission: 16.5 percent parts distribution system.
• Wheel Station: 37.5 percent

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 39

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Caterpillar® Brake System

Caterpillar ®  Brake System. Cat oil-cooled, multiple disc brakes offer exceptional, fade-resistant braking
and retarding for maximum performance and productivity in all haul road conditions. Integrated Braking
Control combines retarding and traction control into one system for optimum braking efficiency.

  1 Parking/Secondary Piston
  2 Service/Retarding Piston
2 3 Friction Discs
  4 Steel Plates
1 5 Actuating Springs
6 Cooling Oil In
7 Cooling Oil Out

7
3

5 6

Integrated Design. The Caterpillar designed and

developed non-fade, oil-cooled braking system is
an integral part of the overall truck design, not an
Caterpillar Brake System. Caterpillar oil-cooled add-on or afterthought.
multiple disc brakes for off-highway trucks have a
long development history. When Caterpillar began The integrated design serves four braking systems:
development of an off-highway truck in the late • service
1950’s, oil-cooled brakes were an integral part of 
the design. Improvement of the brake has been an • retarding
on going process since those early days. For many
• secondary
years only Caterpillar offered the superior oil-cooled
braking system on off-highway trucks. Several • parking
competitors have since tried to copy the Cat system,
but have not kept up with the advances and The service and retarding functions are actuated
innovations offered by Caterpillar. by modulated hydraulic pressure on the brake piston
that in turn applies a load or force on the brake rotors
and stators. The secondary and parking functions
are actuated by multiple springs acting on the
secondary/parking piston. The springs are released
by modulated hydraulic pressure. Hence, brakes are
always available even in the event of a complete
hydraulic failure very important safety feature.
No other manufacturer has ever offered an oil-cooled
brake with the safety feature of spring applied/oil
released secondary/parking brake.

40 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Caterpillar® Brake System

Four-Wheel Braking. The large Cat trucks have • The friction material has been improved from
four-wheel braking for superior retarding control the original sintered bronze to a cellulose fiber
with wet haul road conditions. Single axle retarding material. To be more environmentally friendly,
limits controllability during slippery road conditions. asbestos ras eliminated from the friction material
Operator security is much greater with the four- in the 1980’s. The friction material is continually
wheel brake system, resulting in greater productivity. being modified to improve frictional, wear and
Trucks with two-wheel or single axle retarding must heat resistance characteristics.
cease operations during conditions of slick haul
roads while Cat trucks can continue to operate. • The energy absorbed by the brakes during
retarding is dissipated by high flow of oil
The parking brake is applied to all four wheels through the discs and separator plates. The oil
to give superior parking capability. The parking is cooled by water-to-oil heat exchangers to
system provides parking capability on grades up give good retarding capability.
to 15 percent with worn brakes at the targeted gross
• Extended life friction material has double the
machine weight. No competitor provides four-wheel wear life of standard brakes and is twice as
parking brakes. Since the parking brake system also
is oil-cooled, inadvertent application while moving resistant to glazing for more consistent
will not “burn-up” the brakes, which is the case braking power with less noise.
for competitors. • Hydraulic Automatic Retarder Control (HARC).
Brake System Design. The Cat oil-cooled disc brake Hydraulically activated automatic retarder control
system delivers exceptional performance due to system electronically controls retarding on grade
superior design features. to maintain optimum engine rpm and oil cooling.
It is designed to modulate the brake system in
• The large frictional area is determined by the order to maintain a constant engine speed, and
gross machine weight to give low retarding it also promotes smoother engagement, better
hp/in2 and high wheel torque for short responsiveness, loping removal, less air system
stopping distances. demand and fewer air system parts. Additional
braking may be applied using the manual retarder
• Front to rear brake torque split is balanced or the brake pedal. HARC is deactivated when the
to give the best braking performance and operator applies the brake or accelerator controls.
to minimize wheel lock-up especially
when in the retarding mode.

• The non-fade characteristic of oil-cooled brakes

enables reduced stopping distances compared
to systems using either dry caliper disc or drum

type brakes.
grades Asand
steeper trucks becamerequirements
regulatory larger, retarding
more stringent, only the Cat trucks were able
to meet legal braking requirements without
modifications.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 41

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Caterpillar® Brake System

1
HARC
2
  1 Service Brake Sensor
2 Engine Sensor
TCS
• Traction Control System (TCS). Caterpillar trucks
3 HARC
4 HARC Switch
5 Brakes
also use the rear oil-cooled brakes for traction
  6 Service Brakes
  7 Axle Speed Sensor
6 control. The exclusive Caterpillar system improves
  8 TCS 7

8 performance in poor underfoot conditions by

3
7 electronically monitoring and controlling wheel
5 6
slippage. Sensors monitor wheel speed and if the
4
difference exceeds a preset limit, the oil-cooled
brake is actuated on the faster spinning wheel.
• HARC vs. ARC. With a standard differential output, torque to the
two wheels is always equal. Applying brake torque
• Less chance for engine overspeed to the faster spinning wheel (the one with least
traction) will then give additional torque to the
• Smoother engagement
slower wheel and provide additional tractive
• No loping effort. Normal steering maneuvers do not
actuate the system.
• Less air system demand

• Reduces operating costs

• HARC Production Advantages.

2500

2000
    )
   m
   p
   r
    (
   e1500
    d
   e
   p
    S
   e
   n1000
    i • Integrated Brake Control (IBC). The HARC and
   g
   n TCS are combined into an Integrated Brake Control
    E
(IBC) System to enhance Cat truck performance
500 and increase productivity.

0 10 20 30 40 50 60 70 • Serviceability. Maintenance of the oil-cooled

Time (Seconds) brake is minimal since the brake is enclosed and
sealed. Additionally, brake material wear condition

 With Hydraulic Automatic Retarder Control can be determined

By removal withoutplug
of a service disassembly of theofbrake.
and insertion a
(average speed, 1950 rpm)
simple service tool, wear of the disc pack is easily
 With Manual Retarder Control determined.
(average speed, 1730 rpm)

42 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Caterpillar® Brake System

• Regulations. All brake tests to determine • Komatsu Brake System. The brake system features:
compliance with regulatory requirements are run
with the truck at the maximum allowable gross • Hydraulically applied front and rear dry caliper
machine weight and not at nominal gross machine disc brakes are subject to dirt and moisture entry,
weight as in the past. Seldom will the truck weight which can cause premature wear and/or
be at the nominal because of variations in loading malfunction.
tool fill factors, material density variations, and • Rear brake discs on the high-speed motor
loading tool operator skill. It is imperative then armature develops high torque but very limited
that the truck has adequate brakes when loaded dynamic capability. Small disc diameter of 
to the maximum allowable gross machine weight. 635 mm (25 in) provides limited frictional area.
Caterpillar Brake System Versus Competition. • Spring applied, hydraulically released parking
The brake system on Caterpillar mining trucks brake on high speed motor armature develops
has been designed for optimum braking efficiency high torque but almost no dynamic capability.
and safety.
• Dynamic electric retarding through traction
• Oil cooled multiple disc brakes provide non- motors and grid system.
fade braking and retarding on all four corners.
The 930E-3 and 930E-3SE brake system features:
• Braking force is applied in a ratio of 40 percent
front, 60 percent rear for better handling and • Hydraulically applied front and rear brakes are
controllability. oil cooled multi-disc brakes.

• Automatic electronics control the retarding • Retarding capability with the oil-cooled brakes
function. is limited since oil flow is low.

• Rear brakes provide traction aid. • Spring applied, hydraulically released parking
brake on the high-speed motor armature develops
• Service and retarding brakes are hydraulically high torque but almost no dynamic capability.
applied for greater efficiency.
• Dynamic electric retarding through traction
• Secondary and parking brakes are spring applied motors and grid system.
for added safety.
• Terex/Unit Rig Brake System. The brake system
• The application of emergency brakes can features:
be modulated for a brief period before they
remain applied. • Hydraulically applied front and rear dry caliper
disc brakes are subject to dirt and moisture entry
• The brake system exceeds legal/regulatory which can cause premature wear and/or
requirements at maximum allowable gross malfunction.
machine weight.
• Rear brake discs on the high-speed motor
• Completely sealed system is not affected armature develop high torque but very limited
by environment, including water and dust dynamic capability. Small disc diameter of 
contaminants. 508 mm (20.2 in) on the MT3000, 635 mm
• Brake wear measurement can be undertaken (25 in) on the MT4400 and 787 mm (31 in)
without disassembly. on the MT5900 provides limited frictional area.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 43

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Caterpillar® Brake System

• Spring applied, hydraulically released parking • Spring applied, hydraulically released parking
brake on high-speed motor armature develops brake on high-speed motor armature develops
high torque but almost no dynamic capability. high torque but almost no dynamic capability.

• Accumulators that require routine pressure The EH4500-2 and EH5000 brake system features:
checks and maintenance provide secondary
brake power. • Hydraulically actuated dry caliper disc front
brakes are subject to dirt and moisture entry,
• Service and secondary brakes share the same which can cause premature wear and/or
brake circuit and are more complex. Circuit malfunction.
includes: pump, shuttle valves, pressure reducing
valve, relief valves, accumulators, pilot-operated • Hydraulically actuated oil cooled rear disc
control valves, steering versus brakes priority. brakes.

• Spring applied, hydraulically released parking

brake on high-speed armature has almost no
dynamic capability.

• Liebherr Brake System. The brake system features:

• Standard service brakes use wheel speed discs
on the front with three calipers on the T252,
four on the T262 and five on the T282B.

• Rear brakes use dual disc armature speed discs

with one caliper.

• Multiple calipers cause high heat production.

Euclid/Hitachi EH3500 front and rear dry disc brakes.

• Euclid/Hitachi Brake System. The brake system

on the Euclid/Hitachi EH3000 and EH3500 features:

• Hydraulically applied front and rear dry caliper

disc brakes are subject to dirt and moisture entry,
which can cause premature wear and/or
malfunction.

• Rear brake discs on the high-speed motor

armature develop high torque but very limited
dynamic capability. The small disc diameter of 
EH3000 and EH3500 provides limited
frictional area.

44 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Steering and Suspension System

Steering and Suspension System. Cat designed for excellent maneuverability, superior control
and a comfortable ride.

• Steering Geometry. The three steering geometry

features – kingpin inclination, caster and camber –
are permanently designed and built into the truck 
and require no adjustments during the life of the
truck. The only steering linkage adjustment required
is toe-in which is achieved simply by adjusting the
two tie-rods.

• Kingpin Inclination. The front suspension cylinder

serves as the steering kingpin.

• The kingpin is rigidly attached to the mainframe

by bolts and shear keys and is inclined in the
front elevation view 3 degrees from vertical.

• This kingpin inclination reduces the torque

required to steer the front tires by moving the
center of rotation nearer to the tire than would
be the case if the kingpin were vertical.
Caterpillar Design. Cat steering and suspension • Caster.
system design, first introduced on a 769 in 1963,
are simple integrated designs, built rugged for • From the side view the kingpin is set at
minimal maintenance and long life. 2-1/2 degrees to the vertical to provide caster
or self-alignment for the front wheels.

• Camber.
• The front axle is designed and manufactured
to have one-half degree of camber, which is
reduced to near zero by the load deflections.

• Maximum Tire Life. Good tire life is dependent

upon having minimal tire scuffing. Caterpillar trucks
are designed to maintain near zero toe-in/toe-out,
which is essential to minimize tire scuffing and
extend tire life.

• When either loaded or empty, Cat steering

linkage/ suspension systems are designed to
have near zero toe-in/toe-out when the tie-rods
and front suspension cylinders are properly
adjusted.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 45

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Steering and Suspension System

• Having two tie-rods that pivot with the center

tee-bar minimizes the amount of toe-in/toe-out
that occurs during all conditions of loading Nitrogen
and steering.
• Systems with a single tie-rod inherently have
greater toe-in/toe-out variations. Rebound
Chamber
• Maneuverability. Caterpillar trucks have a
balanced design to give good maneuverability and
yet minimize tire wear. If the turning circle is too
small, extreme tire wear occurs during tight turns.
Cylinder
• Some competitors claim smaller turning circles Housing
than Caterpillar, but pay for those claims with
increased tire wear.
• The Caterpillar truck steering geometry is
designed for Ackerman steering with minimal
steering error even at extreme steering angles. Piston

• The two tie-rod design enables the steering

error to be less than can be achieved with
a single tie-rod.

• Ride Control. The rear suspension geometry is

designed to allow sufficient rear axle oscillation in
conjunction with large front suspension travel to
reduce frame racking while traveling over rough • Design Features. The steering and suspension
terrain. Both front and rear struts have built-in system offers advanced design features:
rebound control to improve ride. To further enhance
the operator’s ride the cab is strategically located • Caterpillar steering systems have top priority
relative to the front axle to minimize the effects of  for the control of the machine in case of a
pitch and bounce. hydraulic failure. This is critical to ensure
the highest possible safety for the operator.
Competitors frequently locate the cab in a position
that exacerbates the effects of pitch and bounce. • To further protect the operator, the main steering
The Caterpillar suspension is located and tuned to hydraulic system is backed by a supplemental
maximize ride qualities and yet give a stable “feel system using pressure accumulators in the
of the road” for the operator. Because of the superior unlikely event the steering pump should
ride qualities of Caterpillar trucks, the operators malfunction. The secondary steering system
have less fatigue and a more secure feeling that is more than adequate to meet SAE J1511 and
results in greater productivity. ISO 5010 standards at the maximum allowable
gross machine weight.

• Twin, double-acting hydraulic cylinders provide

the force necessary to provide precise steering
during all loading and underfoot conditions.

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Steering and Suspension System

• The suspension system is comprised of nitrogen • Four nitrogen over oil cylinders (one at each
over oil cylinders at each of the four corners. corner) provide a highly reliable, long life
Improvements have continued to be suspension system. Nitrogen and oil are
implemented since introduction in 1963 to readily available worldwide.
provide a highly reliable, long life system.
• Strategically located cab relative to the front
• Nitrogen and oil are readily available world axle minimizes the effects of pitch and bounce,
wide for easy maintenance and adjustment. resulting in reduced operator fatigue, greater
security and higher productivity.
• The front and rear cylinders are of sufficient
diameter that the nominal pressure is low • Nominal internal pressure in the suspension
(less than 141 kg/cm2 [2,000 psi]). cylinders is low (less than 141 kg/cm2
[2,000 psi]) because of the large diameter
• The front cylinders are attached to the front cylinders.
spindles by tapered joints that can be separated
for repairs and maintenance. • The rear suspension geometry allows sufficient
axle oscillation in conjunction with large front
Caterpillar Steering and Suspension System Versus suspension travel to reduce mainframe racking
Competition. The Caterpillar integrated steering and while traveling over rough terrain.
suspension system is designed for safer operation
and lower operating cost. • Built-in rebound control improves ride.

• Front suspension cylinders, which serve as • Komatsu Steering/Suspension System.

steering kingpins, are rigidly mounted to the
main frame with built-in adjustment to save • Steering hydraulic system shares oil with hoist
maintenance time and tire wear. system, increasing the potential for cross-
contamination.
• Toe-in/toe-out can be adjusted for varying
conditions but is kept near zero, minimizing • Single tie-rod for steering.
tire wear. • Additional wear points in the Komatsu steering
• Design simplicity and balance gives good and suspension system make it more vulnerable
maneuverability and minimizes tire wear. to hysteresis or “slop.” This may eventually
result in transverse tire oscillations or “wobble”,
• Twin, double-acting hydraulic cylinders provide increased tire wear and reduced stability.
precise steering during all loading and underfoot
conditions. • As turning radius gets tighter, it becomes more
difficult to achieve correct Ackerman steering
• The steering/fan/common rail control system angles, and lateral forces on the tires increase.
is fully hydraulic and completely separate from Ackerman error leads to tire scrubbing during
the other systems to prevent cross contamination turns, and high lateral forces increase tire flex,
and heat from other sources. which can cause sidewall damage.

• Accumulators provide pressure/flow source for • Serviceability of Komatsu suspension and

the supplemental steering system. The secondary steering system requires more downtime.
steering system exceeds requirements of 
SAE J1511 and ISO 5010 standards at the
maximum allowable gross machine weight.

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Steering and Suspension System

• Euclid/Hitachi Steering/Suspension System.

• Front steering and suspension system is complex
using trailing arms. The large number of joints
increases susceptibility to wear and need for
periodic maintenance. Loose joints can cause
excessive tire wear.

• Field evidence indicates that at less than

20,000 hours, the steering and suspension
system can require major restorative work,
including build-up and line boring to front
end. With 10 wear points per side, heavy
reliance is placed on the integrity of the
lubrication system.

• Suspension cylinders are charged with expensive,

hard-to-obtain Neocon X and Helium.

Terex/Unit Rig suspension cylinder.

• Small diameter strut rods result in:

• Terex/Unit Rig Steering/Suspension System. – Dramatically increased strut pressures

• Front suspension and steering system is very – Struts that are difficult to seal
complex and heavy with numerous joints – Leakage possibility under high loads
subject to wear and periodic maintenance.
• Steering hydraulic system is combined with
Loose joints can cause excessive tire wear. the brake system, increasing the potential for
• Steering hydraulic system shares oil with the cross-contamination.
hoist system, increasing the potential for
cross-contamination. • Single tie-rod for steering.

• Single tie-rod for steering. • Suspension system is very serviceable.

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Steering and Suspension System

Terex/Hitachi independent trailing arm suspension.

Euclid/Hitachi frame with trailing

arm suspension system.

Euclid/Hitachi suspension
cylinder charged with Neocon.

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Hydraulics

Hydraulics. Cat hydraulics are designed for dependable performance and precise control.

• Brake System. With the changing demands of 

brake systems, Caterpillar is continuously working
to increase the speed of brake response through
improved valving capabilities.
• Hydraulically controlled valves support the
braking system.

• Specifically crafted and precision tested valves

provide superior operator control.

• Steering System. Caterpillar variable pump

steering systems perform with higher efficiency
and greater reliability.

• Increased flow rates provide faster hydraulics

and greater lift force.

• Cylinders are induction hardened to Caterpillar

specifications for greater longevity.
Integrated Design. Cat hydraulics are integrated
throughout the truck design, including: • Suspension System. Caterpillar suspension system
is designed for excellent maneuverability, superior
• Hoist Systems control, and a comfortable ride.
• Brake System • Strut cylinder rod eyes are inertia welded for
superior strength and reliability, allowing low
• Steering System
stress concentration, bonds as strong as base
• Suspension System material, and twice the fatigue life.

• Hoist Systems. Hoist systems offer superior • Caterpillar mining truck suspension cylinders
controllability and reliability of cylinders: are charged with Nitrogen gas.

• End of stroke control for hoist cylinders is • Unlike competitive systems, which typically
achieved through a proprietary EH valve system, use air or other gases, nitrogen systems respond
which automates the use of electronic snubbers. quickly to absorb a rapid series of shocks.
The nitrogen gas system cushions better (loaded
• Electronic dampening of cylinders restricts or unloaded), controls rebound, helps eliminate
flow of fluids to reduce the speed of cylinder truck pitching and provides superior ride quality
positioning, thus eliminating sudden shocks when loaded.
to the system.
• Cat suspension systems operate effectively
• Cylinder rods are induction hardened to Cat at 1/3 lower pressure than some competitors,
specifications. Case depth typically exceeds which helps minimize seal leakage.
industry standards and extends cylinder life.

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Hydraulics

• Fan Drive System. Caterpillar offers a state of the • Cylinders. A robust cylinder design ensures
art hydraulic demand fan on certain applications, excellent durability.
which increases available power and improves
sound management. The hydraulically driven • Cat induction hardened rods provide higher
fan is standard on the 793D and 797B. surface hardness for increased fatigue strength.

• Because it is more efficient, the Caterpillar fan • Induction hardened at a slightly higher depth
drive system uses less horsepower and consumes of case than the competition (3 mm [0.12 in])
less fuel than the conventional engine driven for greater durability.
fan system utilized by the competition. • Rod assemblies are inertia (friction) welded
• For customers with a focus on sound for cylinder longevity.
management of large mining trucks, • Cylinders are bore honed and roller burnished
Caterpillar offers the lowest dBA in the industry. for superior finish. Cylinder walls are honed to
Sound reduction trucks offer a significant
reduction in spectator sound level. remove minor scratches and other hard to see
imperfections that can cause damage to the
Hydraulic Components. Components are designed cylinder seals. This process produces a highly
and manufactured to strict specifications to ensure symmetrical bore with a surface finish that
the reliability and longevity expected of Caterpillar provides a longer seal life.
machines. Each component is part of an integrated • Caterpillar’s proprietary sealing system includes
system and must meet exacting performance an inboard sealing design in the head, for a more
standards. “robust” design and improved performance.
• Pumps and Motors. Cat pumps and motors are Cat hydraulic rod seals feature a proprietary
designed to respond quickly to hydraulic system urethane material and patented design
improvement.
demands.
• Built to tight tolerances with heavy-duty • Valves. Caterpillar valves offer precise control,
bearings and shafts. quicker response of the hydraulic system, and
reduced operator effort to meet the most exacting
• Field repairable for ease of maintenance. application requirements.

• Proprietary solenoid valves offer greater

performance and reliability through superior
design and process manufacturing.

• Sophisticated software controls are available

for electro-hydraulic
programmable valves.
features This allows
customized to for
customer requirements.

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Hydraulics

• Filters. All filters are custom built to Cat • Tanks. Caterpillar hydraulic tanks are designed
specifications for optimization of system and to ensure hydraulic oil stays in and contaminants
efficiency of application requirements stay out of the hydraulic system.

• Unique Cat filter design features fiberglass • For applications requiring smaller tanks, Cat
spiral roving and acrylic beads, which maintain offers tanks formed from a single sheet of steel
optimum pleat spacing and prevent bunching, by using a deep-drawn process in manufacturing.
collapse and loss of capacity. This allows Cat to stamp out a shape of the tank 
in one piece of metal thus manufacturing a
• High efficiency hydraulic filters are available for stronger tank and eliminating potential leaks.
systems requiring extra cleanliness with tighter
system tolerances and higher operating pressure. • For applications requiring larger tanks, Cat
has greater flexibility by utilizing sheet metal
• Cat high efficiency filters reduce the risk of  weldments in manufacturing for fewer
exposing critical components to abrasives, thus restrictions in the design process.
extending component wear life. These high
efficiency filters trap a higher percentage of  • All tanks are subject to air testing to ensure
fine particles in comparison with some of  system reliability.
competitive standard filters.

• Cat filters will clean the system faster, thus

increasing component life and system efficiency.

• Hoses and Couplings. Caterpillar offers a wide

range of hoses for high, low, medium pressure
and special applications.

• Cat XT™ hose line is impulse tested to one

million cycles – twice the industry standard.

• Cat XT hose has superior construction for

longer life.

• The fabric on Cat XT hoses is impregnated,

not wrapped, around the liner. This unique
process helps prevent pinhole failures.

• Reliable components reduce the risk of leaks

and blown lines.

52 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Operator’s Station

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

• The cabs have been widened to provide an

increase in interior volume and an increase
in glass area.

• Electronically controlled body hoist control

provides better modulation and ease of operation.
Hoist control is hydraulically snubbed for
improved comfort.

• Integrated electronic control for intermittent

windshield wiper, washer and turn signal for
improved reliability.

Operator Efficiency. Ergonomic cab design allows

operators to direct their full attention to machine
control.
• Controls are ergonomically designed and located
for intuitive reach to guarantee easier operation
and maximum convenience.
Caterpillar Operator’s Station. As the world leader
in mining trucks, Caterpillar has designed its cabs • Gearshift lever is contoured to fit the hand.
to provide unsurpassed comfort, control and safety.
Cat advanced electronics and ergonomic • Narrower shift control console contains the
enhancements set a new standard for information parking brake control.
management, operator efficiency and productivity. • Secondary brake is a pedal control, conveniently
Designed for Productivity. Every aspect of the located on the floor for easy operator control.
operator station has been refined to ensure that • Pedal control positioning provides easier, more
operator efficiency contributes fully to machine natural actuation.
productivity.
• Tilt and telescoping steering wheel adds to ease
• Actual gear, engine speed and VIMS status are of operation and comfort.
visible at a glance.

• Transmission console has backlit gear indicators

and ergonomic shift knob.

• VIMS display and operator keypad provide

precise machine status information.
• Exceptional all-round visibility allows confident
maneuvering and increased productivity with
less fatigue.

• With clear sight lines toward the haul road and

to the instrument panel in front, strain on the
operator and fatigue are reduced.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 53

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Operator’s Station

Comfort and Control. The cab has everything the ROPS/FOPS Cab. Caterpillar has its own requirements
operator needs for superior comfort and control, for ROPS testing that surpass the toughest ISO
including: guidelines.

• Fingertip controls. • Integral four-post ROPS is standard.

• Ergonomically designed, fully adjustable air • Cab is resiliently mounted to the mainframe
suspension seat with adjustable armrests and is sound suppressed to isolates the operator
provides optimal driving comfort. from sound and vibration.

• A wide, retractable three-point seat/shoulder • Cab operator sound levels are less than
belt provides a secure, comfortable restraint 80 dB(A).
with three height adjustments and six vertical
adjustment positions.

• Trainer seat has wide hip and shoulder room,

with a backrest and seat belt.

• Integral, adjustable armrests for added comfort

and lumbar support adjustment are standard.

• Powered operator window with sliding window

on trainer’s side.

• Reliable large capacity air conditioning and

heating provides efficient, high volume airflow
though more vents. Controls have been relocated Caterpillar integral ROPS frame.

to the dash. 9576 kilocalorie (38,000 Btu)

heater, optional A/C rated at 7056 kilocalorie Cat Operator’s Station Versus Competition.
(28,000 Btu). Caterpillar Mining Truck cabs are designed to
maximize operator control, safety and productivity.
• Radio ready cab is pre-wired for a 12-volt Cat cabs provide a comfortable and convenient
entertainment radio. Cab is equipped with two environment that minimizes fatigue. Caterpillar has
speakers, antenna, 5-amp converter, and radio its own requirements for ROPS testing that surpass
mount recessed in the headliner. Includes a the toughest ISO guidelines.
provision for add-on communication systems.
• Komatsu Operator’s Station.
• Under seat storage compartment.
• Komatsu mining trucks, from the HD1500-5
to the 930E-3, have integral four-post ROPS,
which means the frame of the cab is the ROPS
structure. The integral ROPS cab mounts directly
to the frame at all four corners and offers rollover
protection on all sides of the operator’s station.

54 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Operator’s Station

• Terex/Unit Rig Operator’s Station.

• Integral ROPS cab with 180-degree vision
meets SAE J1040 May 94 criteria.
• Room for two full-size seats.

• Sound abatement package reduces in cab noise

to 82 dB(A).

• Liebherr Operator’s Station.

• Integral ROPS is standard.

• Room for two full-size seats.

• Cab set back for protection in case of a rear-

end collision.

Euclid/Hitachi cab frame.

• Euclid/Hitachi Operator’s Station.

• Integral ROPS/FOPS in accordance with
J/ISO 3471 standard.

• Double-wall construction made of 11-gauge

inner and outer steel panels.

• Foam rubber lining and foam backed carpet

with multiple layered floor to improve sound
suppression and climate control.

• Closed cab, operating sound level equivalent

to 81 dB(A).

• Three-point rubber isolation-mounted

arrangement to the deck surface minimizes
vibration to the operator compartment.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 55

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Monitoring System

Monitoring System. The VIMS™ monitoring system provides operators, service technicians and mine
 personnel with vital machine health and payload data to keep the large mining trucks performing at 
 peak efficiency and top production levels while lowering cost-per-ton.

  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 4 15

VIMS™ Monitoring System. Intelligent, Caterpillar Data Access. Monitoring and diagnostic information
designed machine monitoring system provides is stored on-board until it can be downloaded for
critical machine health and payload data in real- analysis. Data can be accessed through the message
time to keep the large mining trucks performing at center, transmitted via optional radio or downloaded
top production levels. In addition to the usual VIMS onto a computer for detailed analysis.
monitoring system functionality, the system also
monitors torque converter screen switch, torque Machine Management. Service technicians or mine
converter inlet filter, brake oil temperature, fuel personnel can download data and generate reports
level, ambient air temperature, ‘R’ terminal, front for better machine management. Data can be used
aftercooler temperature, aftercooler coolant level, to improve effectiveness of scheduled maintenance
 jacket-water level, high steering pressure switch, programs, maximize component life, improve
steering oil temperature, steering oil bypass switch machine availability, and lower operating costs.
and payload.

Integrated System Monitoring. Sensors located

throughout the machine systems enable the
VIMS system to quickly exchange and monitor
information from all machine systems for efficient,
high performance operation.

Advanced Diagnostics. VIMS system simplifies

troubleshooting, reduces downtime and lowers
operating costs by identifying abnormal conditions
before they cause extensive damage.

56 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Monitoring System

Speedometer/Tachometer Module. Monitors three Gauge Cluster. Conveniently located gauge cluster
systems: maintains a constant display of vital machine
functions, including:
• Engine speed
• Engine coolant temperature
• Ground speed
• Brake oil temperature
• Gear indicator
• Air system pressure

• Fuel level

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 57

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Monitoring System

• Category III. The highest alert. Immediate

shutdown required to prevent serious damage
to machine or system. Action alarm sounds, and
action lamp flashes until system returns to normal
or shutdown is performed.
Payload Weight Distribution

   s
    d
   a
   o
    L
    l
   a
   t
   o
    T
    f
   o
   e
   g
   a
   t
   n
   e
   c
   r
   e
    P

Payload Weight (Tons)

Keypad. Provides operator or service technician Recommended Payload Range With Production Management

Inefficient Payload Ranges Without Production Management

immediate access to current machine information,
gauge values and stored data through the message
center display. Service personnel also can use the Production Management. Production Management
key pad to access diagnostic information. enhances truck/loading tool effectiveness, improves
Message Center. Displays messages requested fleet productivity and helps extend the life of truck 
by operator and advises operator of abnormal frames, tires, rims and power train components,
machine conditions. while lowering operating and maintenance cost.

Alert System. Three-category warning system alerts

operator of abnormal machine health conditions.

• Category I. No action is required at this time.

Inform service personnel of the alerted condition
as soon as possible.

• Category II. Requires operator to evaluate and

correct situation before continuing work. Warning
lamp flashes and alert indicator lamp lights up.
Instructions are displayed on how machine
operation should be modified or which service
should be performed.

58 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Monitoring System

Payload Management. Max Payload Speed Road Analysis Control (RAC). Customers can more
Manager is a feature that aids in managing the effectively and efficiently manage haul roads with
Caterpillar 10/10/20 Payload Guidelines. Based on this optional advanced solution. By measuring frame,
target payload weight and overload settings, the rack and pitch levels, RAC precisely tracks haul-
VIMS system logs and warns the operator when the road conditions and communicates the information
truck reaches overload after second gear reweigh. in real time via a radio network. The data and reports
The truck will be limited to second gear at 1,750 rpm, generated can be used to improve haul-road
and the automatic retarder speed setting is reduced maintenance and, in turn, cycle times, component
to 1,750 rpm until the load is dumped. life and fuel efficiency. VIMS monitoring system
stores the RAC events and creates a summary
Payload management enables the manager to measurement, called a Fatigue Equivalent Load
enhance truck/loading tool effectiveness and Analysis (FELA), that allows management to track 
productivity levels by preventing overloads that severity and benchmark road conditions. When used
can cause damage to component life and affect with a telemetry system such as the MineStar ®
operator safety. information management system, RAC events can
The Payload Weight Distribution chart illustrates be transmitted in near real time to the mine control
the benefit of managing payloads with VIMS office for immediate action by haul-road maintenance
monitoring system production management tools. crews. RAC is designed to help all Cat truck users
derive more value from their owning and operating
Data Storage. The VIMS monitoring system stores experience.
payload information, which is used to manage
production. The system stores up to 2,400 production VIMS PC. VIMS PC, the off-board reporting software
cycles for a complete record of payload weight, cycle program, allows service personnel to download a
times, distances and actual dates/times. It also allows complete record of machine health and productivity
storage of maintenance data such as Events, Trends, data to a laptop computer for diagnosis and analysis.
Histograms, Cumulatives, Snapshot and Dataloggers. Easy-to-use software enables service technicians
This data allows the user to identify potential and mine personnel to generate health and payload
problems before they occur, utilizing the efficiency reports for more effective machine management.
of Preventative Maintenance. VIMS Supervisor. Optional software allows mine
External Payload Indicators. External lights on both personnel to easily manage and interpret VIMS
sides of the truck signals loading tool operator when monitoring system data for optimum fleet
to cease loading for optimum payloads without management and productivity. The easy-to-use
overloading. Optional external payload display analysis tool has the ability to read the VIMS
with digital numeric monitor is available to replace monitoring system database and generate custom
the standard red/green indicator lamps. reports based on customer preferences.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 59

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Monitoring System

MineStar™ Information Management System. • MineStar Health – Monitors and communicates

The Caterpillar union of mine planning, business machine vital sign information in real time,
management and advanced on-board information enabling remote maintenance/service diagnostics
systems is unparalleled. MineStar information and advanced prognostic analysis. Enhances the
management system helps meet the challenges of  entire maintenance and repair process, allowing
the mining industry by linking the machines in the higher machine availabilities to be attained.
field with business and operating systems to ensure
peak performance of mining assets at the lowest • MineStar Business Enterprise – Provides IT
possible cost. These products deliver customers infrastructure platform for seamless integration
everything from real-time machine health of MineStar information management system
information to GPS-guided production aids. with other mine planning and enterprise resource
The large mining trucks are equipped for quick  planning systems.
and easy installation of MineStar information Competitive Monitoring Systems – Komatsu.
management system products. Specific MineStar Komatsu’s Vehicle Health Monitoring System
information management system products include: (VHMS) mimics the diagnostic capability of the
• MineStar Machine Tracking – Monitors machine Caterpillar VIMS hardware and software. It monitors
locations and fleet movement via GPS, alerting 30-health items and stores a total of 600 records
controllers to delays against expected arrival of event histories. Data can be accessed via personal
times. Provides position analysis of machine computer or satellite link. The website database is
operational and health events. called WebCARE and stores VHMS and other
monitored diagnostic data. This web-based
• MineStar Material Tracking – Tracks and application is only available to Komatsu and
manages material types and grades, improving Distributor personnel, not the customer.
overall ore recovery by ensuring material is

moved to tracking.
stockpile correct destinations.
Allows for Includes
real-timematerial
ore-
grade determination at the excavation face.

• MineStar Production – Monitors and reports

mine production information in real time.
Manages production and delay codes for
accurate machine utilization tracking.

• MineStar Fleet Commander – Advanced

optimization algorithm increases truck/shovel
fleet use. Maximizes shovel production and
minimizes truck wait time, while simultaneously
meeting mine production plan requirements
for material blending.

60 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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System Integration

System Integration. System Integration. Electronically combines virtual power train components to work 
more intelligently and optimize overall truck performance.

  1 Engine Control Module (ECM)

  2 Sensors
3 Electronic Unit Injector (EUI)
 4 Integrated Braking Control (IBC)
 5 Transmission/Chassis Control (TCC)
 6 Transmission
7 Wheel Sensor
 8 Brakes
 9 CAT Data Link

Integrated Electronics System. The electronic The Cat Data Link allows the transmission and the
control modules (ECM’s) and electronic and engine to communicate to optimize overall power
electrical components on Caterpillar mining trucks train performance and reliability, and reduce
form an integrated system, a control network. operating costs. The Transmission and Chassis
These ECM’s are designed and developed by Control (TCC) communicates over the Data Link 
Caterpillar to withstand the punishment of rugged with the engine Electronic Control Module (ECM)
mining applications. They are not automotive to manage engine speed during shifts for increased
controls or automotive-grade components adapted clutch life and operator comfort. The TCC also
for mining applications. Cat electronics are designed controls body hoist, neutral start, rear-axle filtration
to work with each other as a system. The sensors, and automatic lubrication functions.
switches, wiring, connectors and all of the other
Basic
electronic and electrical components on Cat mining
Diagnostics
trucks have been developed for the same demanding SENSORS
SENSORS SENSORS
applications. ECM
ET
IBC TCC

Emissions
Traction Smooth Shifting Altitude Capability
Retarding Abuse Prevention Auto De-rating

Electronic Systems. Cat Mining Trucks feature

advanced electronic systems for superior machine
intelligence.

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System Integration

• Electronic Control Module (ECM). The engine • Transmission and Chassis Control (TCC). The TCC
ECM utilizes advanced engine management module communicates over the Cat Data Link with
software to monitor, control and protect the the engine ECM to manage engine speed during
engine utilizing self-diagnosing electronic sensors. shifts for increased clutch life and operator comfort.
The module controls a wide spectrum of engine When the transmission is in sixth gear, the engine
functions, providing infinitely variable injection is allowed to run out to 2,000 rpm, so the truck 
timing to maintain peak performance. It provides (785-793) can achieve speeds up to 55 km/h
additional features of electronic protection of the (34 mph). The 793D can achieve a maximum
engine during cold starts, high altitude operations, of 60 km/h (37 mph) with the Extra Top Speed
air filter plugging and high exhaust temperature Configuration. The 797B can reach speeds up
conditions. It stores information to permit quick  to 67.6 km/h (42 mph) while traveling in seventh
diagnosis of engine conditions to enable effective gear. The shift points are set at the factory for optimal
maintenance and repairs utilizing the Caterpillar performance, efficiency and component life.
Electronic Technician (Cat ET) service tool.
TCC monitors and records key operating conditions
In operation, whenever the shift cane passes through and parameters for later downloading and diagnostic
neutral and the engine speed is above 1,350 rpm, troubleshooting by service personnel.
the transmission sends a signal to the ECM to
momentarily reduce the engine throttle while the TCC features:
transmission shifts. This prevents the operator • Improved on-board diagnostics
from abusing the machine and leads to improved
component life. • Alphanumeric display

All of this is accomplished with one service tool. • Records intermittent faults
Cummins employees a palm pilot to do some of 
• Provides diagnostic codes
the
havediagnostics, butsystem.
an integrated not all. Cummins does not
• Programmable top gear selection

• Cat Data Link 

• A two-wire connection to an optional service

tool for additional logged information

• Communicates with the engine electronics

for efficient power train management

• Integrated Braking Control (IBC). Hydraulically

activated electronically combines the Hydraulic
Automatic Retarder Control (HARC) and Traction
Control System (TCS) into one, integrated control
system.

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System Integration

• Hydraulic Automatic Retarder Control (HARC). • The precision of HARC (maintaining higher
The hydraulically activated automatic retarder average operating speeds) optimizes system-
control system electronically controls retarding cooling capabilities, reduces torque fluctuations
on grade to maintain optimum engine rpm and oil for improved brake component life and
cooling system. HARC is a standard system on all minimizes the potential for destructive engine
large mining trucks. A dash mounted push button overspeed. HARC modulates the Cat designed
switch activates the HARC system via hydraulics oil-cooled disk brakes for excellent control and
rather than compressed air. Settings are adjustable does not interfere with the manual retarder or
from 1,850-1,950 rpm in increments of 10 rpm. service brake operation.
While HARC modulates the brakes, the operator HARC  1 Service Brake Sensor TCS
2 Engine Sensor
may also apply additional braking force using either 1 2
3 HARC
4 HARC Switch
the manual retarder or the brake pedal. When the 5 Brakes
  6 Service Brakes 6
 7 Axle Speed Sensor
operator applies the accelerator controls or the   8 TCS 7

brake, HARC is deactivated. An auto resume 3

8

feature reactivates the control without 5 6

additional operator input. 4

HARC results in:

• Traction Control System (TCS). The Traction
• Increased production with faster downhill Control System improves traction and truck 
speeds. HARC can increase vehicle speed by performance in poor underfoot conditions by
as much as 15 percent over manual retarder electronically monitoring and controlling wheel
control. The system allows trucks to operate slippage. Axle sensors monitor wheel speed.
at maximum speeds with a consistently high If slippage exceeds a set limit, the oil-cooled
engine speed and enhanced truck handling. disc brakes engage to slow the spinning wheel.
• Excellent controllability and reduced operator Torque is then automatically transferred to the wheel
effort. Automatic brake modulation provides with better traction. TCS utilizes normal differential
a smoother ride, better control in slippery action to provide superior maneuvering in poor
conditions and allows the operator to focus underfoot conditions. Should the sensors fail, normal
more on driving. differential action is still available to maintain
control and steering. Operators feel more confident
• Engine overspeed protection. HARC will with the anti-slip benefits provided by the TCS.
automatically activate when engine speed
exceeds factory-preset levels, regardless of 
other operator inputs, including when the
system is turned “off ”, to help ensure that
engine overspeed conditions do not occur.

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System Integration

Integrated Braking Control Message Center Module

Gauges

Transmission/Chassis
Control

Transmission
Sensors

Brakes Engine
Control
Module

Wheel Sensor Electronic

Diagnostic Unit Injector
Connector

Integration as a Total System. All control modules, CTS reduces stress on the transmission and extends
communicating via the Cat Data Link, were power train life. It achieves this by briefly adjusting
designed and developed to work together as an engine throttle during shift change to control torque.
integrated system to maximize production, efficiency This allows the clutch to engage smoothly.
and extend service life of the components. Smoother shifts reduce operator fatigue and

   e
component wear.
   u
   q
   r
   o
    T
   t
Shift without CTS
• The TCC Transmission and Chassis Controller
   u
   p
   t    )
   u
    O   m
         •
signals the ECM engine controller that the
   n    N
    (
   o
    i
   s
   s
    i
Shift with CTS
transmission is preparing to change gears.
   m
   s
   n
   a
   r
    T
• During shift changes, engine throttle is adjusted
    )
up or down, depending on shift direction, for a
   r    h
   w
   c
   e   n
    I
   o   e Shift without CTS
fraction of a second to alter torque created by
    P   r
   a
    h   u
   c
   u
   q
   t    S
    /
the engine. This allows the transmission speed
    l
    C    P
    H
    (
Shift with CTS
to synchronize for a smoother shift.

• CTS is disabled during the braking or retarding.

• Controlled Throttle Shift (CTS). Engine rpm is The benefits of Control Throttle Shifting extend
regulated during a shift to reduce driveline torque beyond the transmission. Reduced torque levels also
stress for smoother shifts, extended component life lead to improved driveshaft, differential, axle and
and improved operator comfort. Transmission life is final drive life. This means lower major component
a function of two things: number of shifts, and level costs and therefore decreased cost per ton.
of stress on the transmission during each shift.

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System Integration

• Directional Shift Management. Regulates engine After the speed for torque converter drive is reached
speed during directional shifts to prevent damage (approximately 6.5 km/h [4 mph]), the transmission
caused by high-speed directional changes. will shift into neutral. If coasting speed increases
This prevents shifts into reverse when forward to 19.4 km/h (12 mph) after the transmission has
ground speeds are in excess of 4.8 km/h (3 mph). shifted to neutral, the engine will operate in elevated
This protects the transmission from high shock  idle mode (1,300 rpm) to provide proper oil flow
loads created by abusive directional shifts. to the transmission. Neutral coast events will be
logged for each occurrence over 16.1 km/h (10 mph).
The objective of Directional Shift Management is These logged events can be retrieved using Cat
to reduce driveline torque spikes and transmission Electronic Technician (Cat ET).
clutch energy spikes. The machine’s driveline is
designed to withstand torque converter stall (the • Body-up Shift Inhibitor. Prevents the transmission
maximum torque that the converter will transmit from shifting above the pre-programmed gear
to the transmission). If shifts are made from reverse without the body fully lowered.
to forward, or if shifts are made from neutral to • Reverse Neutralized with Body Up. If the hoist
reverse or forward at high engine speed, torque
spikes greater than converter stall levels can be level is activated and the transmission is in reverse,
generated. This can result in accelerated transmission the transmission will automatically shift to neutral.
wear and/or premature final drive or differential • Engine Overspeed Protection. The transmission
failures. Directional Shift Management electronically control senses possible overspeed conditions and
prevents torque levels above converter stall, reducing upshifts one gear. If overspeed conditions occur
the potential for abuse and related driveline in the top gear, the lock-up clutch is disengaged.
component failures.
• Programmable Top Gear Selection.
• Elevated Idle – Neutral Coast Inhibitor. The transmission top gear may be electronically set
Prevents
at speeds the transmission
above 6.5 km/h (4from shifting
mph). to neutral
This protects the using Cat ET. This feature helps operators maintain
speed limits. The TCC lets you electronically limit
transmission against operating with insufficient top gear selection without the use of additional
lubrication. Neutral coasting causes extremely high service tooling or mechanical limiting of the shift
relative transmission clutch speeds and inadequate cane. Unlike the former method of blocking shift
cooling oil flow, which results in accelerated wear cane travel, this electronic limit cannot be improperly
and the possibility of premature transmission failure. overridden by the operator. Reprogramming of the
The ECM engine controller and the TCC top gear can only be accomplished with Cat ET.
transmission and chassis controller are programmed • Anti-hunt Function. The transmission will not
to work together to prevent this from occurring. allow an upshift or downshift for approximately
A sensor on the transmission output shaft determines
ground speed. If the transmission gear selector is 2.3
gearseconds
huntingafter
when a shift has occurred.
operating Thispoint
near a shift prevents
and
placed in the neutral position, the controller will not minimizes transmission shifts to increase
downshift to neutral immediately but will allow component life.
downshifts to the proper gear for the calculated
ground speed as speed is reduced. This maintains • Downshift Inhibitor. The transmission will not
engine speed and oil flow through the transmission. allow a downshift to occur until engine speed
reaches the downshift point, preventing an engine
overspeed condition.

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System Integration

• Retarding Efficiency. No fuel is used during

retarding. The engine provides additional retarding
by running against compression on downhill hauls.
During retarding applications the engine ECM does
not inject fuel into the cylinders for exceptional
fuel economy.
Hydraulic Power Management System

Steering
Control
Main
Oil Cooler
Engine
Fan

Steering
Fan
Cylinders
Pump

Rear Axle Valve

Cooler
Fan

Pump

Hydraulic Tank
Return
Filter
• Diagnostics and Serviceability. The electronic
Rear Axle engine and transmission controls provide enhanced
Lubricator Motor Brake Cooling
Pumps diagnostic capability. This useful data can be
Solid Connection
Brake
Cooling Steering accessed at different levels of detail using the
Drive Motor Tank
display panel in the cab or the Electronic Technician.
• Hydraulic Power Management System. The ability to store both active and intermittent
indicators simplifies problem diagnosis and total
Currently available on the 793D only, the system, repair time, resulting in improved mechanical
also known as common rail hydraulics, reduces
parasitic (unused, wasted) losses in the power availability and lower operating cost.
management system components and the new
hydraulic fan drive system. Two new variable
displacement piston pumps operate the system.
These pumps primarily provide for the steering
and cooling functions, and are independent of the
brake and hoist circuit. One pump is dedicated to
a new on-demand hydraulic fan drive system.
The other pump feeds a new priority valve and
provides hydraulic pressure and flow to feed steering,
brake cooling, rear axle filtration (RAX), and the
optional RAX cooler systems. The system continues
to allow priority for the steering system while using
an improved power management scheme for brake
cooling and RAX functions. By reducing the losses,
the system is able to provide more horsepower to
the ground.

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System Integration

• Diagnostic Codes. Diagnostic codes are generated

when a control computer detects an input or an
output, which is out of the ordinary, such as an
open or short circuit. Diagnostic codes are electrical
problems by nature and are identified by name
when using Cat ET. An example would be Parking
Brake Pressure Switch Short to Ground. Cat ET will
list the number of occurrences, the service hour
when the fault occurred, the first and last time.

• Events. An event is recorded when a performance

parameter such as engine oil pressure crosses a
predetermined threshold, indicating that something
has happened out of the ordinary. Cat ET displays
Caterpillar Electronic Technician (Cat ET).
Allows for easy access to service diagnostic data the Event, the number of occurrences, the service
hours of the first and last occurrence.
through the use of a single service tool. Cat ET
accesses data stored in the controls via the Cat
Data Link, which allows information on transmission
shift data, engine speed, fuel consumption and other
data to be retrieved.

The Caterpillar Electronic Technician provides a

window to the service and operational information
in the machine’s electronic controls. It can be used
to review logged and active diagnostic codes and
recorded events. Cat ET is an easy to use, intuitive
windows-based service tool, which significantly
reduces downtime and repair cost by providing
valuable troubleshooting aids. For example, Cat ET
can be used to individually test each injector in order
to identify an injector requiring service preventing
time-consuming exhaust port temperature readings.
Caterpillar’s integrated machine electronics allow the
Cat ET service tool to be used to monitor, configure,
and troubleshoot the engine, transmission and
braking system controls. Cat ET’s service capability
has three major components: Review of diagnostic
and event codes, real time monitoring and data
logging, and diagnostic tests.

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System Integration

• Monitoring. Cat ET can be used to monitor a wide

variety of machine parameters, the parameter list • Diagnostic Tests. Cat ET can be used to
being displayed can be selected from default lists force certain signals to be generated to simulate
or customized. operational events and confirm functionality.
For example, Cat ET can be used to test the
Cat ET can also be used to data log parameters to High Coolant Temperature Lamp by temporarily
capture transient or intermittent problems. Data can overriding the signal from the control computer.
be retrieved and analyzed on the spot or stored for This provides a quick and cost effective means
later use. For certain parameters, data stored in the of testing electrical circuits.
ECM can be displayed in a histogram format using
Cat ET. • Flashing. Cat ET provides a simple means of 
updating a machine’s software by flashing in the
latest software, software files can be e-mailed and
flashed the same day they are made available from
Caterpillar.

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Truck Bodies

Truck Bodies. A variety of Caterpillar designed and built truck bodies ensure optimal performance and 
reliability in tough mining applications. Cat dealers can help build an optimum hauling system to
maximize truck payloads and extend body and truck wear life.

Caterpillar designs the bodies using the best tools

and methods
approach backed
in the by the
industry. most advanced
Caterpillar analysis
has developed
a dynamic model of the entire truck that has been
verified with extensive field-testing at a variety of 
sites from around the world. Caterpillar is the only
body manufacturer that uses a full-truck dynamic
approach to body design and analysis. These tools
and methods allow our engineers to identify high
stress areas and evaluate design solutions to meet
body life goals without additional weight.

Our approach is called System Structural Analysis

and Virtual Product Environment (SSA/VPE).
This is exciting comprehensive technology that
models all load inputs to the body so our engineers
have the information necessary to design the most
efficient, durable body for the intended application.
Body/Chassis Integration and Design. Caterpillar
body and chassis are designed as one model, in
which the body forms an integral part of the
dynamic modeling and stress analysis of the
complete truck.

Because Caterpillar designs and manufactures the

entire truck from the tires to the body, Caterpillar
bodies are designed with a depth of understanding
our competitors cannot match. Our engineers look 
at the body as part of a haulage system that includes
the ground interface of the wheels, tires and terrain;
suspension; chassis and structure; drive train; and
body and payload. The result of this understanding
is a suite of body offerings that fit well with the
chassis – that yield expected payload and volume
requirements and proper loading front to rear for
the optimum safety and performance of the truck.

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Truck Bodies

With the desire to extract the most value from the

truck, Caterpillar pioneered the philosophy of Mine
Specific Design (MSD) offering more specialized
bodies to increase payload and to meet specific
application requirements. MSD is a method
we use to specify a body that meets the specific
requirements of the mine. The process starts with
an evaluation of the mine’s operating characteristics
and ends with a properly sized and configured body.
Along the way we evaluate the application and
determine the right combination of volume, wear
and impact liners to meet the specific requirements
of the mine.

The MSD II and “X” lightweight bodies are intended

to maximize payload while still giving acceptable
life. The MSD II body yields the highest payload
but the “X” body gives better durability while still
System Structural Analysis Integration giving excellent payload. Caterpillar is the world’s
leader in lightweight bodies.
Caterpillar Body Systems. When selecting the proper
body for a particular application, it is important to Traditional dual slope and flat floor bodies find
take into consideration the material fragmentation, their best fit in Greenfield sites and other heavier
density and abrasiveness as well as the loading duty applications.
tool, load, dump and haul road conditions, and The gateless coal body is a unique design that
maintenance practices. The better understanding achieves target payload without the need for
of the local conditions the better the match. a heavy and maintenance intensive tailgate.
Caterpillar pioneered the introduction of lightweight Each of the five body styles Caterpillar offers is
bodies, which today are well accepted in the mining sized to deliver target payload with minimal spillage.
industry. The combination of better payload Consult your Caterpillar dealer to begin the body
performance with excellent durability is achievable selection process by filling out a site profile.
with a careful loading and maintenance strategy.

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Truck Bodies

• Tail extensions are used to help retain the rear

portion of the pile and limit load spillage on
haul roads, extending tire life.

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
Virtual Product Environment vehicle components such as brakes, tires and
drive train, reducing component life and
increasing maintenance costs and repairs.
Electronic Hoist Control. Provides the operator with
better control of the load when dumping, including Body Design. Cat truck bodies are designed
over-center load control and modulated control for optimal strength, capacity and durability.
throughout the operating range. The automatic Wear surfaces are equipped to handle even the
body-snubbing feature reduces impact on the toughest impact and abrasion over the long haul
frame, hoist cylinders and operator. without diminishing capacity.
Body Liners. A variety of liner options are available • Five-sided beams tie in the sidewall and floor
to save weight and extend the body system’s life.  junctions add increased body rigidity and
Wear surfaces and liners are equipped to handle strength.
tough impact loads while resisting abrasion.
Wear plates deliver long life in high wear areas. • Wide ribs in body floor provide increased
Modular liner plate packages: durability and impact support.

• Smooth plate • Full-length stringers create strength and

rigidity throughout the bed.
• Rock box
• Box section beams offer increased durability
• Zipper grind in the floor, sidewall, top rail, corner and cab
canopy areas.
• Mechanically Attached Wear Plate System
(MAWPS) Manufacturing Processes. Caterpillar truck bodies
are built at multiple facilities across the globe
Custom Body Options. Tail extensions, sideboards,
leveraging the industry’s leading body manufacturing
tumblebars, rock boxes and rock shedders are
procedures and tooling. Caterpillar owns the entire
available to maintain payload, reduce spillage
process (cutting, forming and welding/fabrication),
and improve hauling efficiencies.
all from a single design source. Both one-piece and
• Sideboards are designed to maximize or attain multi-piece shipping configuration options are
gross machine weight. available from the factory to meet a variety of 
customer needs.

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Truck Bodies

Caterpillar truck body designs utilize materials that • Mine Specific Design (MSD II) Body. The MSD II
provide maximum performance (balance of payload is the standard of the industry for lightweight bodies.
and durability) and achieve field repairability Offered in a flat floor configuration, this second-
requirements (weld repairable anywhere in generation MSD body combines industry-leading
the world). payload with excellent durability. This body is
intended for mature mines using good operation
Cat Truck Bodies. Matching the truck body to the and maintenance practices that want to extract the
application is a critical part of achieving the best maximum payload from each cycle we offer the
value from your Caterpillar Mining Truck. MSD II. With a large variety of liner options
Caterpillar starts with a focus on meeting the available, the MSD II can be properly configured
particular needs of the application. Caterpillar to meet the particular application profile of a specific
offers five body choices to achieve the best mine site. This design offers the best payload
match of volume, payload and life. performance with good durability. Over the life of 
• MSD II the truck, the MSD II body will require replacement.

• “X” • X Body. The “X” body is more durable in design

than the MSD II – expect slightly lower payload
• Dual Slope with the “X” body. The intent of the “X” body is to
meet a heavier duty application range with greater
• Flat Floor
volume and payload than the Dual Slope of Flat
• Gateless Coal Floor body. The understructure is more substantial
than the MSD II and is better able to handle the
rigors of poorly shot material or Greenfield sites.
The “X” body is intended to be more general
purpose in nature than the MSD II and will fit well
with contractors who will be operating the body in
more than one site or mature mines with difficult
conditions. As with the MSD II, the “X” offers a
wide variety of liner configurations.

MSD II Body.

Dual Slope Body.

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Truck Bodies

• Dual Slope and Flat Floor Bodies. For years • Gateless Coal Body. Due to the low material
the strong and durable Dual Slope and Flat Floor density of coal, a larger body is required to deliver
bodies have delivered excellent value and long life. target payload. Traditionally a compromise body
They are relatively heavy but strong enough to was offered that combined one of the above bodies
withstand the most demanding mining conditions with a tailgate to give greater volume and control
such as poor material fragmentation or Greenfield spillage. The exclusive Caterpillar Gateless Coal
sites. The accepted standard of the industry until body, available for the 777 through 793 truck 
the advent of the MSD family of bodies – the Dual models, eliminates the heavy and maintenance
Slope is intended for the most demanding sites and intensive tailgate with a kicked up floor design that
for users who may want to operate the truck in more gives the volume required to meet target payload
than one site. A limited liner configuration is in coal haulage applications. Because the tailgate
available. The Flat Floor body is a body intended is eliminated the target payload is higher with the
for very demanding sites where the controlled dump Gateless Coal body than a competitive body with
characteristics of a flat floor body are required. a tailgate. It is intended for coal haulage only, not
It offers better payload capability than the Dual for an application requiring a combination of coal
Slope body but less than the MSD II or “X” bodies. and overburden haulage.

Caterpillar Body Systems Versus Competition.

Throughout the history of Large Mining Trucks
there have been Non-Cat sources for standard Cat
bodies attachments such as liners and tailgates, etc.,
and optional truck bodies. Originally, these optional
bodies were simply “specialty bodies” not offered by
Caterpillar, including Coal, Fly Ash, Slag and other
“niche market” products. As these Non-Cat sources
became more aggressive, they began pursuing the
sale of complete truck bodies initially for Non-Cat
Chassis and then later included bodies for
Cat Chassis.

Flat Floor Body. Today, there are several sources Caterpillar considers
“Globally Competitive” and from time to time others
for specific local markets. In some cases these
competitors have an initial transaction price
advantage and a payload advantage. However, they
typically quote bodies without any liners creating

the impression
lower of higher
price. None payload
have the depth capacity and
of engineering,
manufacturing, sales and after-market support
as provided by Caterpillar and its Dealers.
Quoting Cat bodies, we have to ensure we are
providing an “apples to apples” comparison
of body weight and payload capacity.

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Truck Bodies

When challenged by customers to provide • Minerite. A newly formed source, (just over 2-years
competitive pricing against these sources, it is old) with previous background at WESTECH in
necessary to gather adequate information from the both Engineering and sales, is Minerite. This team
competitive proposal to create an accurate “apples probably has the best background and understanding
to apples” comparison. These sources all have new of the basic needs of the market of all the sources.
and unique features, but not all are proven reliable. It offers its own version of a “Light-Weight” body
for Cat and a Non-Cat chassis as well as its own
For the most part, the concepts have not been version of a “Gateless Coal” body. Recently, the
thoroughly analyzed from an engineering company added an automatic, hydraulic tailgate
prospective. The sources listed below have had to its “Gated Coal” bodies. Minerite is located in
aggressive marketing philosophies to “make the central Wyoming and has mostly concentrated on
sale now and worry about the performance issues the market in the Rocky Mountain area, including
later”, (if at all). In the beginning the sources won Canada. While initially trying to work with the
business, but in many cases the customers returned dealers, it has accepted orders directly from the
to Caterpillar after their first experience. end user as well.
Today, these sources have evolved to better products • Phillipi-Hagenbuch. Since the early 1970’s,
with fewer issues. The competitors include the Phillipi-Hagenbuch has been a body and attachment
following: source. The company’s first product was a “tailgate”
• Westech. For over 25 years, Westech has been a developed by the founder when he was still employed
body supplier to Caterpillar, building standard Cat at Caterpillar in the late 1960’s. Phillipi-Hagenbuch
bodies and some specialty bodies for the 777 thru the expanded its original line into a complete “Gated
793 models. One result of this long-term association Coal Bodies” line. As the predominate source for
is Westech, better than many sources, understands the Coal Bodies for over 20 years, it expanded into a
need for proper fit-up to the Chassis. The company COMBO body equipped with a “Flip-Over” tailgate
offers bodies for all trucks, a “Light-Weight” body that pivoted to the front and out of service when
for all Cat models and also its own version of a handling Over Burden. The company more recently
“Gateless Coal” body. Westech also provides a added a version of a “Semi-Light” rock body,
“Gated Coal” style upon request. The company is resulting in several issues with these offerings
located in Wyoming with good access to mine sites including:
in the USA and Canada and is reportedly pursuing • Much heavier than proposed consequently
manufacturing alliances with companies in Brazil reduced payloads.
and Australia. It typically sells directly to the end
user, retaining part of what it considers normal • Poor axle splits, which in some cases, the
Dealer Mark-Up. So far, the company has been units could not be dumped.
the most “Honest” and accurate with its proposals,
technically speaking, but the question is how it will • Early hour failures that were not always
support its products after the sale. warranted.

While the company marketed through Dealers, it

is prone to selling direct and is a very secretive and
aggressive source. It is assumed the company is
probably working on something new at this point.

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Truck Bodies

• Trinity. A division of a major Barge and Rail Car • Dicsa. The first to develop the true “Light Weight”
builder, Trinity includes several rail car maintenance body in the early ’90’s in Chile for KMS trucks was
operations nationwide. The parent is a multi-billion Dicsa. At this time Dicsa was, in fact, the KMS
dollar entity and is located in San Antonio, TX with dealer for much of South America. In the late ’90’s
first and second operations (cutting and forming) KMS took this dealership back, but Dicsa continued
conducted at the Mexico facility. The company its mining parts and service business, including the
offers low price bodies. Its “body business” began Dicsa truck bodies. It expanded from KMS chassis
with subcontract manufacturing for Unit Rig and to all other OEM’s, including Cat. The company
Komatsu Mining Systems (KMS) and evolved into went through numerous radically new and unique
its own designs, which include numerous features design changes and at present, is in PHASE 9.
copied from these designs – very little new or little Dicsa continues to offer the lightest bodies with
of its own. Early units were dimensionally larger and reasonable success in South America but only
heavier than stated and in several instances, load limited success in other parts of the world so far.
distribution was a big problem. Loads had to be Dicsa has several bodies in Australia in Coal
placed well to the rear of the body in order to dump, overburden and Gold Mining operations with
creating significant spillage, etc. Historically, Trinity unclear results in the Coal Mines. The Gold Mine
sales observe Caterpillar premiums of nearly only recently was commissioned. The company
25 percent, offering bodies with similar dimensions experienced a drastic failure in a Labrador Iron
and payloads. However, with the issues mentioned mine on KMS 830E chassis and has not provided
above, there is no doubt customers will come back  the best solution for the Canadian Tar Sands.
to Caterpillar. Current designs for the 793 are wider than our
maximum width recommendation, seemingly very
high above the frame with a questionable (and
unproven) mounting system. In South America,
Dicsa, is successful, offering a full, on-site body
maintenance program covering all the costs with
an Hourly Rate ($/HR).

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Truck Bodies

• Conymet/Duratray. Originating in Chile as The SDB is a product well suited for cohesive
a general welding fabrication and repair shop, material sites with lots of carry-back, but our
Conymet/Duratray, evolved into truck body opinion is this is not a cost-effective solution
repairs and a “Body Assembly Source” for the for rock applications. The company has reduced
local Caterpillar Dealers. Through this involvement, payloads because it is heavier than our MSD II,
the company next designed (copied) its own steel and we expect the actual maintenance costs will
bodies for Caterpillar trucks. Then it offered cheaper be quite high as well.
bodies and a full-body maintenance program.
In 2001 the company purchased the DURATRAY
SDB (suspended dump body) product line from
Pacific Dunlop in Australia. The purchase included
orders on hand for over 20 units, mostly for the
DIVAK 830E fleet in Canada. Through a very
aggressive marketing program it won several deals
around the world, which brought the company’s
total sales to date near 200 units since start up.
It so far, prices these units at near 50 percent of the
prices previously established by Pacific Dunlop and
has again included on-site maintenance programs,
which conceals the real operational costs. It seems
this business strategy is coming to an end though
in several sites where Conymet’s costs are so high
it is raising rental and maintenance contract costs
significantly. The customers are not accepting this
and will return to Caterpillar.

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Manufacturing

Manufacturing. Caterpillar manufacturing means quality.

Operator performing leak test of inner and

outer dual cone seals of rear wheel station.
Operator setting preload on differential bearings.
Fabrication. Fabrication of the truck frame is of the
Caterpillar Manufacturing. All Caterpillar Mining greatest importance in the manufacturing of trucks,
Trucks are produced in Decatur, IL. The Decatur the frame being the backbone. As a consequence,
Plant is a state-of-the-art, world class manufacturing there is a weld procedure written for every weld in
facility, ISO-9001 certified by Det Norske Veritas. the frame identifying each parameter to be controlled
Every manufacturing cell is certified to Mining and to provide consistent quality. Copies of weld
Construction Equipment (MCE) Division standards procedures pertinent to each weld station are
and Caterpillar corporate standards. Design control, available at that station for the ready reference
commercial support, and product support activities of the welder.
are all located at this facility under the Cat Mining
Trucks Product Manager. Fabrication, machining,
assembly, wash, paint, test and adjust are completed
in two buildings (785-793 in building B and 797
in building D). A truck does not leave the building
until it is a finished product, ready-to-ship.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 77

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Manufacturing

Computer Controlled Machining Centers.

Computer controlled machining centers incorporate
the latest technology to deliver the highest quality
components in the industry. These state-of-the-art
machining centers with automatic tool changers
allow multiple machining operations to be completed
on a single machine complex. This eliminates the
potential of relocation errors associated with moving
a piecepart from one machine and fixture to another.
Operator assembling rear axle assembly for shipping. Palletized, permanent setup fixtures promote better
quality and accelerate production by removing the
 Welding. Welding is accomplished in three ways. need to make setups between running different part
There are automatic welding machines guided by numbers. Custom designed chucks insure parts are
laser beams, robot welders performing routine properly located in machining centers, increasing
welding tasks and skilled employees producing dimensional accuracy. The machining centers have
more demanding weldments with special equipment. tool management systems that automatically track 
All frames are produced using arc-welding processes and compensate for tool wear, utilize redundant
that conform to 1E0099 Caterpillar specifications. tooling and alert the operator when new tooling or
Two processes are used predominately for production servicing is required. All pieceparts are 100 percent
purposes in the plant: flux cored arc welding (cored traceable because each part is marked with machine
wire) and gas metal arc welding (solid wire). operator identification and a date.

Heavy-duty tack weld fixtures are utilized to ensure

proper fit up and adequate weld joint root opening.
To achieve the best mating of parts and accuracy
of critical dimensions, weld joints and locators are
pre-machined. Weld positioners (360° rollover
fixtures) are used to position welds in a flat position
for the deepest penetration and highest quality welds
while affording the most comfort of the welder.

All welders are trained, tested, qualified and

periodically re-qualified in-house at the MCE
weld school. They are qualified according to
ANSI/AWS D1.1, D14.3 and ISO 9606.

All
and weldments are 100 percent
audited ultrasonically. visuallyweldments
All critical inspected Automated machining cell for truck repair spindles.

are 100 percent ultrasonically inspected. There is

100 percent traceability on all weldments.

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Manufacturing

Assembly Highway. The assembly highway offers

the quality advantage of assembling the product
in a stationary position with the convenience of 
automated movement through the assembly
process. Automatic Guided Vehicles (AGVs)
deliver trucks to each stage of assembly where
skilled personnel use proven procedures to
assemble them. Assemblers are empowered to
regulate the flow through their assembly cell to
ensure the completeness of assembly in the most
workmanlike manner.

Since customers typically order a truck optimized

for their specific mine application, the assemblers
work from assembly instructions tailored to the
specific model and serial number. Each truck is
essentially custom-built from the ground up to
the dealer/customer specification. Each assembly
instruction is signed off by the assembler performing
it giving 100% traceability.

Automatic torque control tools are utilized

throughout the assembly process to ensure every
truck shipped has been produced to specification.
All torque control tools are checked and maintained

through an auditing procedure

the cell certification process. directly linked to
Test facilities support product development at Decatur.

Quality Control. A quality team supports every

manufacturing cell. That quality team’s membership
includes the cell operators, their supervisor, the
design engineer responsible for that portion of the
product design, a manufacturing and systems
engineer/processor, a welding engineer/technician,
a materials representative, a computer numerical
control programmer and a quality auditor. They are
responsible for solving any problem confronting the
cell, tracking internal and external quality indicators,
preparing the cell for certification and continuous
quality improvement.

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Manufacturing

Measurement accuracy is critical to quality Diagnostic and Functional Testing. After completion
manufacturing. Caterpillar has invested in a of the assembly process every mining truck is
co-ordinate measurement laboratory, coordinate visually inspected, then its critical functions tested
measuring machines (located in the manufacturing and any required adjustment performed in a state-
cells), and a large L&K co-ordinate measuring of-the-art test cell. Engines (all previously tested
machine (CMM) to ensure total accuracy. At the at the Large Engine Center), transmissions (all
time of its installation it was the world’s largest previously tested at the Transmission Business
single bridge CMM. The side rails, bridge and Unit), hydraulics, brakes, and electrical systems
probe rail are constructed entirely of granite to are all included in this testing. The testing is
make it less susceptible to temperature and humidity performed utilizing computer controlled test
variation and it is housed in climate-controlled room. equipment to eliminate all subjectivity from the
Its repeatability is 0.00635 mm (0.00025 in). test. All test results become part of the truck ’s
The CMM is capable of measuring the frames of  history file.
the 785C, 789C and 793D mining trucks. There are
150+ dimensional checks on each truck frame.
Approximately 10 percent of all mining truck 
frames are checked. After any engineering changes
or repair of production machines, the first ten frames
are checked to ensure process control. A portable
laser system is used to measure critical dimensions
on the 797B mining truck.

80 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Product Support

Product Support. Caterpillar dealers have what it takes to keep mining trucks productive.

Reman parts available for Cat Mining Trucks

include:

• Axle housings
• Brake Shoes

• Clutch Plates

• Electronic Control Modules

• Engines

• Engine Components

• Final Drive Groups

• Hydraulic Cylinders and Rods

• Hydraulic Pump, Motors and Parts

• Reaction Hubs
Caterpillar Reman Parts. In building machines for
a lifetime, Caterpillar recognizes that keeping them • Torque Converters
productive at the lowest cost is essential. This is one
• Transmissions
reason why the Caterpillar remanufacturing process
is so extensive. State of the art salvage techniques, Purchasing a Caterpillar Mining Truck represents
strict re-use guidelines, advanced manufacturing a value decision for the lifetime of the machine.
systems and unequalled quality control systems
ensure that Reman parts are as good as new and No other mining
an extensive truck
line of manufacturers
quality, cost saving provide such
part options.
as strong as ever. The remanufacturing process
incorporates the latest engineering design changes Caterpillar Certified Rebuild (CCR). A Cat Certified
ensuring components meet the latest performance Rebuild would usually be performed when a mining
standards and carry an as-new warranty. truck has reached 30,000-40,000 hours and
availability and productivity are declining.
Reman is a way to support the Caterpillar product Following rebuild, a significant productive
and reduce operating costs over the life of the life (20,000-30,000 hours) can be expected.
machine. Cat Reman parts are priced at a fraction
of new and, together with the credit for the used The Cat Certified Rebuild process applies to an
core, represent real savings in equipment costs. entire machine. The process has been developed,
promoted and is audited by Caterpillar. Only Cat
dealers perform this process. Machines are rebuilt
to like-new condition and effectively utilize their
second life.

The CCR program provides an additional purchase

option of new or used – Certified Dealer Rebuilt
machines.

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Product Support

There also is a Cat Certified Power Train (CPT) • Typically about 100 engineering updates
program available to rebuild the power train at are incorporated into rebuilds.
half the CCR life at about half the cost of a CCR
on average.
Extended power train coverage from Cat Insurance
is available also.

Cat Certified Rebuild benefits:

• Reduced cost per ton.

• Improved machine performance and

availability provided by engineering updates.

• Typically 50 percent to 60 percent of new

machine cost for customer-owned machines.

• New serial number.

• Cat Financial Services including financing

and insurance.

• Like-new appearance.

• Higher resale value.

• Warranty. CCR includes a warranty provided by

the Cat dealer
for new trucks.and is thenot
It does same as stated
include warranty
extended frame Caterpillar Truck Payload Guidelines.
repairability or MARC support from Caterpillar. Specified maximum operating weights are
An extended power train warranty is available. frequently misapplied with regards to off-highway
trucks in the marketplace. “Maximum”, which
Cat Certified Rebuilds include:
means, “must not exceed”, which is used as the
• Quality Processes. target, results in regulatory and product support
concerns pertaining to “acceptable” overload.
• Engineering Updates.
Technically, any overload will adversely affect
• Mandatory Parts Replacements with over component life and potentially decertify brakes
7,000 parts are automatically replaced.
and/or steering.
a maximum In response,
operating weightCaterpillar developed
and associated
The quality of CCR is assured:
payload guidelines used in support of warranty,
• More than 350 tests and inspections have Maintenance and Repair Contracts (MARCs) for
been performed. mining trucks. Caterpillar paid particular attention
to specifications in light of the technical implications
• Highly trained experts perform rebuilds. of the “10/10/20” guidelines.
• Caterpillar-developed procedures are used
for remanufacture.

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Product Support

According to the guidelines, available payload is Modifications to brake service procedures are
directly related to Empty Machine Weight, so that required to maintain certification on models 785C
reducing empty weight provides increased to 793C. Specifically, brake wear must be reduced
payload capacity and vice versa. For example, to 75 percent of current allowable, which enables
Gross Machine Weight (GMW) less Empty Machine SAE and ISO standards to be maintained up to
Weight (EMW) equals Target Payload. EMW target payload plus 20 percent.
includes all attachments (installed at the factory,
by dealer and customer), full fuel and fluids, • Component Life Implications. The 10/10/20
appropriate calculations of debris, and tires. payload guidelines carry significant implications
relative to component life. Data indicates that for
The Caterpillar 10/10/20 Payload Guidelines state: every 1-ton decrease in payload from maximum
“No more than 10 percent of payloads may exceed target, component life will increase by
1.1 times the truck ’s Target Payload, and no single approximately 1 percent. Overload is the most
payload shall ever exceed 1.2 times the Target significant factor in life shortfalls of planned
Payload, which is the Maximum Operating Weight.” component replacement goals. Haul road
conditions, machine maintenance and operation
techniques also are significant contributors. As the
10/10/20 payload guidelines may exceed tire and
rim association rating guidelines for earthmoving
vehicles, it is recommended that users of the
guidelines contact their supplier to discuss
application, site conditions, haul roads and
allowable tire loads before adopting the policy.

• Specifications. The Payload Guidelines apply to

the Cat 777D, 777F, 785C, 789C, 793C, 793D and
797B trucks.

Operate within the 10/10/20 payload guidelines

requires careful attention to specifications.
Caterpillar suggests operation below the 1.2 times
Target Payload for engineering impact and safety.
The covered trucks were tested to meet ISO and
SAE steering and braking certification standards
at 20 percent over target payload.

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 83

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Product Support

• Summary. In summary, the 10/10/20 truck 

payload guidelines provide for:

• Consistent payload variation benchmarking.

• Basis for MARC cost/productivity adjustments.

• Establishment of braking and steering

certification limits.

Competitive Payload Information. Komatsu:

Publishes a nominal payload defined by Komatsu’s
payload policy for its mining trucks, except for
HD1500-5 that still publishes maximum calculated
payload. Nominal payload is calculated considering
100 percent fuel, but it is unclear whether this
includes body attachments or debris.

It appears that Komatsu’s payload policy established

that overloads between 105 percent and 110 percent
• Payload Management. Max Payload Speed are allowed on an infrequent basis but shall not
Manager is a feature that aids in managing the exceed more than 10 percent of all loads in a
Caterpillar 10/10/20 Overload Policy. Based on given month.
target payload weight and overload settings, the
VIMS monitoring system logs and warns the
operator when the truck reaches overload after
second gear reweigh. The truck will be limited
to second gear at 1,750 rpm, and the automatic
retarder speed setting is reduced to 1,750 rpm
until the load is dumped.

Payload management enables the manager to

enhance truck/loading tool effectiveness and
productivity levels by preventing overloads that
can cause damage to component life and affect
operator safety.

The Payload Weight Distribution chart illustrates

the benefit of managing payloads with VIMS
monitoring system production management tools.

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Product Support

Hitachi: Publishes a nominal payload, which Terex: Publishes maximum calculated payloads.
represents 90 percent of maximum payload. Details about calculations are not available in
Payload calculation includes 50 percent fuel specalogs.
but body attachments or debris are not included. Liebherr: Publishes maximum calculated payloads.
It appears Hitachi developed Payload Guidelines Details about calculations are not available in
in response to the Caterpillar 10/10/20 Payload specalogs.
Guidelines. Hitachi’s guidelines establish exceeding
maximum payload is allowed 10 percent of time,
but exceeding 110 percent maximum payload one
time voids warranty.

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Safety

Safety. Caterpillar machines and systems are designed with safety as the first priority.

Brake Systems. On Cat Mining Trucks, the brake

system is designed to function under severe
conditions and to allow operators to work with
confidence. Service brakes and retarders are
actuated by modulated hydraulic pressure, while
secondary and parking functions are actuated by
multiple springs acting on the secondary/parking
piston, which is hydraulically released. This system
ensures that brakes are always available even in the
event of a complete hydraulic failure when they
would be applied automatically.

Caterpillar brakes are oil-cooled and have large disc

and plate surfaces to ensure more reliable fade-
resistant performance than shoe type and dry disc
brake systems. Four corner braking with a 60/40
(rear/front) split in braking effort provides better
control in slippery conditions. All large Cat Mining
Trucks have Integrated Braking Control (IBC),
Product Safety. Caterpillar has been and continues
which incorporates all the advantages of the
to be proactive in developing off-highway trucks
proven Traction Control System (TCS), Hydraulic
that meet and exceed safety standards. Caterpillar
Automatic Retarder Control (HARC) system and
engineers actively participate as leaders in the
normal brake control systems into one simplified
development of new regulations and safety standards
module. These features are standard.
and updating of existing ones. Since standards vary
from country to country and around the world, and
are sometimes even in conflict, Caterpillar has been Steering Control
double-acting Systems.
cylinder Caterpillar’s
steering system istwin
designed
instrumental in the development of safety standards to deliver precise control under all loading and
that are uniform and accepted worldwide. underfoot conditions.
Safety is not an afterthought at Caterpillar, but an The main steering hydraulics are backed up by a
integral part of all machine and systems designs. supplemental system using pressure accumulators
While legislation requires that all manufacturers that would be automatically activated in the unlikely
must meet certain safety standards, Caterpillar event of steering system failure. This supplemental
aims to deliver exceptional safety. system meets SAE J1511 and ISO 5010 standards
at the maximum allowable gross machine weight.

Integral ROPS Cab. Resiliently mounted to the main

frame to reduce vibration and sound, the integral
ROPS structure is designed as an extension of the
truck frame. The ROPS/FOPS structure provides
“five-sided protection” for the operator and meets
SAE J1040, SAE J231, ISO 3471 and ISO 3449
standards. The cab also meets ANSI/SAE J1166
operator sound exposure requirements. The integral
ROPS cab is standard on Caterpillar mining trucks.

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Safety

Operator Comfort. Caterpillar has designed mining

truck cabs to provide the best in safety and comfort
while maximizing operator control and productivity.
The Caterpillar suspension system is positioned
and tuned for maximum ride qualities and yet
gives a stable “feel of the road” for the operator.
To further enhance the operator’s ride, the cab is
strategically located to minimize the effects of 
pitch and bounce. Because of the superior ride
qualities of Caterpillar trucks, the operators have
less fatigue and a more secure feeling resulting
in greater productivity.

Cab design has been refined so that full attention can

be directed to machine control. Ergonomics and High-Intensity Discharge (HID) Lights.
visibility are given careful attention in positioning
machine controls. The location of the controls plays 1) High Beams/Upper Low Beams
a vital role in minimizing operator fatigue and
contributes to a safer operation. Clear lines of sight 2) Lower Low Beams/Fog Lamps
toward the haul road and the instrument panel make
3) High Beams/Upper Low Beams
more information visible at a glance. Improved head
light illumination, windscreen defrosting and warning 4) Backup Lights
alarms provide safer operating in adverse conditions.
Six optional HID lights – on fender, fog and rear
Standard Safety Features. Additional standard safety lights – are designed to improve operator visibility

features on Caterpillar mining trucks include: during

operatornight operations,
productivity and increase
in high machine and
hour mining
• Slip resistant surfaces
applications. The 35-watt, high-intensity gas
• Retractable, 75 mm (3 in) wide orange discharge light produces 3,200 lumens of light.
three-point operator restraint. The light produced is whiter, which creates the
perception of more light. HID lights are
• Wide-angle mirrors approximately 70 percent efficient and twice as
bright compared with 20 percent to 25 percent
• Body raised indicator
efficiency for halogen lights because more energy
• Body restraint cable is given off as light instead of heat. The life
expectancy of HID lights is also four to eight
• Guardrails times longer than halogen lights.
• Convenient guard rails

• Reverse neutralizer when dumping

• Low interior sound levels

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Safety

Payload Guidelines. Safety is integral to Caterpillar’s  Working Safely. Caterpillar’s holistic approach to
approach to maintaining the highest productivity safety in mining means efforts are directed not only
in mining machine operation. For example, the at product design for safe performance and operation,
10/10/20 Payload Guidelines assure customers but also at ensuring products contribute to a safer
that brakes and steering have sufficient capacity working environment for miners. Environmental
to perform at a 20 percent overload. impacts are considered, training packages are
developed and Caterpillar actively promotes and
participates with customers in achieving ever
improving safety standards. Caterpillar operator
and service training programs reinforce the need
for safe procedures and videos and lecture materials
enable mine sites to conduct refresher courses to
ensure safety considerations are always in mind.

At Caterpillar, safety is a first priority!

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Technical Specifications – 785C vs. Competition (109-150 tonnes [120-165 tons])

MANUFACTURER TEREX/ TEREX/ TEREX/  

UNIT RIG CAT UNIT RIG UNIT RIG KOMATSU HITACHI CAT
MODEL MT3000 785C MT3300 MT3300 AC HD1500-5 EH3000 785C HAA

Engine Model 16V2000TA 3512B QSK45 12V4000 QSK45 12V4000 3516B

Engine Manufacturer MTU/DDC CAT CUMMINS MTU/DDC CUMMINS MTU/DDC CAT
Drive ELECT – DC MECH ELECT – DC ELECT – AC MECH ELECT – AC MECH

OPERATING SPECIFICATIONS

Maximum Gross Vehicle Weight kg 206 300 249 480 249 480 249 480 249 476 278 964 249 476
(lb) (455,000) (550,000) (550,000) (550,000) (550,000) (615,000) (550,000)
Chassis Weight ** kg 77 111 99 448 77 610
(lb) (170,000) (219,244) (171,100)
Body without Attachments kg 21 300 24 041 21 300
(lb) (46,958) (53,000) (46,958)
Empty Weight kg 97 451 101 495 105 234 111 928 100 462 123 489 100 153
(lb) (214,880) (223,758) (232,000) (246,800) (221,481) (272,244) (220,800)
Payload – Target/Nominal tonnes 136+ 140 136
(tons) (150+) (154) (150)
Payload – Maximum tonnes 109 See 10/10/20 136 136 136 – 149 155
(tons) (120) Guidelines (150) (150) (150 – 164) (171)
Notes about Payload and Weights: N/A Empty weight N/A Empty weight Empty weight Empty weight
includes lubricants, with 50% fuel with 50% fuel. with 50% fuel,
coolant, 100% Payload based no body liners.
fuel, debris upon the weight Nominal
(4% of chassis of additional payload
weight), no body equipment defined as 90%
attachments such as of payload
bo dy line r. w it h s tanda rd
equipment

DIMENSIONS

Wheelbase mm 5334 5180 5334 5334 5410 5640 5182

(in) (210) (204) (210) (210) (213) (222) (204)
Overall Length mm 12 167 11 022 12 167 12 344 11 379 11 550 11 024

(in) (479) (434) (479) (486) (448) (455) (434)

Overall Width mm 6502 6640 6502 7112 6629 7450 6325
(in) (256) (262) (256) (280) (261) (293) (249)
Tire Width mm 6121 6277 6248 6248 5994 6630 6274
(in) (241) (248) (246) (246) (236) (261) (247)
Loading Height mm 4877 4968 5436 5232 4953 5380 4978
(in) (192) (196) (214) (206) (195) (212) (196)
Height – Body Raised mm 10 744 11 207 10 795 10 795 11 430 12 600 11 201
(in) (423) (442) (425) (425) (450) (496) (441)

 WEIGHT DISTRIBUTION

Front Axle – Empty 49% 47% 49% 52% 46% 49% 48%
Rear Axle – Empty 51% 53% 51% 48% 54% 51% 52%
Front Axle – Loaded 33% 33% 33% 33% 33% 33% 34%
Rear Axle – Loaded 67% 67% 67% 67% 67% 67% 66%

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Technical Specifications – 785C vs. Competition (109-150 tonnes [120-165 tons])

MANUFACTURER TEREX/ TEREX/ TEREX/  

UNIT RIG CAT UNIT RIG UNIT RIG KOMATSU HITACHI CAT
MODEL MT3000 785C MT3300 MT3300 AC HD1500-5 EH3000 785C HAA

ENGINE
Model 16V2000TA 3512B QSK45 12V4000 QSK45 12V4000 3516B
Manufacturer MTU/DDC CAT CUMMINS MTU/DDC CUMMINS MTU/DDC CAT
Bore mm 170 159 165 159 165 170
(in) (6.7) (6) (7) (6) (7) (7)
Stroke mm 190 190 190 190 190 190
(in) (7.5) (7) (7) (7) (7) (7)
Displacement L 51.8 45 49 45 49 69
(in3) (3,158) (2,746) (2,972) (2,746) (2,972) (4,211)
Max Altitude m 3050 3658 3048 4612
(ft) (10,000) (12,000) (10,000) (15,130)
Number of Cylinders 16 12 12 12 12 12 16
Rated Speed rpm 1,900 1,750 1,900 1,900 1,900 1,900 1,750
High Idle rpm 1,935 1,935
Low Idle rpm 700 700
Net Power kW 839 1005 1025 1171 1048 1304 1005

(hp) (1,125) (1,348) (1,375) (1,570) (1,406) (1,748) (1,348)

Gross Power kW 899 1082 1119 1286 1108 1398 1081
(hp) (1,205) (1,450) (1,500) (1,725) (1,486) (1,875) (1,450)
Net Torque N•m 6767 5810 7612 6767
Torque Rise 23% 23%
Engine Weight kg 2540 6667 5307 6044 5813 6668
(lb) (5,600) (14,700) (11,700) (13,325) (12,815) (14,700)

OPTIONAL ENGINE

Model QSTA30 16V2000 QSK45

Manufacturer CUMMINS MTU/DDC CUMMINS
Bore mm 159
(in) (6)
Stroke mm 190
(in) (7)
Displacement L 45
(in3) (2,746)
Number of Cylinders 12 16 12
Rated Speed rpm 1,900 1,900 1,900
Net Power kW 835 954 1104
(hp) (1,120) (1,279) (1,480)
Gross Power kW 895 999 1193
(hp) (1,200) (1,340) (1,600)
Net Torque N•m
Engine Weight kg 2948 2540 5814
(lb) (6,500) (5,600) (12,820)

90 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Technical Specifications – 785C vs. Competition (109-150 tonnes [120-165 tons])

MANUFACTURER TEREX/ TEREX/ TEREX/  

UNIT RIG CAT UNIT RIG UNIT RIG KOMATSU HITACHI CAT
MODEL MT3000 785C MT3300 MT3300 AC HD1500-5 EH3000 785C HAA

COOLING SYSTEM
Fan Diameter mm 1828.8 1778
(in) (72) (70)

TRAVEL SPEEDS

Forward 1 km/h 12.1 11.0 12.1

(mph) (7.5) (6.8) (7.5)
Forward 2 km/h 16.3 14.6 16.4
(mph) (10.2) (9.1) (10.2)
Forward 3 km/h 22.2 19.5 22.2
(mph) (13.8) (12.1) (13.8)
Forward 4 km/h 29.9 24.5 29.9
(mph) (18.6) (15.2) (18.6)
Forward 5 km/h 40.6 32.6 40.6
(mph) (25.2) (20.3) (25.2)
Forward 6 km/h 54.8 44.2 54.7
(mph) (34.0) (27.5) (34.0)
Forward 7 km/h 58.0
(mph) (36.0)
Reverse 1 km/h 11.0 10.6 10.9
(mph) (6.8) (6.6) (6.8)
Elec. Drive Max. km/h 62.0 70.0 64.0 54.7
(mph) (39.0) (44.0) (40.0) (34.0)

REDUCTIONS

Differential 2.10 2.647 2.100

Final Drive 10.83 7.235 10.833

TIRES
Tires 30.00R51 33.00R51 33.00R51 33.00R51 33.00R51 36.00R51 33.00R51
Weight kg 2068 2304 2304 2304 2304 2152 2304
(lb) (4,560) (5,080) (5,080) (5,080) (5,080) (4,745) (5,080)
Optional Tires 36.00R51

BRAKES – REAR

Discs per Side 2 10 2 2 2 10

Outside Diameter mm 508 874.5 511 511 511 875
(in) (20) (34.46) (20) (20) (20) (34)
Total Area cm2 89 729 79 572 14 298 89 727
(in2) (13,908) (12,334) (2,216) (13,908)

BRAKES – FRONT
Disc per Side 2 9 1 1 1 9
Outside Diameter mm 715.3 990 990 1060 715
(in) (28.18) (39) (39) (42) (28)
Total Surface Area cm2 61 270 79 572 15 001 61 270
(in2) (9,497) (12,334) (2,325) (9,497)
Dry Disc OD mm 1016
(in) (40)

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 91

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Technical Specifications – 785C vs. Competition (109-150 tonnes [120-165 tons])

MANUFACTURER TEREX/ TEREX/ TEREX/  

UNIT RIG CAT UNIT RIG UNIT RIG KOMATSU HITACHI CAT
MODEL MT3000 785C MT3300 MT3300 AC HD1500-5 EH3000 785C HAA

REFILL CAPACITIES
Fuel Tank 1 L 2271 1893 2271 2271 2120 2839 1893
(gal) (600) (500) (600) (600) (560) (750) (500)
Fuel Tank 2 L 2500 2498
(gal) (660) (660)
Cooling System L 269 379 303 454 532 323 379
(gal) (71) (100) (80) (120) (141) (85) (100)
Crankcase L (132) 204 215 220 193 213 204
(gal) 35 (54) (57) (58) (51) (56) (54)
Differential and Final Drives L 436 536 526
(gal) (115) (142) (139)
Front Wheels (Each) L 14 14
(gal) (4) (4)
Steering Tank L 90 91
(gal) (24) (24)
Steering System L 117 189 117
(gal) (31) (50) (31)
Brake/Hoist/Conv Tank L 337 576 337
(gal) (89) (152) (89)
Brake/Hoist/Conv System L 641 900 641
(gal) (169) (238) (169)
Trans Tank L 76 76
(gal) (20) (20.1)
Trans System L 248 153 248
(gal) (66) (40.5) (65.5)
Brake/Hoist Tank L 564 564 564
(gal) (149) (149) (149)
Brake/Hoist Hydraulic System L 814 813 813 566
(gal) (215) (215) (215) (150)

92 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Technical Specifications – 789C vs. Competition (163-200 tonnes [180-220 tons])

MANUFACTURER TEREX/ TEREX/ TEREX/  

UNIT RIG HITACHI CAT LIEBHERR KOMATSU UNIT RIG UNIT RIG
MODEL MT3600B EH3500 789C T252 730E MT3700B MT3700AC

Engine Model 12V4000 12V4000 3516B 12V4000 K2000E 12V4000 12V4000

Engine Manufacturer MTU/DDC MTU/DDC CAT MTU/DDC CUMMINS MTU/DDC MTU/DDC
Drive ELECT – DC ELECT – DC MECH ELECT – DC ELECT – DC ELECT – DC ELECT – AC

OPERATING SPECIFICATIONS

Maximum Gross Vehicle Weight kg 297 000 324 324 317 515 331 120 324 322 324 263 335 600
(lb) (655,000) (715,000) (700,000) (730,000) (715,000) (715,000) (740,000)
Chassis Weight ** kg 107 330 98 293
(lb) (236,619) (216,700)
Body without Attachments kg 26 717 27 045 25 612
(lb) (58,900) (59,625) (56,464)
Empty Weight kg 124 700 134 047 129 238 140 320 140 592 131 065 149 660
(lb) (275,000) (295,519) (284,925) (327,000) (309,950) (289,000) (330,000)
Payload – Target/Nominal tonnes 171 176+ 184
(tons) (189) (195+) (203)
Payload – Maximum tonnes 154 – 172 190 See 10/10/20 181 172 – 186 186
(tons) (170 – 190) (210) Guidelines (200) (190 – 205) (205)
Notes about Payload and Weights: Maximum GVW Empty weight Empty weight N/A Empty weight N/A N/A
not to exceed with 50% fuel, includes with 100%
 the following: no body liners. lubricants, fuel, no options.
GE 776 Traction Nominal payload coolant, 100% Nominal payload
Motor 636,100 lb defined as 90% fuel, debris defined by Komatsu’s
(288 480 kg) of payload (4% of chassis payload policy
GE 788 Traction with standard weight), no body
Motor 655,000 lb equipment attachments
(297 000 kg)

DIMENSIONS

Wheelbase mm 5537 5640 5700 5817 5893 5639 5639

(in) (218) (222) (224) (229) (232) (222) (222)
Overall Length mm 13 056 12 240 12 177 13 259 12 827 13 056 13 056

(in) (514) (482) (479) (522) (505) (514) (514)

Overall Width mm 7315 8126 7674 7493 7544 7315 7341
(in) (288) (320) (302) (295) (297) (288) (289)
Tire Width mm 6782 6750 6926 7188 7036 6782 7264
(in) (267) (266) (272) (283) (277) (267) (286)
Loading Height mm 5436 5460 5206 5588 5613 5791 6096
(in) (214) (215) (205) (220) (221) (228) (240)
Height – Body Raised mm 11 811 12 630 11 902 12 192 12 522 11 862 11 963
(in) (465) (497) (469) (480) (493) (467) (471)

 WEIGHT DISTRIBUTION

Front Axle – Empty 51% 49% 47% 40% 48% 47% 46%
Rear Axle – Empty 49% 51% 53% 60% 52% 53% 54%
Front Axle – Loaded 33% 33% 33% 33% 33% 32% 32%
Rear Axle – Loaded 67% 67% 67% 67% 67% 68% 68%

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 93

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Technical Specifications – 789C vs. Competition (163-200 tonnes [180-220 tons])

MANUFACTURER TEREX/ TEREX/ TEREX/  

UNIT RIG HITACHI CAT LIEBHERR KOMATSU UNIT RIG UNIT RIG
MODEL MT3600B EH3500 789C T252 730E MT3700B MT3700AC

ENGINE
Model 12V4000 12V4000 3516B 12V4000 K2000E 12V4000 12V4000
Manufacturer MTU/DDC MTU/DDC CAT MTU/DDC CUMMINS MTU/DDC MTU/DDC
Bore mm 165 165 170 165 159 165 166
(in) (7) (7) (6.7) (7) (6) (7) (7)
Stroke mm 190 190 190 190 159 190 191
(in) (7) (7) (7.5) (7) (6) (7) (8)
Displacement L 49 49 69 49 50 49 49
(in3) (2,972) (2,972) (4,211) (2,972) (3,070) (2,972) (2,972)
Max Altitude m 3048 2300 3048 3048
(ft) (10,000) (7,500) (10,000) (10,000)
Number of Cylinders 12 12 16 12 16 12 12
Rated Speed rpm 1,900 1,900 1,750 1,900 1,900 1,900 1,900
High Idle rpm 1,935
Low Idle rpm 700
Net Power kW 1175 – 1398 1414 1320 1175 – 1398 1388 1175 – 1398 1398

(hp) (1,575 – 1,875) (1,896) (1,771) (1,575 – 1,875) (1,860) (1,575 – 1,875) (1,875)
Gross Power kW 1286 – 1510 1510 1417 1286 – 1510 1491 1286 – 1510 1510
(hp) (1,725 – 2,025) (2,025) (1,900) (1,725 – 2,025) (2,000) (1,725 – 2,025) (2,025)
Net Torque N•m 8,200 8,976
Torque Rise 23%
Engine Weight kg 6045 7810 4671 5294 6045 6045
(lb) (13,325) (17,225) (10,300) (11,670) (13,325) (13,325)

OPTIONAL ENGINE

Model QSK45 QSK45 QSK45 QSK60

Manufacturer CUMMINS CUMMINS CUMMINS CUMMINS
Bore mm 159 159 159 159
(in) (6) (6) (6) (6)
Stroke mm 190 190 190 190
(in) (7) (7) (7) (7)
Displacement L 45 45 45 60
(in3) (2,746) (2,746) (2,746) (3,661)
Number of Cylinders 12 12 12 16
Rated Speed rpm 1,900 1,900 1,900 1,900
Net Power kW 1084 – 1382 1084 – 1383 1084 – 1383 1603 – 1752
(hp) (1,454 – 1,854) (1,454 – 1,854) (1,454 – 1 ,854) (2,150 – 2,350)
Gross Power kW 1193 – 1491 1193 – 1342 1193 – 1491 1715 – 1864
(hp) (1,600 – 2,000) (1,600 – 1,800) (1,600 – 2 ,000) (2,300 – 2,500)
Net Torque N•m
Engine Weight kg 5310 6122 5310 8852
(lb) (11,700) (13,500) (11,700) (19,515)

OTHER OPTIONAL ENGINE

Model K2000E K2000E

Manufacturer CUMMINS CUMMINS
Model 16V4000
Manufacturer MTU/DDC

94 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Technical Specifications – 789C vs. Competition (163-200 tonnes [180-220 tons])

MANUFACTURER TEREX/ TEREX/ TEREX/  

UNIT RIG HITACHI CAT LIEBHERR KOMATSU UNIT RIG UNIT RIG
MODEL MT3600B EH3500 789C T252 730E MT3700B MT3700AC

COOLING SYSTEM
Fan Diameter mm 1981
(in) (78)

TRAVEL SPEEDS

Forward 1 km/h 11.6

(mph) (7.2)
Forward 2 km/h 15.7
(mph) (9.8)
Forward 3 km/h 21.3
(mph) (13.2)
Forward 4 km/h 28.7
(mph) (17.8)
Forward 5 km/h 38.9
(mph) (24.2)
Forward 6 km/h 52.6
(mph) (32.7)
Reverse 1 km/h 10.5
(mph) (6.5)
Elec. Drive Max. km/h 56.4 55.7 55.7 54.7 65.0
(mph) (34.0) (34.6) (34.6) (34.0) (40.0)

REDUCTIONS

Differential 2.350
Final Drive 10.833

TIRES

Tires 36.00R51 37.00R57 37.00R57 37.00R57 37.00R57 37.00R57 40.00R57

Weight kg 2152 3084 3084 3084 3084 3084 3084
(lb) (4,745) (6,800) (6,800) (6,800) (6,800) (6,800) (6,800)
Optional Tires 36R51 40R57 46/90R57
37.00R57

BRAKES – REAR

Discs per Side 2 2 13 2 2 2 2

Outside Diameter mm 511 635 874.5 635 635 635 635
(in) (20) (25) (34.46) (25) (25) (25) (25)
Total Area cm2 14 298 14 298 116 283 14 298 14 298 14 298 14 298
(in2) (2,216) (2,216) (18,024) (2,216) (2,216) (2,216) (2,216)

BRAKES – FRONT

Discs per Side 1 1 12 1 1 1 1

Outside Diameter mm 991 1060 715.3 1143 1168 1118 1118
(in) (39) (42) (28.18) (45) (46) (44) (44)
Total Surface Area cm2 15 001 81 693
(in2) (2,325) (12,662)

SUSPENSION SYSTEM

Total Stroke – Rear mm 275 165 335 273 273

(in) (11) (6.5) (13) (11) (11)
Total Stroke – Front mm 355 307 279 355 355
(in) (14) (12.1) (11) (14) (14)

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 95

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Technical Specifications – 789C vs. Competition (163-200 tonnes [180-220 tons])

MANUFACTURER TEREX/ TEREX/ TEREX/  

UNIT RIG HITACHI CAT LIEBHERR KOMATSU UNIT RIG UNIT RIG
MODEL MT3600B EH3500 789C T252 730E MT3700B MT3700AC

STEERING SYSTEM
Steering Angle degrees 41 36
Number of Cylinders 2 2 2 2 2 2 2
Turning Radius – Front m 26.8 25.6 27.5 24.7 27.2 27.2
(ft) (87.9) (84.0) (90.3) (81.0) (89.4) (89.4)
Turning Circle Clearance Diameter m 30.2 30.2 28.0
(ft) (99.2) (99) (91.9)

HOIST SYSTEM

Body Raise secs 19 17.9 18.9 20 21 19 22

Body Float Down secs 17.3 22
Body Power Down secs 12 15.6 9 15 12 14

BODY
Body Type Flat Floor N/A Dual Slope† N/A Flat Floor Flat Floor Flat Floor
Capacity – S truck m3 77 80 73 77 77 92 92
(yd3) (101) (105) (96) (100) (101) (121) (121)
Capacity – Heaped 2:1 m3 111 115 105 108 111 123 123
(yd3) (146) (151) (137) (141) (145) (161) (161)
† Dataprovided is for a representative body. Several dual slope, flat floor, coal and mine specific design (MSD) bodies are available. All weights, capacities, and
dimensions are dependent on the machine configuration (body type, attachments, tires, and optional equipment selected).

REFILL CAPACITIES

Fuel Tank 1 L 2877 2839 3222 3140 3217 2877 2877

(gal) (760) (750) (851) (830) (850) (760) (760)
Fuel Tank 2 L 3785 3633
(gal) (1,000) (960)

Cooling System L 348 323 663 409 348 492

(gal) (92) (85) (175) (108) (92) (130)
Crankcase L 215 213 291 223 215 204
(gal) (57) (56) (77) (59) (57) (54)
Differential and Final Drives L 583
(gal) (154)
Front Wheels L 21
(gal) (6)
Steering Tank L 130 731
(gal) (34) (193)
Steering System L 189 189 510
(gal) (50) (50) (135)
Brake/Hoist/Conv Tank L 531
(gal) (140)
Brake/Hoist/Conv System L 909
(gal) (240)
Trans Tank L 79
(gal) (21)
Trans System L 223
(gal) (59)
Brake/Hoist Hydraulic Tank L 662 662 662
(gal) (175) (175) (175)
Brake/Hoist Hydraulic System L 890 566 927 731 890 890
(gal) (235) (150) (245) (193) (235) (235)

96 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Technical Specifications – 793D vs. Competition (218-254 tonnes [240-280 tons])

MANUFACTURER TEREX/ TEREX/  

CAT LEIBHERR KOMATSU KOMATSU UNIT RIG UNIT RIG HITACHI
MODEL 793D T262 830E-AC 830E MT4400 MT4400AC EH4500-2

Engine Model 3516B 16V4000 QSK60 QSK60 QSK60 QSK60 16V4000

Engine Manufacturer CAT MTU/DDC CUMMINS CUMMINS CUMMINS CUMMINS MTU/DDC
Drive MECH ELECT – DC ELECT – AC ELECT – DC ELECT – DC ELECT – AC ELECT – AC

OPERATING SPECIFICATIONS

Maximum Gross Vehicle Weight kg 383 749 390 090 385 848 385 852 390 930 392 290 480 362
(lb) (846,000) (860,000) (850,650) (850,650) (862,000) (865,000) (1,059,000)
Chassis Weight** kg 119 597
(lb) (263,666)
Body without Attachments kg 32 138 27 669 27 669
(lb) (70,832) (61,000) (61,000)
Empty Weight kg 156 519 156 940 164 200 162 505 160 998 170 975 198 096
(lb) (345,045) (346,000) (362,000) (358,259) (355,000) (377,000) (436,727)
Payload – Target/Nominal tonnes 218+ 221 223 254
(tons) (240+) (244) (246) (280)
Payload – Maximum See 10/10/20 218 236 236 282
Guidelines (240) (260) (260) (311)
Notes about Payload and Weights: Empty weight N/A Empty weight Empty weight Empty weight Empty weight Empty weight
includes lubricants, with 100% fuel, with 100% fuel, with 50% fuel with 50% fuel with 50% fuel,
coolant, 100% no options. no options. and autolube and autolube MTU/DDC engine,
fuel, debris Nominal payload Nominal payload capacities capacities 50/90 R57 tires.
(4% of chassis defined by defined by Nominal payload
weight), no body Komatsu ’s Komatsu’s defined as 90%
attachments payload policy payload policy of payload
with standard
equipment

DIMENSIONS

Wheelbase mm 5905 6096 6350 6350 6401 6401 6150

(in) (233) (240) (250) (250) (252) (252) (242)
Overall Length mm 12 862 13 335 14 148 14 148 13 894 14 072 14 300

(in) (507) (525) (557) (557) (547) (554) (557)

Overall Width mm 7680 7391 7315 7315 7976 7976 9050
(in) (302) (291) (288) (288) (314) (314) (356)
Tire Width mm 7605 7214 7290 7290 7569 7976 8340
(in) (299) (284) (287) (287) (298) (314) (328)
Loading Height mm 5871 5944 6706 6706 6223 6147 6220
(in) (231) (234) (264) (264) (245) (242) (241)
Height – Body Raised mm 13 113 12 649 13 411 13 411 12 776 12 700 14 300
(in) (517) (498) (528) (528) (503) (500) (561)

 WEIGHT DISTRIBUTION

Front Axle – Empty 46% 45% 50% 50% 48% 50% 50%
Rear Axle – Empty 54% 55% 50% 50% 52% 50% 50%
Front Axle – Loaded 33% 33% 33% 33% 33% 33% 34%
Rear Axle – Loaded 67% 67% 67% 67% 67% 67% 66%

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 97

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Technical Specifications – 793D vs. Competition (218-254 tonnes [240-280 tons])

MANUFACTURER TEREX/ TEREX/  

CAT LEIBHERR KOMATSU KOMATSU UNIT RIG UNIT RIG HITACHI
MODEL 793D T262 830E-AC 830E MT4400 MT4400AC EH4500-2

ENGINE
Model 3516B 16V4000 QSK60 QSK60 QSK60 QSK60 16V4000
Manufacturer CAT MTU/DDC CUMMINS CUMMINS CUMMINS CUMMINS MTU/DDC
Bore mm 170 165 159 159 159 159 165
(in) (6.7) (7) (6) (6) (6) (6) (7)
Stroke mm 215 185 190 190 190 190 190
(in) (8.5) (7) (7) (7) (7) (7) (7)
Displacement L 78 63 60 60 60 60 65
(in3) (4,760) (3,863) (3,661) (3,661) (3,661) (3,661) (3,967)
Max Altitude m 2750
(ft) (9,000)
Number of Cylinders 16 16 16 16 16 16 16
Rated Speed rpm 1,750 1,900 1,900 1,900 1,900 1,900 1,900
High Idle rpm 1,960
Low Idle rpm 700
Net Power kW 1743 1796 1761 1761 1706 1855 1939

(hp) (2,337) (2,409) (2,360) (2,360) (2,287) (2,487) (2,600)

Gross Power kW 1801 1864 1865 1865 1865 2013 2014
(hp) (2,415) (2,500) (2,500) (2,500) (2,500) (2,700) (2,700)
Net Torque N•m 10,806 10,930
Torque Rise 23%
Engine Weight kg 8664 6528 9608 9608 7534 8854
(lb) (19,100) (14,391) (21,182) (21,182) (16,611) (19,515)

OPTIONAL ENGINE

Model 12V4000 16V4000 16V4000 QSK60-L

Manufacturer MTU/DDC MTU/DDC MTU/DDC CUMMINS
Bore mm 165 165 165 159
(in) (7) (7) (7) (6)
Stroke mm 185 185 185 190
(in) (7) (7) (7) (7)
Displacement L 63 63 63 60.2
(in3) (3,863) (3,863) (3,863) (3,674)
Number of Cylinders 12 16 16 16
Rated Speed rpm 1,900 1,900 1,900 1,900
Net Power kW 1705 1706 1855 1920
(hp) (2,287) (2,287) (2,487) (2,575)
Gross Power kW 1510 1865 2014 2014
(hp) (2,025) (2,500) (2,700) (2,700)
Net Torque N•m 10,630
Engine Weight kg 4672 7173 7173
(lb) (10,300) (15,813) (15,813)

OTHER OPTIONAL ENGINE

Model QSK60, K2000E

Manufacturer CUMMINS

COOLING SYSTEM

Fan Diameter mm 1981

(in) (78)

98 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006

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Technical Specifications – 793D vs. Competition (218-254 tonnes [240-280 tons])

MANUFACTURER TEREX/ TEREX/  

CAT LEIBHERR KOMATSU KOMATSU UNIT RIG UNIT RIG HITACHI
MODEL 793D T262 830E-AC 830E MT4400 MT4400AC EH4500-2

TRAVEL SPEEDS
Forward 1 k m/h 11.8
(mph) (7.3)
Forward 2 k m/h 15.9
(mph) (9.9)
Forward 3 k m/h 21.5
(mph) (13.4)
Forward 4 k m/h 29.1
(mph) (18.1)
Forward 5 k m/h 39.4
(mph) (24.5)
Forward 6 k m/h 54.3
(mph) (33.7)
Reverse 1 km/h 10.9
(mph) (6.8)
Elec. Drive Max. km/h 64.0 48.8 58.0 64.0 66.9
(mph) (40.0) (30.3) (36.0) (40.0) (41.6)

REDUCTIONS

Differential 1.80
Final Drive 16.00

TIRES

Tires 40.00R57 40.00R57 40.00R57 40.00R57 40.00R57 50/80R57 50/90R57

Weight kg 3493 3493 3493 3493 3493
(lb) (7,700) (7,700) (7,700) (7,700) (7,700)
Optional Tires 44/80R57 46/90R57 46/90R57 46/90R57 50/80R57
44/95R57 40.00R57
46/90R57

BRAKES – REAR

Discs per Side 15 2 2 2 2 2 2

Outside Diameter mm 874.5 635 635 635 635 635
(in) (34.46) (25) (25) (25) (25) (25)
Total Area cm2 134 590 14 298 14 298 14 298 14 298 14 298 180 741
(in2) (20,861) (2,216) (2,216) (2,216) (2,216) (2,216) (28,015)

BRAKES – FRONT

Disc per Side 10 1 1 1 1 1 1

Outside Diameter mm 874.50 736 1213 1213 1168 1168 1213
(in) (34.5) (29) (47.79) (47.79) (46) (46) (48)
Total Surface Area cm2 89 817 17 032 17 032 17 032
(in2) (13,921) (2,640) (2,640) (2,640)

SUSPENSION SYSTEM

Total Stroke – Rear mm 106.7 279 279 184 184

(in) (4.2) (11) (11) (7) (7)
Total Stroke – Front mm 132.1 335 335 305 305
(in) (5.2) (13) (13) (12) (12)

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 99

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Technical Specifications – 793D vs. Competition (218-254 tonnes [240-280 tons])

MANUFACTURER TEREX/ TEREX/  

CAT LEIBHERR KOMATSU KOMATSU UNIT RIG UNIT RIG HITACHI
MODEL 793D T262 830E-AC 830E MT4400 MT4400AC EH4500-2

STEERING SYSTEM
Steering Angle degrees 36 40
Number of Cylinders 2 2 2 2 2 2 2
Turning Radius – Front m 28.42 29 30 30 30
(ft) (93.2) (94) (100) (100) (98)
Turning Circle Clearance Diameter m 32.66 32 28 28
(ft) (107.2) (106) (93) (93)

HOIST SYSTEM

Body Raise secs 20.25 21 25 25 22 22

Body Float Down secs 19.26 27 27 24
Body Power Down secs 17.51 14 24 24 15

BODY
Body Type Dual Slope† N/A Flat Floor Flat Floor Flat Floor Flat Floor
Capacity – S truck m3 96 84 117 117 100 100 108
(yd3) (126) (110) (153) (153) (131) (131) (142)
Capacity – Heaped 2:1 m3 129 119 147 147 144 144 159
(yd3) (169) (156) (193) (193) (188) (188) (208)
† Dataprovided is for a representative body. Several dual slope, flat floor, coal and mine specific design (MSD) bodies are available. All weights, capacities, and
dimensions are dependent on the machine configuration (body type, attachments, tires, and optional equipment selected).

REFILL CAPACITIES

Fuel Tank 1 L 4354 3310 4542 4542 3028 3028 3785

(gal) (1,150) (875) (1,200) (1,200) (800) (800) (1,000)
Fuel Tank 2 L 4922 4920
(gal) (1,300) (1,300)

Cooling System L 973 568 568 591 591 697

(gal) (257) (150) (150) (156) (156) (184)
Crankcase L 265 280 280 250 261 242
(gal) (70) (74) (74) (66) (69) (64)
Rear Axle Housing L 1022
(gal) (270)
Front Wheels (Each) L 21 27
(gal) (5.5) (7)
Steering Tank L 227 901 901
(gal) (60) (238) (238)
Steering System L 341 473 291
(gal) (90) (125) (77)
Brake/Hoist Tank L 769 662 662
(gal) (203) (175) (175)
Brake/Hoist System L 1375 1325 946 946 908 908 965
(gal) (363) (350) (250) (250) (240) (240) (255)
TC/Trans Sump L 102
(gal) (27)
TC/Trans System L 189
(gal) (50)

100 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006
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Technical Specifications – 797B vs. Competition (272 tonnes+ [300 tons+])

MANUFACTURER TEREX/ TEREX/  

HITACHI KOMATSU KOMATSU UNIT RIG UNIT RIG CAT LIEBHERR
MODEL EH5000 930E-3 930E-3SE MT5500B MT5900AC 797B T282B

Engine Model 16V4000 QSK60 QSK78 QSK60 QSK78 3524B 16V4000

Engine Manufacturer MTU/DDC CUMMINS CUMMINS CUMMINS CUMMINS CAT MTU/DDC
Drive ELECT – AC ELECT – AC ELECT – AC ELECT – AC ELECT – A C MECH ELECT – AC

OPERATING SPECIFICATIONS

Maximum Gross Vehicle Weight kg 528 208 501 974 504 400 557 823 557 823 623 690 591 939
(lb) (1,164,500) (1,106,670) (1,112,000) (1,230,000) (1,230,000) (1,375,000) (1,305,000)
Chassis Weight kg 167 865 214 820
(lb) (370,078) (473,600)
Body without Attachments kg 30 362 47 264
(lb) (66,936) (104,200)
Empty Weight kg 213 185 211 681 212 994 231 332 231 332 270 677 229 064
(lb) (469,991) (466,672) (469,567) (510,000) (510,000) (596,744) (505,000)
Payload – Target/Nominal tonnes 284 290 345+
(tons) (312) (320) (380+)
Payload – Maximum tonnes 315 290 326 326 – 353 See 10/10/20 363
(tons) (347) (320) (360) (360 – 390) Guidelines (400)
Notes about Payload and Weights: Empty weight Empty weight Empty weight Empty weight Empty weight Empty weight N/A
with 50% fuel, with 100% fuel, with 50% fuel. with 100% fuel with 100% fuel includes
standard no options. GVW including and autolube and autolube lubricants,
MTU/DDC Nominal payload options, liners, capacities capacities coolant, 100%
engine. Nominal defined by fuel, and fuel, debris
payload defined Komatsu ’s payload (4% of chassis
as 90% of payload payload policy weight), no body
with standard attachments
equipment

DIMENSIONS

Wheelbase mm 6150 6350 6350 6655 6655 7200 6553

(in) (242) (250) (250) (262) (262) (283) (258)
Overall Length mm 14 420 15 596 15 596 15 392 15 392 14 530 14 478

(in) (570) (614) (614) (606) (606) (572) (570)

Overall Width mm 9050 8687 8687 9449 9449 9154 8788
(in) (356) (342) (342) (372) (372) (360) (346)
Tire Width mm 8520 8331 8331 9195 9195 9761 8712
(in) (336) (328) (328) (362) (362) (384) (343)
Loading Height mm 6500 7061 7061 6858 6858 7083 6452
(in) (256) (278) (278) (270) (270) (278) (254)
Height – Body Raised mm 14 280 14 021 14 021 13 437 13 437 15 292 13 284
(in) (562) (552) (552) (529) (529) (602) (523)

 WEIGHT DISTRIBUTION

Front Axle – Empty 49% 47% 50% 49% 49% 44% 46%
Rear Axle – Empty 51% 53% 50% 51% 51% 57% 54%
Front Axle – Loaded 32% 33% 33% 33% 33% 33% 34%
Rear Axle – Loaded 68% 67% 67% 67% 67% 67% 66%

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 101
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Technical Specifications – 797B vs. Competition (272 tonnes+ [300 tons+])

MANUFACTURER TEREX/ TEREX/  

HITACHI KOMATSU KOMATSU UNIT RIG UNIT RIG CAT LIEBHERR
MODEL EH5000 930E-3 930E-3SE MT5500B MT5900AC 797B T282B

ENGINE
Model 16V4000 QSK60 QSK78 QSK60 QSK78 3524B 16V4000
Manufacturer MTU/DDC CUMMINS CUMMINS CUMMINS CUMMINS CAT MTU/DDC
Bore mm 165 159 170 159 170 170 165
(in) (7) (6) (7) (6) (7) (7) (7)
Stroke mm 190 190 190 190 190 215 190
(in) (7) (7) (7) (7) (7) (8) (7)
Displacement L 65 60 78 60 78 117 65
(in3) (3,967) (3,661) (4,760) (3,661) (4,760) (7,146) (3,967)
Max Altitude m 2591
(ft) (8,500)
Number of Cylinders 16 16 18 16 18 24 16
Rated Speed rpm 1,900 1,900 1,900 1,900 1,900 1,750 1,800
High Idle rpm 1,950
Low Idle rpm 700
Net Power kW 1939 1902 2558 1847 2445 2513 1848

(hp) (2,600) (2,550) (3,429) (2,478) (3,278) (3,370) (2,478)

Gross Power kW 2014 2014 2611 2014 2611 2648 2013
(hp) (2,700) (2,700) (3,500) (2,700) (3,500) (3,550) (2,700)
Net Torque N•m 10,930 16,004
Torque Rise 22%
Engine Weight kg 9608 10 100 8852 10 800 16 780 7484
(lb) (21,182) (22,266) (19,515) (23,810) (37,000) (16,500)

OPTIONAL ENGINE

Model QSK60-L 16V4000 20V4000 Tier 1 QSK78

Manufacturer CUMMINS MTU/DDC MTU/DDC CUMMINS
Bore mm 159 165 170
(in) (6) (7) (7)
Stroke mm 190 190 190
(in) (7) (7) (7)
Displacement L 60 65 78
(in3) (3,661) (3,967) (4,760)
Number of Cylinders 16 16 20 18
Rated Speed rpm 1,900 1,800 1,800 1,900
Net Power kW 1920 1848 2548
(hp) (2,575) (2,478) (3,415)
Gross Power kW 2014 2013 2723 2610
(hp) (2,700) (2,700) (3,650) (3,500)
Net Torque N•m 10,630
Engine Weight kg 7173 10 372 11 294
(lb) (15,813) (22,870) (24,900)

OTHER OPTIONAL ENGINE

Model QSK78 20V4000 Tier 2 QSK60

Manufacturer CUMMINS MTU/DDC CUMMINS
Model 20V4000 20V4000
Manufacturer CUMMINS MTU/DDC

COOLING SYSTEM

Fan Diameter mm 2438

(in) (96)

102 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006
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Technical Specifications – 797B vs. Competition (272 tonnes+ [300 tons+])

MANUFACTURER TEREX/ TEREX/  

HITACHI KOMATSU KOMATSU UNIT RIG UNIT RIG CAT LIEBHERR
MODEL EH5000 930E-3 930E-3SE MT5500B MT5900AC 797B T282B

TRAVEL SPEEDS
Forward 1 km/h 11.3
(mph) (7.0)
Forward 2 km/h 15.2
(mph) (9.5)
Forward 3 km/h 20.5
(mph) (12.7)
Forward 4 km/h 27.7
(mph) (17.2)
Forward 5 km/h 37.2
(mph) (23.1)
Forward 6 km/h 50.3
(mph) (31.2)
Forward 7 km/h 67.6
(mph) (42.0)
Reverse 1 km/h 12.9
(mph) (8.0)
Elec. Drive Max. km/h 66.9 64.5 64.5 65.0 65.0
(mph) (41.6) (40.0) (40.0) (40.0) (40.0)

REDUCTIONS

Differential 1.265
Final Drive 16.670

TIRES

Tires 53/80R63 53/80R63 53/80R63 55/80R63 55/80R63 59/80R63 55/80R63

Weight kg
(lb)
Optional Tires 55/80R63 56/80R63
58/80R63

BRAKES – REAR

Discs per Side 2 2 2 15 2

Outside Diameter mm 787 787 1067 711
(in) (31) (31) (42) (28)
Total Area cm2 180 741 194 050 194 050 198 387
(in2) (28,015) (30,078) (30,078) (30,750)

BRAKES – FRONT

Disc per Side 1 1 1 10 1

Outside Diameter mm 1308 1308 1067 1194
(in) (52) (52) (42) (47)
Total Surface Area cm2 18 548 194 050 194 050 132 258
(in2) (2,875) (30,078) (30,078) (20,500)
Dry Disc OD mm
(in)

SUSPENSION SYSTEM

Front Strut Diameter mm 400

(in) (16)
Rear Strut Diameter mm 381
(in) (15)
Total Stroke – Rear mm 239 239 184 184 165
(in) (9) (9) (7) (7) (6.5)
Total Stroke – Front mm 328 328 305 305 318
(i ) (13) (13) (12) (12) (12 5)

September 2006 Cat ®  Mining Trucks 785C, 789C, 793D, 797B 103
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Technical Specifications – 797B vs. Competition (272 tonnes+ [300 tons+])

MANUFACTURER TEREX/ TEREX/  

HITACHI KOMATSU KOMATSU UNIT RIG UNIT RIG CAT LIEBHERR
MODEL EH5000 930E-3 930E-3SE MT5500B MT5900AC 797B T282B

STEERING SYSTEM
Steering Angle degrees 40 39
Number of Cylinders 2 2 2 2 2 2 2
Turning Radius – Front m 30 25 25 32 32 39.9 33.6
(ft) (99) (81) (81) (106) (106) (130.9) (110)
Turning Circle Clearance Diameter m 30 30 40.5 36.6
(ft) (97) (97) (132.8) (120.1)

HOIST SYSTEM

Body Raise secs 22 21 21 28 28 25.0 28

Body Float Down secs 24 24 24 18.5
Body Power Down secs 23 23 12 12 18.1 18

BODY
Body Type N/A Flat Floor Flat Floor Flat Floor Flat Floor MSD II † N/A
Capacity – S truck m3 144 171 171 158 158 187 122
(yd3) (188) (224) (224) (207) (207) (245) (160)
Capacity – Heaped 2:1 m3 196 211 211 218 218 241 184
(yd3) (257) (276) (276) (285) (285) (315) (240)
† Data
provided is for a representative body. Several mine specific design (MSD) bodies are available. All weights, capacities, and dimensions are dependent on the
machine configuration (body type, attachments, tires, and optional equipment selected).

REFILL CAPACITIES

Fuel Tank 1 L 3785 4542 4542 3028 3028 3785 4730

(gal) (1,000) (1,200) (1,200) (800) (800) (1,000) (1,250)
Fuel Tank 2 L 4920 4920 6814
(gal) (1,300) (1,300) (1,800)

Cooling System L 697 594 719 591 757 1194 456

(gal) (184) (157) (190) (156) (200) (315) (120)
Crankcase L 242 280 341 250 390 417 240
(gal) (64) (74) (90) (66) (103) (110) (63)
Differential and Final Drives L 701
(gal) (185)
Front Wheels (Each) L 27 61
(gal) (7) (16)
Steering Tank L 947 947 235
(gal) (250) (250) (62)
Steering System L 291 432 570
(gal) (77) (114) (150)
Brake/Hoist Hydraulic Tank L 1033 1033 996
(gal) (273) (273) (263)
Brake/Hoist Hydraulic System L 965 1325 1325 1211 1211 1842 1510
(gal) (255) (350) (350) (320) (320) (486) (400)
TC/Trans Sump L 190
(gal) (50)
TC/Trans System (Includes Sump) L 629
(gal) (166)

104 Cat ®  Mining Trucks 785C, 789C, 793D, 797B September 2006
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Notes

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